WINMAX MILL

PROGRAMMING DOCUMENTATION

v9.1 & v10.1

June 2015 704-0116-501 Revision D

The information in this document is subject to change without notice and does not
represent a commitment on the part of Hurco Companies, Inc. (Hurco). The software
described in this document is furnished under the License Agreement to customers. It is
against the law to copy the software on any medium except as specifically allowed in the
license agreement. The purchaser may make copies of the software for backup purposes.

Hurco Manufacturing Company reserves the right to incorporate any modification or

improvements in machines and machine specifications which it considers necessary, and
does not assume any obligation to make any said changes in machines or equipment
previously sold.

Hurco products and services are subject to Hurco’s then current prices, terms, and
conditions, which are subject to change without notice.

© 2015 Hurco Companies, Inc. All rights reserved.

Patents:U.S. Patents B14,477,754; 5,453,933; Canadian Patent 1,102,434; Japanese

Patents 1,649,006 and 1,375,124; other Patents pending.

Hurco, Max, Ultimax, and WinMax are Registered Trademarks of Hurco Companies, Inc.

AutoCAD, Autodesk, and DXF are registered trademarks of Autodesk, Inc.

MS-DOS, Microsoft, and Windows are registered trademarks of Microsoft Corporation.

Many of the designations used by manufacturers and sellers to distinguish their products
are claimed as trademarks. Hurco has listed here all trademarks of which it is aware. For
more information about Hurco products and services, contact:

Hurco Companies, Inc.

One Technology Way
P.O. Box 68180
Indianapolis, IN 46268-0180

For Hurco subsidiary contact information, go to Hurco’s Web site:

www.hurco.com

i - WinMax Mill Programming Documentation 704-0116-501

DOCUMENTATION CONVENTIONS
This documentation uses several conventions to explain the safety features and
emphasize key concepts. These conventions are described in this section.

Additional information is available on the machine’s Documentation CD.

Console Buttons and Keys

References to console buttons and keys appear in bold text throughout the
documentation. For example, the Start Cycle button appears as the Start Cycle button
and the Manual key appears as the Manual console key in text.

Refer to the Getting Started with WinMax manual for information about console buttons
and keys, in addition to other information about using softkeys and the pop-up text entry
window.

Icons
This manual may contain the following icons:

Caution/Warning

The operator may be injured and the machine severely damaged if the
described procedure is not followed.

Important

Ensures proper operation of the machine and control.

Troubleshooting

? Steps that can be taken to solve potential problems.

Hints and Tricks

Useful suggestions that show creative uses of the WinMax features.

Where can we go from here?Programming and Operation Information

Lists several possible options the operator can take.

WinMax Mill Programming Manual 704-0116-501 Documentation Conventions — ii

Hurco provides documentation for using WinMax software on a control or desktop in two
formats: on-screen Help and PDF. The information contained in both formats is identical.
The programming and operation information is continually updated with each software
version. For example, when v08.01.02 is updated to v08.01.03 or some higher version,
the Help and PDFs are updated accordingly. Therefore, the most current information is
installed on the control with the software. This information is not included on the Machine
Documentation CD because of this reason.

This document explains how to use the On-screen Help on the control and how to copy
and print or view the information on a PC.

On-screen Help contains information about the current screen. If Help is not available for
a screen, a Welcome screen appears with access to the Table of Contents, Index, or
Search functions.

• To view the on-screen Help directly on a Hurco control, select the Help
console key.
• To view the on-screen Help on the desktop software, select the Help icon in
the menu bar.

PDF files are available on the control’s hard drive. These files can be copied from the hard
drive to a USB memory device and transferred to a PC for viewing and printing.

Using the On-screen Help

On-screen Help provides information about using WinMax. The Help is context-sensitive
to the screen level. Press the console Help button to display the Help topic for the current
screen. The following list describes Help functions:

• Buttons in the upper left-hand corner of the Help screen are used to move
through Help topics and print screens.

• Use the Hide button to hide the navigation pane.

• Use the Back button to return to the previous Help screen.
• Use the Print button to print the current displayed Help topic, if a printer
is attached and configured. See Printing the Programming Manuals, on
page 2 - iv for more information about printing.

• Use the arrow buttons to move between pages within a Help topic and to
move through topics.
• Use the Contents tab for a list of information sorted by subject:
1. Select the “+” to expand the topic and view sub-topics.
2. Select the topic to display it.

• Use the Index tab to show the Help index:

1. Quickly scroll to an index topic by typing the topic in the box at the top of
the index.
2. Select a topic and the Display button to view the topic.

iii - Documentation Conventions 704-0116-501 WinMax Mill Programming Manual

 • Use the Search tab to search the Help for a word or phrase:
1. Type the search word(s) into the text box at the top of the pane.
2. Select the List Topics button. A list of topics that contain the search
word(s) is displayed.
3. Select a topic and the Display button to view that topic.

• Use the Favorites tab to save Help topics for quick access:
1. Select the Add button at the bottom of the pane to add the current topic.
2. Select a topic from the Favorites list, and select the Display button to view
it.
• Select a topic from the Favorites list, and select the Remove button to
remove it from the list.

Printing the Programming Manuals

The WinMax On-screen Help is also provided in PDF format for easy printing. The
information contained in the PDF files is identical to the on-screen Help. The PDF files
may be copied to a floppy disk or USB memory device to be transferred to a PC for
printing. Here are the steps to access the PDF files:

1. From the Input screen, select the F8 softkey.

2. Select the F7 softkey.
3. In the left-hand pane, navigate through the folders:

• For WinMax on a machine, the path is D:\Hurco\\hlp.

• For WinMax Desktop on a PC, the path is C:\Program Files\\hlp.

The PDF files will appear in the right-hand pane.

The SHOW ALL FILE TYPES field in User Interface Settings must be
set to YES (default is NO) in order to see the PDF files in the
directory. Access the SHOW ALL FILE TYPES field in Auxiliary Mode,
Utilities/ User Preferences/ User Interface Settings.

4. Highlight the PDF file(s) in the right-hand pane, and select the COPY F2
softkey.
5. Ensure that your media is loaded (either a floppy disk in the disk drive or a
USB memory device in the USB port), and navigate to the proper location in
the left-hand pane of the DISK OPERATIONS screen (either the floppy drive A:
or the USB port E:). Highlight the desired location.
6. Place the cursor in the right-hand pane and select the PASTE F3 softkey to
paste the PDF file(s) to the desired location.

You may now remove your media and load the PDF file(s) onto a PC for printing.

WinMax Mill Programming Manual 704-0116-501 Documentation Conventions -iv

v - Documentation Conventions 704-0116-501 WinMax Mill Programming Manual
TABLE OF CONTENTS
Documentation Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Console Buttons and Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
Using the On-screen Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Printing the Programming Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv

Getting Started with WinMax Mill

Machine and Console Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 1

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 2
Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 3
Jog Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 9
Machine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 17
Machine Operations Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 18
Communications Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 20
Spindle and Automatic Tool Changers . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 23

Program Manager . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 27
Managing Program Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 27
Program Properties . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 33
Disk Operations . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 34
FTP Manager . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 35

Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 37
System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 38
User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 39
Serial Port Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 44
FTP Server Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 44
WinMax Uptime . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 44
Rotary Axes Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 45
Select Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 46
Data Logging Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 46
Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 47
Additional Utilities Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 47
Printing Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 47
Integrator Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 50
Serial I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 51
Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 51

Machine Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 55
Machine Parameters Page 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 56
Machine Parameters Page 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 59
Machine Parameters Page 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 63
Machine Parameters Page 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 70
Machine Parameters Pages 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 72
Estimated Run Time Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 73

Programming Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 75
WinMax Interface Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 76
Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 84

WinMax Mill Programming Manual 704-0116-501 Table of Contents -viii

 Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 85
Rotary Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 90
Part Fixturing and Tool Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 93
Work Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 93
Stock Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 95
Tool Calibration Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 96
Tool Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 100
Part Program Tool Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 110
Tool Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 115
Tool and Material Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 117
Program Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 118
Import / Export Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 121
Copy and Change Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 124
Review Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 126
Manual Safety Override Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 128
Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 131
Max5 UI Graphics Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 134

Machine Operation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 135

Machine Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 136
Recovery and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 137
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 138
Automatic Tool Changers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 141
Tool Fixture Option (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 148
HMX Automatic Pallet Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 151
Dual-Zone Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 155
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 159
Stop Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 165
Restart Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 167
Shutdown Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 167

UltiMotion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1 - 173

Conversational Programming

Conversational Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 1
Part Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 2
Programming Dual-Zone Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Pecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 8
Cutter Compensation (preliminary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 9
Calculated Plunge Points for Milling Cycles . . . . . . . . . . . . . . . . . . . . . . . . .2 - 14
Lead In/Out Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 15

Milling Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 17
General Guidelines for Creating a Milling Block . . . . . . . . . . . . . . . . . . . . . .2 - 18
Lines and Arcs (Mill Contour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 19
Mill Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 26
Mill Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 29
Mill Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 31
Mill Ellipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 33
3D Mold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 34
Helical Plunge (Ramp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 44
Mill Thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 51
Mill Stick Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 54
Mill True-Type Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 56

ix - Table of Contents 704-0116-501 WinMax Mill Programming Manual

 Stick Lettering Along Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 59
True-Type Lettering Along Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 62
HD3 Serial Number Stick Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 65
Mill HD3 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 69
Insert Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 70
Swept Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 74
Mill Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 79
Mill Polygon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 84

Holes Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 87
Drill Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 88
Tap Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 97
Bore and Ream Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 98
Back Spotface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 101
Bolt Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 102
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 103
Bolt Circle to Holes Locations or Pattern Locations Conversion . . . . . . . . . . .2 - 104
Holes to Pattern Locations Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 105
Holes End Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 105

Patterns Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 107

Patterns Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 108
Loop Rectangular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 109
Loop Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 110
Loop Angular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 111
Loop Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 112
Pattern Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 113
Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 114
Mirror Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 115
Pattern End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 115

Special Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 117

Position Data Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 118
Graphics On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 119
Change Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 119
Change Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 121
Machine Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 122
Lube Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 122
Comment Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 123
Insert Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 123
Tool Change Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 124

NC/Conversational Merge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 129

DXF Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 131

DXF Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 132
DXF Build Data Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 133
DXF Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 135
Edit Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 136
DXF Layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 138

UltiPockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 139
Helical Plunge with UltiPockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 - 143

WinMax Mill Programming Manual 704-0116-501 Table of Contents -x

NC Programming

NC Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 1
NC Part Programming Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 2
NC Editor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 6
Starting a New NC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 8
NC Editor Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 9
NC Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 20
NC Probing Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 25

Preparatory Functions - G Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 27

G Code Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 30
G Code Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 31
Setting Work Coordinate Systems with G10 . . . . . . . . . . . . . . . . . . . . . . . .3 - 59
Setting Tool Offsets with G10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 60
Plane Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 62
Tool and Radius Offsets (G40–G49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 73
Special Program Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 102
Coordinate System Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 137
Feed Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 139
Canned Cycle Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 142
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 145
Canned Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 146
Canned Cycle Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 148
Canceling or Replacing Canned Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 150

Spindle Speed - S Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 151

Tool Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 153

D Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 153
L Codes (BNC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 153
T Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 153

Miscellaneous Functions - M Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 155

M Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 157
Program Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 160
Axis Limit Overrides (M210, M211, M212) . . . . . . . . . . . . . . . . . . . . . . . . . 180

NC Productivity Package Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 183

Macro Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 184
Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 185
Program Control Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 200
Subprograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 205
Modal Subprograms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 214
User Defined Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 216
NCPP Variable Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 224
Programming Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 - 234

xi - Table of Contents 704-0116-501 WinMax Mill Programming Manual

Probing

Tool Probing Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 1

Tool Probing in Absolute Tool Length Mode . . . . . . . . . . . . . . . . . . . . . . . .4 - 2
Tool Probing in Zero Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 8
Tool Quality Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 14
Appendix A: Tool Probe Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 18
Appendix B: Tool Probe Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 26

Part Probing Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 31

Part Setup—Part Probe Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 32
Part Probe Calibration and Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 34
Part Quality Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 - 67

Rotary Programming

Rotary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 1
Rotary Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 2
Rotary Part Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 5
Universal Transform Plane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 8
Transform Plane (configurations other than Universal) . . . . . . . . . . . . . . . .5 - 13
Universal Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 14
Rotary A and Rotary A Tilt B Configuration . . . . . . . . . . . . . . . . . . . . . . . .5 - 24
Tilt A Rotary C Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 29
Rotary B Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 34
Tilt B Rotary C Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 - 37

Extended Shop Floor

UltiMonitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 1
LAN Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 2
Configuring a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 4
Using FTP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 8
Extended Shop Floor (ESF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 - 12

Field Name Glossary

Field Name Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 - 1

Error Messages and Alarms

Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 1

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 - 28

Record of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

WinMax Mill Programming Manual 704-0116-501 Table of Contents -xii

xiii - Table of Contents 704-0116-501 WinMax Mill Programming Manual
MACHINE AND CONSOLE BASICS
These topics are discussed in this section:

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 2
Consoles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 3
Jog Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Emergency Stop Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Programming Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 5
Axis, Spindle, and Machine Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Machine Operations Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 18
Communications Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 20
Spindle and Automatic Tool Changers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-1
Machine Components
Before using the machine, you should become familiar with its components. Because of
European Committee (CE) requirements, Hurco machines sold in Europe differ somewhat
from those sold elsewhere. The figure below identifies some of the easily recognized
components of a machine. The console is in front of the machine, facing the operator’s
area.

1 Console

2 Way Cover

3 Table

4 Spindle

5 Machine Base

6 Chip Conveyor

7 Tool Changer

Figure 1–1. Hurco Machine with Dual-Screen Console

Hurco machines are available with several hardware and software options. Information
about these options is available from Hurco or your Hurco Distributor.

1 - 2 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Consoles
The console, and the electrical components required to operate it, are called the “control”
or the “CNC” (Computer Numeric Control). Some electrical components are built into a
separate enclosure kept in the machine’s electrical cabinet. Some internal components,
such as drives and memory, are like those in a PC. Only the parts of the Windows®
operating system that are necessary to run Hurco CNCs are used. Customers are not
permitted to install software on the WinMax control. Pictured below are the Max5 dual-,
Max4 dual-, and Max4 single-screen consoles.

Max5 dual-screen console

Max4 dual-screen console Max4 single-screen console

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-3
Control Panel Function Groups
The buttons, keys, and knobs on the dual- and single-screen consoles are grouped by
their functions. Here are the control panel groups on single- and dual-screen consoles:

3
2 1

1. Machine Control buttons

2. Axis and Spindle Control dials

3. Jog Control functions

4. Machine Operations keyboard

5. Programming keyboard

1 - 4 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Emergency Stop Buttons
There is an Emergency Stop button located on each console and one on the Remote Jog
Unit. Press the Emergency Stop button to stop all spindle and table motion. This button
locks down when pressed. To release it, twist the button in the direction indicated by the
arrows.

Learn the location of all Emergency Stop buttons on the machining

center before operating.

If the Emergency Stop button is pressed during execution of a part

program, the tool must be jogged clear of the part before resuming
operation.

When the Emergency Stop button is pressed, a special error file is created and saved to
the machine hard drive in a folder called NavESTOP. These files record the machine
conditions at the time the Emergency Stop button is pressed. These files can be retrieved
when necessary for service purposes; refer to Retrieve Log and Diagnostic Files, on page
1 - 59 for more information.

Programming Keyboard
Program a job at the machine while reading from a blueprint or program worksheet. The
prompts on the Text screen lead you through each element of a part program. Enter
machine operations, part dimensions, and other parameters by selecting the appropriate
screen softkeys and console buttons.

Set up and run part programs, and manage part program files using the following data
entry keys:

• Text Screen Data Entry

• Softkeys
• Numeric Keypad
• Pop-up Text Entry Window
• Graphics Screen Data Entry

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-5
Text Screen Data Entry
Text screen data entry keys are used for entering programming information into the Text
screen’s fields. These keys are located in the center of the console’s Programming
Keypad.

Programming Mode
Programming Mode console keys are named for the screens they activate:

• Input – displays the main programming screen used to create and edit part
programs. From this screen, access Part Setup, Tool Setup, Part
Programming, Program Parameters, Copy and Change Blocks, and Restore
and Erase menus.
• Auxiliary – accesses program storage management, system configuration
settings, DXF files, reset master, and the upgrade system files menus.
• Review – for Conversational programs, provides an outline view of the
blocks currently programmed, including type of block and tool used. Jump to
a desired block by typing the block number and pressing Enter. For Numerical
Control (NC) programs, the Review key displays or re-displays the NC part
program.
• Help – displays help text. Place the cursor on a field in question and press
the Help key. If help text is available, it will appear in a pop-up window. Help
is not available for all screens.

These keys function as they would on a standard PC keyboard:

• Insert - type over and replace current text.

• Delete - delete the character to the right of the cursor.
• Home - position the cursor before a line of text.
• End - position the cursor at the end of a line of text.
• Page Up - position the cursor at the beginning of the previous page.
• Page Down - position the cursor at the beginning of the next page.

Text Screen Cursor Control Keys

These keys control cursor movement and perform programming operations:

• Arrow keys - move the cursor from one field to the next, or advance a part
program to the next data block.

• Enter key (↵) - accept the information typed in a text field, or move to the
next field.
• Special Function keys / keyboard shortcuts:
• alt + Input—display the Pop-up Text Entry Window.
• alt + Help—produce a bmp screen capture.
• alt + right arrow—tab through fields or through the windows in File
Manager.

1 - 6 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
 • alt + left arrow—reverse tab through fields or the windows in File
Manager.
• alt + Select—simulate a right mouse click.
• alt + F + left arrow—reverse tab through fields or the windows in File
Manager. (Same function as alt + left arrow.)
• alt + F + Select—simulate Shift + left mouse click.
• C (clear) console key—press to clear the value at the current cursor
position. The C key works like an Esc key on a keyboard.
• F + Delete—delete the character to the left of the cursor.
• F + Help—produce a bmp screen capture.
• F + End—move the cursor to the end of a list.
• F + Home—move the cursor to the top of a list.
• F + Page Down—move through a list.
• F + Page Up—move through a list.
• F + Select—simulate a left mouse click.
• F + up arrow—move cursor to previous data block.
• F + down arrow—moves cursor to next data block.
• F + left arrow—moves cursor to previous element.
• F + right arrow—moves cursor to next element.
• F + decimal (.)—enable Full Precision Editing. This feature displays a
pop-up window showing 12 digits to the right of the decimal for the
current field.
• F + Draw—switch to the DXF drawing on the graphics screen.
• F + 1 through 8—simulate function keys on keyboard (F1, F2, F3,...F8).

Numeric Keypad
The numeric keypad allows you to enter numbers and calculate values in the Text screen.
Perform the following operations with this keypad:

• Enter numeric data into fields on the screen.

• Perform calculations using the mathematical symbols (÷, ×, −, +) on the
keypad.

Optional Computer Keyboard

If the console is equipped with an optional computer keyboard, use it to enter data into a
field. Press the Enter key to update a field and advance the cursor.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-7
Axis, Spindle, and Machine Control
The following keys and knobs are used to control machine movement and adjust the
spindle and axes.

Override Knobs
Three knobs on the upper console allow you to override the programmed axis feedrate,
rapid, and spindle speed.

The Override knobs function as follows:

• Axis Feed Rate - controls the programmed axis feedrate during an auto run
program. Turning the dial to counterclockwise slows the feedrate; turning the
dial to clockwise speeds the feedrate. Selecting Min slows the spindle to 10%
of the nominal value. Selecting Max increases the feedrate to 150% of the
nominal value.
• Spindle Speed - controls the spindle speed. Turning the dial
counterclockwise slows the spindle; turning the dial clockwise increases
spindle speed. Selecting Min slows spindle speed to 640 RPM slower than the
nominal value. Selecting Max increases spindle speed to 640 RPM faster than
the nominal value.
• Rapid Override - overrides the programmed rapid traverse; the speed at
which the table moves from one point to another. Selecting Min slows the
table speed to 10% of the nominal value. Selecting Max increases the table
speed to 150% of the nominal value.

1 - 8 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Jog Units
A jog unit is used to manually jog the axes and control machine operation. Hand-held, or
remote, jog units can be removed from the console and carried closer to the work piece.

Max5 Remote Jog Units

Max5 console offers a choice of remote jog units:

• Basic—portable hand-held unit with axes and machine operation controls.

• Premium—portable hand-held jog unit with all the features of the Standard
jog unit, plus an LCD touchscreen that displays axes position in Manual mode,
Part Setup, Tool Setup, Work Offsets, and Aux Work Offsets.

Max4 Remote Jog Unit

The Console Jog Unit is standard on the Max4 console.

The hand-held remote Max4 Jog Unit is an option on the Max4 console.

Jog Unit Operation

Basic operation of a jog unit is as follows:

1. Select an axis with the Axis Select Switch.

2. Use the Jog Feed Keys:
a. Select either the + or – Jog Feed Keys.
b. Adjust Jog Feed Override to override the programmed axis feedrate.

OR

3. Use the Hand Wheel Multiplier:

a. Select a hand wheel resolution with one of the Hand Wheel Multiplier Keys.
b. Rotate the Jog Hand Wheel.
Other than the Emergency Stop button, the Jog Unit does not affect
running programs.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-9
Setting Jog Unit Parameters
To access the parameters :

1. Press the Manual Mode console key to display the Manual screen.
2. Press the Manual Function (F2) softkey. The Jog Unit parameters are
displayed:
• Manual Jog Feed— enter the desired manual jog axis feedrate. The
range is from 0.0 to the machine’s maximum feedrate.

An axis may have a maximum jog feedrate slower than other axes. This
slower axis can only move at its maximum jog feedrate (and not the
higher feedrate of other axes).

For example, the X and Y axes on a machine each have a maximum jog
feedrate of 787 inches per minute (ipm). The Z axis has a maximum jog
feedrate of 100 ipm. Without using the jog feedrate override, the X and Y
axes can jog at 787 ipm, but the Z axis is limited at 100 ipm.

• Manual Spindle Speed —enter the spindle speed when the Spindle On
console key is pressed. This value can not be greater than the machine’s
maximum spindle speed. Entering a negative value (e.g., -500) causes
the spindle to reverse (turn counterclockwise) at that speed.
• Rotary Jog Feed (for machines with rotary or swivel axes)—enter the
jog feedrate in RPM.

1 - 10 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Max5 Remote Jog Units
Basic Remote Jog Unit
Pictured belows is the Basic Unit. See Remote Jog Units, on page 1 - 15 for more details.

Flashlight
Handle

Store Position

Emergency Stop

Stop Cycle

Start Cycle
Rapid Jog Rate Knob

Feed Hold

Flashlight On/Off

Axis Select Knob

Handwheel Multipliers

Jog Feed

Jog Handwheel

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-11
Premium Remote Jog Unit
Pictured below is the Max5 Premium Remote Jog. See Remote Jog Units, on page 1 - 15
for more information.

Handle Flashlight

Store Position

Emergency Stop
LCD Touchscreen
(Premium and
Wireless)

Stop Cycle

Start Cycle
Rapid Jog Rate Knob

Feed Hold

Axis Select &

Flashlight On/Off
Override Knob
feed
rapid
spindle
Handwheel Multipliers

Jog Feed

Jog Handwheel

1 - 12 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
This is the view of the back of the Max5 Remote Jog Unit (both Basic and Premium):

Enable button

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-13
Max4 Remote Jog Unit

1. Emergency Stop Button

2. Store Position Key
3. Hand Wheel Multiplier Keys
4. Jog Hand Wheel
5. Jog Feed Keys
6. Jog Feed Override
7. Axis Select Switch

1 - 14 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Remote Jog Units
• Emergency Stop—stops all spindle and table motion. See Emergency Stop
Buttons, on page 1 - 5 for more information.
• Store Position—records the current axis position in the part program’s setup
screens.
• LCD screen (available only on Premium units)—displays Manual mode
(MAN), Part Setup (PSU), Tool Setup (TSU), Work Offsets (WO), and Aux
Work Offsets (AWO).

Mode Selections appear at the bottom of the LCD screen. Use the
touchscreen to select a mode; a check mark appears by the current selection.
Scroll up, down, left, and right, and select items using the touchscreen.

• MAN—manual mode. The display shows machine or part positions for X,

Y, and Z. Positions are zone relative on dual-zone machines.
• PSU—Part Setup. The display shows current part setup information.
Values for X, Y, Z, A, B, C, as well as rotary centerline X, rotary centerline
Y, and Z table offset are shown. Positions are zone relative on dual-zone
machines.
• TSU—Tool Setup. The display shows current tool setup information. The
initial tool displayed is the current tool in spindle.
• WO—Work Offsets. The displays shows G54, G55, G56, G57, G58, G59
and Shift values.
• AWO—Aux Work Offsets. The display shows offsets 1-93.

• Start Cycle (Max5)—activates machine operation. The Start Cycle button on

the Remote Jog Unit must be used in conjunction with the Enable button,
located on the back of the jog unit. Press and hold the Enable button and
press the Start Cycle button on the jog unit. The Enable button can be
released after the cycle is started.

Both the Enable button and the Start Cycle button must be held
down to run the spindle with the enclosure doors open.

• Feed Hold (Max5)—stops all axes movement (except a tap operation) when
the tool is in the programmed feedrate region. Pressing the button a second
time allows machine positioning to resume.
• Stop Cycle (Max5)—stops axes movement, then stops the spindle.
• Axis Selector (& Override) Knob – selects the axis to jog (0, X, Y, Z, A, B).
On Premium unit only, this knob also control the override mode: feed, rapid,
or spindle.
See Setting Jog Unit Parameters, on page 1 - 10 for instructions on
setting the Jog Unit parameters.

• Flashlight (Max5)—toggle flashlight or machine work light on and off with

this button. A short duration press toggles the flashlight. Flashlight
illuminates from the top of the remote jog unit. A longer duration press
toggles the machine work light.
• Rapid Jog Rate Knob (Max5)—controls the rapid jog rate when an axis is
selected on the Axis Selector (& Override) Knob. On Premium model, when

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-15
 the Axis Selector & Override Knob is set to override mode (one of the bottom
three positions), the Rapid Jog Rate Knob controls the override (feed, rapid,
or spindle).
• Jog Feed Override (Max4)—control the jog speed (10% to 150%) of the
nominal value. Use this dial to touch off the tool and move the X and Y axes
to touch off the part for Tool and Part Setup.
• Jog Feed Keys —select minus (-) or plus (+) jog direction.
• Jog Handwheel —select minus (-) or plus (+) jog direction.
• Handwheel Multiplier Keys - defines the hand wheel resolution.
• x1 - defines a one-to-one ratio (each click equals .0001 inch, or .00254
mm).
• x10 - defines a 10-to-one ratio (each click equals .001 inch, or .0254
mm).
• x100 - defines a 100-to-one ratio (each click equal s 0.01 inch, or .254
mm. One full turn equals 1 inch, or 25.4 mm).
• Enable button—on machines with CE enabled, must be held to use the Start
Cycle button and the +/- jog on the unit.

Enable Button
The Max5 Remote Jog, Max4 Remote Jog, single-screen and dual-screen consoles may be
equipped with an Enable button. The Enable button is functional only on machines that
have CE enabled.

The Enable button has three positions: fully up (off), middle (on), and fully down (off).
The button must be in the middle position to be enabled. The Enable button is required
for the following operations:

• Start Cycle (on Max5 Remote Jog only)—press and hold the Enable button
and press the Start Cycle button on the unit. The Enable button can be
released after the cycle is started.

Both the Enable button and the Start Cycle button must be held
down to run the spindle with the enclosure doors open.

It is not necessary to use the Enable button when using the Start Cycle
button on the console.

• +/- Jog—press and hold the Enable button while simultaneously selecting
either “+” or “-” button to jog the selected axis, only when the enclosure
doors are open. If the enclosure doors are closed, it is not necessary to use
the Enable button to jog the axes.

It is not necessary to press and hold the Enable button to jog the axis using
the hand wheel at x1, x10, or x100 speeds.

1 - 16 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Machine Control
Machine Control buttons start and stop machine operation. The buttons function as
follows:

• Power On - enables the relay control system. This button must be

illuminated to operate the machine, but may be switched off while creating or
editing a part program.
• Start Cycle - activates machine operation. When the machine is in an active
mode, the Start Cycle flashes to indicate the machine is ready. When this
button is pressed again, the light switches off.

To turn Control Power On:

1. Press the Power On console button.

2. Press the Manual Mode console key.
3. Press the Start Cycle console button.
Never press the Start Cycle button without knowing exactly what the
machine will do.

• Stop Cycle - stops axes movement, then stops the spindle.

• Feed Hold (Motion Hold on Max console) - stops all axes movement, except
a tap operation, when the tool is in the programmed feedrate region. Pressing
the button a second time allows machine positioning to resume.

To Stop an Automatic Machine Operation:

Press the Stop Cycle button to stop the axis, then the spindle.

Or

1. Press the Feed Hold (or Motion Hold) console button to stop axis motion.
2. Press the Spindle Off console key to stop the spindle.
3. Press the Feed Hold (or Motion Hold) console button again.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-17
Machine Operations Keys
The Machine Operations console keys are needed to run part programs and control the
machine during cutting. These keys are labeled under the Machine Mode, Spindle, Tool
Changer, and Coolant groupings.

Machine Mode
The Machine Mode console keys have these functions:

• Auto - allows you to run a part program automatically. See Auto Mode, on
page 1 - 160 for more information.
• Interrupt - halts machine operation during automatic execution of a
program to allow manual functions, such as cleaning the work piece. See
Stop Motion, on page 1 - 18 for more information. Press Auto or Single to
resume the part program and most cycles that were manually started by the
operator (such as Chip Auger or Conveyor).
• Single - provides access to the Single Cycle screen. In this mode, the
machine stops the axes after each automatic operation. In Conversational
Programming the machine halts (with the spindle running) after each hole
operation, contour segment, or milling subroutine. For NC Programming, the
machine halts with the spindle running after each data block is executed.
Pressing the flashing Start Cycle button causes the automatic machining
operation to resume. For information on the Single Cycle screen softkeys, see
the Auto Mode, on page 1 - 160 section. The softkeys are the same on both
screens.
• Test - provides access to perform a program test run to identify potential
problems before cutting the part. For more information, see Auto Mode, on
page 1 - 160.
• Manual - provides access to manual machine operations that allow axis
positioning with the jog unit. See Manual Safety Override Mode, on page 1 -
134 for more information.

Stop Motion
If you observe a problem during the cutting process or simply want to stop the machine
to make some adjustments, you may press one of three buttons to stop motion:

• Feed Hold—stops all axes movement (except a tapping operation in

progress), when the tool is in the programmed feedrate region. Pressing the
button a second time allows machine positioning to resume without loss of
position, provided no other button or key has been pressed.
• Interrupt Cycle—halts machine operation during automatic execution of a
program to allow manual functions such as cleaning the work piece. Pressing
the Interrupt button performs the following actions:
1. Stops all motion except the spindle.
2. Pulls the tool straight up and out of the part.
3. Stops the spindle.
4. Displays the manual screen on the console.

1 - 18 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
To restart the part program, press the Auto button followed by the Start Cycle button.

If any key other than the Auto button is pressed to restart the
program, the system cancels the execution of the part program.

• Emergency Stop—all motion stops and power is shut off to the spindle,
relay control, and servo systems. An emergency stop message with recovery
instructions appears at the bottom of the text screen. To release an
Emergency Stop button, twist the button in the direction indicated by the
arrows and pull the button up.
After the last choice is selected, the following sequence occurs:

1. A prompt is displayed to press the Start button while the

console Start Cycle button flashes.
2. When the Start Cycle button is pressed, the program
begins running at the specified point of the Start Block.
3. When the specified End Block is reached, the display
indicates that Recovery Restart mode is complete and the
Start Cycle button flashes again.
4. If the Start Cycle button is pressed again, then the
program will rerun using the same Start and End Blocks.

Spindle
• On—activates the spindle if the machine is in manual mode. The Start Cycle
button must also be pushed to start spindle rotation.
• Off—stops spindle rotation during manual operation if the Spindle On button
was previously pressed.

Tool Changer
• Auto—activates the automatic tool changing function. When selected, all
operator-initiated tool changes will be automatic.
• Manual—activates the manual tool changing function. When selected, all
tools must be manually inserted into or removed from the spindle; bypassing
the automatic tool changer.

Coolant
• Auto—activates the selected coolant to spray whenever the tool is below the
Retract Clearance plane. The coolant turns off when the tool moves above
the Retract Clearance plane, or during a tool change. This key cannot be
activated in Manual mode. Pressing this key a second time turns off the
coolant operation.
• Primary—functions only on machines equipped with a primary (i.e., flood)
coolant system. Activates the primary coolant system when the machine is in
Auto or Manual mode, and overrides an Coolant Auto operation. Pressing the
Primary key a second time turns off this operation.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-19
 • Secondary—functions only on machines equipped with a secondary coolant
system (e.g., Coolant Through Spindle, CTS). Activates the secondary
coolant system when the machine is in Auto or Manual mode and overrides
Coolant Auto operation. Pressing the Secondary key a second time turns off
this operation.

Communications Panel
All communication ports are located on the Comm Port panel assembly on machine
control cabinet. The following connectors are available:

Port Connector Type Use

10-base T RJ45 Network (Ethernet)

Indexer 8-pin military Indexer

PORT 1 and Port 2 9-pin RS-232C Serial Communications

USB USB jump drive Not available for use.

The communication ports are typically arranged as follows:

Figure 1–2. Communications Panel

1 - 20 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
RS-232C Serial Port
The RS-232C serial ports can be used to connect peripherals to the machine. These ports
may be addressed separately. The standard baud rates are software-selectable. The ports
can be used as an output or input, depending upon the software.

The connector pin designated for the RS-232C signal is shown below:

Figure 1–3. Male 9-Pin D-Type Connector

While the signals present at the serial port conforms to the RS-232C standard, not all
standard RS-232C signals are available. Some peripheral devices may provide RS-232C
control signals that are not available at the port described here. However, such devices
can usually be adapted to the port. In some cases, it may be necessary to add jumpers to
the connector. Signals available at the serial port are:

Pin Signal Name Signal on the Pin

1 Data Carrier Detect (DCD) Not used by the control.
Receive Data (RXD) Data received (by machine) in serial format from
2
peripheral device.
Transmit Data (TXD) Data transmitted (by machine) to peripheral
3
device in serial format.
4 Data Terminal Ready (DTR) Not used by the control.
Signal Ground (SG) Line establishing the common ground reference
5
potential for all interface lines.
Data Set Ready (DSR) Signal to notify printer that transmitter is ready
6
for transmission.
Request to Send (RTS) Line used by control to instruct peripheral device
to get ready to receive data. Data can be
7
transmitted after the Clear-To-Send signal is
received from connected peripheral device.
Clear to Send (CTS) Control line used by peripheral device to indicate
8
that it is ready to receive data from machine.
Ring Indicator (RI) Signal indicates modem has received the ring of
9
an incoming call.

To connect a peripheral to the machine, fabricate an adapter cable. If a properly shielded

low capacitance cable is used, cable lengths of up to 100 feet are permissible.

Be certain that you use the correct cabling before connecting the device to the machine.
Consult the peripheral manual to determine whether the peripheral is a Data Terminal
Equipment (DTE) or Data Communication Equipment (DCE) device. The Hurco machine is
a DTE device, and in most cases, so is a personal computer. A printer may be either a DTE
or DCE device.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-21
Indexer Port
Indexing signals are always present at the Indexer port, so there is no need to turn it on.
It is the customer’s responsibility to provide a harness from the Indexer to the Indexer
port. Before making this harness, see the Parts Listing and Diagrams Manual for the
correct pin-outs.

Network Port
The 10baseT (RJ45) connector is used with the Ultinet option. This option requires an
ethernet card, cabling from the ethernet card to the communications panel, and an
optikey diskette to enable the option.

USB Port
The USB Port (Universal Serial Bus) is a high-speed port that allows you to connect
devices, such as printers and jump drives to the panel. You can use a jump drive to
transfer files.

1 - 22 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Spindle and Automatic Tool Changers
Hurco machining centers use either a Swing-Arm Random Pocket Automatic Tool Changer
(ATC) or a Horizontal Chain Type ATC. Both types of ATCs function essentially the same.

Each tool is inserted into a tool holder before being loaded into the spindle. The
orientation hole in the tool holder must always line up with the orientation key in the tool
changer. Tool changer stations are numbered to identify and locate each tool.

Only use tools that are dimensioned for the maximum spindle speed.

For machine series-specific ATC information, see Automatic Tool

Changers, on page 1 - 139.

Loading a Tool into the Spindle

Use this procedure to manually load a tool into the spindle:

1. Press the Machine Mode Manual console key to prevent the ATC from moving
while you insert a tool. The Manual screen appears.
2. Touch the Orient Spindle softkey to position the spindle for tool insertion. If
there is a tool in the spindle, refer to Removing Tools from the ATC Magazine,
on page 1 - 25.

3. Insert the tool holder into the spindle. Make sure the tool holder slots align
with the spindle head guides.
4. Release the Spindle Unclamp button to secure the tool in the spindle. Be
certain that the tool is firmly seated.
5. Touch the Tool In Spindle softkey. The Tool In Spindle field appears.
6. Make sure the tool number in the Tool In Spindle field matches the number of
the tool in the spindle. If the numbers do not match, enter the correct tool
number.
7. To load a tool into the ATC magazine, see the Loading Tools into the ATC
Magazine, on page 1 - 24 section.

Unloading a Tool from the Spindle

To manually remove a tool from the spindle, follow these steps:

1. Press the Manual Mode console key. The Manual screen appears.
2. Hold the tool to prevent it from dropping.
3. Press the Spindle Unclamp button. The spindle unclamp button is either on the
side of the spindle, or the front of the spindle. Refer to Parts Listing and Wiring
Diagrams Manual for your machine for a drawing showing the Spindle Unclamp
button location.
4. The tool disengages. Pull the tool out of the spindle.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-23
 5. Release the Spindle Unclamp button when the tool is free.

Loading Tools into the ATC Magazine

The ATC takes a tool from the spindle and automatically loads it into the magazine, if
space allows. The tool’s location in the magazine is recorded in the ATC Map (the
Horizontal Chain Type ATC does not use an ATC Map). Before loading a tool into the ATC
magazine, the Servo power must be On, and the machine must be calibrated.

Do not manually load tools directly into the magazine.

To load the tool currently in the spindle into the ATC magazine:

1. Press the Manual Mode console key.

2. Select the Tool Management softkey. The Spindle tab displays the Tool in
Spindle, Next Tool, and ATC Map (Swing-Arm Random Pocket ATC only) fields
appear.
3. Verify that the Tool In Spindle value matches the tool currently in the spindle.
If the numbers do not match, enter the correct tool number.
4. Enter the same tool number into the Next Tool field.
5. Press the Tool Changer Auto console key.
6. Enter a new tool number into the Next Tool field. The ATC Map field must be
Auto.
7. Press the Tool Changer Auto console key. The Start Cycle light begins flashing.
8. Clear the tool changer and shut the enclosure door. Press the Start Cycle
button. The Tool In Spindle field will be updated to the next tool value.
• If the Next Tool is an Auto tool, it was placed into the magazine when the
previous tool was removed from the spindle.
• If the Next Tool is a Manual tool, you will be prompted to insert it into the
spindle.

1 - 24 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
Removing Tools from the ATC Magazine
Remove tools from the ATC magazine by following these steps:

1. Press the Manual Mode console key.

2. Select the Tool Management softkey to display the Tool in Spindle. If there is
no tool in the spindle, set the Tool In Spindle field to 0 (zero).
The ATC Map field will indicate if the tool selected is in the magazine,
and its location.

3. Enter the tool number (of the tool you want to remove in the magazine) into
the Next Tool field.
4. Press the Tool Changer Auto console key to move the Next Tool into the
spindle.
5. Clear the tool changer area and shut the enclosure door. Press the Start Cycle
button to initiate the tool change.
6. Press the Spindle Unclamp button and manually remove the tool from the
spindle.
7. Repeat steps 2 through 6, as needed, to remove additional tools from the ATC
magazine.

Large Tools in the ATC Magazine

A part program may require tools with large diameters. These tools can be manually
loaded by the operator, or automatically loaded.

The ATC magazine capacity is reduced by half for tools larger than 80
mm (125 mm for some machines).

Follow these steps to load large tools into the ATC magazine:

1. Touch the ATC Map softkey from the Spindle screen. The ATC Map appears.
2. Touch the Max. Tool Dia. More than XX mm softkey.
3. An “ATC Map will be cleared! Are you sure you want to change Max. Tool
Diameter to more than XX mm?” message appears.
Each time you switch between large and small tools, the entire ATC
Map will be cleared and the magazine must be reloaded.

4. Select the Yes softkey. The ATC Map will clear, then reappear. Only the odd
numbered tool pockets will be available.
5. Reload tools into the magazine using the “Loading a Tool into the Spindle”
section.
6. Return to the default setting of Maximum Tool Diameter XX mm or Less by
using the previous procedure and touching the Max. Tool Dia. XX mm or Less
softkey.

Getting Started with WinMax Mill 704-0116-501 Machine and Console Basics 1-25
1 - 26 Machine and Console Basics 704-0116-501 Getting Started with WinMax Mill
PROGRAM MANAGER
These topics are discussed in this section:

Managing Program Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 33

Program Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 39
Disk Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 40
FTP Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 41

Managing Program Files

Program Manager shows all part programs that are in the control’s memory to edit or run.
Use the Program Manager menu to create, open, save, and close programs. Features of
the Program Manager include:

• Ability to load more than one program at a time.

• Ability to load Conversational and NC programs at the same time.
• Ability to copy blocks from one program into another (blocks are copied in
Program Review; Program Manager is used to switch between programs to
facilitate copy and paste).

Program in use lock

Unsaved programs
Program storage location

List of programs

Snapshot of part

File type
and description

Figure 1–1. WinMax Program Manager

Getting Started with WinMax Mill 704-0116-501 Program Manager 1-27

 Sort the program list by Program Name or Path by selecting the
corresponding header. Select the Program Name header once to sort
the list alphabetically. Select the Program Name header again and
sort the list in reverse alphabetical order.

Program Manager softkeys are:

• New—creates a new part program. Choose the program type by selecting

one of these softkeys:
• Conversational Program—creates a new conversational part program.
• NC Program—creates a new NC part program (extensions for NC part
programs are determined by the NC dialect set in User Preferences. The
.NC extension is also supported.).
• Job List—creates a new job list (.HJL file extension). See Job Lists, on
page 1 - 37.
WinMax gives new programs the default name NONAME (for
example, NONAME1.HWM). When new programs are created, they
should be renamed with a suitable name and be saved to the hard
drive or other media.

• Open—opens a part program that is saved to the hard drive, network drive,
floppy disk, or USB memory device. The Load Program screen opens, where
you can locate the program from the list, as in the following example:

3. Select to
open
1. Select folder

2. Select
program
file

Figure 1–2. Load Program screen

To find a program, navigate through the folders in the left pane by selecting
“+” or “-” to expand or collapse. Select a folder to view its contents in the
right pane.

1 - 28 Program Manager 704-0116-501 Getting Started with WinMax Mill

 Sort the program list by File, Size, or Date by selecting the
corresponding header. Programs with the same date will be sorted
alphabetically.

Select the File header once to sort the list alphabetically. Select the
File header again to sort the list in reverse alphabetical order.

Files with the same name may be loaded into Program Manager if
they are saved in different locations. If an attempt is made to load a
file that has the same name and same location as a file already
loaded into Program Manager, a message appears confirming that
the file should be loaded again. If YES is selected the file will be re-
loaded and any unsaved changes will be lost.

HD3 and XML1 files will be listed with .HWM extension in Program
Manager. HWM is Hurco’s conversational program file type. SAVE AS
must be used to re-save the program as HD3. Using SAVE will save
the program with the HWM extension. Programs cannot be saved
with the .XML1 extension.

• Load—opens an HWM, NC, or XML1 file.

• Import—opens an HD3 file.
• Stream Load—optimizes memory utilization for loading and running NC
program files that are too big to be stored in memory. The NC program
loads as it is run. This method should be used only when you want to run
the program; the file cannot be edited or drawn when opened this way.
Only one NC file can be loaded at a time using Stream Load.

Programs loaded with Stream Load must be re-loaded each time WinMax
is shutdown. In addition, files cannot contain NCPP calls, and subroutines
cannot be in the same file.

• Save—saves the current part program to a hard drive, network drive, floppy
disk, or USB memory device. If the program has a path indicated in Program
Manager, it will be saved to the same location.

Hurco recommends the following storage areas in My Computer:

• 3½ Floppy (A:)
• PART_PROGS (D:)
• USB Device (E:)
• My Network Places (if the UltiNet option is installed)

Programs cannot be saved to the root level of the My Computer or

My Documents directories. You must open these to see the directory
listing before you can save to these areas.

• Save As—allows the current part program to be saved with a different name,
as a different file type, or in a different location. Also used to save files with
the default NONAME program name. Type the program name in the File Name
box and select the file type, as in the following example:

Getting Started with WinMax Mill 704-0116-501 Program Manager 1-29

 To rename a program, highlight the entire name in the FILE NAME field and
type or use alpha/numeric console keys to replace the name. To modify
character(s) in the name, highlight the name, select again in the field, and
use the cursor keys, delete, and the alpha/numeric keys to change the name.
When the filename is completely highlighted, the filename extension does not
have to be re-entered; the extension selected in the SAVE AS TYPE field will
be added to the name entered in the FILE NAME field.

For Conversational programs, the following file types are available from the
Save As Type drop-down list:

• .HWM—WinMax Mill conversational format

• .HD5—WinMax Desktop conversational format (desktop only)
• .HD3—Ultimax conversational format

To save as an HWM file, select the Save softkey.

To save as an HD3 (or HD5) file, select the Export softkey.

For NC programs, SAVE AS will default extensions to the selected NC dialect,

either FNC (ISNC) or HNC (Basic NC). If another extension is desired, include
the extension with the filename in the FILE NAME field. For example,
SAMPLE. NC.

The job list extension is .HJL.

• Close—opens a menu to close selected program or all programs.

• Program Properties—stores properties for the selected part program.
• Disk Operations—opens the Disk Operations screen to browse available
folders and files, and cut, copy, paste, rename, and delete files.
• FTP Manager—displays external network connections (with the Ultinet
option).

1 - 30 Program Manager 704-0116-501 Getting Started with WinMax Mill

Job Lists
A job list is a collection of programs, or “jobs,” that run sequentially to complete a part.

A job list is made up of jobs. A job can be a single file or it can be made up of several
files; for example, a job might be a Conversational program and the NC programs that
are called in it using NC/Conversational Merge.

Job list files have the file extension .HJL. To create a new job list:

1. Select the Job List softkey on the Program Manager New Program screen. A
new program with the .HJL extension is added to the program list. See also
Managing Program Files, on page 1 - 33.
2. Select the Save As softkey and type a name in the File Name field. Select the
Save softkey.
3. Open the new .HJL file. The Job List screen opens.
4. Type a name for your Job List in the Name field and press the Enter key.
5. Select Add Job softkey. The Job screen opens.
6. Type a name for your job in the Name field and press the Enter key.
7. Select the Select Files to Add softkey. The Program Manager screen opens
where you can select the files for your job.
8. Repeat steps 5-7 for as many jobs and files as you want to add.
Individual program files must be programmed and saved prior to
being added to a Job List.

Here is a sample job list:

Use the Add Job softkey to open a job

screen.

Use the Remove Job softkey to remove a

job from the job list.

Use the Edit Job softkey to edit a job.

Use the Move Job Up and Move Job

Down softkeys to rearrange the job order

The Start Cycle setting controls how the job files are run:

• Once Per Job—Start Cycle console button must be pressed to repeat the
job.
• Once Per List—Start Cycle console button must be pressed to repeat the full
list.
• Continuous Loop—Job List continuously runs in a loop without the need to

Getting Started with WinMax Mill 704-0116-501 Program Manager 1-31

 use the Start Cycle button.
The Force File Reload setting, when Yes, specifies that any previously loaded file will
be closed and reloaded before it is run as a part of the job list. This is useful if any
program information is dynamically changed while running and needs to be reloaded to
take effect.

From the Job List screen, you can select a job to view or edit.

Here is sample job that contains an NC program and the NC state file:

Use Add File to Job softkey to enter a

file path to add a new file to the job.
OR
Use Select Files to Add softkey to
browse for files in Program Manager.

Use the appropriate softkeys to edit the

file path, remove a file from the job, or
change the order of the files in the job.

Running the Job List

Job lists are executed from the Auto screen. Partial program runs can be specified using
the Start Job and End Job fields.

Recovery Restart is supported with job lists. If machine operation is interrupted:

• during an NC program run, the NC Editor restart screen opens so the restart
marker can be set.
• during a Conversational run, the Auto screen opens so the block range and
restart operation can be set.

1 - 32 Program Manager 704-0116-501 Getting Started with WinMax Mill

 Drawing is disabled when a Job List is the active file.

Program Properties
Program properties store and manage properties for the selected part program.

See the Field Glossary for definitions of the Program Properties fields:

Description

Display Units

Material

Name

Path

Program Type

Write Protection

Getting Started with WinMax Mill 704-0116-501 Program Manager 1-33

Disk Operations
Disk Operations displays available directories and files. Cut, copy, paste, rename, and
delete program files from Disk Operations.

See also:

Managing Program Files, on page 1 - 33

Import / Export Functions, on page 1 - 127

NC States, on page 1 - 127

Retrieve Log and Diagnostic Files, on page 1 - 59

Directory Window Files Window

Figure 1–3. Disk Operations

When a directory is highlighted in the Directory window, the softkeys are:

• Cut Directory—deletes the directory from one location to be pasted into

another location
• Copy Directory—makes a copy of the directory (but does not delete) to be
pasted into another location
• Paste Into Directory—pastes the directory or file that has been cut or
copied. For example, to copy a directory and paste it into a new location:
1. Highlight the directory you wish to copy.
2. Select the COPY DIRECTORY F2 softkey.
3. Highlight the folder in which you wish to place the copied directory.
4. Select the PASTE INTO DIRECTORY F3 softkey.

1 - 34 Program Manager 704-0116-501 Getting Started with WinMax Mill

 • Create Directory—creates a new directory.
• Rename Directory—renames a directory.
• Delete Directory—removes the directory.
• FTP Manager—displays the external network connections (with Ultinet
option).

When a file is highlighted in the Files Window, the softkeys are:

• Cut—deletes the file from one location to be pasted into another location.
• Copy—makes a copy of the file (but does not delete) to be pasted into
another location.
• Paste—pastes the file that has been cut or copied. For example, to copy a file
and paste it into a new location:
1. Highlight the file you wish to copy.
2. Select the COPY F2 softkey.
3. Highlight the folder in which you wish to place the copied file.
4. Select the PASTE F3 softkey.
• Rename—renames the file.
• Delete—removes the file.
• Load—loads the file into the Program Manager.
• FTP Manager—displays the external network connections (with Ultinet
option).

FTP Manager
FTP Manager allows you to transfer programs from a remote location (host), such as a PC
or machine, to a local PC or another machine, using the UltiNet option. See WinMax Mill
Options for more information.

Getting Started with WinMax Mill 704-0116-501 Program Manager 1-35

1 - 36 Program Manager 704-0116-501 Getting Started with WinMax Mill
UTILITIES
Utilities are accessed with the Auxiliary console key. Select the Auxiliary console key and
this window with softkey selections appears on the screen:

Figure 1–1. Auxiliary Screen

Use the softkeys on the Auxiliary screen to navigate to other parts of WinMax Mill. Also
toggle the Edit Lockout feature on and off with the Toggle Edit Lockout State softkey.
See Edit Lockout, on page 1 - 46 for more information.

Select the Utility Screen softkey to access the Utility screen. These functions are
available and are described in this section:

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 44
User Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 45
Additional Utilities Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
Printing Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 53
Integrator Support Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 56
Serial I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 57
Log Files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 57

Getting Started with WinMax Mill 704-0116-501 Utilities 1-37

System Configuration
The SYSTEM CONFIGURATION softkey on the Utilities screen displays machine, control,
and software information. Softkeys on the System Configuration submenu are:

• WinMax Configuration—changes WinMax configuration settings.

• Machine Specifications—changes machine specifications.
• Backup Config & Machine Files—copy Configuration and Machine files to a
directory or to a USB memory device or floppy disk.
• Restore Config & Machine Files—use saved files to overwrite existing
Configuration and Machine files.

WinMax Configuration
The WinMax Configuration softkeys are:

• Software Version—displays the current version of WinMax Mill.

• Software Options—displays the current software options. An option can be
toggled on or off using the Enable Selected Option and Disable Selected
Option softkeys; the option state is displayed as Installed or Disabled.
• Motion Configuration—displays the current motion system.
• Ladder File Configuration—Ladder files bridge communication between the
machine and the software. The current version of the Ladder files on the
machining center, the total number of Ladder files, and any mismatched
Ladder files that may cause a software conflict are displayed.
• Language File Configuration—displays the language files.
• WinMax IP Address—displays the current IP address of the CNC.

Machine Specifications
Displays specific information about the machining center that was entered during
software/machine installation.

See the Field Glossary for definitions of the Machine Specifications fields:

Machine Class Minus/Plus A/B/C Direction Travel Limit

Machine Hour Meter Minus/Plus X/Y/Z Direction Travel Limit

Maximum Contouring Rate Number of Axes Present

Maximum Rapid Traverse Rate Vertical/Horizontal

Maximum Spindle Motor Speed

Maximum Spindle Tool Speed

1 - 38 Utilities 704-0116-501 Getting Started with WinMax Mill

Backup Config & Machine Files
Backup files can be used to restore corrupted Configuration and Machine files on the hard
drive. Select this softkey and choose the location to copy the files. Backup files can be
copied to any directory on the hard drive or to a USB memory device or floppy diskette.

Restore Config & Machine Files

Select this softkey to use saved Configuration and Machine files to overwrite existing files
stored on the hard drive.

User Preferences
WinMax software can be modified to change how certain information is displayed or
calculated. For example, certain interface elements, Conversational and NC settings,
machine parameters, and languages can be modified.

Select the User Preferences softkey on the Utilities screen to access to the following:

• User Interface Settings, on page 1 - 46

• Conversational Settings, on page 1 - 48
• NC Settings, on page 1 - 48
• Autosave Settings, on page 1 - 49
• Tool Utilities and Settings, on page 1 - 49
• Machine Parameters, on page 1 - 61
• Serial Port Settings, on page 1 - 50
• FTP Server Settings, on page 1 - 50
• Rotary Axes Parameters, on page 1 - 51
• WinMax Uptime, on page 1 - 50
• Select Language, on page 1 - 52
• Data Logging Filters, on page 1 - 52
• Advanced, on page 1 - 53

User Preference settings can be saved to a file for backup purposes using the Export
User Preferences button. When this button is selected, the file manager screen opens.
Select a location to save the backup file (filename.setx), then select the Export softkey.
The current user preference settings are saved in this file.

To import saved user preference settings use the Import User Preferences button.

Settings can be restored to factory defaults with the Reset User Preferences button.

Integrator Parameters, Machine Parameters, Rotary Axes

Parameters, and FTP Host cannot be backed up or restored.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-39

User Interface Settings
User Interface Settings change the screen display.

See the Field Glossary for definitions of the User Interface Settings:

Application Font Size Screen Configuration

Edit Lockout Level Screensaver Timeout

Edit Mode Show All File Types

Enable Program Restore Softkey Menu Position

List Icon Size Swap Screens

Edit Lockout
The Edit Lockout feature limits access to certain program functions and screens. Partial
and Full lockout levels are available. Partial lockout prevents changes to the part
program, while Full lockout prevents changes to the program as well as to setup
information. Refer to the table below for a complete listing of features that are affected
by partial and full lockout.

Edit Lockout is enabled or disabled with the Toggle Edit Lockout State softkey located
on the Auxiliary screen. When the softkey is selected, a pop-up box appears prompting
for the password. Enter the password and select OK. The Edit Lockout feature is enabled
(or disabled if it was previously enabled), and a confirmation message appears.

Set Edit Lockout Level to Partial or Full on the User Interface Settings screen:

1. Select the Auxiliary console key. The Auxiliary screen opens.

2. Select the Utility Screen softkey.
3. Select the User Preferences softkey.
4. Select the User Interface Settings softkey. Select Partial or Full in the
Edit Lockout Level field. When Partial is selected, you can also lock out Part
Setup and/or Tool Setup.

When the cursor is in the Edit Lockout Level field, the Change Lockout
Password softkey is available. The first time the feature is used, the
password should be reset from the factory default. This password is
required to enable and disable Edit Lockout.

You will be redirected to the Input screen if you are on a screen that
becomes locked out when you enter the password.

1 - 40 Utilities 704-0116-501 Getting Started with WinMax Mill

Here are the features locked with Edit Lockout:

Feature Partial Full

Part Programming Locked Locked

Program Parameters Locked Locked

Program Review: Multiple Block Locked Locked

Functions (Copy, Paste, Insert, Delete)

Copy/Change Blocks Locked Locked

Erase Functions Erase Part Program and Parameters Locked

locked

Capture Feeds and Speeds (Auto) Locked Locked

DXF Locked Locked

DB Search / Block Jump Locked Locked

Jump to Block (from Error Message) Locked Locked

Import Functions Import Part Program and Locked

Parameters locked

Part Setup Depends on setting Locked

Work Offsets Accessible with Part Setup access Locked

Tool Setup Depends on setting Locked

Tool Setup: Feeds and Speeds When Tool Setup is accessible, feeds Locked
and speeds are updated, but data
blocks that use the tools are not.

Tool Offsets Accessible with Tool Setup access Locked

Part Program Tool Review: Match Accessible with Tool Setup access Locked
Tools, Add Unmatched Tool

User Preferences Accessible Locked

Probing Cycles Accessible Locked

Part Counter Accessible Locked

Fields or softkeys appear grayed out and are not accessible when
lockout mode is enabled. In cases where an entire screen is locked
out, you will be redirected to the Input screen.

Additional Edit Lockout considerations:

• Runtime modifications—Edit Lockout does not prevent a running program

from modifying setup or itself. For instance, if the program uses part or tool
probing blocks or macros that manipulate program variables or part or tool
setup directly, this is allowed.
• Recovery Restart—Recovery Restart is enabled in both conversational and NC
modes when Edit Lockout is enabled. Access to the NC Editor is allowed in

Getting Started with WinMax Mill 704-0116-501 Utilities 1-41

 this case in order to set the restart marker, but text entry and all softkeys
that allow modification of the program (for example, Cut and Paste) are
disabled.
• Overrides—Speed/Feed overrides are controlled by the Override Lockout
parameter in Program Parameters General 1 tab. Since Program Parameters
are not accessible in Partial or Full lockout mode, Override Lockout should be
set to ON so overrides cannot be adjusted while running the program.

Conversational Settings
Conversational Settings control certain aspects of Conversational programming.

See the Field Glossary for definitions of the Conversational Settings:

Check Calc Assist Inconsistencies Math Assist Style

Data Block Tool Entry Feed and Speed Warn Before Saving in Old Format
Update

Default Conversational Program Type

Display Machine Axes For Universal Type

HD3 Save Program Type

NC Settings
NC Setting control certain aspects of NC programming.

See the Field Glossary for definitions of the NC Settings:

BPRNT/DPRNT Output Device Exported NC Decimal Places

BPRNT/DPRNT Output File NC Dialect

Custom NC File Extensions NC Display Type

Diameter Compensation Using Tool Setup Save NC State with Program

Disable Tool Length Offset Table

NC Variable Monitoring settings:

Enable Reset at Program Start

Enable Variable Monitoring

Monitored Variable Number

Variable Reset Value

1 - 42 Utilities 704-0116-501 Getting Started with WinMax Mill

Autosave Settings
Specify Yes or No to enable automatic saving of part programs. When set to Yes, you can
specify the frequency and whether to save the active program only.

See the Field Glossary for definitions of the Autosave Settings:

Enable Automatic Save

Save Active Program Only

Save Frequency

Tool Utilities and Settings

The Tool Utilities and Settings screen is accessed from Utilities/User Preferences. Fields
vary dependent on whether the Tool and Material Library option is loaded.

See the Field Glossary for definitions of the Tool Utilities and Settings:

General tab
Replace In Files

Tool Calibration Mode

Update Data Blocks With Tool Changes

Use Tool Type Checking

Matching tab
Automatically Load Unmatched Tools As Manual

Enable Automatic Matching

Overwrite Existing Zero Calibration

Maximum Diameter Difference

Life Monitoring tab

Enable Tool Life Monitoring

Max Tool Cutting Time Exceeded

Reset Cutting Time on Tool Data Change

The Life Monitoring tab is not displayed if the Tool & Material
Library option is not installed.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-43

Serial Port Settings
Serial Port Settings allows you to set Port 1 and Port 2 settings for protocol, baud rate,
character length, stop bits, and parity. The following fields appear on the Serial Port
Settings screen. Refer to your hardware documentation for your equipment’s specific
settings.

See the Field Glossary for definitions of the Serial Port Settings:

Baud Rate

Character Length

Parity

Protocol

Stop Bits

FTP Server Settings

The WinMax console can serve as an FTP Server. For more information refer to Using FTP,
on page 6 - 8 in Extended Shop Floor.

See the Field Glossary for definitions of the FTP Server Settings:

Enable FTP Server

FTP Server Port

Maximum Idle Time (Mins)

Password

Path

User Name

WinMax Uptime
The WinMax Uptime screen displays the start date time and runtime for the current
session of Winmax.

1 - 44 Utilities 704-0116-501 Getting Started with WinMax Mill

Rotary Axes Parameters
Set the General Rotary Axes Parameters on this screen.

See the Field Glossary for definitions of the Rotary Axis Parameters:

Part Kinematics Z Reference

Rotary Axis ISO Standard

Tilt Axis Preference

Set the specific A, B, C axes parameters (depending on configuration) by selecting the

A/B/C Axis softkeys.

Automatic Centerline Calculation

Machine Coordinate Relative

Rotary Centerline X/Y/Z

For dual-zone machines, parameters can be set for each zone, on the Zone 1 and Zone 2
tabs.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-45

Select Language
Select and register a language on the Language Selection screen:

1. Select a language from the list.

2. Press the Load Language softkey to install the Language files. You can also
press the F1 key to perform this function. The selected language is shown in
the Current Language field.

Language Quick Toggle

You can toggle between two languages from any screen in WinMax using the Language
Quick Toggle feature. To set the primary and secondary languages, highlight a language
in the list and select the Set as Toggle Language 1 (for primary language) or Set as
Toggle Language 2 (for secondary language). The selected languages are shown at the
top of the screen:

Figure 1–2. Language Selection screen

Use Ctrl+L on the keyboard (or virtual keyboard) to switch back and forth between the
languages on any screen in WinMax.

Data Logging Filters

Used for diagnostic purposes only.

1 - 46 Utilities 704-0116-501 Getting Started with WinMax Mill

Advanced
Used for service purposes; requires a password to access.

Additional Utilities Softkeys

• Printing Setup—set printing preferences for program blocks, range of
program blocks, program parameters, part setup, and tool setup.
• Integrator Support Services—for diagnostics and machine configuration;
password required for access.
• Restart Control—exits all control operations, powers down, then restarts
machine and control.
• Shutdown Control—exits all control operations and powers down machine.
• Serial I/O—to begin read/write program operations using screenport 1 or 2.
• Log Files—displays error and status messages that have occurred during
normal operation.

Printing Setup
The Printing Setup F3 softkey on the main Utilities screen provides access to the following
printing functions:

• Part Program Printing—print part program elements.

• Tool Information Printing—print the Tool Library or save it to file.
• Probing Data Printing—print probing part inspection files.
• Serial Numbers Printing—print a report that lists used Serial Numbers.

Part Program Printing

In the Part Program Printing screen you can choose to print some or all of the following
elements:

• Program Blocks (all or a range)

• Program Parameters
• Part Setup
• Tool Setup

After checking the desired elements, select the PRINTING F3 softkey. A pop-up window
appears that contains the selected data. The information can be viewed by selecting the
heading to expand the section; select the heading again to hide the information. The
following softkeys appear in the pop-up window:

Getting Started with WinMax Mill 704-0116-501 Utilities 1-47

 • Print Preview—displays the part program information as it will appear when
printed.
• Print—sends the information to the printer.
• Save As—saves the information as a text file to an external drive.
• Close—closes the pop-up window.

Tool Information Printing

Tool Information Printing is available only with the Tool and Material
Library option.

The TOOL INFORMATION PRINTING F6 softkey on the Tool Utilities and Settings screen
allows you to view and print tool information for all tools saved in the Tool Library:

Print tool list

Save tool list

Figure 1–3. Tool Information and Printing

Select the PRINT button on the Tool Information pop-up to print a list of tools and
settings, as in the following example:

ATC
Tool Number: 23
Tool Type: Ball End Mill
Tool Diameter is 0.0938 inches.
Tool length is 0.5625 inches.
Length of cut is 0.4688 inches.
Number of flutes is 0 inches.
Direction of Spindle Rotation is Clockwise.
Helix Angle is 0°.
Shank Diameter is 0.0938 inches.
Apt Gear Ratio is 1.

1 - 48 Utilities 704-0116-501 Getting Started with WinMax Mill

Apt Tool Number is 1.
Apt Diameter Offset is 1.
Apt Length offset is 1.
Simulation Color is SEQUENTIAL.

MTC
Tool Number: 1
Tool Type: Drill
Tool Diameter is 0.031 inches.
Tool length is 5 inches.
Length of cut is 5 inches.
Number of flutes is 0 inches.
Direction of Spindle Rotation is Clockwise.
Drill Angle is 118.000000°.
Helix Angle is 0°.
Shank Diameter is 0.031 inches.
Apt Gear Ratio is 1.
Apt Tool Number is 1.
Apt Diameter Offset is 1.
Apt Length offset is 1.
Simulation Color is SEQUENTIAL.

Tool Number: 20
Tool Type: Cutting Tap
Tool Diameter is 0.216 inches.
Tool length is 1.296 inches.
Length of cut is 1.08 inches.
Tap Direction: Right Hand.
Tap Chamfer: Bottoming.
Thread Pitch is 0.0417 inches.
Thread Diameter is 0.216 inches.
Helix Angle is 0°.
Flute Style: Spiral Flute.
Shank Diameter is 0.216 inches.
Apt Gear Ratio is 1.
Apt Tool Number is 1.
Apt Diameter Offset is 1.
Apt Length offset is 1.
Simulation Color is SEQUENTIAL.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-49

Probing Data Printing
When Probing Part Inspection files are generated, they are saved to the same location
and with the same filename as the part program with a .TXT filename extension. For
example, the Part Inspection file for the program SAMPLE.HWM is SAMPLE.TXT. Part
Inspection files are printed from the control using the PROBING DATA PRINTING softkey:

1. Select the PRINTING SETUP F3 softkey from Utilities.

2. Select the PROBING DATA PRINTING F3 softkey.
3. Locate the Part Inspection file from the Locate Probing Data Files screen.
4. Select the PRINT F1 softkey to print the file.
Subsequent Part Inspection data from the same part program is
appended to the existing Part Inspection file for that program.

Serial Numbers Printing

You can print a report that lists the Serial Numbers already used in the part program:

1. Select the Printing Setup softkey from Utilities.

2. Select Serial Numbers Printing softkey.
3. The report is displayed in a pop-up window. Select the Print softkey.

Integrator Support Services

The Integrator Support Services screen requires a password to
access and is for Hurco Certified Technicians’ use in configuring and
setting up the machine.

1 - 50 Utilities 704-0116-501 Getting Started with WinMax Mill

Serial I/O
Two serial ports are available on the control. The Serial I/O screen contains Status and
Bytes Transferred fields for both ports. In addition, there are read, write, and abort
softkeys for both ports.

These are the fields on the Serial I/O screen:

• Status—status of serial port.

• Bytes Transferred—number of bytes transferred.

These softkeys are available on the Serial I/O screen. Duplicate sets of fields and softkeys
are available on the Serial I/O screen for Port 1 and Port 2.

• Begin Reading from Port—brings up 2 softkey choices: READ NC FROM

PORT and READ CONV FROM PORT to identify the program format to read.
• Begin Writing to Port—writes the program to the port.
• Abort Port Operation—halts the read or write operation for the port.

Log Files
WinMax provides two log files that are accessed with the Log Files softkey, as well as
status and error listings:

• Active Error Listing, on page 1 - 57

• Active Status Listing, on page 1 - 58
• Error History, on page 1 - 58
• Status History, on page 1 - 59
• Retrieve Log and Diagnostic Files, on page 1 - 59
• Export Log, on page 1 - 60

Active Error Listing

WinMax provides a list of the most recent error messages displayed, up to a maximum of
200 messages. Review messages when troubleshooting or to determine if a problem
recurs.

These are the softkeys on the Active Error Listing screen:

• Previous Page F1—displays the error messages on the previous page of the
Active Error Listing.
• Next Page F2—displays the error messages on the next page of the Active
Error Listing.
• Clear All F4—clears all error messages from the Active Error Listing.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-51

Active Status Listing
The Active Status Listing screen displays current machine status messages. Each item
will include time/date stamp, language file, language file index and the machine status
message currently active in the system. Examples are messages such as “MOTION HOLD
HAS BEEN DEPRESSED,” or “LOW LUBE LEVEL.” As each status changes back to a normal
state, it will be removed from the list (see Status History, on page 1 - 59).

Example:

10:53:39, STATUS.WRC, 32

CHIP DOOR(S) OPEN.

These are the softkeys on the Active Status Listing screen:

• Previous Page F1—displays the status messages on the previous page of

the Active Error Listing.
• Next Page F2—displays the status messages on the next page of the Active
Error Listing.
• Clear All F4—clears all status messages from the Active Status Listing.

Error History
The Error History screen displays a list of all system errors since the last power up (see
Active Error Listing, on page 1 - 57). A plus sign “+” indicates when the error occurred
and a minus sign “-” indicates when the error was cleared.

Examples:

Error occurred:

10:53:40, ERROR.WRC, 110, +

SERVO FAULT – Z AXIS.

Error cleared:

10:57:32, ERROR.WRC, 110, -

SERVO FAULT – Z AXIS.

The history will also display part program errors generated during programming
(interpreter errors). These errors will not display in the Active Error Listing since they are
transient.

Example:

11:39:21, COMPILER.WRC, 3, +

ERROR IN BLOCK 1: TOOL 1 IS AN INVALID TOOL NUMBER.

1 - 52 Utilities 704-0116-501 Getting Started with WinMax Mill

Status History
The Status History screen displays a list of all system messages since the last power up
(see Active Status Listing, on page 1 - 58). A plus sign “+” indicates when the status
went active and a minus sign “-” indicates when the status returned to normal.

Examples:

Status went active:

10:53:39, STATUS.WRC, 32, +

CHIP DOOR(S) OPEN.

Status returned to normal: Log F

10:54:27, STATUS.WRC, 32, -

CHIP DOOR(S) OPEN.

Retrieve Log and Diagnostic Files

When the Retrieve Log and Diagnostic Files softkey is selected, a file manager screen
opens with access to Log and Diagnostic files. Directories are displayed in the left pane;
these include AtcMapLog, Communications, DumpFiles, NavErr, NavTap, NavESTOP,
Profiles, ScreenCaptures, and ThreadMonitor. Select a directory to see its contents (the
files) displayed in the right pane. To help distinguish between files, the date is included in
the filename.

When it is necessary to copy certain files for service purposes, follow these steps:

Due to the large size of some of the files, it is recommended to copy

them from the Hurco machine to a USB flash memory device.

1. Attach the USB flash memory device to the external connector on the
communications port on the machine.
2. Select the appropriate directory from the left-hand pane and select the file(s)
you wish to copy from the right-hand pane.
3. Select the COPY softkey.
4. In the left-hand pane, select the USB flash memory device (will probably
indicate it is E drive in parentheses).
5. Select the PASTE softkey. The files are now on the USB flash memory device,
and can be transferred to a PC to be emailed.

Getting Started with WinMax Mill 704-0116-501 Utilities 1-53

Export Log
The Export Log displays data that is lost or changed when a program is exported from
WinMax (.HWM) to another format (.HD3, .FNC, etc.). Each time a program is exported
from .HWM to another format, the data from the most recent export is displayed and the
older data is erased.

These are the softkeys on the Export Log screen:

• Previous Page F1—displays the previous page if log is longer than one
page.
• Next Page F2—displays the next page if log is longer than one page.
• Clear All F4—erases all information from the Export Log.

1 - 54 Utilities 704-0116-501 Getting Started with WinMax Mill

MACHINE PARAMETERS
The Machine Parameters screens list various parameters, the range of values that can be
set for each parameter, and the current set or default value. The values of the Machine
Parameters may be changed by the operator.

The machine, part, and/or tool may be damaged if parameters are

changed without understanding the machine operation that may be
affected by the change.

The fields that will be displayed on the Machine Parameters screens are dependent upon
machine type. The values shown on the following screen figures are the default factory
settings for HTX and VTX series machines.

Follow these steps to access the Machine Parameters screens:

1. Select the AUXILARY console key.

2. Select the Utility Screen icon.
3. Select the User Preferences softkey.
4. Select the Machine Parameters softkey.

Machine Parameters Page 1, on page 1 - 62

Machine Parameters Page 2, on page 1 - 65

Machine Parameters Page 3, on page 1 - 69

Machine Parameters Page 4, on page 1 - 76

Machine Parameters Pages 5 and 6, on page 1 - 78

Estimated Run Time Parameters, on page 1 - 79

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-55

Machine Parameters Page 1
Parameter Description Range Default

Control Power Off Turns the control off after the specified 0-255 120
Time period of inactivity. minutes

UPS Software Sets the number of minutes the 1-20 1 min

Shutdown Off Time system will wait before it shuts down
after a power loss condition has been
detected.

Enable Retract Z- Enables Z-axis retract upon power 0 (disable) 0

Axis on Power Loss loss, when an M91 is present. 1 (enable)

Auto Balance Enable Adjusts the balance between the 0 (disable) 1

motion card and the servo drives at 1 (enable)
the start of calibration and run
program.

Disable Auto On Disables chip conveyor from turning on 0-1 0

Chip Removal automatically in AUTO mode.

Chip Removal On/ Enables the Chip Removal Delay. 0 (disable) 0

Off Delay Enable 1 (enable)

Chip Removal On Sets the time the chip conveyor/auger 0-9999 0

Delay Time cycles on, when Chip Removal On/Off seconds
Delay is enabled.

Chip Removal Off Sets the time the chip conveyor/auger 0-9999 0
Delay Time cycles off, when Chip Removal On/Off seconds
Delay is enabled.

Enable Dual Zones Sets a dual-zone capable machine as 0 (1 zone - 1

either a single long bed machine, or as long bed)
a dual-zone machine. 1 (dual zones)

Dual Laser Probe Sets tool probe in one or both zones of 0 (one) 0
Present dual-zone machines. 1 (both)

1 - 56 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Control Power Off Time
Turns the control off after the specified period of activity.

The default setting for Control Power Off Time is 120 minutes.

UPS Software Shutdown Off Time

Sets the number of minutes the system will wait before it shuts down after a power loss
condition has been detected. The default is 1 minute.

Enable Retract Z-Axis on Power Loss

Enables Z-axis retract on power loss. 0 disables the retract feature. 1 enables the Z-axis
retract feature. Default is 0.

This parameter must be used in conjunction with M90/M91. The Z-axis retracts upon
power loss when this parameter is set to 1 and an M90 code (Z-axis Retract Enable) is
inserted at the beginning of the program. The retract can be turned on and off within the
program using M90 (on) and M91 (off).

The Z-axis will not retract if the M90 code is not used in the program
in conjunction with this parameter.

Auto Balance Enable

Auto Balance Enable set to 1 will have the logic controller send an auto balance request to
adjust the balance between the motion card and the servo drives at the start of
calibration and run program. No auto balance request will be sent if the parameter is 0.

The default setting for Auto Balance Enable is 1.

Only a trained technician performing diagnostic tuning of the servo

amplifiers should set the Auto Balance Enable value to zero.

Disable Auto On Chip Removal

The Disable Auto On Chip Removal parameter disables the chip conveyor from turning on
automatically in Auto Mode. The range is 0 or 1; 0 is the default. Setting the parameter to
1 will disable the Auto On Chip Removal feature.

Chip Conveyor Parameters

Chip Removal On/Off Delay Enable, Chip Removal On Delay Time and
Chip Removal Off Delay Time parameters are functional only when
the Chip Removal Forward On/Off F2 softkey (Automatic Run
Mode) is set to On.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-57

Chip Removal On/Off Delay Enable
The Chip Removal On/Off Delay Enable parameter is used with the Chip removal On
Delay Time and Chip Removal Off Delay Time parameters to periodically allow the chip
conveyor or auger to remove chips from inside the machine during the part program.

When Chip Removal On/Off Delay Enable is set to 0, this parameter is disabled. Values
entered into the Chip Removal On Delay Time and Chip Removal Off Delay Time will not
be retained.

When Chip Removal On/Off Delay Enable is set to 1, use the Chip Removal On Delay Time
and Chip Removal Off Delay Time parameters to regulate operation of the chip conveyor
or auger.

The default setting for Chip Removal On/Off Delay Enable is 0 (disable).

Chip Removal On Delay Time

When the Chip Removal On/Off Delay Enable parameter is set to 1, the Chip Removal On
Delay Time parameter defines the time that the chip conveyor or auger cycles On to
remove chips from inside the enclosure.

The default setting for Chip Removal On Delay Time is 0 seconds.

Chip Removal Off Delay Time

When the Chip Removal On/Off Delay Enable parameter is set to 1, the Chip Removal Off
Delay Time parameter sets the time that the chip conveyor or auger cycles Off. When the
chip conveyor or auger cycles Off, the screen status display is FWD-Delay, not Stopped.

The default setting for Chip Removal Off Delay Time is 0 seconds.

Enable Dual Zones

This parameter enables zones on a dual-zone machine. 0 sets both zones as a single long
bed machine, and 1 sets the zones as separate zones. The default is 1.

Dual Laser Probe Present

The Dual Tool Probe Present parameter sets tool probe in one or both zones of dual-zone
machines. 0 specifies there is one tool probe; 1 specifies there is a probe in each zone.
The default is 0.

1 - 58 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Machine Parameters Page 2
Parameter Description Range Default

CAL to LS Velocity Sets the feedrate for the X, Y, or Z axis 100-2540 1270
X, Y, Z as it moves toward the calibration limit MMPM
switch during a machine calibration
cycle.
See Cal to LS Velocity Parameters.

CAL to LS Velocity Sets the feedrate for the A, B, or C axis 100-2540 0

A, B, C as it moves toward the calibration limit DPM
switch during a machine calibration
cycle.
See Cal to LS Velocity Parameters.

Disable Tool Picker Turns off the Tool Picker option. 0 (enable) 0
Option 1 (disable)

ATC Disable Disables all automatic tool changer 0 (enable) 0

functions. 1 (disable)

Move to Safety Pos Manual Mode ATC operations are 0 (disable) 0

Manual Mode ATC performed at Safety Position when 1 (enable)
enabled.

Tilt Axis Safety Sets the position for the tilt axis during 0-360 degrees 0
Position an automatic tool change when the
Table Safety Move parameter is set to
Yes for an Automatic Tool Change.

X-Axis Safety Sets the absolute X axis machine Travel Limits 0

Position location to which the table will move (mm)
when the Table Safety Move parameter
is set to Yes for an Automatic Tool
Change. See X-Axis and Y-Axis Safety
Position.

Y-Axis Safety Sets the absolute Y axis machine Travel Limits 0

Position location to which the table will move (mm)
when the Table Safety Move parameter
is set to Yes for an Automatic Tool
Change. See X-Axis and Y-Axis Safety
Position.

ATC Z-Axis Move to On HMX only, moves the Z-axis to zero 0 (disable) 0
Zero Position position at the end of a tool change. 1 (enable)

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-59

Cal to LS Velocity Parameters
The Cal to LS Velocity parameters set the feed rate for each axis as it is moving towards
the calibration limit switch during a machine calibration cycle. Only the axes that are
present on the machine need to be set. The units are indicated in parentheses and can be
MMPM (millimeters per minute), IPM (inches per minute), or DPM (degrees per minute).

• The default setting for Calibrate to Limit Switch Velocity is 1270 MMPM (50
IPM) for the X, Y, and Z axes. The range for Cal to LS Velocity values for the
X, Y, and Z axes is 100 MMPM to 2540 MMPM.
• The default setting for Calibrate to LS Velocity is 0 DPM for the A, B, and C
axes. The range for Cal to LS Velocity values for the A, B, and C axes is 100
DPM to 2540 DPM.
• The default setting for Calibrate to Limit Switch Velocity is 1270 mmpm (50
IPM) for X, Y, and Z axes.
• The default setting for Calibrate to Limit Switch Velocity is 1000 mmpm
(39.37 IPM) for A axis on a VTXU machine.
• The default setting for Calibrate to Limit Switch Velocity is 2000 (78.74 IPM)
mmpm for B axis on an HMX machine.
• The default setting for Calibrate to Limit Switch Velocity is 1000 mmpm (50
IPM) for C axis on a VTXU machine.

Disable Tool Picker Option

Turns off the Tool Fixture (TPS) option, if it is present on your VM, VMX, or VTXU
machine. Refer to the Tool Fixture (TPS) chapter in the Options manual.

The default setting for Disable Tool Picker Option is 0.

The Disable Tool Picker Option parameter is not functional on HMX machines.

ATC Disable
The ATC Disable parameter allows the user to completely disable all automatic tool
change functions. Setting the ATC Disable parameter to 1 disables the Auto Tool Change
button (for performing tool changes in Manual mode or Tool Setup) and the Auto Tool
Change in Auto mode button (for running programs). With ATC Disable set to 1, all tools
will have to be inserted and removed manually using the Spindle Clamp/Unclamp button
mounted on the head.

When ATC is disabled, the Control assumes that the ATC is in a safe
position to allow normal X, Y, and Z axis movement. Input status for
the ATC at home position will not be checked. Failure to ensure that
the ATC is in a safe position may result in machine damage.

The default setting for ATC Disable is 0.

1 - 60 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Move to Safety Pos Manual Mode ATC
When the Move to Safety Pos Manual Mode ATC operations parameter is set to 0 for an
ATC command, the Z axis moves to tool change height and the ATC is completed at the
current X and Y axis position.

The default setting for Move to Safety Pos Manual Mode ATC is 0 (disable).

If this parameter is set to 1, then:

1. The Z axis moves at rapid to zero.

2. The X and Y axes move at rapid to the X- and Y-axis safety positions.
3. The Z axis moves to tool change height.
4. The automatic tool change is completed.
5. The Z axis moves to zero.
6. The X and Y axes move at rapid back to the previous X and Y position.
The Move to Safety Position for Manual Mode ATC only applies to
Manual mode. ATC operations in Auto Mode are not affected by this
parameter. To move the table to the safety position during an
automatic tool change in Auto Mode, set the Move to Safe Pos During
TC from Program Parameters in Input.

Axis Safety Position Parameters

Tilt Axis Safety Position
The Tilt Axis Safety Position parameter sets the position for the tilt axis on the VTXU
machine during an ATC if either one of the following conditions occurs:

• the Move to Safe Pos During TC parameter is set to Yes (for Auto Run mode).
• the Move to Safety Pos Manual Mode ATC parameter (for Manual or Input
modes) is set to 1.

After the Z retracts before the ATC, the tilt axis moves to the position indicated in
degrees. After the automatic tool change completes, the tilt axis returns to the original
position.

The default setting for Tilt Axis Safety Position is 0.

The Tilt Axis Safety Position parameter is not functional for HMX machines, VM machines,
or VMX machines.

X-Axis and Y-Axis Safety Position

The X-Axis Safety Position and Y-Axis Safety Position parameters determine the absolute
X-axis and Y-axis machine locations, in millimeters, to which the table will move when the
Table Safety Move parameter is set to Yes for an Automatic Tool Change. See Program
Parameters for more information.During an automatic tool change with the Table Safety
Move set to Yes:

1. The Z-axis will retract to maximum position.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-61

 2. The X-axis and Y-axis will move at rapid feedrate to the X-Axis Safety Position
and the Y-Axis Safety Position, respectively.
3. The automatic tool change will complete.
4. The X-axis and Y-axis will move at rapid feedrate to the previous X-axis and Y-
axis positions before the move to the X-Axis and Y-Axis Safety Positions.

The X-Axis Safety Position value must not exceed the minimum or maximum travel limits
for the X-axis. The Y-Axis Safety Position value must not exceed the minimum or
maximum travel limits for the Y-axis. If the Table Safety Move parameter is set to No,
these parameters are not used, and steps 1, 2, and 4 above are not executed for an
automatic tool change.

The default setting for X-Axis Safety Position is 0.000 mm. The default setting for Y-Axis
Safety Position is 0.000 mm.

The X-Axis and Y-Axis Safety Position parameters are not functional for HMX machines.

ATC Z-Axis Parameter

ATC Z-Axis Move to Zero Position
This parameter is functional only on an HMX machine. The ATC Z-Axis Move to Zero
Position parameter moves the Z-axis to the zero (0) position at the end of either an Auto
or Manual tool change.

ATC Z-Axis Move to Zero Position set to 0 disables the parameter. ATC Z-Axis Move to
Zero Position set to 1 enables the parameter.

The default setting for ATC Z-Axis Move to Zero Position is 0.

ATC Z-Axis Move to Zero Position parameter is not functional for VTXU, VM, or VMX
machines.

1 - 62 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Machine Parameters Page 3
Parameter Description Range Default

Machine Pause - Sets the time the program pauses 0-60 seconds 0
Flood Coolant when the primary coolant is enabled.

Machine Pause - Sets the time the program pauses 0-60 seconds 0
Secondary Coolant when the secondary coolant is
enabled.

Aux Coolant Console Identifies which auxiliary output the 0-12 0 (disabled)
Button console Aux Coolant button controls.

Pulsating or Delay Sets the Washdown Coolant pump 0 (continuous) 0 or 1

Washdown Enable run cycle; used in conjunction with 1 (pulsating) (depends on
other washdown coolant parameters. machine)
2 (delay)

Alt Washdown Dwell Controls washdown coolant flow on the 0-32767 500 or 1000
right side of the machine enclosure on (.01 sec) (depends on
certain machines. Used in conjunction machine)
with other washdown coolant
parameters.

Alt Dwell Lt Side Controls washdown coolant flow on the 0-32767 (.01 200
left side of the machine enclosure on sec)
certain machines. Used in conjunction
with other washdown coolant
parameters.

Alt Washdown Off Sets the time the washdown coolant 0-32767 (.01 0 or 200
Time flow cycle is paused, on certain sec) (depends on
machines. machine)

Washdown On Delay Defines the time the washdown coolant 0-9999 0

Timer pump is on; used with Washdown Off seconds
Delay Timer.

Washdown Off Defines the time the washdown coolant 0-9999 0

Delay Timer pump is off; used with Washdown On seconds
Delay Timer.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-63

Coolant Parameters
The coolant parameters are used to control coolant flow to the spindle (known as flood
coolant), coolant flow in the machine enclosure (known as washdown coolant), or to turn
the washdown coolant pump on or off. The Washdown Coolant Pump must be On for
Right and Left side operation. Some coolant parameters may not be functional on your
machine. For examples of how to use washdown coolant parameters on your Hurco
machine, see Table 1–1.Washdown Coolant Parameter Examples, on page 1 - 75.

Washdown coolant flow for VMX24, VMX30, VMX42, and VMX50 machines is continuous
to both sides of the enclosure. The amount of washdown coolant used during machining
operations is controlled by cycling the washdown coolant pump.

The VMX60, VMX6030, VMX64, and VMX84 machines are equipped with a butterfly
solenoid that alternates washdown coolant flow between the right and left sides of the
machine enclosure.

This is the washdown coolant flow cycle for VMX64 and VMX84 machines:

1. Coolant flows on right side of machine enclosure (defined in Alt Washdown

Dwell).
2. Pause time of no coolant flow (defined in Alt Washdown Off Time).
3. Coolant flows on left side of machine enclosure (defined in Alt Dwell Lt Side).
4. Pause time of no coolant flow (defined in Alt Washdown Off Time).

The amount of washdown coolant used during machining operations for VMX60,
VMX6030, VMX64, and VMX84 machines is controlled by the time washdown coolant
flows/pauses to each side of the machine enclosure, and/or by cycling the washdown
coolant pump.

VMX64 and VMX84 machines are equipped with a separate Factory-configured timer to
control the Y-axis rear way cover washdown on and off cycles.

Machine Pause - Flood Coolant

Machine Pause - Flood Coolant pauses the running part program for the indicated time
(0-60 seconds) whenever the program enables the primary flood coolant.

The default is 0 seconds.

Both Flood and Secondary Coolant pause parameters can be set to

the same pause time or they may be set separately.

Machine Pause - Secondary Coolant

Machine Pause - Secondary Coolant pauses the running part program for the indicated
time (0-60 seconds) whenever the program enables the secondary (CTS) coolant.

The default is 0 seconds.

Both Flood and Secondary Coolant pause parameters can be set to

the same pause time or they may be set separately.

1 - 64 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Aux Coolant Console Button
Identifies which auxiliary output the console Aux Coolant button controls. 0 is disabled.
1-12 identify the auxiliary output.

M52-M55 and M142-M149 are used in the program to enable the auxiliary equipment or
machine function that the Aux Coolant Console button controls.

Pulsating or Delay Washdown Enable

This parameter is used with other washdown coolant features to regulate washdown
coolant flow for continuous clearing of chips from the machine enclosure.

Parameter operation is determined by machine type.

• VMX24, VMX30, VMX42, VMX50—use this parameter to manage

washdown coolant flow:
• When Pulsating or Delay Washdown Enable = 0, washdown coolant will
continuously flow on the right and left sides of the machine enclosure.
Values in the Alt Washdown Dwell, Alt Dwell Lt Side, or Alt Washdown Off
Time will have no effect on washdown coolant operation.
• When Pulsating or Delay Washdown Enable = 1, do not use this setting
for a VMX24, VMX30, VMX42, VMX50, or VMX60 machine. If unexpected
performance occurs, refer to the Machine Maintenance section of the
Maintenance and Safety Manual.
• When Pulsating or Delay Washdown Enable = 2, the washdown coolant
pump will cycle for the times defined in Washdown Delay On Timer and
Washdown Delay Off Timer.
• The default setting for Pulsating or Delay Washdown Enable is 0.

• VMX60, VMX6030, VMX64, VMX84—use this parameter to alternate

washdown coolant flow on the machine enclosure:
• When Pulsating or Delay Washdown Enable = 0, do not use this setting
for a VMX64 or VMX84 machine. If unexpected performance occurs, refer
to the Machine Maintenance section of the Maintenance and Safety
Manual.
• When Pulsating or Delay Washdown Enable = 1, washdown coolant flow
will cycle for the times defined in Alt Washdown Dwell, Alt Dwell Lt Side
and Alt Washdown Off Time.
• When Pulsating or Delay Washdown Enable parameter = 2, the washdown
coolant pump will cycle for the times defined in Washdown On Delay
Timer and Washdown Off Delay Timer, whether or not washdown coolant
flow is alternating in the machine enclosure.
• The default setting for Pulsating or Delay Washdown Enable is 1.

Pulsating or Delay Washdown Enable is not functional for HMX, VM, and VTXU machines.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-65

Alt Washdown Dwell
This parameter controls the time washdown coolant flows on the right side of the
machine enclosure. Alt Washdown Dwell is used with Alt Washdown Off Time to define
the washdown coolant flow cycle on the right side of the machine enclosure. The value for
Alt Washdown Dwell in 0.01 sec increments, so a value of 500 equates to 5 sec.

Pulsating or Delay Washdown Enable must be set to 1 or 2 to use Alt Washdown Dwell.
Parameter operation is determined by machine type.

• VMX24, VMX30, VMX42, VMX50

• When Pulsating or Delay Washdown Enable = 1, do not use this setting
for a VMX24, VMX30, VMX42, VMX50 or VMX60 machine. If unexpected
performance occurs, refer to the Machine Maintenance section of the
Maintenance and Safety Manual.
• When Pulsating or Delay Washdown Enable = 2, Alt Washdown Dwell is
not functional; entering a value in Alt Washdown Dwell will have no effect
on washdown coolant flow for a VMX24, VMX30, VMX42, VMX50 or
VMX60 machine.
• The default setting for Alt Washdown Dwell is 500 (5 seconds), but set
this parameter to 0 to avoid unexpected performance. If unexpected
performance occurs, refer to the Machine Maintenance section of the
Maintenance and Safety Manual.
• VMX60, VMX6030, VMX64—When Pulsating or Delay Washdown Enable =
1 or 2, define the time for washdown coolant to flow on the right side of the
machine enclosure.
• The default setting for Alt Washdown Dwell is 500 (5 seconds).

• VMX84—When Pulsating or Delay Washdown Enable = 1 or 2, define the

time for washdown coolant to flow on the right side of the machine enclosure.
• The default setting for Alt Washdown Dwell is 1000 (10 seconds).

Alternating Washdown Dwell is not functional for HMX, VM, and VTXU machines.

Alt Dwell Lt Side

On VMX60, VMX64, and VMX84 machines, this parameter controls the time washdown
coolant flows on the left side of the machine enclosure. Alt Dwell Lt Side is used with Alt
Washdown Off Time to cycle washdown coolant flow on the left side of the machine
enclosure. The value for Alt Dwell Lt Side is in 0.01 sec increments, so a value of 500
equates to 5 sec.

Pulsating or Delay Washdown Enable must be set to 1 or 2 to use Alt Dwell Lt Side.
Parameter operation is determined by machine type.

• VMX24, VMX30, VMX42, VMX50—Alt Dwell Lt Side is not functional;

entering a value in Alt Dwell Lt Side will not affect washdown coolant flow for
a VMX24, VMX30, VMX42, VMX50 or VMX60 machine.

• The default setting for Alt Washdown Dwell is 200 (2 seconds), but you
should set this parameter to 0 to avoid unexpected performance. If
unexpected performance occurs, refer to the Machine Maintenance
section of the Maintenance and Safety Manual.

1 - 66 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

 • VMX60, VMX6030, VMX64, VMX84—define the time for washdown coolant
to flow on the left side of the machine enclosure.
• Alt Dwell Lt Side will only function if the Alt Washdown Dwell is greater
than 0. If the value of Alt Washdown Dwell is 0, the machine will ignore
Alt Dwell Lt Side and washdown coolant will not flow on either side of the
machine enclosure.
• If Alt Dwell Lt Side = 0 and Alt Washdown Dwell is greater than 0,
washdown coolant will flow to the left side of the enclosure for the time
defined in Alt Washdown Dwell.
• The default setting for Alt Dwell Lt Side is 200 (2 seconds).

Alternating Dwell Left Side is not functional for HMX, VM, and VTXU machines.

Alt Washdown Off Time

On VMX64 and VMX84 machines, this parameter defines the pause time in the washdown
coolant flow cycle. The value is in 0.01 sec increments, so a value of 500 equates to 5
sec.

Pulsating or Delay Washdown Enable must be set to 1 or 2 to use Alt Washdown Off Time.
Parameter operation is determined by machine type.

• VMX24, VMX30, VMX42, VMX50—Alt Washdown Off Time is not functional;

entering a value in Alt Washdown Off Time will not affect washdown coolant
flow for a VMX24, VMX30, VMX42, VMX50 or VMX60 machine.
• The default setting for Alt Washdown Off Time is 0; this parameter is not
functional for a VMX24, VMX30, VMX42, VMX50, or VMX60 machine.
• VMX60, VMX6030, VMX64, VMX84—When Pulsating or Delay Washdown
Enable = 1 or 2, washdown coolant flow will pause for the time indicated in
the Alt Washdown Off Time after coolant flow on each side of the enclosure.
• If Alt Washdown Off Time is set to 0, the washdown off-time is 0.7 sec.
• The default setting for Alt Washdown Off Time is 200 (2 seconds).

Alternating Washdown Off Time is not functional for HMX, VM, and VTXU machines.

Washdown On Delay Timer

This parameter defines the time (in seconds) the washdown coolant pump is On, and is
used with the Washdown Off Delay Timer to manage coolant usage. The default setting
for Washdown On Delay Timer is 0 seconds.

Pulsating or Delay Washdown Enable must be set to 2 to use Washdown On Delay Timer.

• VMX24, VMX30, VMX42, VMX50—washdown coolant flow will be

continuous to both sides of the machine enclosure during the time the
washdown coolant pump is On.
• VMX60, VMX6030, VMX64, VMX84—the washdown coolant pump is On for
the time defined, whether or not washdown coolant flow is alternating in the
machine enclosure. Table 1–1.Washdown Coolant Parameter Examples, on
page 1 - 75 shows an example where the washdown coolant pump cycles on
and off while washdown coolant flow is alternating on the machine enclosure.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-67

 It is recommended that you follow this formula:

Washdown On Delay Timer = Alt Washdown Dwell + Washdown Off

Delay Timer + ALT Dwell Left Side + Washdown Off Delay Timer

See Table 1–1.Washdown Coolant Parameter Examples, on page 1 -

75.

• The default setting for Washdown On Delay Timer is 0 seconds.

This parameter defines the time (in seconds) the washdown coolant pump is On, and is
used with the Washdown Off Delay Timer to manage coolant usage. Washdown On Delay
Timer is not functional for VM machines.

Washdown Off Delay Timer

This parameter defines the time (in seconds) the washdown coolant pump is Off, and is
used with the Washdown On Delay Timer to manage coolant usage. The functionality of
this feature is dependent upon machine type. Washdown Off Delay Timer is not functional
for VM machines.

Pulsating or Delay Washdown Enable must be set to 2 to use this parameter.

• VMX24, VMX30, VMX42, VMX50—defines the time the washdown coolant

pump is Off.
• VMX60, VMX6030, VMX64, VMX84—defines the time the washdown
coolant pump is Off, whether or not coolant flow is alternating in the machine
enclosure.
It is recommended that you follow this formula:

Washdown Off Delay Timer = Alt Washdown Dwell + Washdown On

Delay Timer + Alt Dwell Left Side + Washdown On Delay Timer

See Table 1–1.Washdown Coolant Parameter Examples, on page 1 -

75.

Washdown Off Delay Timer should be calculated using even multiples

of its value, increasing it by that value.

For example, if the calculated value is 30, then you can increase it to
60, 90, etc.

• The default setting for Washdown Off Delay Timer is 0 seconds.

1 - 68 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Examples for Coolant Parameters Use
VMX24, VMX30, VMX42, VMX50, and VMX60
N95 Codes (Integrator Configuration Parameters)
247 228 248 249 297 298 Result
0 0 0 0 0 0 Continuous washdown coolant flow.
1. Washdown coolant pump on for 20 sec.
2 0 0 0 20 45 2. Pump off for 45 sec.
3. Cycle repeats.

VMX64, VMX84
N95 Codes (Integrator Configuration Parameters)
247 228 248 249 297 298 Result
1. Right side washdown coolant for 8 sec.
2. No coolant for 0.7 sec.
1 800 600 0 0 0 3. Left side washdown coolant for 6 sec.
4. No coolant for 0.7 sec.
5. Cycle repeats.
1. Right side washdown coolant for 8 sec.
2. No coolant for 2.5 sec.
1 800 600 250 0 0 3. Left side washdown coolant for 6 sec.
4. No coolant for 2.5 sec.
5. Cycle repeats.
1. Right side washdown coolant for 10 sec.
2. No coolant for 5 sec.
3. Left side washdown coolant for 10 sec.
4. No coolant for 5 sec.
2 1000 1000 500 30 60
5. Washdown coolant pump on for 30 sec during
right & left cycles.
6. Pump off for 60 sec.
7. Cycle repeats.

Key to N95 Code Column Headings for Tables Above

Integrator Configuration Definition
Parameter
N95:247 Pulsating or Delay WD Enable
N95:228 Alt WD Dwell
N95:248 Alt Dwell Lt Side
N95:249 Alt WD Off Time
N95:297 WD On Delay Timer
N95:298 WD Off Delay Timer

Table 1–1. Washdown Coolant Parameter Examples

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-69

Machine Parameters Page 4

Parameter Description Range Default

Warm-Up Cycle Time Sets the time for each step of the warm- 60-600 120
Per Pass up cycle.

Warm-Up Starting Sets the spindle speed for the initial step 0-25% 1000
Speed of the warm-up cycle. Max RPM

Warm-Up Speed Sets spindle speed increments for each 0-25% 2000
Steps step of the warm-up cycle. Max RPM

Warm-Up Max Sets the spindle speed for the final step 0-Max RPM Machine’s
Spindle Speed of the warm-up cycle. maximum
spindle RPM

Warm-Up Axis Feed Sets the axis feed rate for each step of 0-Max 2920
Rate the warm-up cycle. Rapid

Axis Feedrate Sets the Axis Feedrate Override Minimum 0-99% 10%
Override Min (%) value.

Axis Feedrate Not accessible by the user. Contact a 101-200 150

Override Max (%) Hurco Certified Service representative for
assistance.

Rapid Feedrate Sets the Rapid Feedrate Override 0-200% 10%

Override Min (%) Minimum value.

Rapid Feedrate Not accessible by the user. Contact a 0-200 100

Override Max (%) Hurco Certified Service representative for
assistance.

Rotary Position Out Specifies how to process “Out of position” 0 (ignore) 0

of Tol Proc conditions for the axes. 1 (warn)
2 (error)

1 - 70 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Warm Up Parameters
These parameters allow the operator to configure the machine’s daily warm-up cycle.

• Warm-up Cycle Time Per Pass

• Warm-up Starting Speed
• Warm-up Speed Steps
• Warm-up Max Spindle Speed
• Warm-up Axis Feed Rate

When the warm-up cycle is initiated:

• Spindle speeds up to the Warm-up Starting Speed RPM for the time indicated
in the Warm-up Cycle Time per Pass field.
• X and Y axes move diagonally from corner to corner at the Warm-up Axis
Feed Rate.
• The machine then steps through the warm-up cycle until the Warm-up Max
Spindle Speed is reached. The length of each step is defined by the Warm-Up
Cycle Time per Pass. During each step of the cycle, the spindle speed will
increase to the Warm-up Speed Steps RPM and the axes will run at the
Warm-up Axis Feed Rate.

Altering the default daily warm-up parameters may lead to

inadequate machine warm up that can negatively impact spindle
operations and may void the Hurco warranty.

Refer to your machine’s Maintenance and Safety manual for more

information about warm-up cycles.

Axis Feedrate Override Min (%)

Sets the Axis Feedrate Override Minimum value. This value cannot be greater than or equal to
the maximum value.

Rapid Feedrate Override Min (%)

Sets the Rapid Feedrate Override Minimum value. This value cannot be greater than or
equal to the maximum value.

Rotary Position Out of Tol Proc

Specifies how to process “Out of position” conditions for the axes:

• 0 = ignore
• 1 = post a warning
• 2 = generate an error condition

The default is 0.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-71

Machine Parameters Pages 5 and 6
Parameter Description Range Default

Aux Output 1-12 Enables a confirmation signal for 0 (disable 0

Confirmation Enable completion of each Auxiliary M-code 1 (enable)
Output.

Disable Aux Out 1-12 Disables the specified Auxiliary M-code 0 (enable) 0
During Interrupt Output when an Interrupt cycle is selected 1 (disable)
during Auto Run mode.

Aux Output Parameters

Aux Output 1-12 Confirmation Enable
Aux Output Confirmation Enable set to 1 enables a confirmation signal for completion of
each Auxiliary M-code Output. The program pauses until the confirmation signal is
detected. A setting of 0 will not require a confirmation signal and will not pause the
program during the Auxiliary M-code Output.

The default setting for each Auxiliary Output Confirmation Enable is 0.

Disable Aux Out 1-12 During Interrupt

When set to 1, the parameter Disable Aux Output During Interrupt disables the specified
Auxiliary M-code Output when an Interrupt cycle is selected during Auto Run mode. Upon
return to Auto Run mode, the Auxiliary M-code Output will automatically be re-enabled.
However, if another mode is selected, then the Auxiliary M-code Output will remain
disabled until activated again in Auto Run mode.

A setting of 0 will leave the Auxiliary M-code Output enabled when an Interrupt cycle is
selected during Auto Run mode. It will remain enabled after exit from Interrupt cycle,
even when accessing a mode other than Auto Run.

The default setting for Disable Aux Out During Interrupt is 0 (enable).

1 - 72 Machine Parameters 704-0116-501 Getting Started with WinMax Mill

Estimated Run Time Parameters
Use the Estimated Run Time Parameters to make adjustments to certain machine
operations in order to generate a more accurate estimated program run time.

The Compute Estimated Run Time function on the Auto screen provides an estimate of
the time it takes to run the current part program. Times entered on the Estimated Run
Time Parameters screens are used in the calculation of the overall program run time
estimate.

Select the Estimated Run Time softkey from the Machine Parameters screens to view and
enter Estimated Run Time Parameters. The values are saved upon exit.

Figure 1–4. Estimated Run Time Parameters for a horizontal milling machine

The available parameters are dependent on machine type.

See Auto Mode, on page 1 - 160 for information about the Compute
Estimated Run Time softkey.

Getting Started with WinMax Mill 704-0116-501 Machine Parameters 1-73

1 - 74 Machine Parameters 704-0116-501 Getting Started with WinMax Mill
PROGRAMMING BASICS
The following sections explain basic programming information for Conversational and NC
programming, such as required setup, program checking, editing, and running of the
program.

WinMax Interface Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 82

Input Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 90
Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 91
Rotary Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 96
Part Fixturing and Tool Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 99
Work Offsets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 99
Stock Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 101
Tool Calibration Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 102
Tool Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 106
Advanced Tool Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 109
Change Tool Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 116
Part Program Tool Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 116
Part Program Tool Review for NC Programs . . . . . . . . . . . . . . . . . . . . . . 1 - 117
Tool Matching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 119
Tool Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 121
Tool and Material Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 123
Program Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 124
Import / Export Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 127
Copy and Change Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 130
Review Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 132
Manual Safety Override Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 134
Graphics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 137

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-75

WinMax Interface Environment
There are three ways to navigate and enter data for programming:

• Touchscreen—use the stylus or other pointing device to select softkeys and

drop-down lists for data entry and programming.
• Keyboard—use the function (F1-F12) keys and other keyboard shortcuts for
navigation and to call up screens.
• Ultimax classic edit mode—use the console keys; for example, use the
arrow keys for navigation and the enter key to accept data typed into a field.
See Edit Mode below for more information.

Edit Mode
Edit Mode is set in Utilities. Refer to User Interface Settings, on page 1 - 46. WinMax has
two edit modes:

• Ultimax Classic (default)—in this mode the console arrow keys are used to
move between blocks and segments, and the enter key is used to accept data
after it is typed into a field.
• Windows Dialog—in this mode the console arrow keys do not navigate
through fields and the enter key is not required to accept data typed into a
field.

If you want to... Ultimax Classic Windows Dialog

Enter data into a field Enter key to accept data Enter key to accept data
OR
Down (or Up) arrow to
accept data

Advance to next block Right/Left arrows Next Block/Previous Block

OR softkeys
Next Block/Previous Block OR
softkeys Page Up or Page Down key
OR
Page Up or Page Down key

Advance to next segment Right/Left arrows Next segment/hole softkeys

or operation OR OR
Next segment/hole softkeys Page Up or Page Down key
OR
Page Up or Page Down key

Navigate to next or Left or right arrow keys Page Up or Page Down keys
previous tool in Tool Setup

The right and left arrows will change the selection in fields with drop-
down lists (such as Tool Type in Tool Setup) in either Ultimax Classic
or Windows Dialog mode.

1 - 76 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Full Precision Editing
Numbers with decimals are rounded to the decimal display limit (three digits for metric
and four digits for imperial) when displayed in a field. Full Precision Editing allows you to
view the full number (up to 12 digits after the decimal) and/or to edit it to a more precise
point. With the cursor in a numeric decimal field, press F + decimal (.) on a machine, or
Ctrl + decimal (.) on the desktop to open a pop-up box containing the number.

Figure 1–5. Full Precision Editing Pop-up Box

Edit the number and select OK to save the changes. To close the pop-up box without
saving changes, select Cancel.

Do not use Full Precision Editing to change numbers that are

automatically calculated by WinMax. These numbers are calculated
to their 12-digit maximum accuracy and changing them could result
in changes to other automatic calculations in the program.

Softkeys
Softkeys appear as buttons on the screen; their default location is the right side of the
screen, but they can also be positioned on the left by changing the setting in User
Preferences (see Utilities, on page 1 - 43 for more information). Select a softkey using
one of these methods:

• On the screen, select the softkey.

• On the console, simultaneously press the F key and the number that
corresponds to the softkey (for example, F + 1 will select the F1 softkey).
For dual-console machines, ALT + the softkey number will select softkeys on
the graphics screen.
• On the keyboard (if using), press the corresponding function key (F1, F2, F3,
etc).

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-77

Drop-down Lists
Many fields contain a choice of items that are viewed by pulling down a list:

Touch the small

arrow to view a
drop-down list; use
arrow keys to
highlight choice
and Enter console
button to select

Figure 1–6. Example of a drop-down list

Expand and Collapse Files

In the Program Manager, files can be expanded or collapsed as follows:

Touch the “+” to expand

and view the files and
folders in a folder

Touch the “-” to collapse

(close) and hide the
files and folders in a
folder

Figure 1–7. Example of Expand and Collapse Files

1 - 78 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Sorting and Resizing Columns
On screens that contain columns, data in a column can be sorted ascending to
descending or descending to ascending by selecting the column heading. Columns can be
resized by dragging the column divider in the header.

Select and drag to resize column

Select to sort column

Figure 1–8. Example of Sorting and Resizing Columns

Pop-ups
During machine operation and programming, pop-up boxes may be displayed to convey
prompts or status messages. These pop-up boxes can be closed by selecting the
appropriate button (i.e., YES or NO or OK). Some pop-up boxes may only provide
informational messages and will be displayed for a few seconds before they automatically
close.

Figure 1–9. Pop-up message example

Certain pop-ups, such as the calculator and virtual keyboard, can be minimized by
selecting the “—” in the upper right corner. These pop-ups will remain open but are
“hidden” in the taskbar, and can be viewed again by touching the taskbar button. These
pop-ups can also be closed by touching the “X” in the upper right corner:

Minimize
Close

Figure 1–10. Pop-up showing minimize and close icons

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-79

Status Bar
The Status Bar appears at the bottom of every WinMax screen. It displays the program
name of the current active part program, a calculator icon, the current unit of measure
(inch or mm), the keyboard icon, and the current time. When viewed on a single screen
console, all icons appear in the same status bar; when viewed on a dual-screen console,
the program name and calculator icon appear on the left screen status bar, and the unit
of measure, keyboard icon and time appear on the right screen status bar.

• To use the calculator function, touch the calculator icon.

• To use the on-screen keyboard, touch the keyboard icon.
• To change the unit of measure, touch the unit of measure abbreviation.

WinMax Version

Softkeys

Prompts

Error/Status area

Status Bar

Figure 1–11. Status Bar and other areas

Calculator
Select the calculator icon in the Status Bar to open the calculator. The calculator appears
on screen and is operated using the stylus to select the calculator keys on screen.

Figure 1–12. Calculator pop-up

When the calculator is minimized (with “—” in the upper right), the last calculation is
retained, but when it is closed (with “X” in the upper right), the last calculation is erased.

1 - 80 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Pop-up Keyboard
Enter part program names using the on-screen, pop-up keyboard. The pop-up keyboard
is available for entering text, such as naming a part program.

Figure 1–13. Pop-up Keyboard

1. Either select the keyboard icon located in the screen’s status bar or
simultaneously press the Alt and Input keys on the console to activate the
keyboard.
2. Use a pointing device such as the stylus to select characters from the
keyboard.
3. Press the Enter key to update a field and advance the cursor after the
characters are selected in the text field (e.g., after creating a program name).
4. Select the X located in the lower left corner of the text entry window to close
the keyboard.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-81

On-screen Help
On-screen Help provides information about using WinMax. The Help is context-sensitive
to the screen level. Press the console Help button to display the Help topic for the current
screen. The following list describes Help functions:

• Buttons in the upper left-hand corner of the Help screen are used to move
through Help topics and print screens.
• Use the Hide button to hide the navigation pane.
• Use the Back button to return to the previous Help screen.
• Use the Print button to print the current displayed Help topic, if a printer
is attached and configured. See Accessing the WinMax Help in PDF
format, on page 1 - 89 for more information about printing.

• Use the arrow buttons to move between pages within a Help topic and to
move through topics.
• Use the Contents tab for a list of information sorted by subject:
1. Select the “+” to expand the topic and view sub-topics.
2. Select the topic to display it.
• Use the Index tab to show the Help index:
1. Quickly scroll to an index topic by typing the topic in the box at the top of
the index.
2. Select a topic and the Display button to view the topic.
• Use the Search tab to search the Help for a word or phrase:
1. Type the search word(s) into the text box at the top of the pane.
2. Select the List Topics button. A list of topics that contain the search
word(s) is displayed.
3. Select a topic and the Display button to view that topic.
• Use the Favorites tab to save Help topics for quick access:
1. Select the Add button at the bottom of the pane to add the current topic.
2. Select a topic from the Favorites list, and select the Display button to view
it.
3. Select a topic from the Favorites list, and select the Remove button to
remove it from the list.

1 - 82 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Accessing the WinMax Help in PDF format
The WinMax On-screen Help is also provided in PDF format for easy printing. The
information contained in the PDF files is identical to the on-screen Help. The PDF files
may be copied to a floppy disk or USB memory device to be transferred to a PC for
viewing or printing. Here are the steps to access the PDF files:

1. From the Input screen, select the PROGRAM MANAGER F8 softkey.

2. Select the DISK OPERATIONS F7 softkey.
3. In the left-hand pane, navigate through the folders:
• For WinMax Mill on a machine, the path is D:\Hurco\Winmax Mill\hlp
• For WinMax Desktop on a PC, the path is C:\Program Files\Winmax
Mill\hlp

The PDF files will appear in the right-hand pane.

The SHOW ALL FILE TYPES field in User Interface Settings must be
set to YES (default is NO) in order to see the PDF files in the
directory. Access the SHOW ALL FILE TYPES field in Auxiliary Mode,
Utilities/ User Preferences/ User Interface Settings.

4. Highlight the PDF file(s) in the right-hand pane, and select the COPY F2
softkey.
5. Ensure that your media is loaded (either a floppy disk in the disk drive or a
USB memory device in the USB port), and navigate to the proper location in
the left-hand pane of the DISK OPERATIONS screen (either the floppy drive A:
or the USB port E:). Highlight the desired location.
6. Place the cursor in the right-hand pane and select the PASTE F3 softkey to
paste the PDF file(s) to the desired location.
7. You may now remove your media and load the PDF file(s) onto a PC for
viewing and printing.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-83

Input Mode
Input mode is used for part and tool setup, part programming, setting parameters, and
other information entry. Press the Input key on the console to access the Input screen.

The following softkeys appear on the Input screen:

• Part Setup—access the Part Setup screen to establish part zero, centerline,
offset Z, safety work region, and other parameters.
• Tool Review—access the Tool Review screen for a summary listing of all
tools used in active program (see Part Program Tool Review, on page 1 - 116
for more information).
• Part Programming—access and create data blocks of a part program. The
current program's data blocks appear on screen when this softkey is used.
Delete, add, edit, and navigate through the data blocks. The NC editor is
displayed for NC programs.
• Program Parameters—access General, Milling, Holes, Probing, and
Performance parameters. NC parameters are accessible for NC programs.
• Import / Export Functions—import parts of a previously saved Conversational
program or NC state, export NC state to file, or import/export the tool library.
• Copy and Change Blocks—make changes to several blocks at one time and/or
copy and change blocks within the active program.
• Erase Functions—erase sections of the current program.
• Program Manager—access and manage other part programs.

Erase Functions
Erase functions erases (deletes) programs or components (part setup, tool setup, and
program parameters):

• Erase Part Setup—resets Part Setup to the default values.

• Erase Tool Setup—deletes tools in Manual Tools, Auto Tools, and spindle.
The Erase Tool Setup softkey deletes ALL tools from the control, and
cannot be undone.

• Reset Program Parameters—resets Program Parameters to the default

values.
• Erase Program—deletes the part program data blocks but retains the
program name.
• Unload Program—removes program from the Program Manager, including
the filename. This does the same function as CLOSE PROGRAM in the
Program Manager.

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Part Setup
Part Setup Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 94
Part Setup Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 94
Rotary Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 96
Stock Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 101

Part setup establishes the locations of part zero in X, Y, and Z relative to the machine's
absolute zero. Part Zero may be located anywhere on the fixturing or the part. During
machine calibration, each axis moves to its + or - travel limits. Machine zero, identified
during machine calibration, is the location to which each axis moves to determine a fixed
point where the X, Y, and Z axes become tangent. This value does not change after
calibration.

1. Part Zero

2. Workpiece

3. Machine Zero

4. X Axis

5. Y Axis

Figure 1–1. Part Zero Relative to Machine Zero Viewed Looking Down at Table

Program the axes to move within the coordinate system as shown below:

-X Table moves to the left

+X Table moves to the right

-Y Table moved toward the operator

+Y Table moves away from

-Z Spindle moved down into the part

+Z Spindle moved up away from part

Figure 1–2. Axis Motion

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-85

 1. Table

2. Part (Workpiece)

3. Machine Absolute - Z Axis

4. Tool Zero Calibration Plane

Figure 1–3. Part Zero in Z (Tool calibration Plane)

Part Setup Coordinate Systems

Machine Coordinate System
The Machine Coordinate System is fixed to the machine frame and does not move when
the machine axes move. This coordinate system is located at the spindle nose center
when all machine axes are at their zero positions.

Unrotated Coordinate System

The Unrotated Part Coordinate System is present on a 4-axis or 5-axis machine and is
located at the Workpiece Coordinate system when all the machine’s axes are at their Part
Setup Zero locations. This coordinate system moves with the machine’s linear axes, but
does not rotate with the rotary axes. The Unrotated Coordinate system is generally used
only by NC Post Processors that do not use Tool Center Point Management.

Workpiece Coordinate System

The Workpiece Coordinate System is fixed to the physical workpiece fixtured to the table;
it moves and rotates when the machine axes move.The coordinate system is fixed to the
part fixtured on the machining center’s table. The Workpiece Coordinate System is
typically set in the user’s CAD/CAM system or on the part drawing used for programming
the tool paths.

1 - 86 Programming Basics 704-0116-501 Getting Started with WinMax Mill

The Machine Coordinate, Workpiece Coordinate, and Unrotated Coordinate systems are
shown in the figure below:

1. Machine
Coordinate System

2. Unrotated Part
Coordinate System

3. Workpiece
Coordinate System

Figure 1–4. Part Setup Coordinate Systems

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-87

Part Setup Fields
See the Field Glossary for definitions of the Part Setup fields:

A Centerline X / Y / Z Offset Z Part Zero Y TIS / Tool in Spindle

B Centerline X / Y / Z Part Part Zero Z X/Y Skew (DEG)

C Centerline X / Y / Z Part Zero A Part Zero Z Shift Zone

Disable Centerlines Part Zero B Probe Z Z Table Offset

Feed Part Zero C Safety Work Region

Machine Part Zero X Spindle

The fields on the Part Setup screen vary depending on machine

configuration and tool calibration mode.

Use the Safety Work Region fields on the Part Setup screen to
enter values to define the safety region. Type the value in the field,
or jog each axis to the desired safety region, and press the Store
Position button on the jog unit.

Out of range entries in the Safety Work Region appear in red. See
Machine Specifications for ranges.

Always enter the Z(-) parameter (Z Bottom) to prevent the tool from
drilling through the part and into the table.

Use the Z(+) field (Z Top) to define the clearance above the part and
fixture.

Use the Z(+) field with a Position block. The Z Top value reduces
rapid Z motion for Position blocks. The spindle retracts to the Z Top
value above the tool zero calibration for Position blocks.

Part Setup Softkeys

Part Setup contains these softkeys:

• Work Offsets—Accesses the work coordinates G54-G59 and a set of shift

values for NC programs. These are used to set multiple part zeroes for
multiple parts fixtured to the table and milled consecutively using the same
program.
• Tool Setup—Accesses Tool Setup screen to enter the descriptions of tools that
will be used in the part program.
• Part Programming—Accesses fields to enter the exact description of how the
part will be cut. See Part Programming in the Conversational Programming
manual for more information.
• Program Parameters—Accesses the Program Parameters screen to specify
data common to all program data blocks.
• Part Probing—Accesses the Probing parameters screen (available only with

1 - 88 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 the Probing option). See Part Probing Option.
• Store Machine Position—Sets the current axis position as a Part Zero
location. The cursor location determines which axis (X or Y) will be set.

These are the softkeys on the second Part Setup screen, accessed with the More 
softkey:

• Stock Geometry—Accesses fields to specify the dimensions of the stock

material so it displays properly in graphics.
• Orient Spindle—Allows the spindle to be positioned for tool insertion or
removal.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-89

Rotary Part Setup
Ensure that the B-axis angle is at zero degree when measuring Z Table Offset, Offset Z,
and Zero Calibration fields for 5-axis machining.

For conversational programs, B-axis Part Setup Offset must be zero degree.

1. Workpiece Coordinate System

2. Zero Calibration (positive value)

3. Offset Z (positive value)

4. Z Table Offset (positive value)

Rotary Part Setup for Zero Calibration mode

See Tool Calibration Modes, on page 1 - 102 for more information about tool calibration.

In addition to standard Part Setup fields, Part Setup for rotary programming in Zero
Calibration mode includes part zero for the rotary axis and the rotary centerline fields.

Manually type the values directly into the Part Setup fields, or use the
jog unit to set the values. Follow these steps to use the jog unit to enter
the Part Setup values:
1. Use the jog unit to move the appropriate axis until it is in the
position that you want to define as part zero.
2. Select the Store Machine Position softkey or the Store Posi-
tion button on the jog unit.

Zero Calibration Rotary Centerline Calculation

Hurco recommends automatically calculating the rotary centerline. Use the following
steps:

1. Enter Part Zero X and Part Zero Y field values, either manually or by using the
jog unit to store the machine position.

1 - 90 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 2. Place the cursor in the Part Zero X, Part Zero Y, or Offset Z field to make the
Calculate Rotary Offsets softkey available.
3. Select the Calculate Rotary Offsets softkey. The machine automatically
calculates the values for the rotary centerline fields.

1. Center of cylindrical part and center of

rotary table

2. Part Zero

3. A Centerline Y

4. A Centerline Z

Figure 1–5. Rotary Centerline

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-91

 1. Part Zero

2. X Center

3. Y Center

4. Rotary Centerline

5. Rotary Centerline

6. Rotary Table

Figure 1–6. Rotary Centerline

When the part is fixtured to the center of the rotary-axis table, the
rotary centerline is the Y-Z center point of the part.

1 - 92 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Part Fixturing and Tool Loading
Before entering data into the part and tool setup screens for a part program, first fixture
the work piece to the table and load a tool into the spindle.

In order to determine the starting point (part zero) in the part, first fixture the work piece
(raw material or stock) to the machine tool table. This process, called fixturing, can be
accomplished using a variety of clamping devices, such as vises and toe clamps. Select
the fixturing device that will hold the work piece securely without getting in the way of
the cutting tool while the part is being made.

You may want to insert a tool in the spindle to use as an edge finder when identifying part
zero. Press the Manual button in the Machine Mode grouping to display the Manual
screen. Use the Tool in Spindle field and softkey to enter the tool number for the edge
finder tool.

Insert this tool as described in Loading a Tool into the Spindle, on page 1 - 23. The tool
will need to be calibrated as described in Tool Setup, on page 1 - 106.

Work Offsets
The Work Offsets softkey displays up to six work coordinates (G54-G59) and a set of
shift offset values. These are used to set multiple part zeroes for multiple parts fixtured to
the table and milled consecutively using the same program.

The X, Y, Z, and optional Rotary A and B work offset values can be entered for G54 to G59
codes. The coordinates defining G54 are the part zero coordinates for the original part
defined on the Part Setup screen. When the G54 coordinates are changed on this screen,
the part setup is also changed.

These work offsets are stored in memory, but not with the part program. They are not
saved to a disk file and need to be re-entered.

The shift offset coordinates, which follow the six work coordinates on the screen, move all
of the part zero coordinates as a group. This incremental value is useful when you place
part fixtures on the table in a different location and want to shift all of the work offsets to
the newly fixtured location. The G54-G59 offset values do not change on the screen when
shift offset values are entered.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-93

For dual-zone machines, specify the zone for each offset:

Set zone for each

work offset

Figure 1–7. Work Offsets on a dual-zone machine

Values for the Zone field are:

• 0—zone undefined (the active zone when only one is in use)

• 1—Zone 1
• 2—Zone 2

Auxiliary Work Offsets

There are 93 additional X, Y, Z, and optional Rotary A and B work offsets available on the
AUX WORK OFFSETS screen. These are accessed with the Aux Work Offsets F6 softkey
on the WORK OFFSETS screen.

To access any of these offsets call G code G54.1 Pn, where n is 1 thru 93. For example,
to change to auxiliary work offset 46 you would call G54.1 P46 in your NC program.

To update work offset values, use data setting G code G10 L20 Pn to set the Auxiliary
work offsets values. For example, to update work offset 46 value call G10 L20 P46
X12.5 Y3.0 Z-0.5

Following is a sample NC program that uses Auxiliary Work Offsets:

%
G90G80
T1M6F100
G10 L20 P1 X1 Y1 Z.-1
G10 L20 P93 X10 Y10 Z-.1
G54.1 P1 (change work part setup to 1)
G1X0.Y0.Z0.
X1.

1 - 94 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Y1.
X0.
Y0.
G54.1 P93 (change work part setup to 93)
G1X0.Y0.Z0.
X1.
Y1.
X0.
Y0.
M02

Stock Geometry
Stock Geometry allows you to specify the dimensions of the stock material so it displays
properly in graphics (when Stock Outline field is enabled in Graphics Settings).

For dual-zone machines, choose Zone 1 or Zone 2 tab to specify stock geometry settings.

See the Field Glossary for definitions of the Stock Geometry fields:

Apply Border To Top Manual Stock Sizing Y Length

Border Size Radius Y Ref Position

Direction Stock Type Z Length

Length X Length Z Ref Position

Manual Border Sizing X Ref Position Zero Ref

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-95

Tool Calibration Modes
Tool measurement and Part Setup Z measurements can be set with one of two modes:
Zero Calibration or Absolute Tool Length. The mode is selected in Utilities/User
Preferences/Tool Utilities and Settings. See Tool Utilities and Settings, on page 1 - 49.

If a program’s tools were calibrated using one mode, and that

program is loaded into a control that is set to the other mode, a
message is displayed that the program’s tool calibrations cannot be
used. The program data is loaded, but the tool calibration data is
not; tool calibration fields are set to zero.

Absolute Tool Length mode

With the Absolute Tool Length method, the absolute length of the tool from the spindle
nose to the tip of the tool is stored in Tool Setup. Each tool used in a program should be
calibrated to the same gauge device set on table top. To use Absolute Tool Length Mode:

1. In the Tool Setup screen, enter the number of the tool to be calibrated into the
Tool Number field.
2. If the tool is in spindle, jog Z down to the gauge block.
3. Select Store Machine Position softkey or button on the Jog Unit.
4. Part Zero is stored separately in the Part Zero Z field in Part Setup and is the
distance from Machine Zero to the Z0 of the workpiece:
a. Select Part Setup softkey.
b. In Part Zero Z field, use calibrated tool to touch off Z0 of the workpiece
and select the Store Machine Position softkey or button on the jog unit.

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Setup of Gauge Device
To use Absolute Tool Length mode, you must define the Z location for the table top and
the touch off device(s). This needs to be done only once unless the touch off device
changes. Access the Tool Measurement screen with the Tool Measurement Settings
softkey on the 2nd set of Tool Setup softkeys (use the More softkey):

Figure 1–8. Tool Measurement screen

See the Field Glossary for definitions of the Tool Measurement fields:

Device

Height

Notes

Touch-Off Device

Z Location

Z Reference

To set the Z Reference position

1. Advance to Z Reference field.
2. Place a gauge of known length on table top.
3. Jog Z-axis down and carefully touch spindle nose to top of gauge block.
4. Select Store Machine Position softkey or press the store position button on
remote jog unit.
The Part Kinematics Z Reference value from Rotary Axes Parameters
may also be used as the Z Reference value by selecting the Set to
Part Kinematics Ref softkey.

5. Subtract the length of the gauge block from the value stored in Z Reference

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-97

 field.
With Z Reference field highlighted, you can type in length of the
gauge block followed by enter. For example, if Z Reference measures
-562.259, using a 200 length gauge, type “200-” and enter to set Z
Reference to -762.259.

Once Z Reference is set it does not have to be changed or set again,

even if new devices are used. This field and the calculated Z Location
fields should not be edited.

To set up a gauge device

1. In the Touch-Off Device field, select the device number to be used when
measuring tool length. Up to six different devices can be set, but only the one
currently selected in the Touch-Off Device field is active when setting tool
length.
2. Advance to the row number that corresponds to the touch-off device number.
3. In the Device column, select gauge.
4. In the Height column, enter the height of the gauge.
Z Location field will be automatically calculated by adding the height
to the Z Reference value. Do not edit Z Location column.

5. Multiple gauges can be set up by specifying height in the appropriate row (1-
6). However, the active device for measuring tool length is the one specified in
the Touch-Off Device field.
All values set in Tool Measurement Settings are retained in the
control and are applicable to all programs. They are not program
specific.

To set up a probe device

1. Follow the steps to set up a single gauge device (for example, set up gauge for
device) and set touch-off device to Device 1.
2. In Tool Setup, use any tool to touch-off on the Device 1 gauge.
3. Select Store Machine Position softkey or Store Position button on jog unit.
4. In Tool Measurement Screen, select the touch-off device to be used when
probing tool length.
5. In the appropriate row, select Probe as the device from the drop-down Device
list.
6. Jog the tool down to the probe until probe is engaged.
7. With cursor in the Z Location column, select Store Position button on jog unit
or Store Z Location softkey. This will calculate the height of the probe from Z
Reference.

Also see Tool Probing in Options for more information.

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Zero Calibration Mode
With the Zero Calibration method of tool measurement, tools are calibrated to a plane in
the Z-axis as referenced from the Z Home position. Each tool used in a program should
be calibrated to the same plane. To use Zero Calibration mode:

1. In the Tool Setup screen, enter the number of the tool to be calibrated into the
Tool Number field.
2. If the tool is in spindle, jog Z down to the reference plane or gauge block.
3. Select Store Machine Position softkey or button on the Jog Unit.
All tools should be calibrated to the same reference plane.

4. If the reference plane is not the same as Z=Part Zero for program depth:
a. Select Part Setup softkey.
b. In Offset Z field, enter distance from reference plane to Part Zero, or use
calibrated tool to touch off Z=0 plane and select the Store Machine Position
softkey or button on the Remote Jog Unit.

If the plane that all tools are touched off of is the top of the workpiece, all program
dimensions for Z will be from Z=0. If the plane is not the top of the workpiece (as when a
gauge block is used), the operator can use the Offset Z field in Part Setup to set the
distance from the gauge block or other plane to the top of the workpiece plane. See Part
Setup, on page 1 - 91 for more information.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-99

Tool Setup
Tool Setup Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 106
Tool Setup Softkeys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 106
Advanced Tool Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 109
Change Tool Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 116

Use the Tool Setup screen to describe the tools that will be used for the part program.
You can access Tool Setup from several screens by using the Tool Setup softkey.

To review all tools currently programmed, go to the Tool Review screen.

When running a previously created part program, Tool Setup must

be carefully checked to be certain the tools described for the old
program match the tools planned for the new program. If a tool
breaks or is not available when running a previously created part
program, the Tool Setup information must be changed.

Tool Setup Fields

See the Field Glossary for definitions of the Tool Setup fields:

Coolant Flutes Speed (RPM) Tool Type

Cutting Time Location Spindle Touch-Off Device

Diameter Machine Surface Speed TPI

Diameter Wear Part Thread Diameter Zero Calibration

Feed Pitch Tool Cal Length

Feed/Flute Plunge Feed TIS / Tool in Spindle

Feed/Rev Shank Diameter Tool Number

The fields on the Tool Setup screen vary depending on machine

configuration and tool calibration mode.

Tool Setup Softkeys

Softkeys perform the following functions:

• Delete Tool—Deletes all program settings for the tool number entered in the
Tool Field, for a Manual tool. If the tool is in Spindle or Auto, this softkey is
not active.
• Part Setup—Accesses Part Setup screen.
• Part Programming—Accesses fields to enter the exact description of how the
part will be cut.
• Tool Offsets—Available only for NC programs. The tool length offsets appear

1 - 100 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 on the screen. Tool offsets are tool lengths used to compensate tool length
without altering the NC program.

Tool offsets are not saved with the NC program.

• Use the Positive Tool Length Compensation (G43) or Negative Tool Length
Compensation (G44) codes. A G49 code specifies tool offset cancel. An
H00 also cancels an offset.
• The G43 and G44 codes set a mode of operation within the program that
is in effect until a G49 or H00 is used. If an H code is used without a G43
or G44, in effect, the value stored in the tool length offset table is used as
the calibrated tool length.
• If a zero is entered for the Tool Offset value (Tool Offset H Table), the
control uses the Tool Offset value entered in Tool Setup for the tool
length.
• If a value greater than zero is entered for the Tool Offset value (Tool
Offset H table), the control replaces the value set in Tool Setup with the
Tool Offset H Table value.
• The four keyboard arrows, Page Up, and Page Down keys scroll through
the 01 to 200 offsets.
• When the Store Machine Position softkey is pressed, a negative Z value
reflecting the Z axis machine position is entered on the screen.

• Tool Home—Allows you to move the tool quickly away from the part. Using
this softkey after Tool Calibration is much faster than pressing the axis jog
buttons on the jog unit. Press this softkey and then press the Start Cycle
button to move the spindle to the change height.
• Set Tool Zero (Zero Calibration mode)—stores the Z-axis position of the
tool tip when at workpiece or gauge block plane. To use this softkey, carefully
jog the tool in the spindle down to the top of the part or to the fixture defined
at the Tool Calibration point and then press the softkey. The system stores
the position of the tool into the current part program and the number appears
in the Zero Calibration field on the Tool Setup screen. This can also be
accomplished by pressing the Store Position button on the jog unit. On the
screen the part display for “Z” changes to zero. In Zero Calibration mode, all
tools used in a part program will need to be calibrated to the same plane.
A warning message is displayed if the edited tool is not the tool in
spindle. Select OK to store the current position for the tool that is
being edited. Select Cancel if you do not want to set tool zero for
that tool.

• Set Length Using Touch-Off Device (Absolute Tool Length mode)—

stores the tool length when using a gauge or other touch-off device. For a
gauge, carefully jog the tool in the spindle down to the top of the gauge and
select the softkey. The system stores the tool length in the Tool Cal Length
field.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-101

 This softkey is active when the following is true:

1. The Tool Probe Parameters Type field is set to No Tool

Probe. This field is accessed in Tool Setup:
a. Select the More softkey.
b. Select the Tool Probing softkey.
c. Select the Tool Probe Setup softkey.
2. The Part Probe Parameters Present field is set to Yes.
This field is accessed in Part Setup:
a. Select the Part Probing softkey.
b. Select the Part Probe Parameters softkey.

• Set Tool Zero Using Gauge Block (Zero Calibration mode; Probing
only)—stores the Z-axis position of the tool tip when using a gauge block
into the Zero Calibration field and marks the tool as probed so it can be used
in Part Probing. To use this softkey, carefully jog the tool in the spindle down
to the top of the gauge at the Tool Calibration plane and press the softkey.
This softkey is active when the following is true:

1. The Tool Probe Parameters Type field is set to No Tool

Probe. This field is accessed in Tool Setup:
a. Select the More softkey.
b. Select the Tool Probing softkey.
c. Select the Tool Probe Setup softkey.
2. The Part Probe Parameters Present field is set to Yes.
This field is accessed in Part Setup:
a. Select the Part Probing softkey.
b. Select the Part Probe Parameters softkey.

Second set of Tool Setup softkeys:

• Advanced Tool Settings—set Tool Geometry, Feed and Speed, Surface Finish
Quality, and other tool information.
• Change Tool Number—Allows you to change the tool number for the current
tool displayed.
• Tool Probing—Accesses the Probing Parameters, see Program Parameters,
on page 1 - 124. Probing is available only with BMCs.
• Program Parameters—Accesses the program parameters.
• Part Program Tool Review—Accesses the tool review screen.
• Tool Measurement Settings (Absolute Tool Length mode)—accesses
the Tool Measurement screen where touch-off device height is set.

1 - 102 Programming Basics 704-0116-501 Getting Started with WinMax Mill

Advanced Tool Settings
Tool Geometry, on page 1 - 110
Feed and Speed, on page 1 - 112
NC SFQ, on page 1 - 114
Supplier, on page 1 - 115
Notes, on page 1 - 115
Edit Apt Parameters, on page 1 - 115

Basic tool information is stored in Tool Setup and additional information can be set in the
Advanced Tool Settings screens. Tool Geometry, Feed and Speed information, SFQ, and
other tool information are set in the Advanced Tool Settings screen.

Advanced Tool Settings are optional; it is not necessary to adjust

these settings in order to run part programs. They are available to
simplify programming and increase program efficiency.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-103

Tool Geometry
Tool dimensions are set in the Geometry tab. Fields denoted with a * are required in
order to draw a tool in Solid Graphics; however, these fields are automatically populated
with information from Tool Setup, as ratio of entered diameter. A picture of the tool is
displayed, and when a field is selected, that area on the picture is denoted.

Tool length field

is selected and
corresponding
area is denoted
on picture

Figure 1–9. Tool Geometry

Most fields on the Geometry screen correspond to tool type; see the following table for
information about these fields. Additional Geometry fields are:

Color

Direction

The following table provides the tool-type specific fields:

1 - 104 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 Thread Diameter
Shank Diameter

Neck Diameter
Chamfer Angle

Ream Chamfer
Cutting Edges

Stylus Length
Length of Cut

Tip Diameter
Tool Length

Tip Length
Drill Angle

Tip Angle
Diameter

Radius
Flutes

Angle
TPI
Drill X X X X X X

Tap X X X X

Boring head X X X X X

End Mill X x x x

Face Mill x x x X X X

Ball End Mill X X X X X

Back Spotface X X X X X

Probe X X X X

Gun Drill X X X X X X

Center Drill X X X X X X X X

Chamfer Mill X X X X X X

Bull Nose Mill X X X X X X

Ream X X X X X X

Spot Drill X X X X X

Forming Tap X X X X X

Counter Bore X X X X X X X

Counter Sink X X X X X X

Keyseat Mill X X X X X X

Thread Mill
Single Cutter X X X X
(SC)

Thread Mill
Multi Cutter X X X X X X
(MC)

Taper Radius
X X X X X X X
End Mill

Corner Round
X X X X X X X
Mill

Dove Tail Mill X X X X X X X

Engraving Mill X X X X X

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-105

 Tip Diameter is used to calculate Milling Type offset for Chamfer
Mill, Corner Round Mill, and Taper Radius End Mill.

When Shank Diameter, Length of Cut, and Tool Length are set
as a ratio of the diameter, values will be automatically recalculated if
the diameter changes or until a user-defined value is entered.

When used in a Thread Milling cycle, the Length of Cut and Pitch
are used to calculate the number of passes in the cycle.

Feed and Speed

Feed and Speed in Advanced Tool Settings is available only with the
Tool and Material Library option.

Feed and Speed settings are carried over from Tool Setup or can be specified in the Feed
and Speed tab for specific tool and material combinations in a part program. Choose one
of the materials from the work material list for a specific tool and enter the feeds and
speeds for both roughing and finishing for that tool and work material combination. This
information is saved in the Tool and Material Library and can be utilized in future part
programs without re-entering the speeds and feeds: When the Program Parameters for a
part program specify a work material, the tool number will recall the feed and speed for
that material.

Regardless of the material set in the Feed and Speed tab, the main
Tool Setup screen will always display feeds and speeds for
“Unspecified” material.

Specify work
material

Specify
Roughing & Speed and Feed
Finishing are calculated or
can be specified
in these fields

Figure 1–10. Advanced Tool Settings: Feed and Speed

Roughing and finishing tool parameters can be specified.

See the Field Glossary for definitions of the Feed and Speed fields:

1 - 106 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 Chipload Plunge Feed

Coolant Speed (RPM)

Feed Surface Speed

Feed/Rev Tool

Max Depth

Peck Depth

Feed and Speed Calculations

The WinMax software automatically performs tool feed and speed calculations for each
tool programmed in Tool Setup, on page 1 - 106. The calculations are carried over to
each data block in the part program using the programmed tool.

The software uses data to perform the calculations from these Tool Setup fields:
Diameter, Speed (RPM), Surface Speed (FPM) or (MPM), Flutes, and Feed/Flute (Tooth).
Feeds and speeds are related using the following formulas: Speed Formulas, on page 1 -
113 and Feed Formulas, on page 1 - 114.

Calculated values are carried forward to the Mill Feed field and Speed (RPM) field for
milling and holes data blocks. You can override automatically calculated values in a data
block by inserting a user defined value. If you manually change a calculated value in Tool
Setup, you will be prompted to update feeds and speeds for the part program data
blocks.

For fields that display truncated decimal point values, you may view
the non-truncated value by pressing and holding the CTRL key and
pressing the period (.) key.

Speed Formulas

The WinMax software uses these formulas to automatically calculate the spindle speeds:

Metric Mode:

Surface Speed x 100

English Units:

If the calculated RPM exceeds the maximum spindle RPM entered in

Machine Specifications, the value appears in red font color.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-107

 If you enter the Surface Speed (fpm) value, the Speed (RPM) value
will be calculated for you.

If you enter the Speed (RPM) value, the Surface Speed (fpm) value
will be calculated for you.

In some cases, calculation rounding may slightly alter a calculated

value.

For example, if you enter a value of 7000 RPM for the Speed field in
Tool Setup for a Drill operation, the calculated value for Surface
Speed is 458 fpm.

However, if you enter a Surface Speed of 458 fpm in the Surface

Speed field, the calculated value for Speed is 6997 RPM.

Feed Formulas

For Milling data blocks, specify the number of flutes for the tool in the Flutes field.

The software uses the following formula to calculate the Mill Feed:

For Holes operations, flutes are not specified for the tool.

The software uses this formula to calculate the Mill Feed:

If the calculated feedrate exceeds the maximum contouring feedrate

for the machine, an error is generated during the program run.

NC SFQ
NC SFQ in Advanced Tool Settings is available only with the NC/
Conversational Merge option.

Surface finish quality in NC programming is set in the NC SFQ tab of Advanced Tool
Settings. Change Enable Tool SFQ to YES and adjust the Tool SFQ value. This
automatically sets the SFQ value whenever the tool is used in NC programming and will
override the SFQ value set in Program Parameters or with the G05.3 setting.

See the Field Glossary for definitions of the NC SFQ Fields:

Enable Tool SFQ

Tool

Tool SFQ

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Supplier
Supplier in Advanced Tool Settings is available only with the Tool and
Material Library option.

The Supplier tab is optionally used to store information about tool supplier and orders in
memo-type fields.

Notes
Notes in Advanced Tool Settings is available only with the Tool and
Material Library option.

The Notes tab is used to store notes and miscellaneous information about a tool in a
memo-type field.

Edit Apt Parameters

The Edit Apt Parameters fields are defined as follows:

• Tool—displays the tool number and type entered on the Tool Setup screen.
This field cannot be edited. To change tools, go to Tool Setup, on page 1 -
106.
• NC Gear Range—define the spindle gear range. 0 = Low; 9 = High.
• NC Tool Number—indicate the starting tool in the tool changer. The range is
0 to 999.
• NC Diameter Offset—indicate the tool diameter to be used for cutter
compensation. This field is used for posting only. This will not affect a file that
is saved as an ISNC file.
If Cutter Comp is selected from the Output Tool Path As field on the
Post Processor Configuration screen, the value in the NC Diameter
Offset field will be put into the APT file. This value will refer to the
tool diameter offset on the target machine. If Centerline is selected
from the Output Tool Path As field, then the value entered in the NC
Diameter Offset field will not affect the APT file.

• NC Length Offset—indicate the length offset at the machine tool.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-109

Change Tool Number
The Change Tool Number softkey allows you to change the number of an existing tool or
copy an existing tool and give it a different number while retaining the tool with the same
number.

To change the Tool Number or create a copy of a tool, display the tool in the Tool Setup
screen. With the cursor in the Tool Number field, select the More softkey to display the
next softkey menu. Select the Change Tool Number softkey. The Current Tool
Description and New Tool Number fields are displayed. Type the new number into the
New Tool Number field and select one of the following softkeys:

• Change Tool Number—changes the number of the tool to the new Tool
Number. The old tool number is simply changed to the new number. If the
new tool number is already assigned to another tool, then the tool numbers
are swapped. If the Tool Library option is enabled, the tool number is also
updated in the spindle or ATC.
• Copy Tool—adds a new tool that is identical to the Current Tool Description.

If the New Tool Number is not in the current program or Tool & Material
Library, the current tool is copied to the New Tool Number. If the New Tool
Number is already used in the current program or Tool & Material Library, a
prompt appears that the New Tool Number selected will be replaced with a
copy of the current tool.

Part Program Tool Review

Use the PART PROGRAM TOOL REVIEW softkey on the Program Review screen to review
the tools used in a specific part program. This screen lists all tools used in a program, and
the program block where they are used. The location column indicates if the tool is in
Manual, Auto, or Spindle.

List of tools
used in program

Supplier, Order,
Notes, Tool Life
tabs can be used to
keep track of
other tool
Program blocks information
in which
highlighted
tool is used
(highlight block
and select the
Edit Block
softkey to jump to
the program block)

Figure 1–11. Part Program Tool Review of a Conversational program

1 - 110 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 Start typing a tool number to jump to that tool in the review list. The
Jump to tool pop-up box opens; select OK to go to that tool in the
list.

Tool information can be entered into the Supplier, Order, and Notes tabs at the bottom of
the Part Program Review screen.

Tool notes can be entered and viewed on the Notes tab in the Part
Program Tool Review screen and the Advanced Tool Settings screen.
Notes can also be viewed in the Select Tool screen (accessed with
the Select Tool from List softkey when entering a tool in a program
block).

The Supplier, Order, and Notes tabs are only available with the Tool &
Material Library option.

Part Program Tool Review for NC Programs

Part Program Tool Review in NC programming scans the current NC program for T codes
to determine the tools used in the program. T codes are ignored if they are inside a
comment (surrounded by parentheses) or if they are an argument in a macro call
(preceded by a G65).

Tools are listed by number. When a tool is selected (highlighted), the Block list will display
the number and NC text of all blocks that contain the T code for a tool change to the
selected tool, as shown below:

List of tools
used in program

Program blocks
in which
highlighted
tool is used
(highlight block
and select the
EDIT BLOCK F1
softkey to jump to
the program block)

Figure 1–12. Part Program Tool Review of an NC program

Jump to a program block by highlighting the block and selecting the

Edit Block softkey.

If a tool in the current NC program is not defined in Tool Setup, it appears in the Tool

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-111

Review list as an unknown tool with a diameter of 0 and an unknown location. This is
shown below.

Figure 1–13. Tool Review showing Unknown tool in NC program

An undefined tool can be added to the NC tool setup by selecting the tool in the list,
selecting the Tool Setup softkey, and selecting a type or entering data for the new tool.
The tool can also be quickly added as an unknown tool with a diameter of 0 by selecting
the Add As Manual Tool softkey.

Part Program Tool Review Softkeys

Softkeys perform the following functions:

• Part Setup—access Part Setup screen. See Part Setup, on page 1 - 91 for
more information.
• Tool Setup—access Tool Setup. See Tool Setup, on page 1 - 106 for more
information.
• Part Programming—access and create data blocks of a part program. The
current program's data blocks appear on screen when this softkey is used.
Delete, add, edit, and navigate through the data blocks. The NC editor is
displayed for NC programs. See Conversational Part Programming for more
information.
• Program Parameters—accesses the Program Parameters screen to specify
data common to all program data blocks. See Program Parameters, on page
1 - 124 for more information.
• Tool Change Review Screen—access the Tool Change Review screen to

1 - 112 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 see all tool changes in the part program. Available with the Tool Change
Optimization option. See Tool Change Optimization in the Options manual for
more information.
• Match Tools—access tool matching results. See Tool Matching, on page 1 -
119 for more information.
• Add As Manual Tool—adds the highlighted unmatched tool as a Manual tool
in the Tool & Material Library and assigns it the next available tool number.

Tool Matching
When a new program is loaded and the Tool & Material Library option is enabled:

1. The new program’s tools are compared to the tools in the Tool & Material
Library to identify a match by tool type and diameter.
The diameter is set in the Tool Matching: Maximum Diameter
Difference field in Tool Utilities and Settings, on page 1 - 49.

2. If only one tool match is found, the program will use that tool number,
including the Zero Calibration, from the Tool & Material Library. Note that Feed
and Speed data will not be replaced in the program.
3. If more than one match exists, WinMax then looks at tool number. If it finds
the same tool number, type, and diameter, it will match the tool.
4. If there are no matches, tools are either loaded into the Tool & Material Library
as Manual, or users can select from a list of tools in the Tool & Material Library
that are similar to the unmatched tool. The AUTOMATICALLY LOAD
UNMATCHED TOOLS AS MANUAL field in Tool Utilities and Settings, on page 1
- 49 controls this:
• When the field is set to Yes, any unmatched tools from the new part
program will be added to the Tool & Material Library and will be assigned
to the first available tool number.

For example, a new program is loaded with tool #12 as a 0.375 inch end
mill. If tool #12 in the Tool & Material Library is not a 0.375 inch end mill
and no other tool in the Tool & Material Library is a 0.375 inch end mill,
then this tool will be added to the Tool & Material Library as a Manual tool
and will be assigned the first available tool number.

• When the field is set to NO, a prompt to match tools appears. Answer YES
to the prompt to review the unmatched tools.

Tools that are unmatched are displayed in Tool Matching Results.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-113

Tool Matching Results
When tools from the part program cannot find a matching tool in the Tool & Material
Library, these unmatched tools are listed in the Tool Matching Results screen, accessed
with the MATCH TOOLS softkey from the Tool Review screen. Unmatched tools from the
current part program are listed in the “Tools to be matched” section; for imported
programs, the Import Number (No.) column contains the tool number saved in the
original program. When each unmatched tool is highlighted, a list of tools from the Tool &
Material Library with the same tool type are listed in the lower, “Closest matches” section.
Tools of the same type are listed in order of closest to furthest diameter difference from
the highlighted tool.

Unmatched
Tools Import Tool
Number

Difference in
tool diameter List of similar tools
from in Tool Library (list
unmatched corresponds to the
tool highlighted tool)

Figure 1–14. Tool Matching Results

The Choose As Replacement softkey appears when you select a tool from the Closest
matches list. Use this softkey to replace an unmatched tool with the selected tool from
the Tool & Material Library.

If there is not a match in “Closest matches,” use the Add As Manual Tool softkey to add
the tool to the Tool & Material Library.

The Save To Database softkey appears when you select an unmatched tool from the
list. Select the softkey to save the tool to the Tool and Material Database.

Saving a tool to the Tool and Material Database will not match a tool
with an existing tool in the Tool & Material Library. The program will
still consider the tool unmatched and will not run until a match is
selected or a new tool is added to the Tool & Material Library.

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Tool Management
Tool Management screens are accessed in Manual Mode with the Tool Management
softkey. Tool information can be stored independent of the part program data using the
Tool & Material Library option. Program-specific tool information (such as feed rate and
speed) created for one program can be reused when tools are selected from the library
for a subsequent program. Tool Management tabs are:

• Spindle—shows the tool located in the machine’s spindle.

• Auto—lists the tools that are in the machine’s tool magazine.
• Manual—lists the tools that may be utilized on the machine but are not
currently in the machine’s magazine or spindle. The Manual tab is active only
with the Tool & Material Library option.

Spindle
The Spindle tab displays information about the tool in spindle and allows you to set the
next tool to execute a tool change, or to change the current tool in spindle. The Move
Tool to Spindle softkey moves the tool in the Next Tool field to the spindle.

See the Field Glossary for definitions of fields on the Spindle tab (fields displayed vary
depending on machine and/or configuration):

Axes Status Next Tool

Axis Limit Switches Orientation

F / Feed Part

Machine S / Spindle

Magazine TIS / Tool in Spindle

Auto
The Auto tab lists the tools in the ATC (automatic tool changer) magazine. Tools are listed
by pocket number. The view can be customized to show only occupied pockets or to
disable even-numbered pockets (for large tools), using the check boxes at the top of the
screen.

Softkeys on the Tool Library Auto tab are:

• Move Tool To Spindle—when spindle is empty, highlighting a tool on the

Auto or Manual lists will enable this softkey. Select to confirm and the tool will
appear on the SPINDLE tab. The control will prompt to insert the tool into the
spindle.
• Select Tool—highlight a tool in the list and touch this softkey to select the
tool.
• Clear Pocket—removes the selected tool from the pocket.
• Clear All Pockets—removes all tools from the Auto list.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-115

Manual
The Manual tab shows tools available for use that are resident on the control, but are not
currently in the spindle or ATC. The Manual tab is active only with the Tool & Material
Library option:

Softkeys are:

• Move Tool To Spindle—when spindle is empty, highlighting a tool on the

Auto or Manual lists will enable this softkey. Select to confirm and the tool will
appear on the SPINDLE tab. The control will prompt to insert the tool into the
spindle.
• Insert Tool—moves a tool from Manual to Auto.
• Tool Setup—accesses the Tool Setup screen.
• Change Tool Number—allows you to change the number of a tool in the
list. See Change Tool Number, on page 1 - 116 for more information.
• Clear Tools—clears (removes) tools from the list:

• Clear Selected Tool—removes highlighted tool from the Tool Library.

• Clear Auto And Manual Tools—removes all tools from the Tool Library.
• Clear Auto Tools—removes all tools in Auto from the Tool Library.
• Clear Manual Tools—removes all tools in Manual from the Tool Library.

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Tool and Material Database
The Tool and Material Database is available when the Tool & Material Library option is
enabled. It is accessed in Auxiliary Mode. Tool and material information can be entered
and stored in the database. The materials entered into the database are available in the
work material list located on the Feed and Speed tab in Tool Type Setup/Advanced Tool
Settings. This information is saved in the material database and can be utilized in future
part programs without re-entering the speeds and feeds.

To add a tool to the database:

1. Select the Tools tab.

2. Select Add Tool softkey.
3. Enter the tool information in the fields. See Advanced Tool Settings, on page 1
- 109 for more information about these fields.

Softkeys on the TOOLS tab are:

• Add Tool—accesses Tool Type Setup screen to add a tool to the database.
• Edit Tool—accesses Tool Setup to edit tool.
• Delete Tool—deletes the selected tool from the database.

To add a material to the database:

1. Select the Materials tab.

2. Select the Add Material softkey.
3. Type the name of the material in the Name field.
4. Add any notes in the Notes field.
5. The entry is saved by exiting the screen.

Softkeys on the MATERIALS tab are:

• Add Material—add a new material to the database.

• Edit Material—change the specifications of a material in the database.
• Delete Material—delete a material from the database.
• Select Material for Part Program—uses the highlighted material in the
current part program.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-117

Program Parameters
Program parameters are displayed on tabs for General 1, General 2, Milling 1, Milling 2,
Holes, Probing, and Performance. The Performance tab in WinMax is active when the
SelectSurface Finish Quality option is enabled. The programmer has the option to make
changes to any or all of the program parameters and save them as user defaults. The
user defaults and original WinMax defaults can be restored by using the appropriate
softkey. Parameters can be altered with the Change Parameters data block during
program execution. Refer to Change Parameters, on page 2 - 121 in Conversational
Programming for details.

Refer to NC Part Programming for information about NC Parameters.

See the Field Glossary for definitions of parameters on the General 1 tab:

Chord Error Rapid Traverse

Enable Pecking Retract Retract Clearance

Clearance

Override Lockout

Peck Clearance Plane

Pecking Retract Clearance

See the Field Glossary for definitions of parameters on the General 2 tab:

Automatic Safe Repositioning Move to Safe Pos During

Retract Override TC

Depletion Retract Tool Change Optimization

First Peck Offset

Include Offset Z in Tool Zero Cal

Interrupt Cycle Z Retract

See the Field Glossary for definitions of parameters on the Milling 1 tab:

Blend Offset Finish Speed (%)

Blend Overlap Finish XY

Cutter Comp Parameter Finish Z

Default Pocket Overlap Milling Direction

Finish Feed (%) Stock Allowance Mode

See the Field Glossary for definitions of parameters on the Milling 2 tab:

1 - 118 Programming Basics 704-0116-501 Getting Started with WinMax Mill

 Allow Plunge Outside Pocket Mill Plunge Ramp Slope

Finish Plunge Helix Radius Mill Plunge Type

Finish Plunge Ramp Slope Operator Specify Pocket

Start

Finish Plunge Type Pocket Plunge Near Center

Mill Plunge Helix Radius

The Milling 2 Parameters fields are available only when the Helical
Plunge option is installed.

See the Field Glossary for definitions of parameters on the Holes tab:

Bore Dwell

Bore Orient Retract

Drill Dwell

Tap Retract (%)

See the Field Glossary for definitions of parameters on the Probing tab:

Automatic Tool Monitoring

Diameter Tolerance

Length Tolerance

Retain Probed Part Setup

Start Coordinate Reference

Probing parameters affect Tool Quality Monitoring and Part Probing.

See Tool Quality Monitoring, on page 4 - 14 and Part Probing Option,
on page 4 - 31 for more information.

See the Field Glossary for definitions of parameters on the Performance tab:

Smoothing Tolerance

Surface Finish Quality (Finishing Default)

Surface Finish Quality (Roughing Default)

Surface Finish Quality (SFQ) is enabled with the SelectSurface Finish Quality option. SFQ
parameters can be modified in either Conversational or NC programming. The default
SFQ for roughing is 80 and finishing is 20. Recommended values are:

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-119

 SFQ Desired Result

1-20 High precision parts /finishing

21-79 Good surface quality / finishing, semi-finishing

80-100 High throughput / roughing

Table 1–1. Recommended SFQ values

If SelectSurface Finish Quality is not enabled, conversational

roughing tools use SFQ of 80 and conversational finishing tools use
SFQ of 20; NC default is 50.

Softkeys on the Program Parameters screen are:

• Save As User Defaults—saves the selected field’s value as the user-defined

default value.
• Restore User Defaults—restores the user-defined values to a field that has
been populated with other values.
• Restore WinMax Defaults—restores the WinMax-defined values to a field
that has been populated with other values.
Change Parameters program blocks load the user-defined
parameters set in Program Parameters.

• NC Parameters—accesses NC Configuration Parameters. These parameters

are available only with NC Part Programming.

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Import / Export Functions
Import Functions imports Part Setup, Tool Setup, Program Parameters, Part Program
information, and/or NC states from an existing Conversational program or NC State file
into the active part program. Tool lists and Tool and Material Database can also be
imported or exported from this menu (with the Tool & Material Library option installed).

1. Select the Import / Export Functions softkey from the Input screen.
2. Select the appropriate softkey to import from a Conversational file, or to
import or export NC state or Tool Library.
3. Choose the origination or destination file, or select an operation for the Tool
Library then select the appropriate file.
4. Select the Import or Export softkey.
5. Choose one or more components from the list and select the Begin Operation
softkey.

Conversational Components
These are the Conversational components that can be imported from an existing part
program into a new part program:

• Part Setup—imports the Part Setup from the selected program into the
current part program.
• Tool Setup—imports tools from the Tool Setup of the selected part program
to the current tool setup on the machine. If the Tool & Material Library option
is enabled, unique tools are added as Manual and other tools may be
matched (see Tool Matching, on page 1 - 119).
• Program Parameters—imports the Program Parameters from the selected
program into the current part program.
• Part Program—imports the part program from the selected program into the
current part program.

NC States
NC components are stored in the NC State file on the control. Only one NC State file
exists on a control, and it is updated as changes are made to current or new NC
programs.

When transferring an NC program from one machine to another the NC State file from the
can be imported or exported using the Import (or Export) NC State From (To) File
softkey. These are the components that can be imported into an NC file:

• Program Parameters—imports the Program Parameters.

• Part Setup / Work Offsets—imports the Part Setup and Work Offsets.
• Tool Setup—imports tools from the Tool Setup of the selected part program
to the current tool setup on the machine. If the Tool & Material Library option
is enabled, unique tools are added as Manual and other tools may be
matched (see Tool Matching, on page 1 - 119).

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-121

 • Tool Offsets—imports Tool Offsets.
• NC Parameters—imports the NC parameters.
• NC Variables—imports NC variables.
The imported components will replace the current components from
the open program; they are not merged together.

NC States are saved as follows:

1. Select the Import / Export Functions softkey from the Input screen.
2. Select the Save NC State To File softkey.
3. Choose the location to which the file will be saved in the Save State File
screen.
4. Type the name of the file in the FILE NAME field, or use the default,
ncstate.ncsx, which appears automatically in this field.
It is recommended to rename the NC States file to match the active
part program. When renaming, you must retain the .ncs extension at
the end of the file name. For example, Program Name.ncsx.

5. Select the SAVE F1 softkey to save the NC States file. A message that the file
saved successfully will briefly appear on screen.

Importing NC States into Conversational Programs

NC States information that is valid for Conversational programs (the Part Setup, Tool
Setup, and Program Parameters) can be imported into a Conversational program.

1. Make sure the current part program is Conversational.

2. Select the IMPORT FUNCTIONS softkey from the Input screen.
3. Select the IMPORT NC STATE FROM FILE softkey.
4. Choose the NC States file from which components will be imported and select
the LOAD F1 softkey. Either file may be used to import any component.
5. Choose one or more components from the list and select the BEGIN
OPERATION softkey.
6. Select OK to continue the import operation.

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Import and Export Tool Library
Import and Export Tool Library functions are available only with the
Tool and Material Library option.

The Import / Export Tool Library softkey allows you to move tool information from the
WinMax control to other locations and vice versa.

Import / Export Tool Library submenu softkeys are:

• Export Auto And Manual Tools—save Auto and Manual tools to a different
directory.
• Export Manual Tool List—save only the Manual tools to a different
directory.
• Import Into Manual Tool List—load tools into the control from a directory.
All tools are imported into the Manual list, even if they were exported as Auto
tools.

The ATC positions are not retained when tools are imported.

• Export Tool and Material Database—save tool templates and materials to

a different directory.
• Append Tool and Material Database—load tool templates and materials
into the control from a directory. These are added to the existing database on
the control.
• Replace Tool and Material Database—load tool templates and materials
into the control from a directory. The existing database is replaced.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-123

Copy and Change Blocks
To make changes to several data blocks at one time, use the Copy and Change Blocks
softkey to access the Block Editor.

These are the softkeys:

• Copy Blocks—Duplicate the specified data blocks in another location in the

part program.
• Move Blocks—Remove the specified data blocks from their current location
and transfer them to another location in the part program.
• Delete Blocks—Remove the specified data blocks from the part program.
• Modify Dimensions—Add offsets to the axes' coordinate dimensions currently
stored in the part program for a range of blocks.
• Change All Feeds, Speeds, and Tools—substitutes new feeds and speeds
for all tools within the specified range of data blocks.
• Change Feeds and Speeds by Tool—substitutes new speeds and feedrates
for a specified tool within a range of data blocks.
• Change Surface Finish Quality—changes the SFQ value(s) for the specified
block range.

Copy, Move, or Delete Blocks

The COPY BLOCKS screen is used to duplicate the specified data blocks in another
location in the part program.

The MOVE BLOCKS screen is used to remove the specified data blocks from their current
location and transfer them to another location in the part program.

The DELETE BLOCKS screen is used to remove specified data blocks from the part
program.

See the Field Glossary for definitions of the Copy/Move/Delete Block fields:

End Block

Put Block Before

Start Block

Modify Dimensions
Modify Dimensions allows you to add offsets to the axes' coordinate dimensions currently
stored in the part program for a range of blocks.

These softkey choices appear when you select the Modify Dimensions softkey:

See the Field Glossary for definitions of the Modify Dimensions fields:

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 A Offset Start Block

B Offset X Offset

C Offset Y Offset

Change Z-Start Z Offset

End Block

Enter the modifications in the fields and select the Make The Change softkey to modify
the programmed dimensions.

Modified dimensions are applied to Pattern blocks that provide their

own reference points: Loop Rotate center points, Loop Angular
reference and center points, Mirror Image reference point, and Scale
reference point.

Changing Feeds, Speeds, Tools, and SFQ

Feeds, Speeds, and Tools, and SFQ can be changed for a range of blocks in a part
program.

See the Field Glossary for definitions of the Change Feed, Speeds, Tool and SFQ fields:

Change Finish SFQ Put Block Before New Tool

Change Rough SFQ New Feed Put Block Before

Change Tool New Finish Tool Rough SFQ

End Block New Plunge Feed

Finish SFQ New Speed (RPM)

Enter the changes in the fields and select the Make the Change softkey.

The Copy Blocks, Move Blocks, and Delete Blocks softkeys are
also available for editing a current program.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-125

Review Mode
The Program Review screen is accessed with the console Review key.

Sub-blocks within the

selected data block

List of program’s
data blocks
Select to jump
to selected
data block or
sub-block

Tools and Notes for

the selected block

Figure 1–15. Program Review Screen

Data blocks and sub blocks of the active part program are displayed. Program blocks can
be moved and added in the Program Review screen.

Start typing a block number to jump to that block in the review list.
The Jump to block pop-up box opens; select OK to go to that block
in the list.

Jump to the program block by highlighting the block in the list and
selecting the Part Programming softkey.

Tool data and notes are displayed in the Tools and Notes tabs:

• Tool information for the selected data block is displayed in the Tools tab.
When a tool is selected the Edit Tool softkey is displayed and will open Tool
Setup for the selected tool.
• Notes can be entered for the selected data block or sub block in the Notes
tab. Notes are displayed on the Review screen and with the data block when
the blocks are printed.

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Program Review softkeys are:

• Multiple Block Functions—allows multiple blocks to be cut, copied, or

pasted between programs:
• Cut—highlight data block(s) and touch this softkey to delete from the
current program. Block(s) can then be pasted into the same or a different
program.
• Copy—highlight data block(s) and select this softkey to make a copy that
can be pasted into the same or a different program.
• Paste—places previously cut or copied data block(s) above the
highlighted data block.
• Delete—highlight data block(s) and touch this softkey to permanently
remove the block from the program.
Multiple blocks can be selected simultaneously by holding the F and
Alt keys while pressing the up or down arrow keys.

• Convert to Rotary—converts linear dimensions to rotary dimensions; a

flat geometry can be wrapped around a cylinder, given a radius. Blocks
that can be wrapped are: contour, circle, frame, slot, polygon, TrueType
lettering holes (locations), and patterns (loop linear, loop rectangular, and
mirror). You will be prompted to enter a cylinder radius.

If centerlines are enabled in Part Setup, the Z values in the blocks are not
adjusted. If the centerlines are disabled, the Z axis becomes the radius in
the block and the cylinder radius is applied to the value.

• Convert to Linear—converts rotary dimensions to linear dimensions.

For WinMax Desktop and WinMax Mill on machines not equipped with
rotary, the Default Conversational Program Type must be
changed to a rotary type in order to convert the program to rotary.
This is changed in Conversational Settings in Utilities.

• Delete Block / Delete Sub Block—deletes the highlighted data block or

sub-block.
• Part Programming—allows you to edit the selected data block or sub-block.
See Part Programming in the Conversational Programming manual for more
information.
• Program Parameters—access General, Milling, Holes, Probing, and
Performance parameters. NC parameters are accessible for NC programs.
• Part Setup—access the Part Setup screen to establish part zero, centerline,
offset Z, safety work region, and other parameters.
• Part Program Tool Review—review the tools used in the part program.
• Insert Block / Sub Block Before—inserts a new program block or sub-
block before the selected block or sub-block.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-127

Manual Safety Override Mode
For machines with CE safety circuit switches enabled, the Manual Safety Override mode
allows the enclosure doors to be opened when the system is in Manual mode so the
operator or supervisor can perform limited manual machine operations.

While the doors are open, manual jog feed is restricted. The jog feed is limited to 2
meters per minute, or approximately 80 inches per minute, with manual safety override
enabled. No jogging is permitted with manual safety override disabled.

Manual operations that cannot be started with the doors open,

regardless of manual safety override mode, are:

• Spindle On
• Park Machine
• Warm Up Machine
• Calibrate Machine
• Spindle Orient
• Chip Removal
• Tool Changer Functions

When the Manual Safety Override mode is enabled, it remains enabled until control
power is turned off, the Emergency Stop button is pressed, or machine power is turned
off. A fault will disable the Manual Safety Override mode also.

If you try to jog the axes with the doors open without enabling the manual safety
override mode, a prompt appears to cycle the keyswitch or enter the access code to
enable jog.

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CE Diagnostics
To enable the Safety Override mode, access the CE Status & Diagnostics screen.

1. From the Manual mode screen, select the Diagnostics softkey.

2. Select the CE Diagnostics softkey. The following screen appears:

Figure 1–16. CE Status & Diagnostics Screen

The fields on the CE Status & Diagnostics screen are defined as follows:

• CE Configuration—Displays CE logic configuration. Enabled or disabled in

Integrator Support Services.
• Door Lock Status—Displays status of all doors with CE safety circuit
switches Unlocked or Locked. The Door Switch Status must be Closed when
the Door Lock Status is Locked.
• Door Switch Status—Displays status as Closed or Open. The switch must be
Closed when the Door Lock Status is Locked.
• Limited Manual Operations—Displays status as Disabled or Enabled.
Status is Enabled after entering an access code. Enabled allows limited safe
motion with the doors open.
• EIR Relay State—Displays status as Disabled or Enabled. When enabled, the
enclosure doors have been locked due to a process request or an active
process.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-129

Entering the Access Code
A numeric access code is required to enable Limited Manual Operations. Follow these
steps to enter the access code:

1. Select the Enter Access Code softkey. A message appears with a prompt for
entering a 4 digit code.
2. Enter a numeric code using the console keypad. Asterisks (*) appear
representing each entered digit. When the fourth digit is entered, the asterisks
and message disappear.
Using a non-numeric key cancels the operation.

When the code is successfully entered, the Limited Manual Operations feature is enabled,
as indicated in the status field.

For initial setup of the Access Code, the user is prompted to enter a new code and then to
enter the same code a second time before it is accepted.

Changing an Existing Access Code

To change an existing access code, follow these steps:

1. Select the Change Access Code softkey. A message appears asking you to
enter the current code.
2. Enter the current numeric code from the console keypad. A message appears
asking you to enter the new code.
3. Enter the new code. A message appears asking you to re-enter the new code
for confirmation.
• If the new code is not re-entered, the code is not changed.
• When the new code is verified, the code will change and a message
appears to confirm the action.

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Graphics
WinMax graphics include Toolpath and Solid Graphics, on page 1 - 138. Real-time graphic
animation is available with the Runtime tool, which shows a simulated tool cutting the
part on screen while the machine is cutting the actual part.

Solid graphics and Runtime tool are only available with the
Advanced Verification Graphics option.

Graphics Settings
Graphics preferences are set in the Graphics Settings screen, which is accessed with the
Graphics Settings softkey.

See the Field Glossary for definitions of the Graphics Settings fields:

Background Color Override Machine Show Graphics Tool Path

Configuration

Default View Part Surface Show Roughing Tool Universal Type

Path for 2D Surfaces

Default Zone Plunges Show Roughing Tool Use Chord Error

Path for 3D Surfaces From Program

Enable Runtime Tool Rapids Stock Outline

Display

Graphics Chord Error Refresh Speed Stock Transparency

Graphics Optimization Rotary Axis ISO Tilt Axis Preference

Standard

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-131

Toolpath and Solid Graphics

Toolpath graphics displays a wireframe view of the part. Toolpath is also animated to
show the tool in motion if the runtime tool is displayed (only available with the Advanced
Verification Graphics option).

Solid graphics displays a solid 3-dimensional part; only available with the Advanced
Verification Graphics option.

Denotes the
view selected

Indicates
the stage of
processing

Figure 1–17. Solid graphic display

The console Draw button initiates drawing. The Draw Options menu is displayed (for both
Toolpath and Solid) to control drawing and animation:

• Draw Options—displays the following draw options:

• Draw (Pause)—starts drawing the part. When drawing is in progress,
the softkey displays PAUSE—select it to pause the drawing. When paused,
the softkey displays DRAW—select it to resume drawing.
• Accelerated Draw—displays only the completed drawing without
showing each block as it is drawn. There may be a delay before the
completed drawing appears on screen; selecting the Show Progress
softkey displays the drawing at the current point each time the softkey is
selected.
• Single Step—displays only one step or program block at a time.
Subsequent selection of SINGLE STEP will execute the next step or block.
• Next Tool Change—displays cutting from one tool change to the next.
• Clear Graphics—clears the part drawing from the screen.
• Save Session—saves the current part drawing after a successful draw.
Allows the drawing to be loaded for faster drawing at a later time
(especially useful for large programs).
• Load Session—loads current program drawing that was previously saved
with the Save Session softkey.

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 • Select View—choose XY plane, XZ plane, YZ plane, Isometric, or All Views.
For dual-zone machines, the Select Zone softkey displays Zone 1, Zone 2, or
All Zones.
• Zoom—magnifies an area of the graphic. Select the softkey and choose one
of the following:
• Zoom In—magnify incrementally by 20% each time the softkey is
selected.
• Zoom Out—shrink view incrementally by 10% each time the softkey is
selected.
• Smooth—toggle on or off to sharpen image when drawing completes or
with zoom, pan, rotate, etc. An icon located in the top left corner of the
graphics screen shows if smoothing is on or off (icon can be toggled as
well):

Indicates that smoothing is toggled ON.

Indicates that smoothing is toggled OFF.

• Default Zoom—returns to the zoom level to the default value.

• Fit To View—returns drawing to the default position, rotation, and zoom
levels.
• “Touch-and-drag”—place stylus at a point on the screen and drag it to
expand the box over the area you wish to magnify. When stylus is lifted
from screen the area will be magnified.

• Pan—moves the graphic up, down, left, or right. Use the softkeys (Pan Up,
Pan Down, Pan Left, Pan Right, or Center), or touch the screen and drag the
graphic. Fit to View returns the drawing to the default position, rotation, and
zoom levels.
• Rotate—changes the rotation of the graphic. Softkeys include Rotate Up,
Rotate Down, Rotate Left, and Rotate Right. Default Rotation returns rotation
to the default value.
• DB Search—jumps to a selected data block. Select the softkey, touch an
area on the graphic touchscreen, and select the JUMP TO BLOCK softkey.
• Snapshot—creates an image of the solid drawing that is stored with the file.
The image is displayed on the Program Manager screen when the program is
highlighted.
• Graphics Settings—displays the Graphics Settings screen.

Getting Started with WinMax Mill 704-0116-501 Programming Basics 1-133

Max5 UI Graphics Screen
The Max5 Graphics screen is available as an option for Max4 consoles and WinMax
desktop software. This graphics screen shows solid renderings of the tool paths and stock
removal for the program. In addition, the appropriate console LEDs light when the
coolant is programmed to be on, when the spindle is programmed to be on, and when
there is a programmed tool change.

This updated graphics screen uses many of the same features of the Max4 Toolpath and
Solid graphics.

Zoom in and out

Pan in selected direction
Rotate in selected direction in ISO view

Reset All to original view

Opaque view
Measure
Fill

XY Side view XZ End view YZ Top view

Isometric view Quad view (all of above)

Run the entire Part program

Run Single block or segment of program
Run Program until programmed Tool
change
Graphics Speed Control buttons

Draw Control buttons

Select point on drawing

Jump to location in program

Capture graphic
Smooth lines
Access screen Settings

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MACHINE OPERATION BASICS
The following sections explain basic machine operation.

Machine Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 134

Recovery and Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 135
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 136
Automatic Tool Changers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 139
HMX Automatic Pallet Changer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 149
Dual-Zone Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 153
Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 157
Stop Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 163
Restart Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 165
Shutdown Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 165
Servo Drive Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 166

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-135
Machine Start Up
Calibrate Machine
Calibrating establishes the machine reference point (absolute zero) for each axis.
Absolute zero is the location on the table, usually a corner or near a corner, where the X
and Y axes intersect. This value does not change.

To calibrate the machine, press the Manual Mode console button. "Uncalibrated" will be in
the Cal Status field.

Establishing Servo Power

Perform the following steps to establish servo power:

1. If necessary, release all Emergency Stop buttons. Twist the button in the
direction indicated by the arrows to release it.
2. Press the Manual Mode console button.
3. Press the console Power On button to turn on the machine. The Power On
button lights up.
4. If there is a servo or spindle error, press the Reset Servos and Spindle softkey
to clear it. The Start Cycle button begins flashing.
5. Press the Start Cycle button to turn on the machine servos. The Start Cycle
button stops flashing.

Axes Calibration
To calibrate all axes, follow these steps:

1. Press the Calibrate Machine softkey. The Start Cycle button begins to flash off
and on.
2. Press the flashing Start Cycle button. The Axis Limit Switches field indicates
the current status of the machining center’s limit switches as each axis
calibrates.
3. The machine position display (at the top of the text screen) shows zero (0) for
all axes when the calibration process is complete.

Warm Up Machine
If the machine has been idle for an hour or more, it is recommended that the warm up
cycle be run. Warming up an idle machine before part cutting improves component
reliability and machine performance. You must be in Manual mode to run a warm up
cycle.

Follow these steps to warm up the machining center:

1. The control power must be on and the axes must be calibrated. There must
not be any tool in the spindle, and the Tool in Spindle field on the Manual
screen must be 0.

1 - 136 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 2. Select the Warm Up Machine softkey. The Start Cycle button begins flashing.
3. Press the Start Cycle button (to cancel the warm up cycle, press any Mode
console button or softkey before pressing the Start Cycle button). The axes
slowly move from one end of the machine to the other. The spindle moves at a
low RPM for five minutes.
4. The warm up cycle completes in 15 minutes. The Manual screen reappears and
axis movement stops.

Follow these steps to cancel the warm-up cycle:

1. Press the Feed Hold console button.

2. Press the Spindle Off button.
3. Press the Feed Hold button a second time, or press the Stop Cycle button.

Reset Master
To restart the control (reboot the system) without switching the power to the machine
tool off and back on again, follow these steps:

1. Press the Auxiliary console button. The Auxiliary screen appears.

2. Press the More softkey.
3. Press the Reset Master softkey. The Yes and No softkeys appear. When the Yes
softkey is pressed, the system will reboot. Pressing the No softkey aborts the
reset process.
Be sure to save any part program you’re working on before resetting
the master. In NC Programming, an unsaved part program will be
permanently erased. In Conversational Programming, the part
program will be saved, but any changes made after the last autosave
will be lost.

Recovery and Restart

Restart a part program at almost any point within the program - typically, the point at
which the running program was interrupted.

If the Emergency Stop button was used to stop machining, machine power must be
restored before restarting the program.

To restart the program, follow these steps:

1. Select the console Auto button. The Start Block default is 1, and the End Block
default is the last block of the program.
2. Enter the proper Start Block and, optionally, an End Block if other than the end
of the program.
3. Select the Recovery Restart softkey.
4. If the Start Block contains multiple choices for restart, prompts are displayed
to select the proper point of restart.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-137
Manual Mode
Manual mode controls machine settings and operations.

These are the softkeys for Manual mode:

• Tool Management—Access tool information for Spindle, Auto Tools, and

Manual Tools.
• Manual Function Setup— Set manual spindle speed and jog feed, retract tool,
execute a manual rapid move, turn chip removal on and off, turn washdown
coolant on and off, and turn worklight on and off from this screen.
• Diagnostics— Access the CE Status & Diagnostics screen and the ATC &
Machine Diagnostics screen. See Manual Safety Override Mode, on page 1 -
134 and ATC and Machine Diagnostics, on page 1 - 145 for more information.
• Park Machine—Center the table and leave the spindle at the home position.
• Warm Up Machine—Warm up an idle machine.
• Orient Spindle—Ensures that the Z axis is at the correct height for a tool to
be inserted in the spindle.
The ORIENT SPINDLE softkey will not function unless the enclosure
doors are completely closed.

• Reset Servos and Spindle—Activates only to enable recovery from certain

types of electronic hardware faults such as overloads.
• Calibrate Machine—Establish absolute zero for each axis on the machining
center.

See the Field Glossary for definitions of the fields on the Manual mode screens (fields
displayed vary depending on machine, configuration, and/or program type):

A Jog Along Tool Axis Orientation X

Axes Status Machine Part Y

B Magazine Rotary Jog Feed Z

C Manual Jog Feed Rotary Rapid Feed

Coordinate System Manual Rapid Feed S / Spindle

F / Feed Manual Spindle Speed TIS / Tool in Spindle

Manual Function Setup

Set manual spindle speed and jog feed, retract tool, execute a manual rapid move, turn
chip removal on and off, turn washdown coolant on and off, and turn worklight on and off
from this screen. Some fields vary depending on machine type.

Softkeys are:

1 - 138 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 • Retract Tool—retracts the tool.
• Retract Tool Along Tool Axis (Tilt B axis machines)—retracts tool along
the tool axis.
• Toggle Jog Along Tool Axis (Tilt B axis machines)—toggle on and off
• Manual Rapid Move—accesses the manual rapid move parameters.
• Chip Removal Forward On/Off—turns the chip conveyor on in a forward
direction. Also turns conveyor off.
The Chip Conveyor continues to run when you exit the Manual
screen. If you want to stop the conveyor, you must use this softkey
before you exit the screen (E-stop will also stop the conveyor).

• Chip Removal Reverse On/Off—turns the chip conveyor on in a reverse

direction. Also turns conveyor off.
The Chip Conveyor continues to run when you exit the Manual
screen. If you want to stop the conveyor, you must use this softkey
before you exit the screen (E-stop will also stop the conveyor).

• Washdown Coolant On/Off—turns the washdown coolant on and off.

• Worklight On/Off—turns the worklight on and off.

Manual Rapid Move

Manual Rapid Move executes a single axis rapid move to a specific position at a controlled
feedrate. The operator can enter an axis position, either in machine or part coordinates,
and initiate the move to that position at a specified feedrate. More than one axis end
position may be entered, but the move occurs only on the axis that is selected with the
corresponding Rapid Move softkey.

Softkeys are:

• Rapid Move X—enables the rapid move in X.

• Rapid Move Y—enables the rapid move in Y.
• Rapid Move Z—enables the rapid move in Z.
• Rapid Move A—enables the rapid move in A (softkey is inactive if the
machine is not equipped with a rotary/tilt A axis).
• Rapid Move B—enables the rapid move in B (softkey is inactive if the
machine is not equipped with a rotary/tilt B axis).
• Rapid Move C—enables the rapid move in C (softkey is inactive if the
machine is not equipped with a rotary C axis).

To perform a Manual Rapid Move:

1. In Manual mode, select the Manual Function Setup softkey.

2. Select the Manual Rapid Move softkey. The Manual Rapid Move fields are
displayed. (This softkey is grayed out if the machine is not calibrated.)
3. Select Part or Machine coordinate system from the drop-down Coordinate
System list.
4. Set the linear axis feedrate in the Manual Rapid Feed field. Alternatively, set

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-139
 the rotary axis feedrate in the Rotary Rapid Feed field.
5. Specify the end position of the move in the appropriate axis field(s).
6. Select the appropriate Rapid Move softkey to enable the move. When the
softkey is selected, a message is displayed that instructs the operator to press
the Start Cycle button to move the axis. When the Start Cycle button is
pressed, the rapid move is performed.
Only one axis move can be performed at a time. During the move, all
other Rapid Move softkeys are disabled until the move is completed.
Once complete, another softkey can be selected, initiating the next
move.

The Rapid Override knob/potentiometer is active during the move.

Manual Rapid Move values are retained after reboot.

1 - 140 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Automatic Tool Changers
The ATC for HMX, DCX, and VTXU machines is a random-pocket tool changer that tracks
tools in the magazine using an ATC Map. All ATC operations require that the servo power
is on, that the machine is calibrated, and that the ATC is at Home position.

Loading Tools into the ATC Magazine

The ATC takes a tool from the spindle and automatically loads it into the magazine, if
space allows. The tool’s location in the magazine is recorded in the ATC Map (the
Horizontal Chain Type ATC does not use an ATC Map). Before loading a tool into the ATC
magazine, the Servo power must be On, and the machine must be calibrated.

Do not manually load tools directly into the magazine.

To load the tool currently in the spindle into the ATC magazine:

1. Press the Manual Mode console key.

2. Select the Tool Management softkey. The Spindle tab displays the Tool in
Spindle, Next Tool, and ATC Map (Swing-Arm Random Pocket ATC only) fields
appear.
3. Verify that the Tool In Spindle value matches the tool currently in the spindle.
If the numbers do not match, enter the correct tool number.
4. Enter the same tool number into the Next Tool field.
5. Press the Tool Changer Auto console key.
6. Enter a new tool number into the Next Tool field. The ATC Map field must be
Auto.
7. Press the Tool Changer Auto console key. The Start Cycle light begins flashing.
8. Clear the tool changer and shut the enclosure door. Press the Start Cycle
button. The Tool In Spindle field will be updated to the next tool value.
• If the Next Tool is an Auto tool, it was placed into the magazine when the
previous tool was removed from the spindle.
• If the Next Tool is a Manual tool, you will be prompted to insert it into the
spindle.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-141
Removing Tools from the ATC Magazine
Remove tools from the ATC magazine by following these steps:

1. Press the Manual Mode console key.

2. Select the Tool Management softkey to display the Tool in Spindle. If there is
no tool in the spindle, set the Tool In Spindle field to 0 (zero).
The ATC Map field will indicate if the tool selected is in the magazine,
and its location.

3. Enter the tool number (of the tool you want to remove in the magazine) into
the Next Tool field.
4. Press the Tool Changer Auto console key to move the Next Tool into the
spindle.
5. Clear the tool changer area and shut the enclosure door. Press the Start Cycle
button to initiate the tool change.
6. Press the Spindle Unclamp button and manually remove the tool from the
spindle.
7. Repeat steps 2 through 6, as needed, to remove additional tools from the ATC
magazine.

Large Tools in the ATC Magazine

A part program may require tools with large diameters. These tools can be manually
loaded by the operator, or automatically loaded.

The ATC magazine capacity is reduced by half for tools larger than 80
mm (125 mm for some machines).

Follow these steps to load large tools into the ATC magazine:

1. Touch the ATC Map softkey from the Spindle screen. The ATC Map appears.
2. Touch the Max. Tool Dia. More than XX mm softkey.
3. An “ATC Map will be cleared! Are you sure you want to change Max. Tool
Diameter to more than XX mm?” message appears.
Each time you switch between large and small tools, the entire ATC
Map will be cleared and the magazine must be reloaded.

4. Select the Yes softkey. The ATC Map will clear, then reappear. Only the odd
numbered tool pockets will be available.
5. Reload tools into the magazine using the “Loading a Tool into the Spindle”
section.
6. Return to the default setting of Maximum Tool Diameter XX mm or Less by
using the previous procedure and touching the Max. Tool Dia. XX mm or Less
softkey.

1 - 142 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Each VMX or VM machining center is equipped with a swing-arm random pocket
Automatic Tool Changer (ATC).

VM Tool Magazine
The station magazine is positioned vertically on the machine. An electronic motor and
helical gear drive the magazine. When activated, the tool magazine operates as described
below:

1. The requested tool pocket rotates 90° to make the tool available for the swing
arm.
2. The swing arm rotates 60° to simultaneously grab the tool in the pocket and
the tool in the spindle.
3. The spindle unclamps.
4. The swing arm moves down to pull the tools out of the pocket and the spindle,
and then rotates 180°.
5. The swing arm moves up and swaps the tools.
6. Finally, the swing arm and tool pocket return to their original positions.

There are two types of ATCs, which are described in the following sections:

• 40-Taper ATC with 24- or 40-Station Tool Magazine

• 50-Taper ATC with 30- or 32-Station Tool Magazine

40-Taper ATC with 24- or 40-Station Tool Magazine

This tool changer features a magazine with either 24 or 40 tool pockets (stations). The
magazine is positioned vertically on the machine. An electric motor and helical gear drive
the 24- and 40-station magazine. The 24-station magazine is round and the 40-station
magazine is elliptical. Refer to the previous table for the number of tool pockets (stations)
available for a specific machining center.

ATC Sequence
This is the basic sequence of operation of the tool magazine, assuming the magazine is
positioned to the next tool required:

1. The requested tool pocket rotates down 90° to make the tool available for the
swing arm.
2. The swing arm rotates 60° to simultaneously grab both the tool in the pocket
and the tool in the spindle.
3. The spindle unclamps.
4. The swing arm moves down to pull the tools out of the pocket and spindle, and
then the arm rotates 180°.
5. The swing arm moves up and swaps the tools.
6. The spindle clamps the new tool in the spindle and the swing arm rotates back
to 0°.
7. The tool pocket moves back to its original position.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-143
 Figure 1–18. VMX 40-Taper ATC with 24-station Tool Magazine

1 - 144 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
50-Taper ATC with 30 or 32-Station Tool Magazine
The VMX50/50T uses the 50-Taper ATC with a 30-station tool magazine. The VMX64 uses
the 50-Taper ATC with a 32-station tool magazine.

An electric motor, two dogs (cam detents), and three proximity switches control the 50-
Taper tool changer motion. For the VMX64, a free-standing hydraulic unit runs the
rotation of the magazine, magazine locking cylinder, and the tool pot up and down
cylinder. The ATC sequence for the 50-taper ATC is the same as the 40-taper ATC
sequence.

Figure 1–19. VMX 64/50-Taper, 32 Station ATC

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-145
HMX and VTXU Tool Magazine
The ATC can be operated in Auto or Manual machine mode, using ATC Diagnostics.

HMX Machines
For HMX machines, the following steps explain the basic sequence of operation of the tool
magazine, assuming the magazine is positioned to the next tool required.

1. The tool holder rotates to 90°, and the ATC door opens.
2. The exchange arm rotates to 90° and simultaneously grabs the tool in the tool
holder, and if present, the tool in the spindle, if the following conditions are
met:
• The X, Y, and Z axes are at tool change position.
• The spindle is oriented.
3. The spindle unclamps.
4. The exchange arm moves out and simultaneously pulls the tools from the
holder and the spindle, then rotates 180°.
5. The exchange arm moves in and swaps the tools.
6. The exchange arm rotates to 90°.
7. The ATC door closes and the tool holder simultaneously returns to its original
position.

VTXU Machines
The following steps describe the basic sequence of operation of the tool magazine in the
VTXU magazine, assuming the magazine is positioned to the next tool required.

1. The ATC door opens if the following conditions are met:

• The X and Y axes are at tool change position.
• The Z axis is at Height (refer to ATC and Machine Diagnostics, on page 1 -
145 for more information).
• The spindle is oriented.
2. The tool pocket rotates from the Up position to the Down position.
3. The swing arm rotates 90° and simultaneously grabs the tool in the tool
pocket and, if present, the tool in the spindle.
4. The spindle unclamps.
5. The swing arm moves up and swaps the tools, then rotates 180°.
6. The swing arm and tool pocket return to the original positions.
7. The ATC door closes.

1 - 146 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
ATC and Machine Diagnostics
8. ATC and Machine Diagnostics display status and diagnostics information.

ATC and Machine Diagnostics Fields

See the Field Glossary for definitions of the fields on the ATC and Diagnostic screens.
Note not all fields listed here are displayed for every machine model and configuration:

Air Pressure Coolant Status Overload Status Way Lube Level

ATC Axis Positions Exchange Arm Spindle Chiller Z-Axis Position

ATC Door Hydraulic Status Spindle Clamp/

Unclamp

ATC OK to Stop Magazine Lock Spindle Status

ATC Position Magazine Position Start Pushbutton

ATC Status Magazine Reference Tool Holder

ATC Z Axis Position Magazine Status Tool in Spindle

Selecting another softkey before pressing the Start Cycle button cancels the pending
command and causes the Start Cycle lamp to cease flashing. If the requirements for a
softkey action are not met, a message displays indicating why the action cannot be
commanded. The ATC & Machine Diagnostics softkeys are listed below; some softkeys
may not be present on all machines or may appear in a different order:

•
• Tool Holder Up / Down—sets the command to move the Tool Holder Down
or Up. Each press of the softkey switches command between Down and Up.
• For VM, VMX, VTXU machines, Tool Pocket must be Z-axis at Tool Change
Height, Spindle Clamped, and Oriented Down before moving to 60° (90°).

• Exchange Arm Rotate—sets the command to move the Exchange Arm

down, rotate 180° and up. Tool Pocket must be Down, Load Arm must be at
60°, and spindle must be unclamped.
• Exchange Arm Jog Reverse—sets the command to pulse jog the exchange
arm in the reverse direction. Pulse commands will stop once the Exchange
Arm is at 0 degree.
•
• Magazine Pin Lock / Unlock—sets the command to lock or unlock the
magazine pin. Locked is required for ATC to begin.
•

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-147
Tool Fixture Option (TPS)
The Tool Fixture (TPS) option provides an alternative way to manually move tools to and
from the spindle during tool setup or program execution. The TPS software option is
required, as well as a tool fixture. The fixture is attached to the table, near the front
enclosure doors. It is not removable, except for complete removal.

TPS is used as part of a tool change sequence from Tool Setup or Manual or Auto mode.
Tools are laterally loaded into and unloaded from the tool fixture, and use the same
spindle orient position as the ATC arm.

Tools used with TPS are limited by the tool fixture’s height and diameter, as well as ATC
weight restrictions. Tools inserted into the spindle with TPS must be removed with TPS.
You can convert a tool loaded with TPS into an auto tool, as long as it fits the diameter
and weight constraints of the magazine. Once the tool becomes an auto tool, it is no
longer tracked as a TPS loaded tool.

You can insert a tool or remove a tool using TPS in Tool Setup,
Manual Mode or Auto Mode. This section describes tool loading and
unloading using TPS in Tool Setup.

Automatic Tool Removal Using TPS

Follow the instructions below to use TPS to automatically remove a tool from the spindle:

1. Select the Input console key to access the Input screen.

2. Select the Tool Setup softkey.
3. With the cursor in the Tool field, enter the number of the tool you want to
change into the spindle.
4. Select the Auto Tool Change console button. The Start Cycle button begins
flashing.
5. Press the Start Cycle console button to initiate the tool removal process. The
enclosure doors can now be opened. A "Confirm Empty Fixture. Close Doors
and Press Start to Continue" message appears. The Start Cycle button flashes.
6. Make certain the Tool Fixture is empty. Press the Start Cycle button and its
stops flashing.
7. A "Remove Tool X from Fixture, Close Doors & Press Start" message appears
on the screen.
8. Remove the tool from the fixture, close the enclosure doors and Press the
Start Cycle button.
9. The tool entered in step #3 is inserted from the magazine into the spindle.
10. The tool removal is complete.
You must use Manual Mode if the tool you are removing was the last
tool in the spindle.

1 - 148 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Automatic Tool Change Using TPS
Follow the instructions below to complete an Auto Tool change using TPS:

1. Select the Input console button to access the Input screen.

2. Select the Tool Setup softkey to access the Tool Setup screen.
3. With the cursor in the Tool field, enter the number of the tool that will be
inserted into the spindle using TPS.
4. Press the Tool Changer Auto console button. The Start Cycle button begins
flashing.
5. Press the Start Cycle button to initiate the tool change.
a. The Z axis rapids to the home position.
b. The X and Y axes rapid to the Access position. An "Insert Tool X in Fixture.
Press Start" message appears. The Start Cycle button flashes again.
If the Tool in Spindle is 0, a message will appear confirming that the
spindle is empty. If the Tool in Spindle is a number other than 0, the
tool will be removed from the spindle (automatically put into the
magazine or you will be prompted to be removed manually)

6. Insert the tool into the fixture.

7. Close the enclosure doors. Press the Start Cycle button.
a. The Start Cycle button stops flashing.
b. The X and Y axes rapid to the Fixture position.
c. The spindle orients (if it is not already oriented).
d. The spindle unclamps.
e. The Z axis rapids to the Clear position (its position before the tool change
began) - then moves at a fixed, reduced feedrate to the Fixture position.
The spindle clamps the tool.
f. The Z-axis moves to the Fixture position at a reduced feedrate.
g. The spindle clamps the tool.
h. The X and Y axes move to the Clear position (their positions before the tool
change began) at a reduced feedrate.
i. The Z axis rapids to the Tool Change position.
8. The tool change is complete.
A message requesting the tool be removed from the spindle using
TPS will be displayed for any tool that was inserted into the spindle
with TPS. You may use TPS to remove the tool or manually unclamp
the tool to remove it from the spindle.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-149
Bypass TPS in an Automatic Tool Change
Follow the instructions below to complete an Auto Tool change and bypass TPS:

1. Select the Input console button to access the Input screen.

2. Select the Tool Setup softkey to access the Tool Setup screen.
3. With the cursor in the Tool field, enter the number of the tool that will be
inserted into the spindle.
4. Press the Tool Changer Auto console button; the Start Cycle button begins
flashing. Press the Start Cycle button. If there is a tool in the spindle, remove
it before proceeding. If the spindle is empty, the machine moves to the Access
position.
5. When prompted to insert the tool into the fixture, manually insert the tool into
the spindle. To install a tool using TPS, see Automatic Tool Removal Using
TPS, on page 1 - 146.
a. Press the spindle unclamp button and insert the tool. The prompt changes
to "Insert Tool XX in Spindle & Press Start Cycle."
b. Release the unclamp button. The tool is clamped in the spindle.
6. Close the enclosure doors and press the Start Cycle button.
7. The tool change is complete.
Any tool that is inserted into the spindle manually (bypassing TPS)
must be removed manually.

1 - 150 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
HMX Automatic Pallet Changer
The Automatic Pallet Changer (APC) system is standard on HMX machining centers.
Equipped with two pallets, the APC provides the ability to set up a part on one pallet while
a part is being machined on the other pallet.

The B-axis must be squared before any operation can occur. Refer to
Squaring the Pallet, on page 1 - 149 for instructions for squaring the
APC table.

This is the basic sequence of operation of the APC:

1. The APC Pin unlocks.

2. The APC table raises and rotates 180°. Hydraulic solenoids ensure the table
rotates in the proper direction.

The APC table does not rotate through 360°, but rotates in the
opposite direction to return to its previous position.

3. The APC table lowers into position.

4. The APC Pin locks.

Only a Hurco-certified Service Engineer can make adjustments to the

APC Table.

Squaring the Pallet

The pallet is not automatically squared during machine calibration. It must be squared
before it can be used. Follow these steps to square the pallet:

1. Press the MACHINE MODE MANUAL console key.

2. Select the Diagnostics softkey.
3. Select the Pallet Changer Diagnostics softkey to access the APC Diagnostics
screen.
4. Select the More softkey to access the second APC Diagnostic screen.
5. Select the Move Z-axis to APC Position softkey to position the Z-axis at the
APC position. The APC table must be in the down position to move the Z-axis
to the APC position.
6. Select the Square Pallet For Rotation softkey and press the Cycle Start
button. The pallet will rotate into the proper position for the pallet exchange
cycle.
If the B-axis is away from the squared position, selecting the Square
Pallet For Rotation softkey rotates the table at the maximum RPM
back to the squared location.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-151
Operating the APC
The APC can be operated in Auto mode within a Conversational or NC part program.

Follow these steps to operate the APC in a Conversational program:

1. On any Conversational part programming data block, select the

Miscellaneous softkey.
2. Select the Machine Function softkey to display the Machine Function screen.
3. Scroll through the M Code list to select the appropriate code, then select the
Select M Code softkey.

The following M Codes are used to operate the APC (use the scroll bar to view
more M codes, if necessary):

• M51 Cycle APC—requires confirmation from the Operator before a pallet

change cycle is initiated (see details below).
• M56 Cycle APC w/o Notify—complete a pallet change cycle without
confirmation from the Operator.
• M57 Cycle to Pallet #1—place Pallet 1 in the machine without
confirmation from the Operator.
• M58 Cycle to Pallet #2—place Pallet 2 in the machine without
confirmation from the Operator.

Figure 1–20. Machine Function Screen with M Code List

Using M51 does not require indicating whether Pallet 1 or 2 is in the machining
setup area. Before M51 will initiate the APC cycle, the front enclosure doors must
be closed and the APC Ready pushbutton pressed.

• If the front enclosure doors are open when the M51 operation is requested,
the program will be in a Feed Hold state and a message to close the front
enclosure doors will be displayed. Close the doors and press the APC Ready

1 - 152 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 pushbutton to continue the part program.
• If the APC Ready pushbutton has not been pressed when the M51 operation
is requested, the program will be in a Feed Hold state with the following
message displayed, “Pallet setup confirmation required to cycle pallet
changer.” Press the APC Ready and Cycle Start pushbuttons on the APC
Panel to continue the program.
Pressing Feed Hold during a pallet change cycle will stop the cycle.
Releasing Feed Hold will resume the cycle. However, Feed Hold
followed by Spindle Off (or the Stop Cycle button) during a pallet
change cycle will abort the program and the pallet change cycle. The
APC must be returned to the home position using the Pallet Changer
Diagnostics before an Auto program can be run again.

Refer to the NC Programming Manual for instructions on operating the APC within an NC
program.

APC Diagnostics
Follow these steps to access the APC Diagnostics screen:

1. Press the MACHINE MODE MANUAL console key.

2. Select the DIAGNOSTICS softkey.
3. Select the PALLET CHANGER DIAGNOSTICS softkey. The APC Diagnostics
screen 1 opens:
APC Diagnostics Screen 1 APC Diagnostics Screen 2

Figure 1–21. APC Diagnostics Screens 1 and 2

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-153
APC Status Conditions
The APC Diagnostics screen displays the status of inputs for the APC system.

See the Field Glossary for definitions of the fields on the ATC and Diagnostic screens:

APC Clamp Status Pallet in Machine

APC Door Status Pallet Pin

APC Position Pallet Reference

Position

ATC Status Pallet Status in

Machine

B-Axis Status Z-Axis Position

Hydraulic Status

APC Diagnostics Softkeys

The APC Diagnostic softkeys are functional only when Servo Power is On and the machine
is calibrated. These are the APC Diagnostic softkeys.

• Cycle Pallet Changer—sets the command to complete a full rotation of the

APC Table. This function will perform a full APC cycle. The Z-axis will move to
the APC position, the B-axis will square, the APC table will raise, the APC
table will rotate 180 degrees, and will then lower.
• Raise Pallet Changer—sets the command to lift the APC Table to the Up
position. The B-axis must be squared and the Z-axis must be at the APC
position.
• Rotate APC to Position 1—sets the command to rotate the APC table to
Position 1 inside the machining area. The B-axis must be squared and the
APC must be in the raised position, and Position 1 must not be in the
machining area.
• Rotate APC to Position 2—sets the command to rotate the APC table to
Position 2 inside the machining area. The B-axis must be squared and the
APC must be in the raised position, and Position 2 must not be in the
machining area.
• Lower Pallet Changer—sets the command to lower the APC table to the
Down position. The Z-axis must be in the APC position. The table must be at
Pos 1 or Pos 2.
• More—opens the second APC Diagnostics screen.
• Move Z-Axis to APC Position—sets the command to move the Z-axis to the
APC position. The APC table must be in the down position to move the Z-axis
to the APC position.
• Square Pallet for Rotation—sets the command to square the pallet.
• Enable APC Jog Mode—allows the operator to jog the APC table up and
down and also jog the APC table 180 degrees. When selected, a message
displays indicating to proceed with caution:

1 - 154 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 This message is displayed until the APC Diagnostics screens are exited or
until an E-stop occurs.

APC Jog Mode

The operator should verify the position of the Z-axis before jogging the APC. From APC
screen 1, the operator can select Raise Pallet Changer, Lower Pallet Changer, Rotate APC
to Position 1, or Rotate APC to Position 2. Once a function has been selected, the green
Start Cycle button flashes and a message is displayed:

Figure 1–22. APC Diagnostic screen 1 with APC Jog Mode messages

The operator can then press and hold the green Start Cycle button to jog the APC. The
operator must hold the Start Cycle button down while jogging. Once the Start Cycle
button is released, the jogging function stops. The operator must select a softkey
function again to enable the jogging.

Once selected, the APC Jog Mode remains enabled until the operator
navigates away from the APC diagnostic screens or an E-stop occurs

Dual-Zone Machining

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-155
Dual-zone machining provides the ability to set up a job in one zone while machining in
the other zone.

To use both zones on a dual-zone capable machine, the Enable Dual Zones parameter
must be set to enable dual zones. This is done in Machine Parameters:

1. Select the Auxilary console key.

2. Select the Utility Screen icon.
3. Select the User Preferences softkey.
4. Select the Machine Parameters softkey.

The Enable Dual Zones parameter is listed on Page 1 of Machine Parameters. Set this
parameter to 1 to enable dual zones (1 is the default setting). When this parameter is set
to 0, the machine can be used as a single long bed vertical machine.

The zone partition must be removed to use as a single long bed

vertical machine.

See Machine Parameters, on page 1 - 61 for more information about the Enable Dual
Zones parameter.

Part Programming for Dual-Zones

Each zone has its own coordinate system, so a Change Part Setup data block is used to
modify the coordinates for each zone. This Change Part Setup block is used to switch
zones while running a program. At the beginning of the program and at each point where
a zone change is required, insert a Change Part Setup block:

1. From the Input screen select Part Programming, the Insert Block Before
softkey, the Miscellaneous softkey, and the Change Part Setup softkey. A
Change Part Setup block is added.
2. Modify Part Zero X, Y, Z (Part Zero Z is available only if using Absolute Tool
Length mode) for the zone.
3. Modify Offset Z (if using Zero Calibration mode only) for the zone.
4. Specify the zone the part setup applies to in the Zone field.
• 1 = Zone 1 (the left-side zone when facing the machine).
• 2 = Zone 2 (the right-side zone when facing the machine).
• 0 = the current zone. Zone 0 can be used when dual zones are enabled
but you do not need to run the program in a particular zone. Setting the
Zone field to 0 will run the program in the zone that the spindle currently
occupies.

Zone field is not displayed in single long bed configuration.

1 - 156 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Viewing Graphics
Graphics can be displayed in one or both zones:

1. Press the Draw console key to display the Graphics screen.

2. Select the Select View softkey. Select the All Views softkey.
3. Select the Select Zone softkey.
4. Select Zone 1, Zone 2, or All Zones.
The zone setting must match the zone of the program (or be set to
All Zones) to view the part program in Graphics.

The zone is displayed in the lower left corner of the graphics display:

Figure 1–23. Isometric view of parts in both zones

Dual-Zone Operation
Programs can be run in one zone while the other zone is accessible to the operator for set
up or other functions.

Setup Confirmation
Each zone door is equipped with a green Zone Setup Confirmation button and a red
Emergency Stop button:

Emergency Stop Button Confirmation Button

Figure 1–24. Emergency Stop and Zone Confirmation buttons

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-157
The green Zone Setup Confirmation button must be pressed to confirm that the zone is
ready before the spindle will move into the zone to start machining.

The red Emergency Stop button will stop all machine operation when pressed.

Running Programs
To run a program, press the Cycle Start button. A pop-up confirmation message appears,
and the green Zone Setup Confirmation button flashes on the door of the zone where the
program will run. Push the green flashing button to confirm setup. If the spindle head is
in the current zone for program, no confirmation is required.

While the program is running, you are able to set up in the other zone. When the door to
the second zone is closed and the program completes its run in the first zone, the green
Zone Setup Confirmation button on the second zone door flashes. Press it to start
machining in the that zone.

• In dual-zone configuration, the door of the opposite zone can be opened until
the green Zone Setup Confirmation button is pressed. The door must be
closed before the confirmation will be accepted and the door locked.
• To unlock the door while the spindle head is in the opposite zone, press the
green Zone Setup Confirmation button to cancel confirmation.
• With CE enabled the door will not open when the green Zone Setup
Confirmation button is lit.

1 - 158 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Auto Mode
Programs are run in Auto Mode. Press the Auto button on the console to access Auto
Mode to check for errors, compute estimated run time, recovery/restart, perform a dry
run, or run a part program.

Figure 1–25. Auto Mode screen

The following softkeys are available in Auto Mode:

• Use Editing File—selects the active program file to run. If this softkey is not
selected, WinMax defaults to the last program run. If the last program run
does not match the program that is being edited (as indicated in status bar),
the operator will be prompted to select which program to run.
• Feed & Speed Optimization—fine tunes program execution, using the Axis
Feed Rate and Spindle Speed dials to adjust values. This softkey is disabled in
Test Mode.
• Linear Thermal Compensation—accesses the Linear Thermal
Compensation table where parameters are set to manage linear growth. See
Linear Thermal Compensation, on page 1 - 159.
• Check for Errors—checks the program from the Start Block through the End
Block and displays error status. The number of the data block containing the
error is included in the error message.

The time required for error checking depends upon the program’s length and
complexity. Select the Abort Operation softkey to stop error checking at any
time.

• Compute Estimated Run Time—provides an estimate of time it takes to

run the program. Select the Abort Operation softkey to stop computing
estimated run time.

Error checking automatically occurs during Compute Estimated Run Time.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-159
 • Recovery Restart—restarts a conversational or NC part program; typically
at the point at which the program was interrupted. This softkey is disabled in
Test Mode.
• For Conversational Programs—if necessary, Conversational Start and End
blocks can be changed from the default.

For Mill Contour data blocks: Recovery Restart only occurs at segment 0
of a Mill Contour data block, not at a segment within a data block.

For Pattern data blocks: the user is prompted to specify which pattern or
block instance to restart at and to provide any additional restart
information for the start block. See Patterns Overview, on page 2 - 110 of
the Patterns chapter, for more information.

• For NC Programs—use the following softkeys to restart an NC program

after it was aborted either by the machine or the operator. Preparatory
functions such as coolant, feeds and speeds, and offsets will be executed
before machining resumes, and Tool Vector input is checked.

• Set Restart Marker—manually sets the restart marker. An “R” will

appear to the left of the block selected, and will clear if the program
successfully runs.
• Auto Set Restart Marker—automatically marks the last block being
executed when the program was stopped, or where an error occurred
during error checking.
• Reset Restart Marker—clears the Restart Marker and cancels the
Recovery Restart operation. Can be used on a block after a G41/G42.
• Set End Marker—indicates the block that system should use to end
program verification and execution. An “E” is inserted to the left of the
block.
• Reset End Marker—restores end marker to its default position at the
end of the program.
• Dry Run—active in Test Run mode only. Performs a program test run to
identify potential problems before cutting the part. Specify all or a portion of
the part program that will be tested in the Start and End blocks.

Trace the tool over the part at the programmed minimum Z level with the
Spindle Off. Peck cycles and roughing passes are skipped.

If the Z Start value is set below the stock surface, the Minimum Z
value must be programmed so the tool does not plunge into the part.
A message appears requesting the Minimum Z value. Note that
Minimum Z will be shifted by patterns.

• Run Program—initiates program execution and displays monitoring

information. Disabled in Test Mode. When selected, the program is buffered
and the Start Cycle button flashes. Pressing the Start Cycle button starts the
program run. If the machine is not calibrated, the Manual screen immediately
displays.

Changes made to a program while running take effect when the Start
Cycle button is pressed again.

1 - 160 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Linear Thermal Compensation
Linear Thermal Compensation parameters allow axis adjustments to compensate for
linear growth. Offsets can be set for any linear axis, at specified time intervals, in minutes
(up to 99,999,999). Between two and ten entries can be set.

Since compensation is applied to the machine X-, Y-, and/or Z-axes,

it cannot be used to compensate spindle thermal growth on rotary
machines when the spindle is not aligned to the machine Z-axis.

Linear Thermal Compensation is enabled in the Auto Mode screen, where the reference
time is set in the Current Time field. Current Time is increased automatically during
program run, and is paused when the program is finished. Time and offsets remain
unchanged when the program is not running.

Offsets can be imported using the Import Offsets from File softkey. Offsets can be
saved/exported using the Export Offsets to File softkey.

Determining Offset Time and Positions for Linear Thermal Compensation

The Linear Thermal Compensation table is part-specific. A gauge or probe can be used to
determine the offsets by measuring reference surfaces.

1. Turn off Linear Thermal Compensation (Enable set to NO on Auto Mode

screen).
2. Measure reference surfaces.
3. Run part program. At identified intervals (in minutes), quickly measure
reference surfaces using same tool or probe, at same locations.
4. Recovery restart the part program.
5. Repeat step 3 and 4 until the part program is finished or measurement values
stabilize.
6. Record the intervals (time) and position differences into the Linear Thermal
Compensation table.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-161
Auto Mode Monitoring
The Auto Mode Monitoring screen appears when the Run Program softkey is selected
and program execution begin. Real-time machine and part locations and machine status
are shown, as well as Spindle Load Monitor, the data block and type of operation, and the
part count.

For NC programs, five lines of NC code are shown; to view more NC code as the program
runs, select the NC Monitor softkey. The bottom portion of the screen is reserved for
program status and error messages.

5 lines of
Spindle Load NC code
Monitor

Figure 1–26. Auto Mode Monitoring screen

See the Field Glossary for definitions of fields on the Auto mode screens (fields displayed
vary depending on machine, configuration, and/or program type):

Axis Limit Switches End Block Part Count S / Spindle

Block End Job Part Program Name Spindle Load Monitor

Coolant F(%) Part Program Path Start Block

CR / Chip Removal F / Feed Opt Stop On (Off) Start Job

Current Time Machine Orientation Time / Program Run

Time

Enable Linear Thermal Magazine R(%) TIS / Tool in Spindle

Compensation

Part S(%) Zone

These are the monitoring softkeys that may be available for Auto Mode Monitoring:

• Reset Part Count—Part Count is the number of times a program was

executed. To return this value to zero when a new program starts, select the

1 - 162 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 Reset Part Count softkey. A pop-up window opens, where the part count value
can be changed or reset to zero.

Access to the part counter is locked out by Edit Lockout Level

“Full,” set in User Interface Settings. See Edit Lockout, on page 1 -
46 for information.

• Chip Removal Forward On/Off— turn the chip auger in the forward
(clockwise) direction on or off. This selection is saved when the Interrupt
button is pressed or after the program has finished running. If a stop
condition or mode change is made before restarting a new part program or
exiting the interrupt cycle, the saved information is cleared. This softkey is
only available if your machining center uses a chip auger.
• Optional Stop On/Off—pauses the program and shuts off the spindle.
Optional Stop can be turned On and Off through a soft key in the main menu
on the Auto screen while a program is running. When this setting is changed,
the new state applies immediately and applies to all programs.

For NC programs, when Optional Stop is ON, an M01 code in an NC program

will be processed and will cause a program stop (see M00), which will display
a message requesting that the operator press Start Cycle to continue. When
Optional Stop is OFF the code will be ignored.

For Conversational programs, an M01 can be inserted using a Machine

Function data block.

An optional stop can also be set in Position, Rotary Position, and Comment
data blocks by setting the Stop field to Optional. The block will function as if
the Stop field were set to YES when the Optional Stop softkey is enabled. See
Position Data Block, on page 2 - 120 and Comment Block, on page 2 - 125 in
Conversational Programming, and Rotary Position Block, on page 5 - 6 in
Options.

• Select DRO— view machine, part, distance-to-go, workpiece, and/or

transform plane information, displayed in either standard or quad-size DRO
view. See Digital Read Out (DRO), on page 1 - 162, below.
• Coolant Washdown On/Off—turn the coolant washdown on or off for
washing chips from the enclosure.
• NC Monitor—displays a pop-up window containing the current NC code. This
feature allows you to view the code as the program runs; the program name
appears in the Current Program Name box at the bottom of the monitor. The
line of code that is currently being machined is identified in red. When the
“Show Modals” boxed is checked, the current active modals are shown. As
machining progresses, the monitor will scroll through the lines of code. Select
the “Close” button at the bottom of the window to close the NC Monitor.

The NC Monitor softkey is available when an NC program is running or

during the NC portion of an NC/Conversational merged program. In a merged
program, once the monitor is opened, it will display during the NC program
run, and will be automatically hidden during the Conversational run.

• Toggle Rapid Override Lockout—enable or disable overrides to the

programmed rapid traverse using the Rapid Override console knob. A
confirmation message appears; select Yes to confirm the switch.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-163
 • Worklight On/Off—turn the enclosure worklight on or off. This softkey is
only available if your machining center is equipped with an enclosure
worklight.

Digital Read Out (DRO)

The Auto Run screen uses a standard size digital read out (DRO) at the top of the screen
in addition to other fields and information. A Quad-size DRO is available that provides
large-view machine, part, or distance-to-go for the part program that is running.

Select the SELECT DRO softkey on the Auto Program Run screen to change the size of
the digital read out (DRO). From the Select DRO screen you can see real-time machine
information displayed in full-screen view. The softkey menu provides these DRO options:

• Machine / Part (Standard DRO)—shows real-time axes location relative to

machine zero and current part zero.
• Distance to Go (Standard DRO)—shows real-time axes location relative to
machine zero and current part zero, and the remaining distance to
completion of move.
• WorkPC / TR Plane (Standard DRO)—shows real-time axes location
relative to machine zero, workpiece zero, and transform plane zero.
• Machine (Quad-size DRO)—shows in a larger view the real-time axes
location relative to machine zero.
• Part Relative (Quad-size DRO)—shows in a larger view the real-time axes
location relative to current part zero.
• Distance To Go (Quad-size DRO)—shows in a larger view the remaining
distance to completion of each move.
• Dist to Go / Trans (Standard DRO)—shows real-time distance-to-go, and
axes location relative to workpiece zero and transform plane zero.

Use the SELECT DRO softkey to select a different DRO display.

1 - 164 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
 A (c) next to the axis indicates the axis is clamped.

To access the configurable DRO view, select the Auxiliary button, and choose the Launch
DRO softkey.

Concurrent Programming
Concurrent Programming allows you to create or edit a program while simultaneously
machining a different program. When using Concurrent Programming, two part programs
are simultaneously available. To enter Concurrent Programming while machining a part,
press the console Input key. The Auto screen is replaced by the Input screen.

Stop Machine Operation

There are three methods to stop machine operation without turning off the power:

• Emergency Stop
• Park machine
• Control Power Off Timer parameter
The methods described here stop machine operation, but do not
shutdown the control. See Shutdown Control, on page 1 - 165 for
more information about shutting down the control.

If the machine will not be used for several days, or the shop has
power surges or blackouts, turn off machine power at the main
power switch, after stopping machine motion and shutting down the
control.

Emergency Stop
To shut down the machining center quickly, press the Emergency Stop button. All motion
stops and power is shut off to the spindle, relay control, way lubrication pumps, and
servo systems.

Do not use Emergency Stop shut down if the machine has a long
table with heavy equipment attached to one end. Instead, park the
machine so that the weight of the table and any attached equipment
will be evenly distributed.

Before hitting the Emergency Stop button, park the machine or

center the table.

When the Emergency Stop button is pressed, a special error file is created and saved to
the machine hard drive in a folder called NavESTOP. These files record the machine

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-165
conditions at the time the Emergency Stop button is pressed. These files can be retrieved
when necessary for service purposes; refer to Retrieve Log and Diagnostic Files, on page
1 - 59 for more information.

Park Machine
Parking the machine centers the table and places the spindle at the home position. Table
and attached equipment weight is distributed evenly when the machine is parked. Before
parking the machine, the servo power must be on, the machine must be calibrated and
the Tool in Spindle must be 0.

Follow this procedure to park the machine:

1. Press the Manual Mode console button.

2. Select the PARK MACHINE softkey. The Start Cycle button flashes.
3. Press the Start Cycle button. The machine moves to its park position.
4. A message with instructions to return to the power-up condition is displayed.

Control Power Off Timer

Set the Control Power Off Timer on the Machine Parameters screen. All motion stops and
power is shut off to the spindle, relay control, way lubrication pumps, and servo systems.

Where can we go from here?

To restart the machine after the Emergency Stop was pressed, follow
this sequence:

1. Twist the Emergency Stop button to release it.

2. Press the Manual Machine Mode button.
3. Press the Power On button.
4. Press the Start Cycle button.
Or...

To restart the machine after it was parked, follow this sequence:

1. Press the Manual Machine Mode button.

2. Press the Power On button.
3. Press the Start Cycle button.
Or...

If machine will not be used for several days or power surges and
blackouts are common, switch off the machine’s power. After
restarting, calibrate and warm up the machine.

1 - 166 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
Restart Control
The Restart Control command will remove control power, complete an orderly shutdown
of the WinMax Mill control, and then restart.

Follow these steps to use the Restart Control command:

1. Press the Aux/Menu key followed by the Utility Screen softkey to access the
Utilities screen and softkey menu.
2. From the Utilities screen, select the Restart Control softkey to access the
Restart Control command. A pop-up message appears: “Do you really want to
restart the control?”
3. Select Yes or No. When Yes is selected, the Restart Control command is
performed. This feature saves time and avoids having to shut down the entire
machine when it is only necessary to restart the control.

Shutdown Control
The Shutdown Control command will remove control power and complete an orderly
shutdown of the WinMax control.

Hurco recommends using the Shutdown Control command prior to

turning off machine power to ensure that no data is lost.

1. Follow these steps to use the Shutdown Control command:

2. Press the Aux/Menu key followed by the Utility Screen softkey to access the
Utilities screen and softkey menu.
3. From the Utilities screen, select the Shutdown Control softkey to access the
Shutdown Control command. A pop-up message appears: “Do you really want
to shut down the control?”
4. Select Yes or No. When Yes is selected, the Shutdown Control command is
performed.
5. Wait for the shutdown process to finish before shutting off machine power at
the Main Disconnect switch.

Getting Started with WinMax Mill 704-0116-501 Machine Operation Basics 1-167
1 - 168 Machine Operation Basics 704-0116-501 Getting Started with WinMax Mill
ULTIMOTION
Hurco’s UltiMotion system provides the following benefits:

Improved Surface Quality

With Hurco's proprietary smoothing, lookahead and motion control technology, the
UltiMotion system provides significantly improved part surface quality. You'll see
smoother and shinier surfaces, less vibration, less chatter marks, and higher accuracy.

Higher Throughput

Compared with a standard motion system, the UltiMotion system's advanced motion
planning and rapid corner feature can provide decreased cycle time with the same or
even better surface finish quality. This is especially true for parts with complex
geometries or large amounts of repeated tasks, such as drilling or tapping.

Rapid Corner

For programs with a lot of consecutive rapid moves, the UltiMotion system doesn't stop
between two rapids. Instead, it travels through blended corners at very high speed with
only negligible deviation. This saves significant amount of time for repeated tasks, such
as drilling and tapping.

Broader Performance Range for Surface Finish Quality

The Surface Finish Quality (SFQ) mechanism is Hurco's proprietary technology to allow
users to choose better surface finish or higher throughput for their applications via a
simple one-parameter control mechanism. Winmax control automatically adjusts internal
parameters to achieve either better surface quality (smaller SFQ) or higher throughput
(higher SFQ). The UltiMotion system extends the performance range for SFQ to have
even better surface quality for your finish pass and even more time savings in the
roughing or semi-roughing passes.

Higher Quality Rigid and Regular Tapping

The UltiMotion system deploys a coordinated motion control mechanism for regular and
rigid tapping. You no longer need to worry if your tap will pass go/no-go tests; the
UltiMotion system monitors the spindle angle at all times and controls the Z-axis to track
the spindle position.

Smoother Motion Results in Longer Machine Life

Rough motion, vibration, and bumping increase mechanical system fatigue and shorten
machine life. The UltiMotion system's unique acceleration and jerk control, along with its
advanced motion planning, have made it possible to achieve faster, yet smoother motion.
You will get a faster machine with extended machine life.

Getting Started with WinMax Mill 704-0116-501 UltiMotion 1-169

Robust and Consistent Performance Over a Wide Range of Working Conditions

Have you ever had trouble maintaining the equivalent performance with work pieces
weighing from several ounces to several thousands of pounds? The UltiMotion system's
advance and accurate model compensation will help you to maintain the same level of
performance over a wide range of working conditions.

Dynamic Variable Lookahead Algorithm

Hurco's proprietary Lookahead doesn't require a fixed number of blocks lookahead like
conventional controls; instead the lookahead varies dynamically depending on the
geometry and motion profile, but always guarantees there is enough to make optimized
maneuvers.

Smooth and Responsive Handwheel Jogging

Compared with standard system, the UltiMotion system's hand wheel jogging is
optimized to reduce bumping and vibration while providing more responsiveness.

How to Select the Motion System

The UltiMotion option must be installed. To turn it on or off:

1. Select the Auxiliary console button.

2. Select the Utility Screen softkey.
3. Select the System Configuration softkey.
4. Select the WinMax Configuration softkey.
5. Select the Software Options softkey. The software options are displayed.
6. Select the UltiMotion option and use the Enable or Disable Selected Option
softkeys to toggle on or off.

To view the current Motion System:

1. Select the Auxiliary console button.

2. Select the Utility Screen softkey.
3. Select the System Configuration softkey.
4. Select the WinMax Configuration softkey.
5. Select the Motion Configuration softkey. The Motion Configuration screen
opens and the current motion system is displayed.
6. Select either Standard or UltiMotion in the Motion System field. The system
must be restarted for the change to take effect.

1 - 170 UltiMotion 704-0116-501 Getting Started with WinMax Mill

CONVERSATIONAL PROGRAMMING
Conversational programming allows you to create a part program from a blueprint or
program worksheet while working at the machine. Operating selections and prompts on
the screen lead you through the steps necessary to enter the data for a part program.
Machining operation information is stored within data blocks describing each operation to
be performed.

Create and access the data blocks through the Part Programming softkey or icon.

These topics are discussed in the Overview section:

Part Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Programming Dual-Zone Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Pecking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Cutter Compensation (preliminary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 9
Calculated Plunge Points for Milling Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 14
Lead In/Out Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 15

Conversational Programming 704-0116-501 Conversational Programming 2-1

Part Programming
Part Programming is the process of entering data, often from a blueprint, into program
data blocks to create a part.

Data blocks appear in numerical order as they are created.

To create a Conversational Part Program:

1. Press the Input console key to display the Input screen. The Input screen
allows you to access setup functions including Import Functions, Tool Setup,
and Program Parameters. See Input Mode, on page 1 - 90l for more
information.
2. Enter machining operation information in the Part Setup and Tool Setup
functions. This information is stored within data blocks describing each
operation to be performed. Create and access the data blocks through the
Input screen.
3. Select the Part Programming softkey to begin programming. The system
displays either the first block of an existing program or a New Block screen for
new programs.

Data blocks can be managed with the following programming operations:

• Access softkeys to create a new data block or edit an existing data block in
the Input screen.
• View a list summarizing a part program's data blocks on the Program Review
screen. See Review Mode, on page 1 - 132 for more information.
• View the current program's tool list on the Tool Review screen. Refer to Part
Program Tool Review, on page 1 - 116 for more information.
• Use the Insert Block Before softkey to Insert a new data block between two
sequentially numbered blocks. The data blocks following the inserted block
are automatically renumber.
• Holes blocks contain operations, and Mill Contour blocks contain segments.

Part Programming softkeys access the following options:

• Position—Insert instructions to move the tool away from the part (or
fixture), or to stop a program. A Position block is most often used to move
the table to an X-Y location and is normally used at the end of the program
and at any time the tool must be moved to the Z Top position of the Safety
Work Region. See Position Data Block, on page 2 - 120 for more information.
• Holes—Select Drill, Tap, Bore and Ream drilling operations, and Back
Spotface and Bolt Circle hole drilling. The locations of these holes on the part
can be specified using the Locations operation, and the holes can also be
programmed in a Bolt Circle pattern. See Holes Operations, on page 2 - 89
for more information.

2 - 2 Conversational Programming 704-0116-501 Conversational Programming

 • Milling—Program milling operations. See also Lines and Arcs (Mill Contour),
on page 2 - 19, Mill Ellipse, on page 2 - 33, Mill Frame, on page 2 - 29, Mill
Face, on page 2 - 31, Mill HD3 Lettering, on page 2 - 69, and Swept Surface
Parameters, on page 2 - 75. Special milling blocks Triangle, Diamond 1 Face,
Diamond 2 Faces, and Hexagon are accessed with the Special  softkey, see
Insert Pockets, on page 2 - 70 for more information.
• Patterns—Repeat or modify a sequence of one or more data blocks. A
program sequence can be repeated in a rectangular, linear, angular, or
rotated pattern or at specified locations. This operation is also used to scale
or mirror a programmed part. See Patterns Operations, on page 2 - 109 for
more information.
• Miscellaneous—Access these softkey functions:
• Graphics Off and ON; see Graphics On/Off, on page 2 - 121.
• Change Parameters; Change Parameters, on page 2 - 121.
• Change Part Setup; see Change Part Setup, on page 2 - 123.
• Machine Function; see Machine Function, on page 2 - 124.
• Probe Part Setup; see Probe Part Setup Data Block, on page 4 - 65.
• Lube Cycle; see Lube Cycle, on page 2 - 124.
• Comment; see Comment Block, on page 2 - 125.
• Insert; see Insert Block, on page 2 - 125.
• Tool Monitoring (Probing); see Tool Quality Monitoring, on page 4 - 14.
• Part Inspection; see Part Quality Verification, on page 4 - 67.
• Tool Optimize On and Off; see Tool Change Optimization, on page 2 - 126.
• NC Program Call—Access an NC program from within the conversational
program with this softkey. See NC/Conversational Merge, on page 2 - 131.
• Rotary and Transform Planes—Accesses the Rotary New Block menu
where you can access the Rotary Position, Milling, and Patterns, and
Parameters blocks, as well as the Transform Plane and Transform Plane
Groups blocks. See Rotary, on page 5 - 1 for more information.

Conversational Programming 704-0116-501 Conversational Programming 2-3

Block Layout
The layout of most data blocks includes the part geometry at the top of the screen with
the tool information below it, as in the following example:

Part geometry

Operation data

Operation Data
Information about block execution, such as tool, cutter compensation, pocketing,
roughing, finishing, and surface finish quality is entered on the bottom part of the data
block. Fields are displayed on tabs for Roughing, Rest, Finishing, SFQ, and Allowances.
The tabs and fields displayed are dependent on the block, machine type/configuration, or
software options installed:

Roughing tab

This tab contains the tool information for the roughing pass.

• Tool—the tool used for the roughing pass.

• Milling Type—the type of cutting operation.
• Pocket Type (appears when Milling Type is Pocket Boundary)—the pocket
type: Inward, Outward, ADP Zigzag, or ADP 1-Way.
• Mill Feed—the axis feedrate. Value initially displayed has been calculated by
the control and can be retained or changed to a different value.
• Speed (RPM)—spindle speed for the roughing tool. This value is carried over
from Tool Setup, but can be overridden here by typing a value in the field.
• Pocket Overlap (%) (appears when Milling Type is Pocket Boundary,
UltiPockets option required)—the percentage of tool diameter that overlaps
for each pass in a pocket milling operation. If the overlap is less than 50%,
the toolpath may make additional moves to clean out the pocket. For
example (toolpath is red):

2 - 4 Conversational Programming 704-0116-501 Conversational Programming

 Additional corner moves for
Pocket Overlap of 25%

If you change the Pocket Overlap using this field and save the file as
an HD3 file, a Change Parameters data block will be inserted into the
HD3 file to make the Pocket Overlap change. The Change Parameters
block changes only the Pocket Overlap, leaving all other parameters
as they were.

• Peck Depth—the maximum depth to be cut in one pass. If the total depth is
greater than this value, multiple cutting passes occur. Entering a zero (0)
value causes the total programmed depth to be cut in one pass of the tool.
• Plunge Feed—the feedrate for the tool moving from Z Start to Z Bottom.
• Radial Peck Count (appears only in a Mill Thread block)—the number of
radial pecking passes. See Radial Pecks, on page 2 - 53 for more information.
• Radial Peck Depth (appears only in a Mill Thread block)—the incremental
distance from the final cut. See Radial Pecks, on page 2 - 53.

Rest tab

This tab appears only when the Milling type is Pocket Boundary and the Pocket Type is
ADP Zigzag or ADP 1-Way (UltiPockets option required). This tab is used to specify the
tool information for the rest milling pass - to clear out remaining material from corners
when pocketing.

• Tool—the tool used for the rest milling pass.

• Pocket Type—the pocket type: ADP Zigzag or ADP 1-Way.
• Mill Feed—the axis feedrate. Value initially displayed has been calculated by
the control and can be retained or changed to a different value.
• Speed (RPM)—spindle speed for the rest milling tool. This value is carried
over from Tool Setup, but can be overridden here by typing a value in the
field.
• Peck Depth—the maximum depth to be cut in one pass. If the total depth is
greater than this value, multiple cutting passes occur. Entering a zero (0)
value causes the total programmed depth to be cut in one pass of the tool.
• Plunge Feed—the feedrate for the tool moving from Z Start to Z Bottom.

Finishing tab

This tab contains tool information for the finishing pass.

Conversational Programming 704-0116-501 Conversational Programming 2-5

 • Tool—the tool used for the finishing pass.
• Milling Type—the type of cutting operation. This value is carried over from
the Roughing tab and cannot be changed.
• Pocket Type (appears when Milling Type is Pocket Boundary)—the pocket
type for the finish pocketing operations: Inward or Outward.
• Mill Feed—the axis feedrate. Value initially displayed has been calculated by
the control and can be retained or changed to a different value.
• Speed (RPM)—spindle speed for the finishing tool. This value is carried over
from Tool Setup, but can be overridden here by typing a value in the field.
• Plunge Feed—the feedrate for the tool moving from Z Start to Z Bottom.

SFQ tab

This tab is used to specify the surface finish quality for the roughing pass and finishing
pass. SelectSurface Finish Quality option is required.

The default SFQ for roughing is 80 and finishing is 20. Recommended values are:

SFQ Desired Result

1-20 High precision parts / finishing

21-79 Good surface quality / finishing, semi-finishing

80-100 High throughput / roughing

Allowances tab

This tab appears when Stock Allowance mode is set to Data Blocks in Program
Parameters, Milling 1 tab. See Program Parameters, on page 1 - 124 in Getting Started
with WinMax Mill. This allows the stock allowance to be set in the data block rather than
using a global value from Program Parameters.

Set the stock allowances left by the roughing pass:

• Finish XY—specifies the stock width to be left by the roughing pass.

• Finish Z—specifies the stock depth to be left by the roughing pass.

When the cursor is in the Finish XY or Finish Z field, the following softkeys appear:

• Copy Allowances from Parameters—copies the values for Finish XY and

Finish Z from Program Parameters.
• Clear Allowances—zeros out the values in the Finish XY and Finish Z fields.

Select Tool from List

Use the following steps to select a tool using the Select Tool From List softkey:

1. In a program block screen, place the cursor in the Tool field and choose the
Select Tool From List softkey.
2. Locate the desired tool using one of the following methods:

2 - 6 Conversational Programming 704-0116-501 Conversational Programming

 • Scroll through the list of tools and select the desired tool to highlight it.
• Begin typing the number of the desired tool. A pop-up box will appear
when the first digit is entered; enter the entire number and select OK to
jump to that tool number in the list.
3. Select the Select Tool softkey, which enters the tool into the data block or
segment.
If Tool Type Checking is enabled, only tools that are suitable for the
programmed operation can be selected.
Check the Display Tool Notes checkbox to view the Notes for each
tool. Notes can be entered in Part Program Tool Review and
Advanced Tool Settings when the Tool & Material Library option is
installed.
The Select Tool list displays in the sort order most recently used,
when accessed via any screen - data blocks, Tool Management, or
Tool Setup.

Temporary Parameter Change

For some programs, you may want to insert a temporary parameter change block
between data blocks.

1. Display the data block for which the parameter change will first be used.
2. Select the Insert Block Before softkey. The New Block screen appears.
3. Select the Miscellaneous softkey. Choose the Change Parameter Softkey.

See Change Parameters, on page 2 - 121 and Change Part Setup, on page 2 - 123 for
more information.

Automatic Calculations
The WinMax AutoCalc feature enables the system to calculate certain dimensions
automatically after sufficient data has been programmed. Leave a data field blank to
automatically calculate the value for that field. After sufficient data is entered in the other
fields, the system automatically fills in the blank data field(s) and displays “CAL” next to
those field(s).

The screen displays a Store Calculated Value softkey for editing a field with a
calculated value. Select this softkey or the Enter key to store the displayed value into the
part program. Do not re-enter the data, i.e., 8.9199; the data is actually 8.9199xxx and
will be calculated as such when entered with the softkey or Enter key.

If you enter a value and later decide to let the control calculate the data, clear the
entered value by following these steps:

1. Use the Arrow keys or the touchscreen to select the parameter where the
automatic calculation is needed.
2. Press the C (Clear) console key or the Delete key on the keyboard.
3. Press the Enter key. The calculated value is displayed (if the field remains
blank, additional data must be entered so the control can calculate the value).

Conversational Programming 704-0116-501 Conversational Programming 2-7

Programming Dual-Zone Machines
With dual-zone machining, machining occurs in one zone while the other zone is being
used to set up the part. A Change Part Setup data block is used to switch zones. The
Enable Dual Zones parameter must be set for dual zones to use both zones; see Machine
Parameters, on page 1 - 61 in Getting Started with WinMax Mill.

Pecking
Pecking in a Milling Block
Pecking optimizes tool wear, deflection, feeds, and speeds by avoiding a full depth of cut
in a single machining pass.

Pecking is controlled with the Peck Depth field in a milling block. Peck Depth specifies the
maximum depth that is milled per pass:

If the Peck Depth value is non-zero, the following sequence occurs:

1. Tool feeds down to the first peck depth (the value of Z Start minus the
Peck Depth value).
2. Contour is milled.
3. Tool retracts at rapid to Retract Clearance Plane.
4. XY moves at rapid to plunge point.
5. Tool moves at rapid down to the previous peck depth plus the Peck
Clearance Plane.
6. Tool feeds down to the second peck depth (Z start minus 2 times the Peck
Depth value).
7. Cycle repeats until the Z Bottom depth is reached.

If Peck Depth is zero, the total depth to Z Bottom is cut in one pass.

Pecking clearances are set on the Program Parameters screen/General 1 tab:

• Enable Pecking Retract Clearance

• Pecking Retract Clearance
• Peck Clearance Plane

In a Mill Thread block, Radial Peck Depth is used when more than one cutting pass is
required. See Radial Pecks, on page 2 - 53 for more information.

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Cutter Compensation (preliminary)
Cutter Compensation is set in the Milling Type field in a milling program block.

Cutter Compensation allows you to choose the side of the contour the tool should begin
cutting. The programmed tool automatically follows the finished contour of the part when
cutter compensation is selected. Without cutter compensation, the centerline of the
programmed tool follows the print line.

1 Programmed path
2 Cutting tool
3 Path compensating for cutter radius
4 Cutter radius = amount of cutter compensation offset

Figure 2–1. Cutter Compensation

The following diagram shows tool paths using no cutter compensation compared to tool
paths using left and right compensation. When either right or left cutter compensation is
selected, the tool is offset from the cutting path a distance equal to the tool’s radius. The
tool begins cutting at the offset and moves in the selected direction.

1 No Cutter Compensation
2 Cutter Compensation to the left
3 Cutter Compensation to the right
4 Tool
5 Centerline of contour

Figure 2–2. Tool Paths for Cutter Compensation

Conversational Programming 704-0116-501 Conversational Programming 2-9

The following are the types of cutter compensation used for Mill Contours such as Lines,
Arcs, Blend Arcs, Helices, True-Type Lettering, and 3D Blend Arcs:

• On—Locates the center of the tool on the programmed contour of the frame.
• Left—Performs climb milling. Refer to Climb Milling (Left), on page 2 - 12.
• Right—Performs conventional milling. Refer to Conventional Milling (Right),
on page 2 - 12.
• Profile Left—Removes material from a contour for climb milling. Refer to
Profile Left and Right, on page 2 - 13.
• Profile Right—Removes material from a contour for conventional milling.
refer to Profile Left and Right, on page 2 - 13.

The following are the types of cutter compensation used for milling Circles, Frames, and
Ellipses:

• On—Locates the center of the tool on the programmed contour.

• Inside—the tool enters the part inside the contour and blend into the
programmed contour using a 180° arc. Cutter compensation is automatically
employed, and the edge of the tool remains inside a programmed contour.
• Outside—the tool enters the part outside the programmed contour and
follow the outside contour. Cutter compensation is automatically employed,
and the edge of the tool remains outside the programmed contour.
• Inside Tangent—the tool enters the part inside and tangent to the
programmed contour. Cutter compensation is automatically employed, and
the edge of the tool remains inside and tangent to the programmed contour.
The direction the tool travels depends upon the Milling Direction. The tool is
withdrawn from the part inside and tangent to the programmed contour.
• Outside Tangent—the tool enters the part outside and tangent to the
programmed contour. Cutter compensation is automatically employed, and
the edge of the tool remains outside and tangent to the programmed contour.
The direction the tool travels depends upon the Milling Direction. The tool is
withdrawn from the part outside and tangent to the programmed contour.
• Pocket Boundary—the tool cuts the part around the programmed boundary
and avoid any programmed islands or pockets.
• Pocket Type—The Pocket Type field appears with Inward and Outward
softkey and drop-down list box choices when Pocket Boundary or Pocket
Island is chosen for Milling Type. The choices define whether spindle
movement spirals from inside the pocket or outside the pocket.
• Outward—the tool begins cutting operations in the center region of
the pocket and cut outward to the edge of the programmed boundary.
Outward is used only for Circle and Frame data blocks without islands.
• Inward—the tool cuts in from the outside of the defined boundary,
avoiding the defined islands.
• Pocket Island—Defines islands within pockets on a part. As many islands as
desired may be defined (subject to available memory), but all must fit within
the defined boundary and must allow the tool to completely define the island.
A Pocket Island cannot follow an Outward Pocket Boundary.

2 - 10 Conversational Programming 704-0116-501 Conversational Programming

The order in which segments are programmed determines the direction the tool moves
from the start point. Setting Conventional (right) or Climb (left) in Milling Parameters
overrides the direction of the programmed path.

Unless the Blend Offset is set for 0.0 in Milling Parameters, the system automatically
creates Lead In and Lead Out arcs for closed contours. Refer to Lead In/Out Moves, on
page 2 - 15.

Circle
Inside Outside
Centerline Inside Outside Pocket
Tangent Tangent

Ellipse
Inside Outside
Centerline Inside Outside Pocket
Tangent Tangent

Frame
Inside Outside
Centerline Inside Outside Pocket
Tangent Tangent

Conversational Programming 704-0116-501 Conversational Programming 2-11

Climb Milling (Left)
Climb milling is the preferred method of cutter compensation, except when the fixturing
is not rigid. In climb milling, the tool cuts in the same direction as the feeding motion.
This is also known as “in–cut” or “down milling.”

During climb milling, the spindle turns in a clockwise direction. The tool is on the left-
hand side of the cut.

The advantages of using climb milling are as follows:

• The chip starts thick and allows easy penetration into the surface of the part,
causing less tool wear and less power consumption.
• The tool force cuts in and down on the part, helping to hold the part in the
fixture. The more rigid the fixture, the better the hold on the part.
• Chip removal is greater, and there is less re-cutting of chips or marring of the
part surface.
• The cutting fluid is more accessible to the cutting surface.

Conventional Milling (Right)

During conventional milling, the cutting teeth move in the opposite direction to the
feeding motion. This is known as “out–cut” or “up milling.” When using conventional
milling with a clockwise spindle direction, the tool is on the right-hand side of the cut.

The advantages of using conventional milling are as follows:

• The chip thickness starts at zero, causing less impact on the cutting teeth.
This is ideal for setups that are not very rigid.
• The backlash in older machines is greatly diminished.

2 - 12 Conversational Programming 704-0116-501 Conversational Programming

 The programming sequence of Lines and Arcs segments determines
the cutting direction. However, when programming Mill Frames,
Circles and Ellipses, the cutting direction is determined by the values
entered in Program Parameters.

Profile Left and Right

Profile Left and Profile Right work the same as Left (Climb) and Right (Conventional)
milling, except that a Max Offset may be added.

Maximum Offset
The Max Offset field appears when either Profile Left or Profile Right is selected. Max
Offset allows the cutter to be programmed to start at some specific distance away from
the programmed profile and move toward the finished profile, using the Pocket Overlap
parameter, as each pass is completed. It is typically the radius of the largest inscribed
circle minus the tool radius. Manually calculate the value and enter it into this field.

Drawing the part on the graphics screen is the key to determining an

optimum Maximum Offset value.

If a .500" diameter (.25" radius) End Mill is used to machine the part illustrated below (a
circle with a 1" radius), the value for the Maximum Offset field is 0.75".

1 Starting point for the tool

2 Largest inscribed circle in this contour
3 Radius

Figure 2–3. Determining Maximum Offset

If the tool diameter is changed (i.e., the cutter is sharpened to a smaller diameter), the
Maximum Offset value must be manually re-calculated and this new value programmed
into Segment 0 of the Mill Contour's Start block. Refer to Lines and Arcs (Mill Contour), on
page 2 - 19. The Tool diameter is programmed in Tool Setup and cannot be changed in
Part Programming. See Tool Setup in Getting Started with WinMax Mill for more
information.

Conversational Programming 704-0116-501 Conversational Programming 2-13

Calculated Plunge Points for Milling Cycles
The following calculations are for determining the plunge points for milling cycles. The
examples are for Climb Milling.

The Blend-in move is 90° for all examples.

The Arc of Radius = Blend Offset for all examples.

Circle, Inside Circle, Outside

Occurs at 3 o’clock position on the circle.

X Plunge = X Center + Circle Radius - X Plunge = X Center + Circle Radius +

Blend Offset - Tool Radius Blend Offset + Tool Radius

Y Plunge = Y Center Y Plunge = Y Center

Frame, Inside Frame, Outside

Occurs at 6 o’clock position on the frame.

X Plunge = X Corner + (X Length/2) X Plunge = X Corner + (X Length/2)

Y Plunge = Y Corner + Blend Offset + Tool Y Plunge = Y Corner - Blend Offset - Tool
Radius Radius

The plunge points apply to Circle and Frame milling cycles.

2 - 14 Conversational Programming 704-0116-501 Conversational Programming

Lead In/Out Moves
With posted NC programs, use Lead In and Lead Out moves to control the tool path
before the tool moves into position to cut the part.

A positive Lead Angle starts the tool path away from the programmed path when
performing a Lead In move and ends away from the programmed path when performing
a Lead Out move. A negative Lead Angle has the opposite effect.

Toolpath Graphics will not draw the Lead Angle or Lead Length motion.

A Lead In move
B Lead Out move
1 Programmed paths
2 Offset tool path
3 (-) Lead Angle
4 (+) Lead Angle
5 Lead Length

Figure 2–4. Lead In/Out Moves

When you select Milling Type Left, Right, Inside, or Outside, and enable the Display APT
fields in Editor field on the Utilities—Post Processor screen, Lead Angle and Lead Length
fields appear on the Milling data block.

Lead In/Out moves are determined by the lead angle and lead length values. With the
exception of open contours, perform a 90º arc Lead In and Lead Out move.

These NC Programming fields operate similarly to Conversational Blend In/Blend Out

moves (Blend Offset and Blend Overlap values).

Conversational Programming 704-0116-501 Conversational Programming 2-15

Lead Angle
Lead Angle is used with Lead Length to define Lead In and Lead Out moves. Lead Angle is
an angle relative to the direction of the cut, measured 180º from the end of the first
segment.

If starting a contour in the middle of a line or arc, set the Lead Angle at 45º or 90º to
prevent gouging the contour.

Use caution with Lead Angle, because the tool could gouge the part if left at the default of
0.

Lead Length
Lead Length is used with Lead Angle to define Lead In and Lead Out moves. Lead Length
is the length of the Lead In move.

The Lead Length must be larger than the tool's radius. For example, using a 1" diameter
End Mill, the Lead Length would be 0.505".

2 - 16 Conversational Programming 704-0116-501 Conversational Programming

MILLING OPERATIONS
These topics are discussed in this section:

General Guidelines for Creating a Milling Block . . . . . . . . . . . . . . . . . . . . . . . 2 - 18

Lines and Arcs (Mill Contour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 19
Mill Circle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 26
Mill Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 29
Mill Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 31
Mill Ellipse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 33
3D Mold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 34
Helical Plunge (Ramp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 44
Mill Thread. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 51
Mill Stick Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 54
Mill True-Type Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 56
Stick Lettering Along Contour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 59
True-Type Lettering Along Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 62
HD3 Serial Number Stick Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 65
Mill HD3 Lettering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 69
Insert Pockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 70
Swept Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 74
Mill Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 79
Mill Polygon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 84

Conversational Programming 704-0116-501 Milling Operations 2-17

General Guidelines for Creating a Milling
Block
1. Select the Part Programming softkey from the Input screen.
2. Select the Insert Block Before softkey.
3. When the New Block screen appears, select the Milling softkey to display the
milling options shown in the seven softkey selections.
4. Select the milling operation and the first data block screen appears.
5. Enter the geometry values in the appropriate fields/tabs.
6. Enter tool information on the Roughing tab (and on the Finishing tab if a finish
tool will be used). Type the number of the tool in the Tool field and a list of
stored tools appears. Select your tool.
• The tool numbers and their descriptions are entered in Tool Setup. If the
tool information has not been entered or another tool should be added to
the program, select the Tool Setup softkey to update the tool
descriptions for this program.
• Entering a number in the Tool field pulls information from Tool Setup and
automatically loads it into fields on the program block screen. Note that
the Mill Feed and Speed (RPM) fields are filled in based on the information
about the tool.
• To use the UltiPocket option feature, select a pocket boundary. The Pocket
Type field appears when a pocket operation is selected.

Many WinMax screens have fields that appear based on selections

made in other fields. These are conditional fields because they
only appear on a screen under certain conditions.

2 - 18 Milling Operations 704-0116-501 Conversational Programming

Lines and Arcs (Mill Contour)
Mill contour data blocks use segments to create lines and arcs in a part program. A
segment is any single or combined X-Y-Z axis movement at a programmed feedrate. A
series of line and arc segments can be programmed in a single data block, using different
segments, to form a complete contour.

• Start Segment, on page 2 - 19

• Line Segment, on page 2 - 20
• Arc Segment, on page 2 - 21
• Blend Arc Segment, on page 2 - 22
• Helix Segment, on page 2 - 23
• 3D Arc Segment, on page 2 - 24

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Contour screens. Fields displayed on screen may
vary according to machine type, configuration, parameter settings, and/or settings in
other fields.

Block Mill Feed Rough SFQ X Start Z Bottom

Finish SFQ Milling Type Radius XY Angle Z Center

Finish XY Overlap Speed (RPM) XY Length Z End

Finish Z Peck Depth Sweep Angle Y Center Z Point

Lead Pocket Overlap X Center Y End Z Start

Lead Angle Pocket Type X End Y Point

Lead Length Plunge Feed X Point Y Start

Cutter compensation, set in the Milling Type field, determines the

compensation applied to the tool path. See Cutter Compensation
(preliminary), on page 2 - 9 for more information.

Pecking is the use of multiple cutting passes to optimize tool

operation. See Pecking, on page 2 - 8 for more information.

To use pocketing with Mill Contour, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

Start Segment
The first segment in a Mill Contour block is always a Start segment, indicated by the
segment zero (0). Enter the tool that will be used for the entire operation in the Start
segment - all segments in the operation will use this tool. X, Y, and Z Start coordinates
are also entered in the Start segment.

Conversational Programming 704-0116-501 Milling Operations 2-19

Line Segment
For line segments, the Auto-Calc feature automatically calculates certain unknown
dimensions after you enter sufficient data.

The figure below illustrates the XY Length and XY Angle in a Line segment:

• If the X End and Y End coordinates are entered, the system calculates the XY
length and the XY angle values.
• The XY Angle is the angle of the line segment (from the start point to the end
point), measured counterclockwise from the 3 o'clock position.
• If both end points are unknown but the XY Length and XY Angle fields are
programmed, the system calculates the values for the X End and Y End fields.
• If one end point coordinate and the XY Angle field are programmed, the
system calculates the values for the unknown end point and the XY Length
fields.
• If one end point coordinate and the XY Length field are programmed, the
system calculates the values for the unknown end point and the XY Angle
fields. However, unless the XY Angle is known, there are two possible
solutions for the unknown end point, and the correct one must be determined
for the program.
• When two possible solutions exist, the "Another end point exists" message
appears and one of the two possible solutions appears in the unknown field.
You can use the Draw key to view the solution in the Graphics screen. You
can also use the Find Another Endpoint softkey to see the alternate
solution, and view it in Graphics as well. Use the Enter key to accept either
displayed solution.

2 - 20 Milling Operations 704-0116-501 Conversational Programming

The following illustration shows a line segment with unknown Y End and XY Angle:

Arc Segment
The software uses data in the Arc Segment fields as described below to perform
automatic calculations:

• The center points plus the start points or end points provide the arc radius.
• The start points and end points plus the radius provide the two possible
center points.

• Either of the end points and the center point provide the value of the other
end point and the radius.

• When a known center point, start point, or end point and radius are provided,
an unknown center point is provided.

Conversational Programming 704-0116-501 Milling Operations 2-21

Blend Arc Segment
A blend arc is an arc that joins two other segments and is tangent to both. Use a blend
arc to join two line segments, to join a line segment and an arc segment, or to join two
arc segments. The segments to be joined must have a theoretical point of intersection.

Follow this link to the Hurco website to view a Blend Arc

programming video demonstration:

Video Demonstrations at www.hurco.com

Scroll to the bottom of the page and select the video to download.
Internet connection is required.

Two Lines Joined by a Line and Arc Joined by a Two Arcs Joined by a
Blend Arc Blend Arc Blend Arc
1 X/Y Start 1 X/Y Start 1 X/Y Start
2 X/Y End 2 X/Y End 2 X/Y End
3 Segment 1 (Line) 3 Segment 1 (Line) 3 Segment 1 (Arc)
4 Segment 1 End/ 4 Segment 1 End/ 4 Segment 1 End/
Segment 3 Start Segment 3 Start Segment 3 Start
(Point of Intersection) (Point of Intersection) (Point of Intersection)
5 Segment 2 (Blend Arc) 5 Segment 2 (Blend Arc) 5 Segment 2 (Blend Arc)
6 Segment 3 (Line) 6 Segment 3 (Arc) 6 Segment 3 (Arc)

Figure 2–5. Blend Arc Examples

2 - 22 Milling Operations 704-0116-501 Conversational Programming

If the only information known about an arc is its radius, it is easier to program it as a
blend arc if the segments intersect.

Reference values programmed in a previous segment to a blend arc define the start point
of this segment and are displayed in parentheses. These values can only be changed in
the segment in which they were created.

Some guidelines that must be followed when creating a blend arc:

• The first or last segment of a Mill Contour data block cannot be blend arc
segments.
• Blend arc segments cannot be adjacent to one another in a program cannot
be blend arc segments. For example, if segment #2 is a blend arc, neither
segment #1 nor #3 can be blend arc segments.
• Segments that are adjacent to the blend arc segment must intersect at some
point in their theoretical plane. Therefore, if segment #2 is a blend arc,
segments #1 and #3 must theoretically intersect at some projected point.
• The Radius of a blend arc segment cannot be too large to be tangent to both
of the adjoining segments.
• If any coordinate (start point, center point, or end point) is important to the
construction of the two segments to be blended, the segment must be
programmed as an arc and not as a blend arc.
• The Feed field is initially displayed with a value carried forward from the
previous segment. This value can be accepted or changed.

A series of arcs and lines can be programmed in a single data block

to form a complete contour. Press the right Arrow key to program
additional Line and Arc segments for the current data block.

Helix Segment
The software uses data in the Helix fields as described below to perform automatic
calculations:

• The Z End and Sweep Angle provide data to calculate the Lead.
• The Sweep Angle is used to calculate the Z End.
• The X End, Y End, and Lead values provide the Z End.
• The Z End and Lead values provide the X End, Y End, and Sweep Angle
values.
• The X End, Y End, X Center, and Y Center values supply the Radius.
• The Sweep Angle and either the X or Y end point provide the unknown X End
or Y End.

Conversational Programming 704-0116-501 Milling Operations 2-23

3D Arc Segment
Use 3D Arc to create a three-dimensional arc segment.

Do not confuse the 3D Arc feature with the 3D Mold Option. The 3D
Arc feature is always included in the WinMax software. Refer to
WinMax Mill Options for more information on the 3D Mold option.

This diagram shows the relationships of the coordinates to each other:

1 Start Point

2 Center Point

3 X, Y, Z Point

4 End Point

To calculate the centerline of cutter movement, remember these points. Refer to Cutter
Compensation (preliminary), on page 2 - 9 for information about cutter compensation.

• Depending on the axis being worked, X can be interchanged with Y or Z.

• The X and Z points must be calculated for an X-Z arc.
• The Y and Z points must be calculated for a Y-Z arc (all arcs travel through at
least two axes).
• To calculate the centerline in the X axis for a ball-nosed end mill, use this
formula:

Here are the elements of this formula:

Xa = Actual centerline dimension of cutter in X axis

X s = Arc reference starting point in the X axis

Xc = X center point

2 - 24 Milling Operations 704-0116-501 Conversational Programming

 Ri = Radius of arc minus ½ cutter diameter

R = Radius of arc

Follow these guidelines when programming 3D arcs:

• Never program cut right or cut left cutter compensation into a 3D

arc block.
• Always program the centerline of cutter movement.
• Lower the tool calibration point to one-half the cutter diameter by
manually changing the Tool Zero reference point.
For example, when using a 1/4" ball-nosed end mill with Tool Zero of
2.2500" (ball tip touched to work surface), the new zero calibration
is 2.3750". Remember this change when entering Z Up and Z Start
dimensions (which must include the value of this manual change to
the reference point).

Contour End
This block marks the end of the programmed contour. To view the previous segment,
select the Previous Segment softkey. If there are no existing segments, select the
Insert Segment Before softkey or the PAGE DOWN key to create a new segment.

The Contour End screen is shared by Lines and Arcs, Rotary Lines and Arcs, and 3D Mold.

Conversational Programming 704-0116-501 Milling Operations 2-25

Mill Circle
Use the Circle data block to mill circles.

To create a Mill Circle data block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Milling softkey.
4. From the New Block (Milling) screen, select Circle. Mill Circle screen opens.
5. Enter geometry data into the appropriate fields. Field definitions can be found
by following the links below.
6. Enter block operation data into the appropriate tabs and fields. Field
definitions can be found by following the links below. Also see Operation Data,
on page 2 - 4 for more information.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Circle screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

Block Peck Depth Start Angle

Finish SFQ Pocket Overlap Tool

Finish XY Pocket Type X Center

Finish Z Plunge Feed Y Center

Mill Feed Radius Z Bottom

Milling Type Rough SFQ Z Start

Overlap Speed (RPM)

2 - 26 Milling Operations 704-0116-501 Conversational Programming

Mill Circle Example

The sample data in the fields above create the following circle.

Tool plunge point

In this example, Milling Type is ON. Machine movement occurs as follows:

1. Tool moves at Rapid Traverse rate in Z to the Retract Clearance plane.

2. Table moves at Rapid Traverse rate in XY to the Start Angle position at the 3
o’clock position.
3. Tool moves at Rapid Traverse rate to Z Start.
4. Tool moves at Plunge Feed rate to Z Bottom.
5. When the tool reaches Z Bottom, machining continues at Mill Feed with the
center of the tool along the contour, moving clockwise around the circle
(direction set in Program Parameters) until cutting is complete.
6. Tool retracts at Rapid Traverse rate to the Retract Clearance plane.

Cutter compensation, set in the Milling Type field, determines the

compensation applied to the tool path. See Cutter Compensation
(preliminary), on page 2 - 9 for more information.

Conversational Programming 704-0116-501 Milling Operations 2-27

 Pecking is the use of multiple cutting passes to optimize tool
operation. See Pecking, on page 2 - 8 for more information.

To use pocketing with Mill Circle, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

Follow this link to the Hurco website to view a Mill Circle video
demonstration:

Video Demonstrations at www.hurco.com

Scroll to the bottom of the page and select the video to download.
Internet connection is required.

For Rotary Circle, see Rotary Circle - Universal, on page 5 - 16 in the

Rotary manual.

2 - 28 Milling Operations 704-0116-501 Conversational Programming

Mill Frame
The Mill Frame data block supports the creation of frames with or without uniform
corners.

To start a new Mill Frame block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Milling softkey.
4. From the New Block (Milling) screen, select Frame. Mill Frame screen opens.

The Mill Frame block fields appear on two tabs: Geometry and Corners. The frame
geometry parameters are entered on the Geometry tab. Corner Radius specifies the
radius of the reference corner. Use this field if all four corners of the frame will have the
same radius.

To program unique corners (with different radii), parameters are set on the Corners tab.
Select Line or Arc for each corner, and specify a radius for arcs, or length and angle for
lines. If the corner should have neither, geometry should be left as an arc with radius of
0.00, which is the default.

If all four corners of the frame should have the same radius, the
Corners tab does not need to be used; instead use the Corner
Radius parameter on the Geometry tab.
Specifying a value in the Corner Radius field will reset all of the
corners set as Arcs in the Corners tab to that radius. If you are
creating unique corners, do not use the Corner Radius field.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Frame screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

Block Peck Depth X Length

Corner Radius Plunge Feed Y Corner

Finish SFQ Speed (RPM) Y Length

Finish XY Rough SFQ Z Bottom

Finish Z Start Side Z Start

Mill Feed Tool

Milling Type X Corner

For Rotary Frame, see Rotary Frame - Universal, on page 5 - 16 in

the Rotary manual.

Conversational Programming 704-0116-501 Milling Operations 2-29

Mill Frame Example

The sample data in the fields above create the following frame.

In this example, Milling Type is ON. Machine movement is:

1. Tool moves at Rapid Traverse rate to Z Start.

2. Tool moves at Plunge Feed rate to Z Bottom at the mid-point of the bottom
side of the frame (because Start Side is Bottom).
3. When the tool reaches Z Bottom, milling occurs with the center of the tool
along the contour (Milling Type On), moving clockwise around the frame until
milling is complete.
4. Tool retracts at Rapid Traverse rate to the Retract Clearance plane.

2 - 30 Milling Operations 704-0116-501 Conversational Programming

 Cutter compensation, set in the Milling Type field, determines the
compensation applied to the tool path. See Cutter Compensation
(preliminary), on page 2 - 9 for more information.

Pecking is the use of multiple cutting passes to optimize tool

operation. See Pecking, on page 2 - 8 for more information.

To use pocketing with Mill Frame, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

Mill Face
Face milling directs the cutter path so the tool moves over the rectangular face area of
the part, removing material using 60% of the tool diameter from the previous pass (but
the last pass may be less).

Axis positioning places the tool over the next cutting path, and cutting resumes in the
opposite direction.

To start a new Mill Face block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Milling softkey.
4. From the New Block (Milling) screen, select Face. The Mill Face screen opens.

Follow this link to the Hurco website to view a Mill Face programming
video demonstration:

Video Demonstrations at www.hurco.com

Scroll to the bottom of the page and select the video to download.
Internet connection is required.

There are four types of face milling, set in the Milling Type field:

• X Unidirectional—Directs the tool to cut in one direction, parallel to the X

axis, and then move the spindle to the retract clearance value. Axis
movement occurs at rapid traverse to return the tool to the start point of the
next cutting path, which is determined by the system. The start point for
each cut is the tool radius plus blend offset away from the starting edge
corner.
• X Bi-directional—Directs the tool to cut in one direction from the start point,
parallel to the X axis. Axis positioning occurs to place the tool over the next

Conversational Programming 704-0116-501 Milling Operations 2-31

 cutting path, and cutting resumes in the opposite direction. The new cutting
path for the tool is automatically determined by the system.
• Y Unidirectional—Directs the tool to cut in one direction, parallel to the Y
axis, and then move the spindle to the retract clearance value. Axis
movement occurs at rapid traverse to return the tool to the start point of the
next cutting path, which is determined by the system. The start point for
each cut is the tool radius plus blend offset away from the starting edge
corner.
• Y Bi-directional—Directs the tool to cut in one direction from the start
point, parallel to the Y axis. Axis positioning occurs to place the tool over the
next cutting path and cutting is in the opposite direction. The new cutting
path for the tool is automatically determined by the system.

1 Blend Offset

2 X Unidirectional

3 Y Unidirectional

4 X Bidirectional

5 Y Bidirectional

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Face screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

Block Plunge Feed Y Length

Finish SFQ Speed (RPM) Z Bottom

Finish XY Rough SFQ Z Start

Finish Z Tool

Mill Feed X Corner

Milling Type X Length

Peck Depth Y Corner

2 - 32 Milling Operations 704-0116-501 Conversational Programming

Mill Ellipse
The Mill Ellipse block creates ellipses. To start a new Mill Ellipse block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Milling softkey.
4. From the New Block (Milling) screen, select Ellipse. Mill Ellipse screen opens.

Follow this link to the Hurco website to view a Ellipse programming

video demonstration:

Video Demonstrations at www.hurco.com

Scroll to the bottom of the page and select the video to download.
Internet connection is required.

To use pocketing with Mill Ellipse, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

Ellipse axes must be programmed parallel to the respective axes of the machine. X
Radius and Y Radius specify the distance along the X axis from X Center, or along the Y
axis from Y Center, to the edge of the ellipse.

The major axis is the longer or wider axis and can be either the X or Y axis. The minor
axis is the smaller axis. Program an ellipse with the major and minor axes non-parallel to
the machine using a Pattern Loop Rotate routine and rotating the ellipse after it has been
programmed. Refer to Loop Rotate, on page 2 - 114.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Ellipse screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

Block Peck Depth X Center

Finish SFQ Plunge Feed X Radius

Finish XY Pocket Overlap Y Center

Finish Z Pocket Type Y Radius

Mill Feed Rough SFQ Z Bottom

Milling Type Speed (RPM) Z Start

Overlap Tool X Radius

Conversational Programming 704-0116-501 Milling Operations 2-33

 Cutter compensation, set in the Milling Type field, determines the
compensation applied to the tool path. See Cutter Compensation
(preliminary), on page 2 - 9 for more information.

Pecking is the use of multiple cutting passes to optimize tool

operation. See Pecking, on page 2 - 8 for more information.

To use pocketing with Mill Frame, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

3D Mold
3D Mold creates a three dimensional part. Requires the 3D Mold option.

For Swept Surface programming, see Swept Surface, on page 2 -

74 in the Milling chapter of the Conversational Programming manual.

3D Mold Parameters
To create a three-dimensional (3D) part, define a two-dimensional (2D) profile in either
the XY or XZ plane (these are the 3D mold parameters). Repeat the 2D profile along a
straight line (translate) or repeat it around a centerline (revolve) to produce the final 3D
shape (the 3D mold contour). Choose Draw 2D Contour to draw the original 2D contour
that will be manipulated using the 3D operations.

To start a new 3D Mold data block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Milling softkey.
4. From the New Block (Milling) screen, select 3D Mold. 3D Mold screen opens.

Combine of any of the three types into composite contours to machine complex parts:

• XY Revolved About X (About X)—Use a 2D contour programmed in the XY

plane and revolve it about a centerline on the X axis to produce the finished
3D contour.
• XZ Revolved About Z (About Z)—Use a 2D contour programmed in the XZ
plane and revolve it about a centerline on the Z axis to produce the finished
3D contour.
• XZ Translated in Y (Trans Y)—Use a 2D contour programmed in the XZ
plane and translate it in the Y axis.

Select the Edit 3D Mold Contour softkey to access the contour segments. Use the Edit
3D Mold Parameters softkey to reach the parameters screen from any of the contour
screens.

2 - 34 Milling Operations 704-0116-501 Conversational Programming

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the 3D Mold Parameter screens. Fields displayed on screen
may vary according to machine type, configuration, parameter settings, and/or settings
in other fields.

Bidirectional Finish SFQ Start Angle Z Start

Block Mill Feed Step Size

Centerline X Milling Type Stock Allowance

Centerline Y Peck Depth Tool

Centerline Z Plunge Feed Type

Cut Direction Rough SFQ Y End

End Angle Speed (RPM) Y Start

Centerline Y and Centerline Z

1 X Centerline = 0

2 Y Centerline = 5

Figure 2–6. Increased Radius

Conversational Programming 704-0116-501 Milling Operations 2-35

 1 X Centerline = 0

2 Y Centerline = 0

Figure 2–7. Zero Radius

The Centerline Z field determines the Z axis position of the X axis centerline. Changing
the Z axis centerline moves the X axis centerline above or below the part surface. This
alters the depth of the 3D contour. The Z axis centerline is used only for XY Revolved
About X.

To machine the 3D contour below the part surface, enter a negative value in the
Centerline Z field. This value is equal to the radius of the part measured from the Y
centerline.

Here is a convex contour programmed below the part surface:

1 Original Profile

2 Z Centerline

Figure 2–8. Convex Contour Below the Part Surface

Y Start and Y End

2 - 36 Milling Operations 704-0116-501 Conversational Programming

Determine the length of the 3D contour along the Y axis for XZ Translated in Y, as shown
in the example below:

1 Part Zero

2 Y Start

3 Y End

Figure 2–9. Y Start and Y End Fields (XZ Translated in Y)

Conversational Programming 704-0116-501 Milling Operations 2-37

3D Mold Contour
For Swept Surface programming, see Swept Surface, on page 2 -
74 in the Milling chapter of the Conversational Programming manual.

For Lettering Along Contour programming, see Stick Lettering

Along Contour, on page 2 - 59 or True-Type Lettering Along Contour,
on page 2 - 62 in the Milling chapter of the Conversational
Programming manual.

Used in conjunction with 3D Mold Parameters to mill a 3D Mold, program the part
surfaces as a 2D profile in either the XY or XZ plane.

The Start Segment number is always 0. Use segments to program lines and arcs which
create a contour. Repeat the 2D profile along a straight line (translate) or repeat it
around a centerline (revolve) to produce the final 3D shape. The Contour End block
marks the end of the programmed contour.

Select the Edit 3D Mold Parameters softkey to access the parameters screen. The Edit
3D Mold Parameters softkey is not available when the cursor is in either the Block or
Segment field. When you select the Edit 3D Mold Parameters softkey, it changes to
Edit 3D Mold Contour. This softkey is not available when the cursor is in the Block field.

3D Mold Start Segment

See the Field Glossary for definitions of the 3D Mold Contour Start segment fields:

Block

Segment

X Start

Y Start

Z Start

Continue programming the contour by using the Page Down key or by selecting the Next
Segment softkey.

Line, Arc, and Blend Arc softkey choices appear.

2 - 38 Milling Operations 704-0116-501 Conversational Programming

 A contour can also be created by pasting an existing contour into the
program, using Multiple Block Functions on the Program Review
screen. This allows you to use the same segments for a Mill Contour
Block and a 3D Mold Block without entering each segment twice.

• To copy a block, select the contour that you wish to copy

on the Program Review Screen and use the MULTIPLE
BLOCK FUNCTIONS softkey to access the COPY softkey.
• To paste a block, select the 3D Mold Block that you wish
to paste the contour into on the Program Review screen
and use the MULTIPLE BLOCK FUNCTIONS softkey to
access the PASTE softkey.

3D Mold Line
For Swept Surface programming, see Swept Surface, on page 2 -
74 in the Milling chapter of the Conversational Programming manual.

Use the 3D mold Line Segment block to create the geometry for a 3D Mold Line segment.

Some 3D Mold Line fields are automatically calculated with the Auto-Calc feature. See
Automatic Calculations, on page 2 - 7 for more information. Use the Store Calculated
Value softkey to retain a calculated value.

See the Field Glossary for definitions of the 3D Mold Line segment fields:

Block XY Length Z End

Segment XZ Angle Z Start

X End XZ Length

X Start Y End

XY Angle Y Start

Some fields on screen will vary depending on the type of contour selected.

Conversational Programming 704-0116-501 Milling Operations 2-39

3D Mold Arc
For Swept Surface programming, see Swept Surface, on page 2 -
74 in the Milling chapter of the Conversational Programming manual.

Some 3D Mold Arc fields are automatically calculated with the Auto-Calc feature. See
Automatic Calculations, on page 2 - 7 for more information. Use the Store Calculated
Value softkey to retain a calculated value.

See the Field Glossary for definitions of the 3D Mold Arc segment fields:

Block X Center Y Start

Direction X End Z Center

Radius X Start Z End

Segment Y Center Z Start

Sweep Angle Y End

Some fields on screen will vary depending on the type of contour selected.

3D Mold Blend Arc

For Swept Surface programming, see Swept Surface, on page 2 -
74 in Conversational Programming.

A blend arc is an arc that joins two other segments and is tangent to both. Use a blend
arc to join two line segments, to join a line segment and an arc segment, or to join two
arc segments. The segments to be joined must have a theoretical point of intersection.

If the only information known about an arc is its radius, it is easier to program it as a
blend arc if the segments intersect.

Some 3D Mold Blend Arc fields are automatically calculated with the Auto-Calc feature.
See Automatic Calculations, on page 2 - 7 for more information. Use the Store
Calculated Value softkey to retain a calculated value.

See the Field Glossary for definitions of the 3D Mold Blend Arc segment fields:

Block X End Z Center

Direction X Start Z End

Radius Y Center Z Start

Segment Y End

X Center Y Start

Some fields on screen will vary depending on the type of contour selected.

2 - 40 Milling Operations 704-0116-501 Conversational Programming

Roughing and Finishing Tools
In many applications, a Flat End Mill can be used for roughing, followed by a Ball-Nosed
End Mill, which is required for cutting the finished surface.

1 First Data Block Using a Flat End Mill

2 Programmed Contour

3 Material to be Removed by Ball-Nosed End Mill

Figure 2–10. Flat End Mill on a Contour

1 2nd Data Block using a Ball-Nosed End Mill

2 Programmed Contour (Same Contour as DB1)

3 Material to be Removed by Ball-Nosed End Mill

Figure 2–11. Ball-Nosed End Mill on a Contour

Flat End Mill - the cutter path is computed as if a Ball-Nosed End Mill is used. This
computation allows a Flat End Mill to be used for roughing without gouging the part, and
in most cases leaves enough material to be removed for the finished surface using a Ball-
Nosed End Mill.

Conversational Programming 704-0116-501 Milling Operations 2-41

 1 Tool Calibrated on Tip

2 Tool Calculated as center of imaginary ball nose

3 Tool Zero

Figure 2–12. Flat End Mill

Ball-Nosed End Mill - the system computes the compensated cutter path of the ball
center:

1 Tool Calibrated on Tip

2 Tool Calculated as center of ball nose

3 Tool Zero

2 - 42 Milling Operations 704-0116-501 Conversational Programming

 Figure 2–13. Ball-Nosed End Mill

Roughing and Finishing Passes

The Flat End Mill tool path is calculated as a Ball-Nosed End Mill for the roughing pass.

The maximum additional material remaining on the overall 3D contour will not exceed the
tool's radius.

1 Roughing contour using Flat End Mill

2 Finishing contour using Ball-Nosed End Mill

3 Extra Material

Figure 2–14. Roughing and Finishing Passes

Conversational Programming 704-0116-501 Milling Operations 2-43

Helical Plunge (Ramp)
To use Helical Plunge, the Helical Ramp software option must be installed.

The Helical Plunge programming option provides helical plunging as an alternative

machining strategy. Helical plunge and straight plunges can be used separately for
roughing and finishing phases, or they can be used together for the same operation. For
example, you can rough with a helical plunge and finish with a straight plunge.

With Helical Plunging, the tool rotates around the cut and moves down the Z-axis. The
cutting tool is continuously cutting deeper and enters and exists the machined part only
once.

The Helical Plunge fields are located on the Milling 2 tab on the Program Parameters
screen. Set Mill Plunge Type and/or Finish Plunge Type to Helix. Specify the ramp
slope and radius percentage.

• Helical Plunge uses the feedrate programmed by the operator

on the mill circle, mill frame, ellipse, or mill contour start
screens.
• Pattern blocks can be used with helical plunging. A scaled-up or
scaled-down pattern will not affect the diameter of the helix
plunge. When using a mirror image pattern, the helical plunge
will be in the negative Z direction.
• Helical Plunge for rotary mill frames, mill circles, and mill contours
is similar to helical plunging for non-rotary mill frames, mill circles,
and mill contours.

Helical Plunge Milling Parameter Fields . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 45

Helical Plunge (Inside/Outside) for Mill Frames, Mill Circles and Ellipses . . . . . 2 - 45
Helical Plunge with UltiPockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 45
Helical Plunge with Operator Specified Location . . . . . . . . . . . . . . . . . . . . . . 2 - 46
Helical Plunge in the Center of a Pocket. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 46
Helical Plunge with Outward Pocketing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 46
Helical Plunge of Mill Frame Inside with No Pecking and Blend Offset . . . . . . . 2 - 46
Helical Plunging of Mill Frame Inside with Pecking and Straight Plunge Finish Pass and
Blend Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 48
Helical Plunge with Lines and Arcs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 50
Helical Plunge with 3-D Part Programming Option. . . . . . . . . . . . . . . . . . . . . 2 - 50

2 - 44 Milling Operations 704-0116-501 Conversational Programming

Helical Plunge Milling Parameter Fields
On the Program Parameters screen, Milling 2 tab, select Helix in the Mill Plunge Type
field.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Milling 2 (Helical Plunge) screen. Fields displayed on
screen may vary according to machine type, configuration, parameter settings, and/or
settings in other fields.

Allow Plunge Outside Pocket Mill Plunge Helix Radius Pocket Plunge Near Center

Finish Plunge Helix Radius Mill Plunge Ramp Slope

Finish Plunge Ramp Slope Mill Plunge Type

Finish Plunge Type Operator Specify Pocket Start

Helical Plunge (Inside/Outside) for Mill Frames, Mill Circles

and Ellipses
Helical Plunge is similar for milling the inside or outside of mill frames, circles, and
ellipses (with or without blend-in moves). The center location of the helical plunge is the
same as a straight plunge. The direction of the helical plunge (clockwise, CW, or counter
clockwise, CCW) will be determined by the tool spin direction (CW or CCW) and the
milling direction (climb or conventional). If Blend Offset is used, the helical plunge will be
centered about the plunge point of the Blend Offset.

The helical plunge direction that provides a smooth transition to the tool path will be
chosen. Helical plunge is not allowed when Milling Type On is selected.

Helical Plunge with UltiPockets

The Helical Plunge option is used with the UltiPocket option to define the plunging location
when inward pocketing. The operator can specify the pocket plunge location using the
Operator Specify Pocket Start function, or start the pocket plunge near the center by
using the Inward Pocket Plunge Near Center function. See Helical Plunge with UltiPockets,
on page 2 - 145 in Conversational Programming.

When both the Operator Specify Pocket Start and the Inward Pocket Plunge Near Center
are set to No, the plunge locations are used that would have been used without the
Helical Plunge option.

An error message appears if the plunge point specified would violate

the programmed part surface.

Conversational Programming 704-0116-501 Milling Operations 2-45

Helical Plunge with Operator Specified Location
When the operator specifies the plunge point, all of the helix plunge moves will occur at
that location, even for the pocket boundary.

Helical Plunge in the Center of a Pocket

When the Inward Pocket Plunge Near Center field value is Yes (Operator Specify Pocket
Start value must be No), a plunge point near the center of the pocket will be chosen.
Islands near the center will impact upon the plunge point’s location.

When machining a part with a lot of webbing (many small pockets

separated by walls), it may be desirable to disable helical plunging.

Helical Plunge with Outward Pocketing

Helical plunging occurs near the center of the pocket when used with Outward Pocketing,
and only one plunge location is needed. The Operator Specify Pocket Start and the
Inward Pocket Plunge Near Center fields have no effect on Helical Plunge with Outward
Pocketing.

Helical Plunge of Mill Frame Inside with No Pecking and

Blend Offset
The tool will helical plunge to the Z Bottom level and then perform the normal blend-in
move. The direction of the helical plunge arc will smoothly transition to the blend-in arc.
For instance, if the blend-in arc is CCW, the direction of the helical plunge will be CW. The
following isometric views are created by setting the Draw Plunge Moves graphics
parameter field to Yes.

This graphical representation is only for informational purposes and

cannot be viewed with WinMax.

2 - 46 Milling Operations 704-0116-501 Conversational Programming

The graphics show the finish pass only if a finish tool is specified in the frame block, and
do not show individual peck levels.

Figure 2–15. Helical Plunge with No Pecking and Blend Offset (Isometric View)

Conversational Programming 704-0116-501 Milling Operations 2-47

Helical Plunging of Mill Frame Inside with Pecking and
Straight Plunge Finish Pass and Blend Offset
The following example is a Mill Frame Block Type with Inside Milling Type. The finish tool
specified and the peck depth is set to 0.6 inches.

First Peck - The tool helical plunges down to the -first peck depth, then mills another full
circle to ensure that all material down to the first peck is removed. After the full circle is
completed, a 180° blend in arc is performed. The direction of the helical plunge will
always be in the opposite direction of the blend-in arc.

These graphical representations are only for informational purposes

and cannot be viewed with WinMax.

Figure 2–16. First Peck (Isometric View)

Second Peck and All Pecks to Finish Peck Depth - The tool will rapid down to the previous
peck depth plus the peck clearance plane. The tool then helical plunges down to the next
peck depth or the Z Bottom plus the Finish Z. If the tool is at a peck depth, a 360o arc
will be machined. The 360o arc will not be machined if it is the last peck depth. Instead,
a blend-in arc will be machined. The blend-in arc for the last peck depth will be similar to
the one machined for the first peck.

2 - 48 Milling Operations 704-0116-501 Conversational Programming

 Figure 2–17. Second Peck (Isometric View)

Finish Pass - The tool will rapid down to the Z Start and plunge feed down to the Z
Bottom. A blend-in move is performed before milling the frame contour.

When helical plunge is used for roughing passes, a large amount of

material is removed around the point of entry. Therefore, using
helical plunging for the finish passes is probably not necessary.

Figure 2–18. Finish Pass (Isometric View)

If the finish tool is larger than the roughing tool, helical plunges
should also be performed for the finish pass. If a post was created by
the roughing tool (the Helix plunge radius was greater than 50
percent) the finish tool may be cutting into the post.

Conversational Programming 704-0116-501 Milling Operations 2-49

Helical Plunge with Lines and Arcs
Helical plunge with lines and arcs occurs at the start of the contour.

The following example shows helical plunging with right cutter compensation of a
contour.

Figure 2–19. Helical Plunging with Lines/Arcs (Isometric View)

An error message will be displayed if the helical plunge would cut

into a part surface. If this error message appears, move the starting
location of the contour to an area that will not cause interference.

Helical Plunge with 3-D Part Programming Option

Helical plunging is supported in the 3-D Part Programming option. A helical plunge can be
performed when the Mill Plunge Type field is set to Helix.

Only one helical plunge occurs when using a bi-directional tool path. When performing
helical plunge using unidirectional tool path, a helical plunge occurs for each cutter pass.

When programming complex 3-D parts, the operator should review

helical plunge placements in graphical form before milling to ensure
helical plunges from one block do not interfere with neighboring
blocks.

If Mill Plunge Type field is set to Helix, but the helical plunge does not
appear on the graphics screen, check the Z Start field on the Mill 3-D
block screen. The plunges may not appear if Z Start value is too low.

2 - 50 Milling Operations 704-0116-501 Conversational Programming

Mill Thread
The Mill Thread data block mills a part with internal or external threads. Milling can be
clockwise or counterclockwise, and occur from top to bottom or bottom to top.

Thread Direction Down

The following diagram shows the Z positions, and the arrows indicate tool movement
when the Thread Direction is Down. In this case, the tool moves at rapid feedrate to the Z
Plunge Start position, then feeds to the Z Top position. The tool mills down to the Z
Bottom position. It then moves at rapid feedrate out of the hole to Z Plunge Start + Z
retract clearance height (set in Program Parameters).

Z Plunge Start

Z Thread Top

Z Thread Bottom

Figure 2–20. Tool movement when Thread Direction is down

Thread Direction Up

The following diagram shows the Z positions, and the arrows indicate tool movement
when Thread Direction is Up. In this case, the tool moves at rapid feedrate to the Z
Plunge Start position, then feeds down to the Z Bottom position, and mills up to the Z Top
position. The tool then moves at rapid to Z Plunge Start and retracts to the Z retract
clearance height (set in Program Parameters).

Z Plunge Start

Z Thread Top

Z Thread Bottom

Figure 2–21. Tool movement when Thread Direction is up

Conversational Programming 704-0116-501 Milling Operations 2-51

To access the Mill Thread block:

1. From a New Block screen, select the Milling softkey.

2. Select the More softkey twice.
3. Select the Thread softkey. The Mill Thread block opens.

Thread geometry is set in the Thread tab. Specify the radius, TPI/Pitch, inside or outside
threads, start angle, and any taper angle.

Thread location is set in the Location tab. Specify the X and Y centers, the Z plunge start
point, thread top and bottom locations, and the threading direction.

Cutting information is set in the Process tab. Specify cutter compensation, blend type,
and center start.

When using a single-cutter thread mill, the Taper Angle field appears in the Thread tab.
External threads must have a positive taper angle and internal threads must have a
negative taper angle:

-10° Taper with Internal Threads 10°Taper with External Threads

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Thread screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

2 - 52 Milling Operations 704-0116-501 Conversational Programming

 Blend Type Pitch Start at Center Z Plunge Start

Block Plunge Feed Taper Angle

Cutter Length Radial Peck Count Thread Bottom

Direction Radial Peck Depth Thread Top

Enable Cutter Comp Radius TPI

Mill Feed Speed (RPM) X Center

Orientation Start Angle Y Center

Radial Pecks
The Radial Peck feature can be used when more than one cutting pass is required, such
as with harder materials.

Enter an incremental distance from the final cut in the Radial Peck Depth field, and
enter the number of passes in the Radial Peck Count field. Milling occurs as follows:

• Orientation Outside—milling begins at (radius) + (Radial Peck Count x Radial

Peck Depth) position, and proceeds inward for the number of passes (count)
specified, to the final radius cut.
• Orientation Inside—milling begins at (radius) - (Radial Peck Count x Radial
Peck Depth) position, and continues outward in the number of passes (count)
specified, to the final radius cut.

For example:

Radius = 2.0 Final Radius 2.0

Radial Peck Count = 10
Radial Peck Depth = .05
Orientation = Inside
First cut 1.5

Incremental cuts .05

Milling begins at 1.5
[2.0 -10x.05)], makes
10 incremental .05 passes
to finish at 2.0.

If Radial Pecking is not desired, set Radial Peck Count to 1 (default).

Conversational Programming 704-0116-501 Milling Operations 2-53

Mill Stick Lettering
<See also Mill True-Type Lettering, on page 2 - 56.>

The Stick Lettering block supports the HD3 lettering (military text) character set. Use the
X and Y Ref Locations to specify the X and Y reference points—start, center, or end:

Y Reference

Top

Center

Bottom

Start Center End

X Reference

Specify the text, length, and orientation. For example:

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The

2 - 54 Milling Operations 704-0116-501 Conversational Programming

fields listed below appear on the Mill Stick Lettering screen. Fields displayed on screen
may vary according to machine type, configuration, parameter settings, and/or settings
in other fields.

Block Peck Depth X Reference

Char Spacing Plunge Feed X Ref Location

Finish SFQ Rough SFQ Y Length

Finish XY Speed (RPM) Y Reference

Finish Z Text Y Ref Location

Mill Feed Tool Z Bottom

Orientation X Length Z Start

Recovery Restart is supported from a specific letter, specified as character number. For
example, to restart from the “R” in HURCO, you would specify character 3 as the starting
character. Recovery Restart is launched from the Auto mode screen.

Conversational Programming 704-0116-501 Milling Operations 2-55

Mill True-Type Lettering
The Mill True-Type Lettering block mills True-Type fonts. These True-Type fonts are
available in different styles and are block-type letters with closed profiles for milling,
which allow cutter compensation - i.e., inside, outside, and pocket milling. Supported
characters include the full character sets for most Western European languages.

Common Fonts Available with Mill True-Type Lettering

Arial (default) Microsoft Sans Serif

Arial Black Palatino Linotype

Comic Sans MS Sylfaen

Courier New Tahoma

Franklin Gothic Times New Roman

Medium
Trebuchet MS
Georgia
Verdana
Impact
Webdings
Lucida Console
Wingdings
Lucida Sans Unicode

Marlett

Specify the text, length, and orientation. For example:

2 - 56 Milling Operations 704-0116-501 Conversational Programming

 Figure 2–22. Example of True-Type Lettering

The X and Y Ref Locations specify the X and Y reference points—start, center, or end:

Y Reference

Top

Center

Bottom

Start Center End

X Reference

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill True-Type Lettering screen. Fields displayed on
screen may vary according to machine type, configuration, parameter settings, and/or
settings in other fields.

Conversational Programming 704-0116-501 Milling Operations 2-57

 Block Mill Feed Speed (RPM) Y Reference

Enable Blend Moves Orientation Text Y Ref Location

Finish SFQ Overlap Tool Z Bottom

Finish XY Peck Depth X Length Z Start

Finish Z Plunge Feed X Reference

Font Pocket Overlap X Ref Location

Mapping Rough SFQ Y Length

2 - 58 Milling Operations 704-0116-501 Conversational Programming

Stick Lettering Along Contour
<See also True-Type Lettering Along Contour, on page 2 - 62.>

With Stick Lettering Along Contour, text is oriented along a programmed contour,
which determines the size and orientation. The contour is grouped with the data block
and programmed like the contours in a 3D mold or Swept Surface data block.

The opening screen is the lettering parameters screen. The text dimensions and spacing
are set in this screen. First, specify how the width of the text is determined, in the Width
Method field:

• Use Contour—the text will be distributed evenly along the contour.

• Specify Width—specify the width measurement in the Text Width field
(appears when Specify Width is selected).

Text Width—field appears when Specify Width is selected as Width Method.

Enter the total width of the text along the contour, or use the Calculate Text
Width softkey to automatically calculate the text width based on the contour
length.

Figure 2–23. Stick Lettering Along Contour Lettering Parameters screen

Use Edit Along Contour softkey to open the Start segment:

Figure 2–24. Stick Lettering Along Contour Start Segment

The contour start segment includes fields to specify which side of the contour the text is
positioned relative to. The text offset specifies distance between the contour and the

Conversational Programming 704-0116-501 Milling Operations 2-59

reference point of the text.

Select the Next Segment softkey to lay the text out on a line, arc, and/or blend arc.
Here is an example with a single arc segment:

Figure 2–25. Stick Lettering Along Contour Arc Segment

A contour can also be created by pasting an existing contour into the

program, using Multiple Block Functions on the Program Review
screen.

Figure 2–26. Example of Stick Lettering Along Contour

Recovery Restart is supported from a specific letter, specified as character number. For
example, to restart from the “R” in HURCO, you would specify character 3 as the starting
character. Recovery Restart is launched from the Auto mode screen.

2 - 60 Milling Operations 704-0116-501 Conversational Programming

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Stick Lettering Along Contour screen. Fields displayed on
screen may vary according to machine type, configuration, parameter settings, and/or
settings in other fields.

Block Peck Depth Text Offset XY Length

Char Spacing Plunge Feed Text Height Y Center

Direction Radius Text Width Y End

Finish SFQ Rough SFQ Width Method Y Start

Finish XY Speed (RPM) X Center Z Bottom

Finish Z Sweep Angle X End Z Start

Font Side of Contour Tool X Start

Mill Feed Text XY Angle

Conversational Programming 704-0116-501 Milling Operations 2-61

True-Type Lettering Along Contour
With True-Type Lettering Along Contour, text (True-Type font) is oriented along a
programmed contour, which determines the size and orientation. The contour is grouped
with the data block and programmed like the contours in a 3D mold or Swept Surface
data block.

True-Type fonts are available in different styles and are block-type letters with closed
profiles for milling, which allow cutter compensation - i.e., inside, outside, and pocket
milling. Supported characters include the full character sets for most Western European
languages.

The font selection dialog box is opened with the Select New Font F3 softkey, when the
cursor is in the Text field on the parameters screen.

Common Fonts Available with Mill True-Type Lettering

Arial (default) Microsoft Sans Serif

Arial Black Palatino Linotype

Comic Sans MS Sylfaen

Courier New Tahoma

Franklin Gothic Times New Roman

Medium
Trebuchet MS
Georgia
Verdana
Impact
Webdings
Lucida Console
Wingdings
Lucida Sans Unicode

Marlett

The lettering parameters are programed on the opening screen. The text dimensions and
spacing are set in this screen. First, specify how the width of the text is determined, in
the Width Method field:

• Use Contour—the text will be distributed evenly along the contour.

• Specify Width—specify the width measurement in the Text Width field
(appears when Specify Width is selected).

Text Width—field appears when Specify Width is selected as Width Method.

Enter the total width of the text along the contour, or use the Calculate Text
Width softkey to automatically calculate the text width based on the contour
length.

Here is an example of a True-Type Lettering Along Contour parameters block:

2 - 62 Milling Operations 704-0116-501 Conversational Programming

Use the Edit Along Contour softkey to open the Start segment:

The contour start segment includes fields to specify which side of the contour the text is
positioned relative to. The text offset specifies distance between the contour and the
reference point of the text.

Select the Next Segment softkey to lay the text out on a line, arc, or blend arc:

Conversational Programming 704-0116-501 Milling Operations 2-63

 Figure 2–27. Example of True-Type Lettering Along Contour

A contour can also be created by pasting an existing contour into the

program, using Multiple Block Functions on the Program Review
screen.

Recovery Restart is supported from a specific letter, specified as character number. For
example, to restart from the “R” in HURCO, you would specify character 3 as the starting
character. Recovery Restart is launched from the Auto mode screen.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the True-Type Lettering Along Contour screen. Fields
displayed on screen may vary according to machine type, configuration, parameter
settings, and/or settings in other fields.

Block Mill Feed Sweep Angle XY Angle

Blank Spacing Milling Type Tool XY Length

Char Spacing Overlap Text Y Center

Direction Peck Depth Text Offset Y End

Finish SFQ Plunge Feed Text Height Y Start

Finish XY Pocket Overlap Text Width Z Bottom

Finish Z Pocket Type Width Method Z Start

Font Radius X Center

Font Side of Contour Rough SFQ X End

Mapping Speed (RPM) X Start

2 - 64 Milling Operations 704-0116-501 Conversational Programming

HD3 Serial Number Stick Lettering
HD3 Serial Number Lettering mills a sequence of unique serial numbers that increment
each time the block is run. The characters are HD3-style (non-true type) and can be
alphabetic A-Z, numeric 0-9, and special characters @#!$^&*()-[]_=+’:;%?/<>,.\.
Alpha characters are all upper case. The last character in the serial number must be
numeric and is incremented by a specified amount.

• Users can manually provide serial number data, which includes a starting
sequence, such as 0001 or ABC001, and an increment which advances the
serial number for each subsequent run.
• Data can originate from a file in which the serial numbers are listed. Each
time the block is run, the next serial number is extracted from the file. The
format of this file must be one serial number per line, each line must end in a
carriage return, line feed sequence, or Return key.

To create an HD3 Serial Number Lettering block from the New Block Screen:

1. Select the Milling softkey.

2. Select the More softkey.
3. Select the Lettering softkey.
4. Select the Serial Number Stick Lettering softkey.

The HD3 Serial Number Lettering screen uses three tabs: Text, Orientation, and Format.

Text tab
The text of the serial number is set up in the Text tab:

The Character Width includes the character left-justified, plus some spacing between it
and the next character to be milled. Spacing between the characters is equal to the tool's
diameter. Because cutter compensation is not used in this routine and letter contouring

Conversational Programming 704-0116-501 Milling Operations 2-65

follows the center of the tool, character spacing can be adjusted by adjusting the tool
diameter in Tool Setup.

To populate serial numbers from a source file, specify From File in the Data Origin
field. The File field and Locate... button appear. The file must be located on the hard drive
or an accessible network drive, or can be on a floppy disk or USB memory device that has
been loaded onto the control. To select the file:

1. Select the Locate... button to browse for the file.

2. Navigate to the location of the file in the dialog box that opens.
3. Select the file.
4. Select the Open button on the dialog box. The file and path appear in the
File field.

Orientation tab
The Orientation fields specify the orientation of the X and Y reference points.

Figure 2–28. Serial Number Orientation tab

Y Reference

Top

Center

Bottom

Start Center End

X Reference

Figure 2–29. X Reference and Y Reference locations

2 - 66 Milling Operations 704-0116-501 Conversational Programming

Format tab
The Format fields indicate whether the serial number should have a minimum length and
what that length should be.

Figure 2–30. Serial Number Format tab

Leading Symbol Example:

Starting Sequence 001

Increment 1

Assure Minimum Length Yes

Minimum Length 5

Leading Symbol A

First Serial Number will be AA001 NOTE: A second “A” is added to starting
sequence of 001 to assure the minimum
length of 5.

Second Serial Number will be AA002

999th Serial Number will be AA999

1000th Serial Number will be A1000 NOTE: The second “A” is no longer needed to
assure minimum length.
If serial number “AA1000” is required, the
Starting Sequence would be AA001 and Assure
Minimum Length would be set to No.

Format tab only assures a minimum number of characters. The

serial number will continue to increment and expand with continuous
running of the block.

Conversational Programming 704-0116-501 Milling Operations 2-67

History tab
The History tab displays the last used and next serial numbers and contains the Reset
Numbering button:

Figure 2–31. Serial Number History tab

The Last Used and Next Serial Numbers are saved in the part program after each cycle so
milling can restart from where it was stopped when the part program was closed.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Serial Number Stick Lettering screen. Fields displayed
on screen may vary according to machine type, configuration, parameter settings, and/or
settings in other fields.

Assure Minimum Last Used Serial Plunge Feed X Ref Location

Length Number

Block Leading Symbol Reset Numbering Y Reference

Character Height Mill Feed Speed (RPM) Y Ref Location

Character Width Minimum Length Starting Sequence Z Bottom

Data Origin Next Serial Number Tool Z Start

Increment Peck Depth X Reference

2 - 68 Milling Operations 704-0116-501 Conversational Programming

Mill HD3 Lettering
Mill HD3 Lettering supports programs created in the legacy Ultimax Classic mode.

Use the X and Y Ref Locations to specify the X and Y reference points—start, center, or
end:

Y Reference

Top

Center

Bottom

Start Center End

X Reference

Figure 2–32. X Reference and Y Reference locations

Specify the character dimensions in Character Height and Character Width, and the
text to be milled in the Text field.

Cutter Compensation is not available for HD3 Lettering. Milling is performed using the
centerline of the tool. Refer to Cutter Compensation (preliminary), on page 2 - 9.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the HD3 Lettering screen. Fields displayed on screen may
vary according to machine type, configuration, parameter settings, and/or settings in
other fields.

Block Speed (RPM) Y Ref Location

Character Height Text Z Bottom

Character Width Tool Z Start

Mill Feed X Reference

Peck Depth X Ref Location

Plunge Feed Y Reference

Conversational Programming 704-0116-501 Milling Operations 2-69

Insert Pockets
Cutter insert manufacturers use the Insert Pockets milling routines to mill pockets in
triangular, diamond, and hexagon shapes. These routines are sold as the Insert Pockets
option and can be defined in one program data block.

To access the Insert Pockets features, select the Milling softkey in a New Block screen,
then Select the More softkey. If the option is installed the next screen will have a
Special softkey. Select that softkey to display the following screen:

Choose Triangle, Diamond 1 Face, Diamond 2 Faces, or Hexagon milling.

Mill Triangle, on page 2 - 71—mills a triangle shape with three equal 60° angles
with one open face.

Mill Diamond, on page 2 - 71—mills a four-sided diamond shape with opposite

angles equal with one or two open faces.

Mill Hexagon, on page 2 - 72—mills a six-sided hexagon shape with every other
angle equal.

For all shapes, the cutting operation is set in the Milling Type field:

• Inside - cuts just the non-open faces of the pocket, including the relief cuts.
• Inside 2 Passes - cuts the same as Inside, except this selection uses a
roughing pass and a finishing pass. During roughing, material is left for the
finish pass.
• Pocket Outside In - cuts along the faces of the insert, including the relief
cuts and then steps inward and cleans out the entire insert by executing
smaller versions of the shape until the center point is reached.
• Pocket 2 Passes Outside In - cuts in the same manner as Pocket Outside
In, except this selection uses a roughing and a finishing pass.

2 - 70 Milling Operations 704-0116-501 Conversational Programming

 • Pocket Inside Out - plunges tool at X-Y center of the insert and cuts
outward, executing larger versions of the shape until the faces and relief cuts
are milled.
• Pocket 2 Passes Inside Out - cuts the same as Pocket Inside Out, except
this selection uses a roughing and a finishing pass.

Mill Triangle
The triangle pocket shape has three equal 60° angles with one open face as shown below.
A relief cut can be programmed in the corner at point 1.

Relief Corner

1
Open Face Radius Centerpoint Orientation = 0

Figure 2–33. Triangle Programming Diagram

Mill Diamond
The diamond pocket shapes have four sides with opposite angles equal.

The Diamond 1 Face has one open face and the option of a right, center, or left relief cut
in the corners at point 1 and point 2 as shown below:

Relief Corners
Angle

Radius
4
Centerpoint Orientation =0
2

Open Face

Figure 2–34. Diamond 1 Face Diagram

Conversational Programming 704-0116-501 Milling Operations 2-71

The Diamond 2 Faces pocket has two open faces and the option of a right, center, or
left relief cut in the corner at point 1 as shown below:

1
Relief
Corners

Angle

4 Radius

Centerpoint Orientation = 0
2

Open Face
Open Face

Figure 2–35. Diamond 2 Faces Diagram

Mill Hexagon
This pocket shape has six sides and every other angle equal. In the diagram below, the
shape has two open faces and the option of a relief cut in the corners at point 1, point 2,
and point 3, and the option of a face relief distance between points 0 and 1 and points 3
and 4.

P-0 Point 0

P-1 Point 1
Radius
P-2 Point 2
Orientation=0
P-3 Point 3
Shape
Angle
X and Y
Centerpoint
P-4 Point 4

P-5 Point 5

R-1 Relief 1
Tool path
R-2 Relief 2

R-3 Relief 3
Relief Distance

Figure 2–36. Hexagon Programming Diagram

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Insert Pockets screen. Fields displayed on screen may

2 - 72 Milling Operations 704-0116-501 Conversational Programming

vary according to machine type, configuration, parameter settings, and/or settings in
other fields.

Block Radius Text

Mill Feed Relief 1 Tool

Milling Type Relief 2 X Center

Orientation Relief 3 Y Center

Peck Depth Shape Angle Z Bottom

Plunge Feed Speed (RPM) Z Start

Conversational Programming 704-0116-501 Milling Operations 2-73

Swept Surface
The Swept Surface option in WinMax allows you to program draft angles for pocket or
island walls with greater flexibility, including Spiral, Constant Z level, and Cusp Height
cutting strategies.

Follow this link to the Hurco website to view a Swept Surface

programming video demonstration:

Video Demonstrations at www.hurco.comScroll to the bottom of the

page and select the video to download. Internet connection is
required.

Swept Surface builds on the WinMax 3D Mold option. The basic elements in Swept
Surface programming are:

• Draw Profile Contour—build the XZ or YZ shape of the part

• Draw Along Contour—build the shape of the contour
• Swept Surface—provide details of how to cut the part

To begin a new Swept Surface program block, perform the following steps:

1. From a New Block screen, select the Milling softkey.

2. Select the More softkey.
3. Select the Swept Surface softkey.
4. Use the drop-down list to select the type of contour in the Type field: Draw
Profile, Draw Along, or Swept Surface.
A Swept Surface program block must contain all three types of
contours: Draw Profile, Draw Along, and Swept Surface.

5. To program Draw Profile Contours or Draw Along Contours, place the cursor in
the Type field, and select the Edit Along Contour or the Edit Profile
Contour softkey.

2 - 74 Milling Operations 704-0116-501 Conversational Programming

Swept Surface Parameters
Swept Surface parameters establish the machining characteristics.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Swept Surface parameter screen. Fields displayed on
screen may vary according to machine type, configuration, parameter settings, and/or
settings in other fields.

Bidirectional Individual Pocket Finish Rough SFQ Type of Corners

Profiles SFQ

Block Mill Feed Pocket First Speed (RPM) Use Cusp Height

Cusp Height Milling Type Pocket Overlap Start Angle Z Roughing

Cut Direction Min Cusp Pocket Rough Step Size Z Start

Overlap (%) SFQ

End Angle Min Z Pocket Type Stock Allowance Y End

Finish SFQ Overlap Profile Number Step Connect

Type

Finish XY Peck Depth Roll End Point Tool

Finish Z Plunge Feed Roll Start Point Type

Swept Surface Contours

Program the part surfaces as a 2D profile in either the XY or XZ plane.

The Start Segment number is always 0. Use segments to program lines and arcs which
create a contour. Repeat the 2D profile along a straight line (translate) or repeat it around
a centerline (revolve) to produce the final 3D shape. The Contour End block marks the
end of the programmed contour.

When creating/editing a contour segment, select the Swept Surface Parameters

softkey to access the parameters screen. When on the parameters screen, the Edit
Profile Contour and Edit Along Contour softkeys appear. Use these softkeys to switch
between the parameter and contour screens; softkeys do not appear if the cursor is in the
Block or Segment fields.

Draw Profile Contour

The Draw Profile Contour screen is displayed as
Swept Surface (Profile Contour).

Set the Type field to Draw Profile(s) and select the Edit Profile Contour softkey. Seg-
ment types are:

• Start Segment
• Line Segment

Conversational Programming 704-0116-501 Milling Operations 2-75

 • Arc Segment
• Blend Arc Segment

A contour can also be created by pasting an existing contour, circle,

frame, slot, or polygon into the program, using Multiple Block
Functions on the Program Review screen.

Draw Along Contour

The Draw Along Contour screen is displayed as
Swept Surface (Along Contour).

Set the Type field to Draw Along and select the Edit Along Contour softkey. Segment
types are:

• Start Segment
• Line Segment
• Arc Segment
• Blend Arc Segment

A contour can also be created by pasting an existing contour, circle,

frame, slot, or polygon block into the program, using Multiple Block
Functions on the Program Review screen.

The Surface Side field (present in Segment 0) specifies on which side of the Along
contour the profile is cut:

• When set to Right, the profile is cut to the right of the contour forming a
surface to the right of the along contour.
• When set to Left, the profile is cut to left of the contour creating a surface to
the left of the along contour.

Start Segment
See the Field Glossary for definitions of the Swept Surface Contour Start segment fields:

Block

Segment

Surface Side

X Start

Y Start

Z Start

Continue programming the contour by using the Page Down key or by selecting the Next
Segment softkey.

Line, Arc, and Blend Arc softkey choices appear.

2 - 76 Milling Operations 704-0116-501 Conversational Programming

 A contour can also be created by pasting an existing contour into the
program, using Multiple Block Functions on the Program Review
screen. This allows you to use the same segments for a Mill Contour
Block and a 3D Mold Block without entering each segment twice.

• To copy a block, select the contour that you wish to copy

on the Program Review Screen and use the MULTIPLE
BLOCK FUNCTIONS softkey to access the COPY softkey.
• To paste a block, select the 3D Mold Block that you wish
to paste the contour into on the Program Review screen
and use the MULTIPLE BLOCK FUNCTIONS softkey to
access the PASTE softkey.

Line Segment
Use the Line Segment block to create the geometry for a line.

Some Line fields are automatically calculated with the Auto-Calc feature. See Automatic
Calculations, on page 2 - 7 for more information. Use the Store Calculated Value
softkey to retain a calculated value.

See the Field Glossary for definitions of the Swept Surface Line segment fields:

Block XY Length Z End

Segment XZ Angle Z Start

X End XZ Length

X Start Y End

XY Angle Y Start

Some fields on screen will vary depending on the type of contour selected.

Arc Segment
Some Arc fields are automatically calculated with the Auto-Calc feature. See Automatic
Calculations, on page 2 - 7 for more information. Use the Store Calculated Value
softkey to retain a calculated value.

See the Field Glossary for definitions of the Swept Surface Arc segment fields:

Block X Center Y Start

Direction X End Z Center

Radius X Start Z End

Segment Y Center Z Start

Sweep Angle Y End

Some fields on screen will vary depending on the type of contour selected.

Conversational Programming 704-0116-501 Milling Operations 2-77

Blend Arc Segment
A blend arc is an arc that joins two other segments and is tangent to both. Use a blend
arc to join two line segments, to join a line segment and an arc segment, or to join two
arc segments. The segments to be joined must have a theoretical point of intersection.

If the only information known about an arc is its radius, it is easier to program it as a
blend arc if the segments intersect.

Some Blend Arc fields are automatically calculated with the Auto-Calc feature. See
Automatic Calculations, on page 2 - 7 for more information. Use the Store Calculated
Value softkey to retain a calculated value.

See the Field Glossary for definitions of the Swept Surface Blend Arc segment fields:

Block X End Z Center

Direction X Start Z End

Radius Y Center Z Start

Segment Y End

X Center Y Start

Some fields on screen will vary depending on the type of contour selected.

2 - 78 Milling Operations 704-0116-501 Conversational Programming

Mill Slot
For Rotary Slot see Rotary Slot - Universal, on page 5 - 19 in the
Rotary chapter.

The Mill Slot block creates a line or arc shape of any width. The slot is defined by a line or
an arc segment and a width. The ends of the slot can be round or square.

Line Slot Arc Slot

Width Width
Top
XY XY End
Start
Bottom

Bottom
Start Point
XY End
Start Point XY Start

Milling begins at the center of the bottom wall of the slot, assuming the shape is parallel
to the X axis (Angle field is set to zero). The same relative “bottom” wall is maintained
when the shape is rotated, so when the Angle field is nonzero, milling begins on the side
that would be parallel with the X-axis if the Angle was zero:

XY End

Start Point

XY Start
Figure 2–37. Line Slot rotated 90°

Conversational Programming 704-0116-501 Milling Operations 2-79

Mill Slot Programming
1. From a New Block screen, select the Milling softkey.
2. Select the More softkey.
3. Select the Slot softkey. The Mill Slot screen contains three tabs: Start,
Geometry, and Caps.

To use pocketing with Mill Slot, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

Start tab
Define the slot shape, width, and common starting information on the Start tab:

Some fields may be automatically calculated when sufficient data

has been entered. The CAL notation appears before the field.

Geometry tab
The fields that appear on the Geometry tab depend on the slot shape selected in the
Start tab (line or arc). Define the slot geometry:

2 - 80 Milling Operations 704-0116-501 Conversational Programming

Caps tab
The slot ends are defined on the Caps tab:

If a Corner Radius exceeds 1/2 of the slot width, WinMax will find the
intersection point to close the contour.

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Slot screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other
fields.

Block Peck Depth Start Cap XY Angle

Corner Radius Plunge Feed Sweep Angle XY Length

Direction Pocket Overlap Tool Y Center

End Cap Pocket Type Width Y End

Mill Feed Radius X Center Y Start

Milling Type Shape X End Z Bottom

Overlap Speed (RPM) X Start Z Start

Conversational Programming 704-0116-501 Milling Operations 2-81

Start Cap and End Cap specify the type of ends the slot uses:

• Line closes the slot with a straight line, passing through the programmed
endpoint:

• Append Arc appends an arc at the ends of the slot length, i.e., center of
semi-circle is programmed endpoint:

• Include Arc includes the arc in the slot length, i.e., outermost edge of semi-
circle is programmed endpoint:

2 - 82 Milling Operations 704-0116-501 Conversational Programming

Mill Slot Sample Program

NOTE: values are metric

DB Data Block Field Name Field Value

1 Mill Slot
Shape Line
Width 30.000
X Start 20.000
Start tab
Y Start 20.000
Z Start 1.000
Z Bottom -10.000
X End 100.000
Y End 20.000
Geometry tab
XY Length [CAL] 80.000
XY Angle [CAL] 0.000
Start Cap Line
Corner Radius 0.000
Caps tab
End Cap Append Arc
Corner Radius n/a
Milling Type Pocket Boundary
Roughing tab
Pocket Type Outward

Conversational Programming 704-0116-501 Milling Operations 2-83

Mill Polygon
For Rotary Polygon information, see Rotary Polygon - Universal, on
page 5 - 19 in the Rotary chapter.

The Mill Polygon data block mills a multi-sided contour with equal-length sides. The
bottom of the polygon is parallel to the X axis at 0° orientation (three o’clock position):

Milling begins on the side of the polygon that is parallel to X at 0° prior to rotation.
Rotation is achieved with the Orientation Angle field.

To access the Mill Polygon block:

1. From a New Block screen, select the Milling softkey.

2. Select the More softkey.
3. Select the Polygon softkey. The Mill Polygon block opens:

Figure 2–38. Mill Polygon screen

To use pocketing with Mill Polygon, the UltiPockets option must be

installed. See UltiPockets, on page 2 - 141 for more information.

2 - 84 Milling Operations 704-0116-501 Conversational Programming

The Sizing Method determines how the polygon size is established:

• Outer Diameter—the diameter of a circle that encompasses the outside of

the polygon, touching it at the corners:

• Inner Diameter—the diameter of a circle contained within the polygon,

touching at the center of each edge:

• Side Length—the length of one side of the polygon:

The Orientation Angle field rotates the part. This field specifies an angle relative to the
X axis that determines where the starting side occurs. An orientation of 0° indicates that
the starting side is at the bottom of the polygon, parallel to the X axis. For example:

0° Angle 45° Angle

Starting Side
Starting Side

The Field Name Glossary, on page 7 - 1 contains definitions of all WinMax fields. The
fields listed below appear on the Mill Polygon screen. Fields displayed on screen may vary
according to machine type, configuration, parameter settings, and/or settings in other

Conversational Programming 704-0116-501 Milling Operations 2-85

fields.

Block Plunge Feed X Center

Corner Radius Pocket Overlap Y Center

Direction Pocket Type Z Bottom

Mill Feed Radius Z Start

Milling Type Side Length

Number Of Sides Sizing Diameter

Orientation Angle Sizing Method

Overlap Speed (RPM)

Peck Depth Tool

A Mill Polygon data block will convert to a Mill Contour data block if
saved as an HD3 program.

2 - 86 Milling Operations 704-0116-501 Conversational Programming

HOLES OPERATIONS
A Holes block consists of the operation (drill, tap, bore, ream, or back spotface) and the
pattern or location (bolt circle or locations).

These topics explain the hole operations:

Drill Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 90
Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Center Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Counterbore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Spotface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Countersink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Gun Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 92
Custom Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 94
Tap Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 99
Bore and Ream Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 100
Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Ream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Bore Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Bore Orient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 102
Ream Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 102
Back Spotface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 103

These topics explain the pattern or location of the hole operation:

Bolt Circle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 104

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 105
Bolt Circle to Holes Locations or Pattern Locations Conversion . . . . . . . . . . . . 2 - 106
Holes to Pattern Locations Conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 107
Holes End Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 107

Conversational Programming 704-0116-501 Holes Operations 2-87

Drill Operations
Select the Drill Operations softkey on the New Hole Operation screen to select the type
of drilling operation. The appropriate screen appears with fields describing the operation.
The drill operations are:

Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Center Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Counterbore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Spotface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Countersink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 91
Gun Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 92
Custom Drill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 94
See Bore and Ream Operations, on page 2 - 100 for information
about bore and ream.

The diagram below shows the relationships of the field names to positions of the tool to
the work piece:

1 Head

2 Part

3 Table

4 Z Start Plane

5 Rapid Traverse

6 Retract Clearance Plane

7 Plunge Feed

8 Z Bottom

Figure 2–39. Reference Points Relative to Drill Operations

Be aware of the drill bits' characteristics. The system does not keep track of the type and
length of flutes on the bits or the shapes of drills with pilots or other multiple-diameter
drills.

This is the machine motion in a basic drilling operation:

1. The table moves at the rapid traverse rate to the programmed X and Y
dimensions.
2. The Z axis moves at the rapid traverse rate to the programmed retract
clearance.
3. When these coordinates are reached, the Z axis moves at the rapid traverse
rate to Z Start.
4. Then the Z axis moves at the programmed plunge feed rate until reaching the
Z Bottom dimension.

2 - 88 Holes Operations 704-0116-501 Conversational Programming

 5. The Z axis dwells the time specified and rapid traverses to the retract
clearance.

The rapid traverse rate, retract clearance, and drill dwell are selected in Program
Parameters or Change Parameters.

When all values are programmed, the Bolt Circle and Locations softkeys are available.
See Bolt Circle, on page 2 - 104 and Locations, on page 2 - 105 for more information.

Drill
Use a drill to create holes that may be complete or may be used as the starting points for
additional drilling operations.

See Drill Fields, on page 2 - 98 for field definitions.

Center Drill
Select Center Drill when the work piece is very rigid to create a guide hole for the drilling
tool that will be used to complete the hole. Center drilling helps keep holes in their proper
locations and prevent runout.

Center drills are special tools with short flutes, but a standard drilling tool may be used to
create these starting holes.

See Drill Fields, on page 2 - 98 for field definitions.

Counterbore
Use Counterbore to enlarge the end of a previously drilled hole. This operation creates an
enlarged area at the end of the hole to accommodate a bolt, cap screw, or pin. These
square-shoulder fasteners can then be inserted flush with the top of the part or slightly
below the surface of the material.

To avoid unneeded tool changes, use Counterbore before drilling the hole.

See Drill Fields, on page 2 - 98 for field definitions.

Spotface
Spotface smooths and squares the surface around a previously drilled hole to provide a
seat for a bolt head, a nut, or the shoulders on mating members. The spotfacing
operation is a shallow counterboring operation. Spotfacing is often used when the surface
of the part is uneven.

To avoid unnecessary tool changes, Spotface can be used before drilling the hole.

See Drill Fields, on page 2 - 98 for field definitions.

Countersink

Conversational Programming 704-0116-501 Holes Operations 2-89

Countersink enlarges the top end of a hole to a cone shape to accommodate the head of
a flat or oval headed machine screw. The hole is enlarged so that when the screw is
inserted, the screw head will be flush with or slightly below the top of the work piece
surface:

See Drill Fields, on page 2 - 98 for field definitions.

Gun Drill
Select the Gun Drill feature when using a very long tool and drilling deep holes, as if
drilling out the center of a gun barrel. A long, rotating tool may whip off center when
approaching the cutting surface, so a drilling cycle that controls the approach to the work
piece and corrects positioning of the tool is required.

The Gun Drill selection positions the tool without rotating the spindle. This allows the tip
of the tool to position precisely in a pre-drilled starting hole, as shown in the diagram
below:

1 Work Piece

2 Planned Path

3 Pre-drilled starting hole

4 Long tool moves into position with the spindle off to

avoid whipping

Figure 2–40. Gun Drilling

To use the Gun Drill features, perform these tasks:

• Describe the gun drill tool during Tool Setup.

• Create a starting hole for the drill as the first step in part programming.
• Create a Gun Drill data block in the part program.

2 - 90 Holes Operations 704-0116-501 Conversational Programming

Each Gun Drill data block must contain at least two operations: one describing the
starting hole and one for the gun drill hole.

To create a Gun Drill data block, begin on a New data block screen and follow these
general steps:

1. Press the Drill Operations softkey.

2. Create the first operation of the data block by describing the starting hole
portion of the data block. Select either the Drill softkey or the Center Drill
softkey. Type in the description of the starting hole into the fields displayed on
the screen.
3. When all of the starting hole data have been entered, begin the second
operation in this data block.
4. Press the Drill Operations softkey and then the Gun Drill softkey.

The following illustration shows the Gun Drill program fields as they relate to a part and
the drilling tool:

1 Work Piece

2 Move at rapid traverse down to Z top

3 Z Top

4 Z Top Feed—feedrate between Z top and Z Start

5 Z Start—spindle begins to rotate at Speed (RPM)

6 Z Bottom

See Drill Fields, on page 2 - 98 for field definitions.

Conversational Programming 704-0116-501 Holes Operations 2-91

Custom Drill
The Custom Drill feature can be used to adjust the feedrate and speed for each step in
the drill cycle: entry into hole, break out through bottom of material, bottom, re-entry
into hole from bottom, out move at top of hole, and the move to retract clearance plane.
Custom Drill is typically used for long hole drill cycles but can be used to customize any
drill cycle.

See Drill Fields, on page 2 - 98 for field definitions.

Tool Tab
The Custom Drill screen is organized into tabs where the feed, speed, and other
parameters are entered for each step of the drill cycle. The first tab is the Tool tab:

Figure 2–41. Custom Drill Tool tab

A list of all hole operations are displayed on the Tool tab to show the relation of the
Custom Drill cycle with other operations in the block. The tool is specified on this screen.

2 - 92 Holes Operations 704-0116-501 Conversational Programming

Entry Tab
The Entry step establishes the speed and feed for the approach move starting at Z Start
and ending at Z Top. The image shows the move from Z Start to Z Top:

Figure 2–42. Custom Drill Entry tab

Break Out Tab

The Break Out tab allows the user to set a feed and speed for the drill operation that
differs from the feed and speed used for the move breaking through the bottom of the
material (typically to avoid whipping). This step is optional and can be skipped by setting
the Enable field to No. When Enable is No, the feed and speed from the Bottom tab are
used for the move from Z Top to Z Bottom, and the pecking parameters are set on the
Bottom tab.

The image shows the plunge move from Z Top to Z Break Out, if enabled:

Figure 2–43. Custom Drill Break Out tab

Conversational Programming 704-0116-501 Holes Operations 2-93

Bottom Tab
The final move through the hole from Z Break Out to Z Bottom is set in the Bottom tab. If
the previous Break Out step is not enabled, then the feed and speed set in this step are
used for the entire move from Z Top to Z Bottom.

The image shows the motion for the plunge move from Z Break Out to Z Bottom:

Figure 2–44. Custom Drill Bottom tab

Re-entry Tab
The Re-entry step allows the user to set a speed and feed for the retract move from Z
Bottom to a Z position back inside the hole (Z Re-entry). This step is optional and can be
skipped by setting the Enable field to No. When Enable is No, the move occurs from Z
Bottom to the next enabled step (Out or Retract). If there are no other enabled steps, the
spindle moves at rapid out of the hole to the Z start location.

The image shows the move from Z Bottom to Z Re-entry, if enabled:

Figure 2–45. Custom Drill Re-entry tab

2 - 94 Holes Operations 704-0116-501 Conversational Programming

Out Tab
The Out step allows the user to set the speed and feedrate for the retract move from Z
Re-entry to Z Out (the Z end position of the retract move from Z Re-entry). This step is
optional and can be skipped by setting the Enable field to No. When Enable is No, the
move occurs from the last enabled step (Bottom or Re-entry) to the Retract step, if it is
enabled. If the Retract step is not enabled, the spindle moves at rapid from the last
enable step (Bottom or Re-entry) out of the hole to the Z start location.

The image shows the move from Z Re-entry to Z Out, if enabled:

Figure 2–46. Custom Drill Out tab

Conversational Programming 704-0116-501 Holes Operations 2-95

Retract Tab
The Retract step allows the user to set the feed and speed for the move from Z Out to Z
Retract. This step is optional and can be skipped by setting the Enable field to No. When
Enable is No, the tool moves at rapid feedrate from the last enabled step (Bottom, Re-
entry, or Out) to the Z Start position.

From Z Retract, the tool moves at rapid feedrate to the retract clearance plane;
therefore, Z Retract should be less than the retract clearance plane. Z Retract can be
greater than, less than, or equal to Z Start.

The image shows the retract move from Z Out to Z Retract:

Figure 2–47. Custom Drill Retract tab

Drill Fields

See the Field Glossary for definitions of the Drill Operations fields:

Block Peck Retract Feed Tool Z Start

Enable Peck Type Z Bottom Z Top

Feed Plunge Feed Z Break Out Z Top Feed

Operation Rapid Peck Retract Z Out Z Top RPM

Peck Depth Speed (RPM) Z Re-entry

Pecking Retract Spindle Stop Z Retract

Clearance

2 - 96 Holes Operations 704-0116-501 Conversational Programming

Tap Operations
To program a new Tap operation:

1. Display the Input screen and select the Part Programming softkey.
2. Select the Insert Block Before softkey.
3. Select the Holes softkey. The Hole Operation screen opens.
4. Select the Tap Operations softkey.
5. Select the Tap or Rigid Tap softkey.
• Tap - programs a standard tapping sequence.
• Rigid Tap - programs a tapping sequence in which the same hole is
tapped repeatedly with precision.

See the Field Glossary for definitions of the Tap Operations fields:

Block Tool

Dwell Time TPI

Operation Z Bottom

Pitch Z Start

Plunge Feed

Speed (RPM)

Conversational Programming 704-0116-501 Holes Operations 2-97

Bore and Ream Operations
The bore and ream operation types are:

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Ream . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Bore Rapid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 101
Bore Orient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 102
Ream Rapid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 102

Use a bore when a straight and accurately round hole is needed. A boring bar usually has
one or, at the most, two blades projecting out from the shank. The blades are adjustable
on many types of boring bars.

1 Shank

2 Blade depth adjustment dial

3 Replaceable cutter inserts

Figure 2–48. Two-Bladed Boring Bar with Adjustment Dial

Use a ream to size a previously drilled hole. A reaming tool has multiple flutes that run
vertically along the shank of the tool. During reaming, the cutter follows the angle of the
existing hole and cannot be used to straighten the angle of the hole.

Figure 2–49. Reaming Tool

To program a new Bore or Ream operation:

1. Display the Input screen and select the Part Programming softkey.
2. Select the Insert Block Before softkey.
3. Select the Holes softkey. The Hole Operation screen opens.
4. Select the Bore and Ream Operations Softkey softkey
5. Select the Bore or Ream operation.

2 - 98 Holes Operations 704-0116-501 Conversational Programming

Bore
Use a bore when a straight and accurately round hole is needed. A boring bar is a tool
with typically one or two blades projecting out from the shank. The blades on many
boring bars can be adjusted to increase or decrease the size of the hole. The illustration
below shows a two-bladed boring bar.

Insert the boring tool into the spindle with the cutting face in line with the tool holder’s
orientation hole, opposite the spindle key. WinMax uses this oriented spindle key angle to
determine the bore orient retract direction.

1 Boring Bar

2 Shank

3 Blad depth adjustment dial

4 Replaceable blades

Figure 2–50. Two-bladed Boring Bar with Adjustment Dial

Ream
Use the Ream feature to size a previously drilled hole. Reaming clears burrs and other
particles left from a drilling or boring operation. During reaming, the cutter follows the
angle of the existing hole and cannot be used to straighten the angle of the hole.

A reaming tool has multiple flutes that run vertically along the shank of the tool as shown
in the following illustration:

Figure 2–51. Reaming Tool

Pecks are not allowed with the reaming feature.

Bore Rapid
Use Bore Rapid when the tool should retract at the Rapid Traverse feedrate programmed

Conversational Programming 704-0116-501 Holes Operations 2-99

in General Parameters or Change Parameters.

Bore Orient
Use Bore Orient to orient the bore at Z Bottom and move the boring bar. The cutting edge
of the boring bar moves away from the surface of the bored hole so that during the next
step the cutting edge will not scrape the walls of the hole. The distance the boring bar
moves is set in the Bore Orient Retract field on the Holes Parameters screen.

Insert the boring tool into the spindle with the cutting face in line with the tool holder’s
orientation hole, opposite the spindle key. WinMax uses this oriented spindle key angle to
determine the bore orient retract direction.

Ream Rapid
Use Ream Rapid when the tool should retract at Rapid Traverse feedrate programmed in
General Parameters or Change Parameters.

See the Field Glossary for definitions of the Bore and Ream Operations fields:

Block Z Bottom

Operation Z Start

Plunge Feed

Speed (RPM)

Tool

2 - 100 Holes Operations 704-0116-501 Conversational Programming

Back Spotface
Use the Back Spotface function to cut out the underside of holes that must be cut through
the workpiece.

To program a new Back Spotface operation:

1. Display the Input screen and select the Part Programming softkey.
2. Select the Insert Block Before softkey.
3. Select the Holes softkey. The Hole Operation screen opens.
4. Select the Back Spotface softkey.

This motion sequence occurs with Back Spotface:

1. Rapid to Z Start minus cutter offset and set the spindle speed to a plunge
speed.
2. Move to Z Plunge minus cutter offset at a closing feedrate to close the cutter.
3. Rapid to Z Bottom minus cutter offset.
4. Dwell for a specified reverse dwell amount, reverse the spindle direction and
ramp to cutting speed to open the cutter.
5. Move up to Z Depth minus cutter offset at a cutting feedrate.
6. Dwell for the drill dwell time (from program parameters).
7. Rapid down a Z Clearance amount.
8. Dwell for the Reverse Dwell time and reverse the spindle direction to plunge
speed to close the cutter.
9. Move to Z Retract minus cutter offset at a closing feedrate to insure the cutter
is closed.
10. Rapid out of the hole.

See the Field Glossary for definitions of the Back Spotface fields:

Block Speed (RPM) Z Retract

Closing Feed Tool Z Start

Operation Z Bottom

Plunge Feed Z Clearance

Plunge Speed Z Depth

Reverse Dwell Z Plunge

Conversational Programming 704-0116-501 Holes Operations 2-101

Bolt Circle
For each Holes block, you must include a Bolt Circle, Locations, or Rotary
Locations operation. The Bolt Circle, Locations, or Rotary Locations softkeys are
not available for the first operation in a Holes block because they require prior operations
to identify the type of operation, the tool, reference points, and machining information.

A Bolt Circle operation executes a series of equally spaced holes in a common circle. This
operation allows skipping holes in the bolt circle.

• All Locations programmed in a block containing a Bolt Circle are executed in

addition to the Bolt Circle pattern.
• All operations programmed in a data block are performed at all locations
specified in that block.

To program a new Bolt Circle operation:

1. Display the Input screen and select the Part Programming softkey.
2. Select the Insert Block Before softkey.
3. Select the Holes softkey. The Hole Operation screen opens.
4. Select and program the hole operation(s).
5. Place cursor in the Operation field and select Next Operation softkey.
6. Select the Bolt Circle softkey.

Enter the number of holes, the radius, and the X and Y center coordinates to establish the
bolt circle pattern. Use the Skip List field to specify positions that should be skipped. For
example, in the diagram below there are 6 holes in the pattern. If you do not want to drill
holes for positions 2 and 5, enter 2 and 5 in the Skip List field

A Start Angle

B X Center, Y Center

C radius

Figure 2–52. Bolt Circle Pattern

See the Field Glossary for definitions of the Bolt Circle fields:

2 - 102 Holes Operations 704-0116-501 Conversational Programming

 Block Start Angle

Operation X Center

Number of Holes Y Center

Radius

Skip List

See Bolt Circle to Holes Locations or Pattern Locations Conversion,

on page 2 - 106 to convert the Bolt Circle to a Holes Locations or
Pattern Locations block.

Locations
For each Holes block, you must include a Bolt Circle, Locations, or Rotary
Locations operation. The Bolt Circle, Locations, or Rotary Locations softkeys are
not available for the first operation in a Holes block because they require prior operations
to identify the type of operation, the tool, reference points, and machining information.

• All Locations programmed in a block containing a Bolt Circle are executed in

addition to the Bolt Circle pattern.
• All operations programmed in a data block are performed at all locations
specified in that block.

To program a new Locations operation:

1. Display the Input screen and select the Part Programming softkey.
2. Select the Insert Block Before softkey.
3. Select the Holes softkey. The Hole Operation screen opens.
4. Select and program the hole operation(s).
5. Place cursor in the Operation field and select Next Operation softkey.
6. Select the Locations softkey.

Specify the X and Y hole locations. Up to 10 locations can be displayed on the screen. The
Page Up/Page Down softkeys appear when there are more than 10 locations
programmed. With the cursor in a Location X or Y field, the Add Location and Insert
Location Before softkeys appear. Select one of these softkeys to either add or insert
fields in the list for entering data. The Delete Location softkey appears when at least
one location is in the list.

Move to the next Block or the next Operation by placing the cursor in the desired field and
selecting the appropriate softkey (Next Block, Next Hole Operation, etc.).

See Holes to Pattern Locations Conversion, on page 2 - 107 to

convert the Locations block to a Pattern Locations block.

Conversational Programming 704-0116-501 Holes Operations 2-103

Bolt Circle to Holes Locations or Pattern
Locations Conversion
A Bolt Circle data block can be copied or converted to either a Holes Locations or Pattern
Locations block. Place the cursor in a Bolt Circle field and the Copy and Convert softkeys
appear:

Copy or convert to
Hole Locations block

Copy or convert to
Pattern Locations block

Figure 2–53. Bolt Circle Hole or Pattern Locations Copy and Convert softkeys

Use the following softkey commands:

• Copy to Hole Locations—a Holes Locations block is created with the Bolt
Circle coordinates, and is inserted before the Bolt Circle operation in the
program. The Bolt Circle operation is maintained in the program. A Holes End
block is inserted after the Hole Locations block.
• Convert to Hole Locations—a Holes Locations block is created with the Bolt
Circle coordinates, and replaces the Bolt Circle operation in the program. The
Bolt Circle operation is removed from the program. A Holes End block is
inserted after the Hole Locations block.
• Copy to Pattern Locations—a Pattern Locations block is created with the
Bolt Circle coordinates, and is inserted before the Holes block in the program.
The Bolt Circle operation is maintained in the program. A Pattern End block is
inserted after the Holes block.
• Convert to Pattern Locations—a Pattern Locations block is created with
the Bolt Circle coordinates. The Bolt Circle operation is removed from the
program, and a Holes Location block with 0.0 coordinates is inserted for a
reference point. A Pattern End block is also inserted after the Holes block.

2 - 104 Holes Operations 704-0116-501 Conversational Programming

Holes to Pattern Locations Conversion
A Holes Locations data block can be copied or converted to a Pattern Locations block.
Place the cursor in a field and the Copy and Convert softkeys appear:

Figure 2–54. Holes to Pattern Locations softkeys

Use the following softkey commands:

• Copy to Pattern Locations—a Pattern Locations block is created with the

Holes locations, and is inserted before the Holes block in the program. The
Holes operation is maintained in the program. A Pattern End block is inserted
after the Holes block.
• Convert to Pattern Locations—a Pattern Locations block is created with
the Holes locations. The Holes Locations block remains in the program with
0.0 coordinates as a reference point. A Pattern End block is inserted after the
Holes block.

Holes End Block

A Holes End block is automatically inserted at the end of each Holes data block.

Conversational Programming 704-0116-501 Holes Operations 2-105

2 - 106 Holes Operations 704-0116-501 Conversational Programming
PATTERNS OPERATIONS
Patterns Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 110
Loop Rectangular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 111
Loop Linear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 112
Loop Angular . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 113
Loop Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 114
Pattern Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 115
Scale. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 116
Mirror Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 117
Pattern End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 117

Conversational Programming 704-0116-501 Patterns Operations 2-107

Patterns Overview
Pattern operations repeat or modify a sequence of data blocks. This may save
programming time by duplicating part geometry to complete a part program or create
multiple parts from one program.

Pattern Nesting
Patterns may only be nested 10 levels deep.

Recovery Restart with Patterns

Recovery Restart can be used to restart the program if milling is interrupted during a
pattern. The Recovery Restart softkey is located on the Auto screen, see Recovery and
Restart, on page 1 - 135 in Getting Started with WinMax Mill.

When Recovery Restart is initiated, the user is prompted to select a starting pattern
number plus any other additional restart information. The program runs the remaining
blocks for the selected pattern instance, then runs all blocks in remaining pattern
instances, and then continues with the remaining program blocks.

With Recovery Restart a program can be restarted at a specific

pattern number, whereas in a partial program run (using the Start
and End block fields on the Auto screen) only blocks can be specified,
including blocks within a pattern, but a specific pattern number
cannot be specified with partial program run.

Example restart scenarios using the following program:

Block 1—Pattern Linear x 3

Block 2—Mill Circle Roughing & Finishing passes

Block 3—Mill Frame Roughing & Finishing passes

Block 4—Mill Contour Roughing & Finishing passes

Block 5—Pattern End

Example 1—Recovery Restart on Pattern Linear: control prompts for the starting pattern
number (1, 2, or 3). All blocks in the pattern are run.

Example 2—Recovery Restart on the Frame block: control prompts for the starting
pattern number, and whether to start on the finishing pass. If pattern number 1 and
finish pass for the frame are specified, it runs the finish pass for the frame in the first
pattern, followed by the entire contour block, then runs the circle, frame, and contour for
all remaining instances of the pattern.

Example 3—Partial Program Run using the Start and End block fields: Start block set to
3 (Frame), end block set to 5 (pattern end), and Run Program softkey selected. Restart
information is not requested; the frame and contour blocks are run for all 3 instances of
the pattern. The circle is not run since it is outside the specified block range.

2 - 108 Patterns Operations 704-0116-501 Conversational Programming

Loop Rectangular
This routine repeats a pattern a specified number of times along lines parallel to the X
and Y axes. The original pattern is always milled at its programmed location. Always
program a Pattern End data block following a Loop Rectangular block.

1 X Axis

2 Y Axis

3 Original Pattern

4 X Distance

5 Y Distance

6 X Number = 3; Y
Number = 2

See the Field Glossary for definitions of the Pattern Loop Rectangular fields:

Block

X Distance

X Number

Y Distance

Y Number

Conversational Programming 704-0116-501 Patterns Operations 2-109

Loop Linear
This routine repeats a pattern a specified number of times along a line defined in the X-Y
plane. Even though the defined line of this pattern is not parallel to the X or Y axes, the
original pattern is always milled at its programmed location and orientation does not
change with respect to the X and Y axes. Always program a Pattern End data block
following a Loop Linear block.

1 X Axis

2 Y Axis

3 Original Pattern

4 Distance

5 Angle

6 X Distance

7 Y Distance

8 Number = 3

See the Field Glossary for definitions of the Pattern Loop Linear fields:

Angle

Block

Distance

Number

X Distance

Y Distance

2 - 110 Patterns Operations 704-0116-501 Conversational Programming

Loop Angular
This routine repeats a programmed pattern a specified number of times along a circular
path. Pattern orientation does not change with respect to the X and Y axes. The original
programmed pattern is not executed at its original position unless the routine places it at
that location. The pattern is only shown in the locations specified by the routine. Always
program a Pattern End data block following a Loop Angular block.

1 X Axis

2 Y Axis

3 Original Pattern

4 XY Center

5 Start Angle

6 Rotate Angle

7 XY Reference

8 Number = 3

See the Field Glossary for definitions of the Pattern Loop Angular fields:

Block Y Center

Number Y Reference

Rotate Angle

Start Angle

X Center

X Reference

Conversational Programming 704-0116-501 Patterns Operations 2-111

Loop Rotate
This routine repeats a pattern along a circular path. Loop Rotate moves the pattern
around the X-Y center point and executes the pattern only at the programmed locations.

The original programmed pattern is not executed at its original position, unless this
routine places it at that location. The pattern is only shown in the specified locations.
Always program a Pattern End data block following a Loop Rotate block.

1 X Axis

2 Y Axis

3 Original Pattern

4 XY Center

5 Start Angle

6 Rotate Angle

7 XY Reference

8 Number = 3

See the Field Glossary for definitions of the Pattern Loop Rotate fields:

Block

Number

Rotate Angle

Start Angle

X Center

Y Center

2 - 112 Patterns Operations 704-0116-501 Conversational Programming

Pattern Locations
For Transform Plane, see Transform Plane (configurations other than
Universal), on page 5 - 13 in Rotary Programming.

Enter a Pattern Location block each time a programmed pattern is to be repeated. The
pattern is repeated by offsetting the pattern with each displacement specified in the
Pattern Location block. Always program a Pattern End data block following a Pattern
Location block.

Use the X, Y, and Z fields to identify the locations where the pattern is to be executed in
the X, Y, and Z axes.

Conversational Programming 704-0116-501 Patterns Operations 2-113

Scale
This routine scales a programmed pattern down or up in a range of 0.100 to 10.000
(10% to 1000%) respectively. Always program a Pattern End data block following a Scale
block.

1 X Axis

2 Y Axis

3 Original Pattern

4 Scaled Pattern

5 XY Reference

6 X Scale = 3; Y
Scale = 2; Z Scale
= not shown

When you use Cutter Compensation (preliminary), on page 2 - 9 in the program, the X
and Y scale factors must be equal, except for these selections where the X and Y scale
factors can be different:

• Circle (ON)
• Frame (ON)
• Ellipse (ON)
• Contour (ON)
• True-Type Font (ON)
• HD3 Lettering

When using Z scaling, the Peck Depth, Retract Clearance Plane, Peck Clearance Plane,
and Z Safety Plane values are not affected.

Z Bottom and Z Start are the values commonly affected by Z scaling.

See the Field Glossary for definitions of the Pattern Scale fields:

Block Z Reference

X Reference Z Scale

X Scale

Y Reference

Y Scale

2 - 114 Patterns Operations 704-0116-501 Conversational Programming

Mirror Image
This pattern programs a part as a mirror image of an existing programmed part. The
routine can execute the mirror image alone or the original part and the mirror image.
Always program a Pattern End data block following a Mirror Image block.

1 X Axis

2 Y Axis

3 Original Pattern

4 Angle

5 XY Point on
Mirror Line

See the Field Glossary for definitions of the Pattern Mirror Image fields:

Angle

Block

Keep Original

Pattern End
There are no fields to enter in this data block. It is a marker at the end of the sequence of
data blocks used in a Pattern operation. There must be an equal number of Pattern blocks
and Pattern End data blocks.

Conversational Programming 704-0116-501 Patterns Operations 2-115

2 - 116 Patterns Operations 704-0116-501 Conversational Programming
SPECIAL OPERATIONS
Special data blocks can be inserted between operational data blocks to change the
position of the table, automatically stop a program, or temporarily change the part
program parameters or set a new part zero.

Position Data Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 120

Graphics On/Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 121
Change Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 121
Change Part Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 123
Machine Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 124
Lube Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 124
Comment Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 125
Insert Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 125
Tool Change Optimization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 126

Conversational Programming 704-0116-501 Special Operations 2-117

Position Data Block
Use a Position block to move the table, or to stop motion so you can adjust the work
piece, or to gain clearance around the tool or work piece. See Part Setup Safety Work
Region in Part Setup, on page 1 - 91 in Getting Started with WinMax Mill.

Use a Position data block instead of a Change Parameters data block in these instances:

• Between operations, when a clamp or raised portion of the part is higher than
the programmed relative clearance.
• When cutting occurs inside a cavity and is followed by work inside another
cavity in which an optimal Retract Clearance for operations in the recessed
areas is below the surface of the part.
• The Z Retract is the same as the Z safety plane height in a Position data
block.

Refer to Change Parameters, on page 2 - 121 for more information.

To program a Position block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey. The New Block screen opens.
3. Select the Position softkey. The Position block opens.
4. Select the order of axis movement with the drop-down lists and specify the
coordinate(s). Multiple axes with the same value will move simultaneously.
5. Specify in the Z Retract field if the Z axis should retract before the axes move
to the specified positions. If Yes, this move happens first.
6. Specify a tool in the Tool field. If a tool is not specified, a tool change does not
occur.
If there is a tool change in the position block, the tool change safety
move occurs and the axes will not return to their pre-tool change
positions. Only axes that did not have a move specified are left in
their pre-tool change positions.

See the Field Glossary for definitions of the Position fields:

Block X

Index Pulses Y

Stop Z

Tool Z Retract

If you want to open the CE Safety enclosure doors after the Position
data block executes (the Stop field is Yes), press the Machine Mode
Interrupt console key, then press the Start Cycle button. The
enclosure doors can be opened and the axes jogged. To resume
program execution, close the enclosure doors and press the Start
Cycle button.

2 - 118 Special Operations 704-0116-501 Conversational Programming

Graphics On/Off
Graphics On and Graphics Off program blocks allow you hide selected operations in the
graphics display. For example, setting a Graphics Off block as block 3 in a part program
and Graphics On as block 10 will hide blocks 4-9 when the part is viewed using Solid or
Toolpath graphics.

To insert a Graphics On or Graphics Off block:

1. From the Input screen, select the Part Programming softkey or icon.
2. Select the Insert Block Before softkey.
3. From the New Block screen, select the Miscellaneous softkey.
4. Select the Graphics On/Graphics Off softkey.

All blocks that are hidden by this operation are still cut when the
program is run.

Change Parameters
Use this feature to change data stored in Program Parameters (Refer to Program
Parameters, on page 1 - 124 in Getting Started with WinMax Mill):

• Change Parameters (General), on page 2 - 122

• Change Parameters (Milling), on page 2 - 122
• Change Parameters (Holes), on page 2 - 122
• Change Parameters (Probing), on page 2 - 122
• Change Parameters (Performance), on page 2 - 122

When a part program is executed, the data selected in Program Parameters are in effect
until the system encounters another Change Parameters data block or until the end of the
program.

When planning a change to the Retract Clearance parameter, consider the following
points:

1. This parameter is defined relative to the Z Start dimension and can optimize Z
axis tool motion between localized operations.
2. If all of the operations are at the same Z Start plane, there is no difference
between a relative and an absolute clearance. However, when groups of
cutting operations are at different Z levels on the part, programming a relative
Retract Clearance can be more efficient than an absolute retract dimension. It
is possible, using a relative Retract Clearance, to eliminate unnecessary tool
motion and save execution time.
3. If the Z Start dimension of the next operation is different from that of the
current operation, the control uses the higher of the two values for Retract
Clearance before positioning the part in the X-Y axes.

Conversational Programming 704-0116-501 Special Operations 2-119

 4. To achieve a Retract Clearance close to the part may require the use of a
Position data block. Programming a Position block causes the tool to retract to
the Z Top (+) of the Safety Work Region.

Examples of areas in which a Position data block must be used rather than a simple
parameter change are as follows:

• Between operations, a clamp or raised portion of the part is higher than the
programmed relative clearance.
• When cutting occurs inside a cavity and is followed by work inside another
cavity in which an optimal Retract Clearance for operations is below the
surface of the part.

Refer to Position Data Block, on page 2 - 120 for information about when to use a
Position block instead of changing parameters.

Change Parameters (General)

Use this feature to change the General Parameters for the current program.

The Change Parameters (General) fields are the same as General

Parameters 1 and General Parameters 2. Refer to Program
Parameters, on page 1 - 124 in Getting Started with WinMax Mill.

Change Parameters (Milling)

Use this feature to change Milling Parameters for the current program.

The Change Parameters (Milling) fields are the same as Milling

Parameters 1 and Milling Parameters 2. Refer to Program
Parameters, on page 1 - 124 in Getting Started with WinMax Mill.

Change Parameters (Holes)

Use this feature to set the Holes Parameters for the current program.

The Change Parameters (Holes) fields are the same as Holes

Parameters. Refer to Program Parameters, on page 1 - 124 in
Getting Started with WinMax Mill.

Change Parameters (Probing)

Use this feature to change the Probing Parameters for the current program.

The Change Parameters (Probing) fields are the same as Probing

Parameters. Refer to Program Parameters, on page 1 - 124 in
Getting Started with WinMax Mill.

Change Parameters (Performance)

2 - 120 Special Operations 704-0116-501 Conversational Programming

Use this feature to change Surface Finish Quality parameters for the current program.

The Change Parameters (Performance) fields are defined the same

as Performance Parameters. Refer to Program Parameters, on page 1
- 124 in Getting Started with WinMax Mill.

Change Part Setup

Use this function to change the part zero coordinates and the Offset Z value. Change Part
Setup values remain in effect until the next Change Part Setup block. The Auto screen will
show the part position relative to the current part setup block. To change the part setup
back to the original parameters, enter another Change Part Setup screen with the original
parameters at the point in the program where the setup must be reset.

Part Zero A and Centerline A fields appear on the screen when the
Rotary option is installed.
When the program will be used to cut more than one part insert
another Change Part Setup data block at the end of the program to
restore the original (default) part setup.

To create a new Change Part Setup data block:

1. From the Input screen, select the Part Programming softkey.

2. Select the Insert Block Before softkey.
3. Select the Miscellaneous softkey.
4. Select the Change Part Setup softkey.

See the Field Glossary for definitions of the Change Part Setup fields:

Block Part Zero C X/Y Skew (DEG)

Offset Z Part Zero X Z Table Offset

Part Zero IV Part Zero Y Zone

Part Zero V Part Zero Z

Part Zero A Part Zero Z Shift

Part Zero B Probe Z

Conversational Programming 704-0116-501 Special Operations 2-121

Machine Function
Insert Machine Function command into a part program with the Machine Function block.

To add a Machine Function block:

1. From the Input screen, select the Part Programming softkey.

2. Select the Insert Block Before softkey.
3. Select the Miscellaneous softkey.
4. Select the Machine Function softkey.
5. Select the desired M Code/function.
6. Select the Select M Code softkey.
7. Enter the number of times the M code should repeat in the Repeat Count
field.
8. Enter delay in the Repeat Delay field.
If the Machine Function softkey appears grayed out, the machine
does not have auxiliary machine or equipment-specific M codes
defined.

See the Field Glossary for definitions of the Machine Function fields:

Block Pallet

Confirm APC Ready Repeat Count

M Code

Lube Cycle
If additional lubrication is needed, insert this block into your program to pulse the lube
pump. The current lube cycle will not be affected. Check your machine manual to see if
your lube reservoir/pump supports programmed inputs. If your lube pump and or
reservoir is actuated by a timer, this option will not function. Most Hurco machines made
after 1998 have timer actuated lube, but the Lube Cycle option is provided for backward
compatibility with older machines. This option is not needed in newer machines due to
higher quality components and adequate lube application.

2 - 122 Special Operations 704-0116-501 Conversational Programming

Comment Block
Comment blocks are useful for the programmer to outline tooling requirements and part
setup data. Comment blocks display text to the operator during program execution when
the block is encountered in the program. The amount of time a comment block is visible
can be programmed in the comment data block. Subsequent machining data blocks will
continue to execute during this time.

When posting Conversational programs to NC, Comment Blocks explain the program code
or provide information, such as setup instructions.

See the Field Glossary for definitions of the Comment Block fields:

Block

Display Time

Line 1-10

Stop

Insert Block
When posting Conversational programs to NC, use an Insert Block to insert up to ten lines
of NC code (Text Option) or up to ten lines of APT code (APT option).

See the Field Glossary for definitions of the Insert Block fields:

Block

Line 1-10

Type

Conversational Programming 704-0116-501 Special Operations 2-123

Tool Change Optimization
Tool Change Optimization reduces the number of tool changes in Conversational
programs. In typical Conversational program execution, each data block is completed
(roughing and finishing) before the program moves to the next data block. With Tool
Change Optimization, operations are completed sequentially by tool; for example, the
program completes all operations that use tool 1 before moving to the operations that
use tool 2, and so on.

For example:

A Mill Frame with tool 1 for roughing and tool 2 for finishing, patterned three
times, with tool 1 in the spindle:

• Without Tool Change Optimization, each frame in the pattern is rough cut
and finish cut before moving to the next frame in the pattern. Sequence
of tool changes: 1, 2, 1, 2, 1, 2. Total number of tool changes = 5.
• With Tool Change Optimization enabled, all three frames are rough cut,
then all are finish cut. Sequence of tool changes:1, 2. Total number of
tool changes = 1.

Using Tool Change Optimization

To use Tool Change Optimization, the Tool Change Optimization parameter must be set to
YES (default is Yes). This parameter is found on the General 2 tab in Program
Parameters:

Figure 2–55. Tool Change Optimization parameter in Program Parameters

In addition, the Tool Change Optimization On block must be inserted ahead of the
program blocks to which it applies. Both the parameter and the data block are necessary
to activate Tool Change Optimization. The Tool Change Optimization Off block is inserted
after the last block in which tool optimization is to occur. This allows flexibility in using

2 - 124 Special Operations 704-0116-501 Conversational Programming

Tool Change optimization on select blocks while maintaining normal tool change sequence
in other blocks of the program.

With Tool Change Optimization on, a data block should not be

dependent on the finishing pass of the preceding block to clear out
stock (material) prior to that data block. With Tool Change
Optimization, the finishing pass has not yet run (because all
roughing operations are completed first), and therefore the finish
material is not yet removed.

To use the Tool Change Optimization On and Off blocks:

1. From a New Block screen, select the Miscellaneous softkey.

2. Select the More softkey twice.
3. Select the Tool Optimize On softkey. The block opens:

Figure 2–56. Tool Change Optimization On block

4. Set the operations that will have tool changes optimized:

• Maintain Operation Level 1 Order—when set to Yes, all Level 1
operations (typically these are the roughing operations) are performed in
block sequence, including any specified tool changes. When set to No, all
Level 1 operations are performed in tool change sequence. Default is No.

For Holes, the first hole operation is treated as a Level 1 operation

and will be executed when other Level 1 operations are executed,
based on the Maintain Operation order. The other hole operations will
always follow the first hole operation. If the hole operation should
not be started until a previous block has been finished, then be sure
to disable Tool Change Optimization prior to hole operation.

• Maintain Operation Level 2 Order—when set to Yes, all Level 2

operations (typically these are the finishing operations) are performed in
block sequence, including any specified tool changes. When set to No, all
Level 2 operations are performed in tool change sequence. Default is No.

Conversational Programming 704-0116-501 Special Operations 2-125

 The Maintain Operation Level 2 Order parameter does not apply to
holes operations.

5. Select the Tool Optimize Off softkey. The Tool Change Optimization Off block is
used to turn off the Tool Change Optimization feature for a block or group of
blocks within a program, after the Tool Change Optimization On block has
been used at an earlier point in the program.

Example

Tool Change
Optimization
Blocks

Figure 2–57. Placement of Tool Change Optimization blocks

In the sample screen above, tool change optimization occurs for blocks 2-6. The
sequence with Tool Change Optimization parameter set to Yes and the Tool Optimization
On block Maintain Operation Level 1 Order and Maintain Operation Level 2 Order set to
No is shown below:

Tool Change Sequence

Block 2 (Tool 1)
Block Type Rough Tool Finish Tool Block 3 (Tool 1)
Block 5 (Tool 1)
1 TCO On Block 6 (Tool 1)
2 Mill Contour 1 3 Block 4 (Tool 2)
3 Mill Frame 1 3 Block 2 (Tool 3)
4 Mill Circle 2 4 Block 3 (Tool 3)
5 Mill Ellipse 1 3 Block 5 (Tool 3)
6 Mill Contour 1 3 Block 6 (Tool 3)
7 TCO Off Block 4 (Tool 4)

Tool Changes = 3

Note in the sequence that all roughing blocks that use the first roughing tool (Tool 1) are
executed in block sequence, before switching to the next roughing tool (Tool 2). After all
roughing operations are completed, all finishing operations that use the first finishing tool
(Tool 3) are executed in block sequence, followed by the block that uses the next
finishing tool (Tool 4). This requires 3 tool changes.

2 - 126 Special Operations 704-0116-501 Conversational Programming

 If a finish tool is not specified in a milling block, the tool listed in the
Roughing tab is considered a finish tool and will be grouped with the
other finish tools.
If a hole block is within a group of blocks that use Tool Change
Optimization, the hole operations are completed as a group. In
addition, the first hole operation’s tool is grouped with the tools of
the other blocks and is completed in the sequence specified by the
Maintain Roughing Sequence.

When Tool change Optimization is not used (no Tool Optimization On block), the sequence
of tool changes looks like this:

Tool Change Sequence

Block 1 (Tool 1)
Block 1 (Tool 3)
Block Type Rough Tool Finish Tool Block 2 (Tool 1)
Block 2 (Tool 3)
1 Mill Contour 1 3 Block 3 (Tool 2)
2 Mill Frame 1 3 Block 3 (Tool 4)
3 Mill Circle 2 4 Block 4 (Tool 1)
4 Mill Ellipse 1 3 Block 4 (Tool 3)
5 Mill Contour 1 3 Block 5 (Tool 1)
Block 5 (Tool 3)

Tool Changes = 9

Note that tool changes occur in block order, resulting in 9 tool changes.

Conversational Programming 704-0116-501 Special Operations 2-127

Tool Change Review
Tool changes are reviewed in the Tool Change Review Screen, accessed with the Tool
Change Review softkey in the Part Program Tool Review menu. Tools are displayed in the
order they are used in the program. All tool changes in a part program are displayed,
even if the Tool Change Optimization feature is not used.

Tools are
displayed in the
order they are
used in program Operation is
listed for each
block:
- Roughing
- Finishing
Data blocks - Hole operation
are displayed in by type
the order they
are executed

Figure 2–58. Tool Change Review Screen

Jump to the data block from this screen in one of the following ways:

1. Select the block in the list and press the Enter console key.
2. Select the block in the list and select the Part Programming softkey.
3. Double-click on the block in the list.

2 - 128 Special Operations 704-0116-501 Conversational Programming

NC/CONVERSATIONAL MERGE
WinMax allows you to execute an ISNC G-code (NC) program from within a
Conversational part program with NC/Conversational merge. G-code programs can be
used and re-used within the Conversational program.

To include this data block in a Conversational program, select the NC Program Call
softkey. Use the Program Number field to initiate the NC program (program number
must not exceed 6999). For programs that use variables, the Argument Type field
allows you to enter argument variables (String or List) to pass to a subprogram. See
WinMax Mill NC Programming for more information about variables and arguments.

To invoke a G-Code program from within a Conversational part program, the program
must be loaded in Program Manager. The first line of NC code following the percent (%)
sign must contain the program number preceded by the letter “O” (not a zero) or a colon
(:), for example, O1234 or :1234. There cannot be any other information on this line and
“O” or “:” must be the first character. The program must end with an M99 to allow other
Conversational program operations after the NC program is complete, as in the following
program (O number and M99 are bolded for emphasis):

Example:
%
O5085
(#1 IS THE START ANGLE)
(#2 IS THE NUMBER OF GEAR TEETH)
(#3 IS THE OUTSIDE RADIUS)
(#11 IS THE INSIDE RADIUS)
(#4 IS THE GEAR CENTER PT X COORD)
(#5 IS THE GEAR CENTER PT Y COORD)
(#6 IS THE GEAR CENTER PT Z COORD)
(#19 IS THE TOOTH TO SKIP)
(#18 IS THE TOOTH RATIO)
/
T1 M06
M03G00G21G90X0Y0Z0S1800
(VARIABLE #4006 - INCHES/METRIC)
IF[#4006EQ20]GOTO10
IF[#4006EQ21]GOTO15
N10#850=25.4
GOTO20
N15#850=1.0
N20G0X-3Y-5
Y5
X8
Y-5
#30=[360.0/#2]

Conversational Programming 704-0116-501 NC/Conversational Merge 2-129

#31=0
#22=[#30*#18]
#23=#30-#22
#24=#11*#850
#25=#3*#850
#26=#20*#23
X#4 Y#5
G90G00G16X#25Y#1
G01Z-.25F20.
WHILE[#31LT#2]DO250
#1=[#1+[#22]]
G03G16X#25Y[#1]R#3
G01X#24Y[#1+#26]
#1=[#1+[#23]]
G03X#24Y[#1-#26]R#11
G01X#25Y[#1]
G15
N200#31=#31+1
N400END250
M99
The states for modal G-codes such as work offsets (G54-G59),
absolute/incremental (G90, G91), or SFQ (G5.3 P__) are retained
until they are explicitly changed. They are not automatically reset at
the end of the subprogram run when you return to conversational.
You must explicitly reset the modal code(s) before ending the NC
subprogram if you do not want to retain the state.

See the Field Glossary for definitions of NC/Conversational Merge (NC Program Call
block) fields:

Argument Type

Block

Program Number

2 - 130 NC/Conversational Merge 704-0116-501 Conversational Programming

DXF OPTION
These topics are discussed in this section:

DXF Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 134

DXF Build Data Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 135
DXF Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 137
Edit Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 138
DXF Layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 140

Conversational Programming 704-0116-501 DXF Option 2-131

DXF Overview
WinMax DXF offers greater flexibility, improved compatibility with AutoCad®, and the
ability to save DXF changes directly to file (avoiding the need to send DXF files back to
the CAD system for editing). The DXF file translation software is compatible with DXF files
generated with Autocad version 12 and earlier.

DXF files are loaded directly into WinMax as follows:

1. Press the Auxiliary console button.

2. Select the DXF icon on the Auxiliary screen.
The DXF Editor is functional in Conversational programs only. If the
DXF Editor is started when the current active program is NC, a
prompt asks if you want to start a new conversational part program.
Answer Yes to create a new Conversational part program.

3. Find the DXF file on the Load DXF File screen, and select it to highlight.
4. Select the Load softkey.
• On single-screen machines, the DXF program blocks are displayed in the
Program Review Screen; use F+Draw (console key) to display the DXF
drawing.
• On dual-screen machines, the DXF drawing is displayed on the graphics
screen. After building the data blocks, the part can be viewed in Solid or
Toolpath graphics using the Draw console key. Switch the screen back to
the DXF drawing using F + Draw (console keys). You can switch the
screen back to the previously drawn graphic (without causing it to be
redrawn) with the Draw console key. To redraw the graphic, select the
Draw console key a second time (or access the DRAW OPTIONS F1
softkey).

DXF units of measurement (INCH or MM) match global WinMax units. When a data block
is built from a CAD drawing, the data block adopts the unit displayed on the WinMax
status bar. In Build DB, changing the WinMax unit will result in a different sized element,
for example, a segment that is 3 inches or 3 mm in length.

Here are the softkeys on the DXF screen:

• Parameters—see DXF Parameters, on page 2 - 137.

• Build DB—see DXF Build Data Block, on page 2 - 135.
• Zoom Window—see Zoom Window, on page 2 - 137.
• Edit Drawing—see Edit Drawing, on page 2 - 138.
• Layers—see DXF Layers, on page 2 - 140.
• Save DXF—saves the DXF file.
• Part Programming—goes to the active part program.
• Quit CAD—exits the DXF CAD option.

The Part Programming softkey or icon toggles back to Part Programming without
closing the DXF file. You may return to DXF at any time by selecting the DXF icon.

2 - 132 DXF Option 704-0116-501 Conversational Programming

DXF Build Data Block
The Build DB softkey accesses the automatic data block building features. The system
creates milling, holes, position, or pattern locations data blocks.

Milling - the Milling operation softkeys perform these functions in Lines/Arcs, Circles,
Frame, 3D Mold, or Ellipse data blocks:

• Accept—loads the entity into the data block.

• Zoom Window—refer to Zoom Window, on page 2 - 137.
• Edit Drawing—refer to Edit Drawing, on page 2 - 138.
• Reverse—reverses the contour direction.
• AutoChain—defines contours by autochaining individual segments together.
• Default Radius—inserts the value of the default radius set in the Frame
screen’s Corner Radius field.
• Exit/Cancel—cancels the operation and returns to the previous screen.

If you are using AutoCAD 14, set the registers to generate Polylines and Ellipses so they
are saved as pline entity types and not splines.

Holes -Holes data blocks are built using the Hole Location Method (F1) or the Hole
Pattern Method (F2):

• Use Hole Location Method—builds Holes Locations blocks from selected

points on the drawing.
• Use Hole Pattern Method—builds Holes Pattern blocks from selected points
on the drawing.

For either softkey, select holes on the drawing with one of three methods:

• Select individual holes on the touchscreen.

• Choose the Window Select softkey and drag across an area of the screen
to select a group of holes.
• Use the Intersect softkey to select two intersecting lines. The point of
intersection becomes the center of the hole.

Select the Accept softkey to create the data blocks.

These are the softkeys in the Holes menu:

• Accept—loads the entity into the data block.

• Zoom Window— refer to Zoom Window, on page 2 - 137.
• Edit Drawing—refer to Edit Drawing, on page 2 - 138.
• Window Select—selects a group of holes on the drawing.
• Intersect—draws a hole at the intersection of two selected lines and
represents the center with a highlighted plus (+).
• Default Order—orders the holes as they were selected in the Auto CAD

Conversational Programming 704-0116-501 DXF Option 2-133

 drawing.
• Exit/Cancel—cancels the operation and returns to the previous screen.

Position - creates a Position data block from the DXF drawing. These are the softkeys on
the Position menu:

• Accept—loads the entity into the data block.

• Zoom Window—refer to Zoom Window, on page 2 - 137.
• Edit Drawing—refer to Edit Drawing, on page 2 - 138.
• Window Select—selects a group of holes on the drawing.
• Intersect—draws a hole at the intersection of two selected lines and
represents the center with a highlighted plus (+).
• Default Order—orders the holes as they were drawn in the original AutoCAD
drawing.
• Exit/Cancel—cancels the operation and returns to the previous screen.

Pattern Locations—builds a Pattern data block. To use, select the softkey and then
select points on the drawing to serve as pattern locations, using one of the following
methods:

• Select individual holes on the touchscreen.

• Choose the Window Select softkey and drag across an area of the screen
to select a group of holes.
• Use the Intersect softkey to select two intersecting lines. The point of
intersection becomes the center of the hole.

Select the Accept softkey to create an empty Pattern Locations data block. Additional
data can then be added either manually or from the DXF drawing.

These are the softkeys on the Pattern Locations menu:

• Accept—loads the entity into the data block.

• Zoom Window— refer to Zoom Window, on page 2 - 137.
• Edit Drawing—refer to Edit Drawing, on page 2 - 138.
• Window Select—selects a group of holes on the drawing.
• Intersect—specifies a pattern location at the intersection of two selected
lines.
• Default Order—orders the holes as they were selected in the Auto CAD
drawing.
• Exit/Cancel—cancels the operation and returns to the previous screen.

2 - 134 DXF Option 704-0116-501 Conversational Programming

DXF Parameters
These parameters link contour segments, define part zero within the drawing, and set the
radius for frame corners.

Use the Move Zero and Select Value softkeys to change the location of part zero. The
part zero symbol is a circle with crosshairs. To change this location manually, move the
cursor to the field for Part X Offset or Part Y Offset and enter the X or Y Offset values.
To change this location graphically and automatically, use the Move Zero softkey.

Frame Radius sets the default corner radius. If the corners of a frame do not have the
same radius, you are prompted to either select a corner radius on the drawing or use the
default value entered in this field for the radius.

The Exit softkey returns to the DXF softkeys.

See the Field Glossary for definitions of the DXF Parameter fields:

Drawing scale

Endpoint Tolerance

Frame Radius

Hole Diameter

Part X Offset

Part Y Offset

Use the check boxes to turn on or off the following parameters:

• Display Geometry—shows selected lines on the graphic display in a color

other than black, illustrating which elements have been selected. Colors can
be changed with the Choose Colors softkey on the Parameters screen.
• Autochain Contours—allows autochaining to be turned off so that a contour
may be created by individually selected segments into a chained contour. By
default, segments are automatically chained to create contours.
• Select Holes by Diameter—selects holes with the diameter specified in the
Hole Diameter field (defined above) when the WINDOW SELECT softkey is
used. This selection allows you to order the hole selection by size, which
optimizes tool changes.

Zoom Window
Use the Zoom Window softkey to enlarge an area of the drawing or zoom out to see a
full view. Use the pointer to touch an area on the screen and drag across the screen to
enlarge an area of the drawing. When an area is enlarged, use the following softkeys:

• Zoom Out—pulls back from the drawing incrementally to the previous

magnification level without re-centering the part in the drawing.
• Fit to View—gives a full scale of the drawing with the part in the drawing

Conversational Programming 704-0116-501 DXF Option 2-135

 auto-centered.
• Pan—relocates the center of the drawing on the Graphic display.
• Exit—returns to the previous menu.

Edit Drawing
Use the Edit drawing feature to extend, join, modify, or split segments that need to be
edited in order to create the proper geometry for the part program.

• Extend—locates the intersection of two lines and extends one or both of the
lines to the intersection point.

To extend lines, select the EDIT DRAWING softkey and then the Extend
softkey. Select the two lines that need to be extended. Both lines are
highlighted when selected and extended to their points of intersection as
shown in the examples below:

A Original drawing

B Edited drawing

1 Extended line

2 Both lines extended

3 Start of arc

4 Selected intersection point

5 Extended arc

• Join—moves a selected line endpoint to the endpoint of a line or arc

segment. Always select as the first endpoint the point that will be joined to
the second endpoint. The endpoint at the opposite end of the first selected
segment remains stationary and becomes a pivoting point. Both segments
are highlighted when selected, and the screen is redrawn to reflect the
joining of the two segments.

• Modify—is used to view or modify the actual geometry data of segments.

Choose the SELECT POINT softkey to view the segment data.

2 - 136 DXF Option 704-0116-501 Conversational Programming

 • The DXF Edit Modify - Arc dialog box appears if you select an arc. Refer to
DXF Edit Modify - Arc, on page 2 - 140.
• The DXF Edit Modify - Line dialog box appears if you select a line. Refer to
DXF Edit Modify - Line, on page 2 - 140.
• The DXF Edit Modify - Point dialog box appears if you select a point. Refer
to DXF Edit Modify - Point, on page 2 - 140.
• The segment appears gray on the Graphic display.

Choose the Accept softkey to retain the changes in the control's memory.

A Original drawing

B Edited drawing

1 Stationary endpoint

2 Selected segment endpoint

3 Joining endpoint

4 Newly joined segment

Figure 2–59. Joined Lines and Arcs

• Split—use to divide segments for selection, de-selection, and chaining.

Segments may be split at midpoint or any point of intersection with other
segments.

To split a segment, first select the segment and then select the point where
the segment will be divided. When a segment is selected for splitting, the
midpoint and all intersection points with the other segments are indicated
with crosshair markers. Follow the directions in the Prompt display.

• Delete—deletes a programmed endpoint.

• Trim—trims a selected segment.
• Explode PCurve—shows an exploded view of a selected PolyCurve. If you
are using Auto CAD 14, set the registers to generate Polylines and Ellipses so
they are saved as pline entity types and not splines.
• Exit/Cancel—return to the Main DXF menu.

Conversational Programming 704-0116-501 DXF Option 2-137

DXF Edit Modify - Arc
The DXF Edit Modify - Arc dialog window contains these fields:

• Start Angle—defines the starting point of the angle.

• Sweep Angle—defines the total number of degrees in the arc to be cut. This
number can be greater than 350.
• Direction—identifies the direction of the arc from the start point.
• Radius—identifies the radius of the arc.
• Center X and Center Y—identify the X and Y coordinates for the center point
of the arc.

DXF Edit Modify - Line

The DXF Edit Modify - Line dialog window contains these fields:

• Endpoint1 X and Endpoint1 Y—define the first endpoints for the X and Y
coordinates.
• Endpoint2 X and Endpoint2 Y—define the second endpoints for the X and Y
coordinates.
• Length—identifies the line length.
• XY Angle—identifies the angle of the XY coordinate.

DXF Edit Modify - Point

The DXF Edit Modify - Point dialog window contains these fields:

• X Value—identifies the X location for the selected point.

• Y Value—identifies the Y location for the selected point.

DXF Layers
Many DXF drawings use layers - an electronic method of representing transparent acetate
overlays used in hand-drawn drafting work.

• Select Layer—toggles the highlighted layer on and off.

• All On—turns on all of the layers.
• All Off—turns off all of the layers.
• Exit—return to the Main DXF menu.

Layer names longer than 31 characters will be shortened during

processing.

2 - 138 DXF Option 704-0116-501 Conversational Programming

ULTIPOCKETS
The UltiPocket™ programming option adds special milling routines for machining pocket
boundaries with islands. This option provides complete clean out of odd-shaped pockets
without cutting the islands programmed inside the boundary. The software automatically
calculates the tool path around islands eliminating the long task of plotting these shapes.
Islands may also be rotated, scaled, and repeated.

The following drawing shows an inward spiral boundary with three differently shaped
islands.

The pocket feature is available for any closed contour data block: Mill Contour, Mill Frame,
Mill Circle, Mill Ellipse, Mill Slot, or Mill Polygon.

To use the UltiPocket feature, first establish the cutter compensation

parameter and then program any UltiPocket data blocks.

• Refer to Milling Parameters.

• Select either Insert Arc or Insert Line for the Cutter Comp Parameter
field. If this field does not appear on the Milling Parameters screen,
the UltiPocket option has not been installed on the control.

Additionally, see these topics:

Helical Plunge with UltiPockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 145

Helical Plunge Using Operator Specify Pocket Start . . . . . . . . . . . . . . . . . . . . 2 - 145

Conversational Programming 704-0116-501 UltiPockets 2-139

Pocket Boundary
The Pocket Boundary is the outside frame of the part. The basic philosophy of the
UltiPocket option is to program the boundary and then tell the system which pockets or
islands to avoid within that boundary. This approach eliminates complex calculations and
shortens the part programming process.

The types of Pocket Boundaries are Outward, Inward, ADP Zigzag, and ADP 1-Way. These
are explained below.

Follow this link to the Hurco website to view a Pocket Boundary video
demonstration:

Video Demonstrations at www.hurco.com

Scroll to the bottom of the page and select the video to download.
Internet connection is required.

Outward
This selection is only for Circle and Frame data blocks without islands. When this routine
is selected, the tool begins from the center region of the part outward to pocket the
entire programmed boundary. This operation is, therefore, the same as the standard
WinMax Pocket selection. With this selection the cutter overlap is controlled by the Pocket
Overlap value on the Milling Parameters screen, not the Pocket Overlap field on the Mill
Circle and Mill Frame screens.

Inward
This selection cuts in from the outside of the defined boundary avoiding the defined
islands. When this routine is selected, the tool enters the part and begins following a path
formed by offsetting the boundary one-half the tool radius, plus the pocket overlap.

To control the percentage of overlap during cutting, enter a value in the Pocket Overlap
field. After the first pass, the tool follows a path produced by offsetting the boundary by
the tool radius, plus the pocket overlap for each pass while avoiding islands inside the
boundary.

After pocketing the boundary, the tool then cuts around the inside of the boundary and
the outside of each island, using the selected blend offset and the programmed tool
radius.

ADP Zigzag
With AdaptiPath (ADP) pocket types the tool makes constant contact with the material
surface to decrease cutting time. ADP Zigzag moves the tool in a zigzag pattern; one
pass is climb milling, the next pass is conventional milling, alternating climb and
conventional passes until complete.

To control the percentage of overlap during cutting, enter values in the Overlap Target
and Min(imum) fields.

For more information, see Climb Milling (Left), on page 2 - 12 and Conventional Milling

2 - 140 UltiPockets 704-0116-501 Conversational Programming

(Right), on page 2 - 12 in Conversational Programming.

ADP 1-Way
With AdaptiPath (ADP) pocket types the tool makes constant contact with the material
surface to decrease cutting time. ADP 1-Way moves only in climb or conventional
direction, skimming the part surface on the return move. Climb or Conventional Milling
Direction is set in the Program Parameters Milling 1 tab. See Program Parameters, on
page 1 - 124 in Getting Started with WinMax Mill.

To control the percentage of overlap during cutting, enter values in the Overlap Target
and Min(imum) fields.

For more information, see Climb Milling (Left), on page 2 - 12 and Conventional Milling
(Right), on page 2 - 12 in Conversational Programming.

Rest Machining
Rest Machining is available with Pocket Boundary ADP Zigzag and ADP 1-Way. Rest
Machining allows you to specify a small tool that is used to clear out remaining pocket
areas, i.e., corners where a bigger tool might not be able to reach. The Rest tab appears
in the tool data area when either ADP Zigzag or ADP 1-Way pocket types are selected
with Pocket Boundary Milling Type on the Roughing tab:

Programming Islands
After programming the mill data block for a boundary, an island can be defined by
creating a Pocket Island data block. As many islands as desired may be defined (subject
to computer memory on the control), but all must fit within the defined boundary and
should allow the tool to completely define the island.

The island data block can be a Mill Frame, Circle, or Contour (provided it is a closed
contour). The Pocket Island data blocks use the standard milling values from the
boundary data block and do not display these parameters on the island programming
screen. The pocket overlap percentage was also defined in the boundary data block.

Mill Contours
To create a Mill Contour data block using the UltiPocket option, set up the operation in the
start segment (segment zero). As in standard WinMax milling, an UltiPocket Mill Contour

Conversational Programming 704-0116-501 UltiPockets 2-141

block consists of segments beginning with segment zero. With the cursor in the MILLING
TYPE field, select one of the Pocket options in the Start segment to indicate whether this
block is the boundary of the part or one of the islands within the boundary. The boundary
must occur first in the program.

The segments after the Start segment are programmed in the same manner as standard
milling lines and arcs. Automatic calculation of unknown points is available for these data
blocks.

Mill Frame
The Mill Frame data block is often used to create the part boundary.

This block is programmed in the same manner as the standard WinMax Mill Frame, with
the addition of the Pocket Overlap percentage.

Mill Circle
The Mill Circle data block is used for both boundaries and islands. It is similar to the
standard Mill Circle data block except that if this block is used to create an island, it uses
the tool from the boundary data block.

Pattern
Pattern data blocks can be inserted to rotate, scale, or repeat islands. Only Pattern data
blocks can be programmed between a boundary data block and an island. As many
islands as desired may be defined (subject to available memory), but all must fit within
the defined boundary.

2 - 142 UltiPockets 704-0116-501 Conversational Programming

Helical Plunge with UltiPockets
The Helical Plunge option is used with the UltiPockets option to define the plunging
location when inward pocketing. Islands created using inward pocketing can influence
plunge locations. A plunge location is determined that will not interfere with pocket
islands.

The plunging location in outward pocketing is the same as a straight plunge. Outward
pocketing is used only for mill frame, mill circle, and ellipse pocket boundaries that do not
have pocket islands. Since islands are not present with outward pocketing, the plunging
location is in the middle of the mill frame, mill circle and ellipse.

When the Helical Plunge option is installed, two additional pocketing-related fields appear
on the Milling 2 tab on the Program Parameters screen. These fields are Operator
Specify Pocket Start and Pocket Plunge Near Center.

The Operator Specify Pocket Start field takes precedence over the Pocket Plunge Near
Center field. If the Operator Specify Pocket Start field is set to Yes, the value of the
Inward Pocket Plunge Near Center field is ignored.

When the Operator Specify Pocket Start field is set to No, the value of the Inward Pocket
Plunge Near Center field is checked. If the Inward Pocket Plunge Near Center field is set
to Yes, a starting location will be determined near the center of the pocket. If both fields
are set to No, the default starting position will be used for the pocket.

Helical Plunge Using Operator Specify Pocket Start

To use the Operator Specify Pocket Start function:

1. Set the Type field to Pocket Boundary on the Mill Contour, Mill Frame or Mill
Circle screen.
2. Set the Pocket Type field to Inward on the Mill Contour, Mill Frame or Mill
Circle screen.
3. Set the Operator Specify Pocket Start field to Yes on the Milling Parameters
screen.
4. The Pocket X Start and Pocket Y Start fields appear on the Mill Contour, Mill
Frame, or Mill Circle screen. The operator identifies the pocket plunge location
with the Pocket X Start and Pocket Y Start fields.

The Pocket X Start and Pocket Y Start fields define the centerline of the
plunge path. This is the location where the helix will be centered. If a straight
plunge is selected, the straight plunge will occur at the location.

The following figure shows the Pocket X Start and Pocket Y Start fields on the Mill Frame
screen. See Helical Plunge (Ramp), on page 3 - 1 for an example using Pocket Start X and
Pocket Start Y fields.

Conversational Programming 704-0116-501 UltiPockets 2-143

 For non-rotary blocks, Pocket X Start and Pocket Y Start define the
XY starting location. For rotary blocks, these fields define the XA
starting location.

An error message will display if the values for Pocket X Start or

Pocket Y Start interfere with the pocket island or pocket boundary.

2 - 144 UltiPockets 704-0116-501 Conversational Programming

NC PROGRAMMING
This documentation describes the use of NC (Numerical Control) Part Programming,
which includes the BNC (Basic Numerical Control) and the ISNC (Industry Standard
Numerical Control) Editor portion of the CNC software as it is used on the machine tool
console. This section explains the following:

NC Part Programming Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

NC Editor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Starting a New NC Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
NC Editor Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 9
NC Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20
NC Probing Part Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25

WinMax Mill NC Programming 704-0116-501 NC Programming 3-1

NC Part Programming Principles
NC part programming adheres to the ANSI/EIA RS–274–D standard terminology with
extensions for BNC and ISNC dialects. In addition, the NC programming facilities were
designed to use as much of the WinMax Conversational system as possible. As a result,
most of the screens are the same in both the NC and the conversational systems. This
allows a smooth transition between the two.

The primary difference between conversational and NC programming is the program

editors. NC programming uses standard G and M codes; whereas, conversational
programming uses plain English or another supported programming language.

The CNC software can read NC files from the serial port directly into
dynamic memory or run NC files that are partially loaded into
dynamic memory. NC files can be serially loaded to the hard disk.

NC part programs can be created using the CNC on the machine tool or off-line CNC
programming software running on a personal computer. NC programs cannot be
converted to conversational programs, nor can NC programs be converted automatically
to any other NC format.

NC Part Program Components

NC programs are a series of characters and words that form program blocks. These
program blocks tell the machine tool how and where to move. The operator needs to
understand the basic program structure and the types of codes in order to create, edit,
and run a program successfully. These components make up NC code:

Program Start
NC data can begin with the with a “%” (percent) character to indicate the beginning of
the file. When a percent character is received, the control starts to accept, check, and
load blocks into its memory. If you are creating a new part program at the control, the
percent character is automatically inserted at the beginning of the program.

Sequence Number
A sequence number serves as a block label; it has no other significance within the part
program except being required with GOTOs in the NCPP option and the M99 jump
command. Sequence numbers are often used to mark the beginning of milling sequences
so you can restart at a given sequence number or recall specific operations within the
program. The maximum sequence number is 9999999.

When programming on an off-line system, sequence numbers should be used sparingly.

Sequence numbers (N words) are optional in the NC Editor, and they are useful in
programs sent over the RS-232 link. However, the absence of sequence numbers permits
faster processing (loading, syntax checking, and parsing) of the part program and can
result in improved part program execution. In addition, omission of these numbers
increases the amount of the program that can fit into memory.

3 - 2 NC Programming 704-0116-501 WinMax Mill NC Programming

 If you request renumbering of part program sequence numbers, any
sequence numbers in GOTO statements will not be updated. You
must then press the (F1) Yes softkey before re-sequencing will take
place. To cancel the renumbering, press the (F8) No softkey. In
general, you will not want to renumber part programs that use GOTO
statements.

Address Characters
An address character is the first character of a word in a program block. The Ignore
Command signals the system to ignore the remainder of the block. The Comment
Command characters are used to delimit comments. The following is a list of the address
characters recognized by this system:

/ Ignore Command
() Comment Command
: Subprogram Number (NCPP Option)
A Rotary Dimension Around X-axis
B Rotary Dimension Around Y-axis
D Tool Diameter Offset
F Feedrate
G Preparatory Functions
H Index into the tool length offset table
I X-axis Arc Center/Offset, X scale factor, Canned Cycle Bore Shift
J Y-axis Arc Center/Offset, Y scale factor, Canned Cycle Bore Shift
K Z-axis Arc Center/Offset, Z scale factor, Canned Cycle Repeat
L Tool Length Offset, Data Set Mode
M Miscellaneous Functions
N Sequence Number
O Subprogram Number (NCPP option)
P Subprogram Number, Dwell Time, Scaling Factor
Q Canned Cycle Bore Shift, Peck Depth
R Rotation Angle, Return Level, Circular Interpolation Radius
S Spindle Speed Function
T Tool Select
X Primary X Motion Dimension, Dwell Time
Y Primary Y Motion Dimension
Z Primary Z Motion Dimension

Special Characters
Special characters are ASCII characters within a file which have special meaning to the
system and cannot be edited. The following special characters are recognized by the NC
software:

• %—Beginning/End of file—signals the system that all of the following

characters are part of the program. The system automatically adds this
character to the beginning of a new program. (% is not used in
subprograms.)

You can also include the % character to signal the End of File.

• E— —signals the NC system that no more legal program characters follow.

WinMax Mill NC Programming 704-0116-501 NC Programming 3-3

 This character is optional to provide compatibility with existing programs that
include EOT characters at the end.
• [CR]—Carriage Return—signals the End of a Program Block.
• [CRLF]—Carriage Return/Line Feed Pair—signals the End of a Program
Block (identical to [CR]).

[CRLF] is not shown when the program is viewed in the NC Editor.

Words
A word is a group of alphanumeric characters. The first character is an address
character—a letter such as M or G. The address character is followed by a signed or
unsigned numeric value. Some sample NC words are “X-.03” and “G00.” One word or
groups of words form a program block.

Block
A block is a group of words terminated by the end-of-block character: a carriage return
[CR] or a carriage return/line feed pair [CRLF]. Each block within a part program must be
terminated with either a [CR] or a [CRLF].

The following illustration shows a typical NC block and its components:

1 Word
2 Address character
3 Numeric character
4 Feedrate word
5 Sequence number
6 Modal preparatory functions