ENGINEERING DOCUMENT

757-4002-373

Rev. B

SUBJECT: Tool Setter Calibration Procedure

for TM Series Turning Centers

Responsible

Bill Mader
Originator

Reviewed/Approved

2/9/05
Date

Dan Ornelas
Mgr. Control Integration Engineering

2/11/05
Date

RECORD OF CHANGES
Engineering Document 757-4002-373
Revision

ECN #

Revision Description

A
B

15833
16021

Original Release
Added section XI on page 14 for fine tuning the
tool setter calibration values.

Tool Setter Calibration Procedure

for TM Series Turning Centers

Rev
By
WCM
WCM

757-4002-373

Date
2/9/05
3/29/06

Rev. B

Appd
By
DEO
DEO

Date
2/11/05
3/30/06

Page 2 of 14

I. INTENT
To provide a standardized procedure for calibrating the tool setter for TM series turning centers.
II. APPLICABILITY
Applies to TM series turning centers with the tool setter option.
III. INDEX
Page 3
Pages 4-5
Pages 6-7
Pages 7-10
Page 10
Pages 11-13
Pages 13-14
Page 14

Getting Started
Tool Setter Stylus Alignment & Adjustmnets
Tool Setter Calibration Screens
X- Tool Setter Calibration
X+ Tool Setter Calibration
Z- Tool Setter Calibration
Z+ Tool Setter Calibration
Fine Tuning Adjustments

IV. GETTING STARTED

Before proceeding with the calibration process, various parts of known sizes will be required for
attachment to the turret during the touch-off process. For the X-axis calibration process, a test
bar (dowel pin or precision tool shank), along with a boring block of matching size, will be
required. For the Z-axis calibration process, a test plate (usually secured with a magnet) will be
required. When calibrating the tool setter, it is not required that one axis be calibrated before the
other for a successful operation.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 3 of 14

V. TOOL SETTER STYLUS ALIGNMENT & ADJUSTMENTS

A. Begin with the basic alignment of the tool setter stylus. Check that the height of the stylus is
adjusted so that the tip of the turning tools is centered up and down to the thickness of the
stylus head. Move the stylus up or down as required by loosening the screw at the base of the
stylus and tighten when positioned properly. Reference Figure 1.

Figure 1 Tool Setter Height Adjustment

B. The head of the stylus needs to be parallel to the Z-axis travel. This is crucial for proper
calibration of the tool setter. Using a tenth indicator, move the indicator tip back and forth
across the head. Reference Figure 2. The head can be adjusted by alternately tightening or
loosening the two set screws located on the right hand side of the tool setter. The adjustment
can be precisely controlled by using this process. Reference Figure 3.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 4 of 14

Figure 2 Indicating the Stylus Head

Figure 3 Adjusting the Stylus Head

Tool Setter Calibration Procedure
for TM Series Turning Centers

757-4002-373

Rev. B

Page 5 of 14

VI. TOOL SETTER CALIBRATION SCREENS

A. From any screen, with the exception of the console test screens, select the Menu button on
the console to display the menu options.
B. Select the Utility Screens soft key.
C. Select the System Configuration soft key (F1).
D. Select the Hardware Configurations soft key (F3). The Hardware Configurations screen
will be displayed with various selections on the soft keys. Reference Figure 4.

Figure 4 Hardware Configurations Screen

E. Caution!! Before proceeding, please be aware that the next step will display the tool setter
calibration screen. Pressing buttons on this screen will cause machine movement to occur.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 6 of 14

F. Select the Tool Setter Calibration soft key (F2). The Tool Setter Calibration screen will
be displayed. Reference Figure 5.

Figure 5 Tool Setter Calibration Screen

VII. X- Tool Setter Calibration
A. Rotate the turret to the desired location for installing the test bar (dowel pin or precision tool
shank) and a boring block.
B. Attach the boring block to the turret and insert the test bar into the holder, making sure that the
bar is securely attached in the holder. Reference Figure 6.
C. After attaching the test bar, check the test bar for parallelism to the machine. Run an indicator
back and forth across the test bar, verifying that the bar is as parallel to the Z-axis as possible.
The bar should not be out of alignment any more than a couple of tenths. Make any necessary
adjustments before proceeding to the next step. Reference Figure 7.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 7 of 14

Figure 6 Dowel pin mounted in boring block with a sleeve

Figure 7 Indicating a dowel pin for parallelism to the machine

Tool Setter Calibration Procedure
for TM Series Turning Centers

757-4002-373

Rev. B

Page 8 of 14

D. Move the axes back to the home position (upper, right-hand corner of the machine).
E. Enter the X- offset into the associated data field. The offset is the distance from X zero (center
of the bar) to the surface of the bar. In this test, this value will be half the diameter, or the
radius, of the test bar. Note: The offset value is always a positive number in millimeters.
F. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the
feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.
G. Move the tool setter into position by pressing the Advance Tool Setter soft key (F6).
H. Slowly jog the axes towards the tool setter, positioning the center of the bar within 10mm of
the topside of the tool setter head. This will be the start position required for performing the
X- calibration process. Reference Figure 8.

Figure 8 Positioning a dowel pin at the tool setter head

I. Press the Calibrate X- soft key (F1) to initiate the calibration process. Press the flashing
Start Cycle button on the console to confirm the operation.
J. The X-axis will begin moving slowly towards the tool setter head. When the test bar touches
the tool setter head, the axis will rapidly move back approximately 10mm in the opposite
direction. If the calibration process was successful, the screen will show a green LED
indicator next to the X- Offset and X- Datem Location data fields. A red LED indicates that
the tool setter is not calibrated for the associated direction.
Tool Setter Calibration Procedure
for TM Series Turning Centers

757-4002-373

Rev. B

Page 9 of 14

K. If the test bar was positioned more than 10mm from the tool setter head, the system will
generate a fault. Re-position the test bar again to within 10mm of the tool setter head and
repeat steps G and H.
VIII. X+ Tool Setter Calibration
A. Rotate the turret to the desired location for installing the test bar and a boring block.
B. Attach the boring block to the turret and insert the test bar into the holder, making sure that the
bar is securely attached in the holder. Reference Figure 6.
C. After attaching the test bar, check the test bar for parallelism to the machine. Run an indicator
back and forth across the test bar, verifying that the bar is as parallel to the Z-axis as possible.
The bar should not be out of alignment any more than a couple of tenths. Make any necessary
adjustments before proceeding to the next step. Reference Figure 7.
D. Move the axes back to the home position (upper, right-hand corner of the machine).
E. Enter the X+ offset into the associated data field. The offset is the distance from X zero
(center of the bar) to the surface of the bar. In this test, this value will be half the diameter, or
the radius, of the test bar. Note: The offset value is always a positive number in millimeters.
F. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the
feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.
G. Move the tool setter into position by pressing the Advance Tool Setter soft key (F6).
H. Slowly jog the axes towards the tool setter, positioning the center of the bar within 10mm of
the bottom side of the tool setter head. This will be the start position required for performing
the X+ calibration process.
I. Press the Calibrate X+ soft key (F2) to initiate the calibration process. Press the flashing
Start Cycle button on the console to confirm the operation.
J. The X-axis will begin moving slowly towards the tool setter head. When the test bar touches
the tool setter head, the axis will rapidly move back approximately 10mm in the opposite
direction. If the calibration process was successful, the screen will show a green LED
indicator next to the X+ Offset and X+ Datem Location data fields. A red LED indicates that
the tool setter is not calibrated for the associated direction.
K. If the test bar was positioned more than 10mm from the tool setter head, the system will
generate a fault. Re-position the test bar again to within 10mm of the tool setter head and
repeat steps G and H.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 10 of 14

IX. Z- Tool Setter Calibration

A. Rotate the turret to the desired location for installing the test plate.
B. Attach the test plate to the turret using a magnet, or by some other means, making sure that the
plate is securely positioned on the face of the turret. Reference Figure 9. Note that the left
side of the test plate is flush with the face of the turret.

Figure 9 Test plate secured with a magnet for Z-axis calibration

C. After attaching the test plate, move the axes back to the home position (upper, right-hand
corner of the machine).
D. Enter the Z- offset into the associated data field. The offset is the distance from the face of the
turret to the surface of the plate. This value may be zero if the plate is secured flush to the
turret face. Otherwise, this value would probably be the thickness of the plate. Note: The
offset value is always a positive number in millimeters. Reference Figure 10.
E. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the
feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 11 of 14

Figure 10 Determining the offset required for Z-axis calibration

F. Move the tool setter into position by pressing the Advance Tool Setter soft key (F6).
G. Slowly jog the axes towards the tool setter, positioning the plate within 10mm of the right side
of the tool setter head. This will be the start position required for performing the Z- calibration
process. Reference Figure 11.
H. Press the Calibrate Z- soft key (F3) to initiate the calibration process. Press the flashing
Start Cycle button on the console to confirm the operation.
I. The Z-axis will begin moving slowly towards the tool setter head. When the test plate touches
the tool setter head, the axis will rapidly move back approximately 10mm in the opposite
direction. If the calibration process was successful, the screen will show a green LED
indicator next to the Z- Offset and Z- Datem Location data fields. A red LED indicates that
the tool setter is not calibrated for the associated direction.
J. If the test plate was positioned more than 10mm from the tool setter head, the system will
generate a fault. Re-position the test plate again to within 10mm of the tool setter head and
repeat steps G and H.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 12 of 14

Figure 11 Positioning the test plate at the tool setter head

X. Z+ Tool Setter Calibration
A. Rotate the turret to the desired location for installing the test plate.
B. Attach the test plate to the turret using a magnet, or by some other means, making sure that the
plate is securely positioned on the face of the turret. Reference Figure 9. Note that the left
side of the test plate is flush with the face of the turret.
C. After attaching the test plate, move the axes back to the home position (upper, right-hand
corner of the machine).
D. Enter the Z+ offset into the associated data field. The offset is the distance from the face of the
turret to the surface of the plate. This value may be zero if the plate is secured flush to the
turret face. Otherwise, this value would probably be the thickness of the plate. Note: The
offset value is always a positive number in millimeters. Reference Figure 10.
E. In order to achieve accurate results, the axis must touch the stylus at a slow feedrate. Set the
feedrate percentage at a value between 10 and 20%; set rapid percentage at 100%.
F. Move the tool setter into position by pressing the Advance Tool Setter soft key (F6).
G. Slowly jog the axes towards the tool setter, positioning the plate within 10mm of the left side
of the tool setter head. This will be the start position required for performing the Z+
calibration process.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 13 of 14

H. Press the Calibrate Z+ soft key (F4) to initiate the calibration process. Press the flashing
Start Cycle button on the console to confirm the operation.
I. The Z-axis will begin moving slowly towards the tool setter head. When the test plate touches
the tool setter head, the axis will rapidly move back approximately 10mm in the opposite
direction. If the calibration process was successful, the screen will show a green LED
indicator next to the Z+ Offset and Z+ Datem Location data fields. A red LED indicates that
the tool setter is not calibrated for the associated direction.
J. If the test plate was positioned more than 10mm from the tool setter head, the system will
generate a fault. Re-position the test plate again to within 10mm of the tool setter head and
repeat steps G and H.

XI. Fine Tuning Adjustments

Some adjustments may still need to be made even after calibrating the tool setter as described in
the above procedures. The system allows for an operator to fine tune the calculated values for
those process that may require tighter standards for part tolerances.
A. After calibrating the tool setter, calibrate a tool, via the Tool Setup screens, using the tool
setter. This should be a standard turning tool that can be used to cut a test part for accuracy.
B. Create and run a program that will use this calibrated tool to turn a part to a specific diameter.
In this example, this will be determining the accuracy of the X- calibration value.
C. After the test part has been cut, measure the diameter of the part for accuracy. Depending
upon the desired tolerances, this measurement may meet acceptable standards. If not, the
calculated value for the tool setter calibration will need to adjusted accordingly.
D. In the Tool Setter Calibration screen, the calculated calibration values are shown in the fields
labeled Datum Location. There will be four different fields, one for X+, X-, Z+, and Z-.
Reference Figure 5. Adjust the X- Datum Location vaule accordingly to achieve a tighter
tolerance.
E. Re-cut the part and measure again for accuracy. The part should be within the desired
tolerances. If not, repeat the adjustment and cutting processes as necessary until the desired
tolerances are achieved.
F. As required, repeat steps B thru E with the appropriate tools in order to fine tune the remaining
Datum Location values in the Tool Setter Calibration screen.

Tool Setter Calibration Procedure

for TM Series Turning Centers

757-4002-373

Rev. B

Page 14 of 14