Machine and Tool Offsets

Machine Offsets

Because it is difficult to place a vise in the exact same position on the machine each time, the distance from Home to the WCS is usually not known until the vise is set and aligned with the machine. Machine set up is best done after the program is completely written, because it is expensive to keep a CNC machine idle waiting for the CNC programming to be done. Besides, the programmer may change their mind during the CAM process, rendering any pre-planned setup obsolete.

To complicate matters further, different tools extend out from the machine spindle different lengths, also a value difficult to determine in advance. For example, a long end mill extends further from the spindle face than a stub length drill. If the tool wears or breaks and must be replaced, it is almost impossible to set it the exact length out of the tool holder each time.

Therefore, there must be some way to relate the Machine Coordinate system to the part WCS and take into account varying tool lengths. This is done using machine Tool and Fixture Offsets. There are many offsets available on CNC machines. Understanding how they work and to correctly use them together is essential for successful CNC machining.

Fixture Offset XY

Fixture offsets provide a way for the CNC control to know the distance from the machine home position and the part WCS. In conjunction with Tool Offsets, Fixture Offsets allow programs to be written in relation to the WCS instead of the Machine Coordinates. They make setups easier because the exact location of the part in the machine envelop does not need to be known before the CNC program is written.

As long as the part is positioned where the tool can reach all machining operations it can be located anywhere in the machine envelope. Once the Fixture Offset values are found, entered into the control, and activated by the CNC program, the CNC control works behind the scene to translate program coordinates to WCS coordinates.

Notice in Figure 4.11 how Fixture Offsets (+X, -Y) are used to shift the centerline of the machine spindle directly over the WCS.

Figure 4.11: Fixture Offset Shifts Machine to WCS

Fixture Offset Z

The Fixture Offset Z value is combined with the Tool Length offset to indicate to the machine how to shift the Z-datum from part home to the part Z-zero, taking into account the length of the tool. Fixture Offset Z may or may not be used, depending on how the machine is set up and operated.

Chapter 6 (CNC Operation) and Appendix B (Alternate Tool Setting Methods) describe the various ways that these two values can be used. Follow the procedure in use at your facility or refer to your machine tool documentation to determine which method to use.

Tool Length Offset (TLO)

Every tool loaded into the machine is a different length. In fact, if a tool is replaced due to wear or breaking, the length of its replacement will likely change because it is almost impossible to set a new tool in the holder in exactly the same place as the old one. The CNC machine needs some way of knowing how far each tool extends from the spindle to the tip. This is accomplished using a Tool Length Offset (TLO).

In its simplest use, the TLO is found by jogging the spindle with tool from the machine home Z-position to the part Z-zero position, as shown on the far left in Figure 4.12 below. The tool is jogged to the part datum Z and the distance travelled is measured. This value is entered in the TLO register for that tool. Problems with this method include the need to face mill the part to the correct depth before setting tools. Also, if the Z-datum is cut away (typical of 3D surfaced parts) it is impossible to set the datum should a tool break or wear and need to be replaced. All tools must be reset whenever a new job is set up. When this method is used, the Fixture Offset Z is not used, but set to zero.

The method shown in the center is much better and used in this book. All tools are set to a known Z-position, such the top of a precision 1-2-3 block resting on the machine table. This makes it very easy to reset tools if worn or broken.

A tool probe is very similar to the 1-2-3 block method, except the machine uses a special cycle to automatically find the TLO. It does this slowly lowering the tool until the tip touches the probe and then updates the TLO register. This method is fast, safe and accurate but requires the machine be equipped with a tool probe. Also, tool probes are expensive so care must be taken to never crash the tool into the probe.

Both the 2nd and 3rd methods also require the distance from the tool setting position (the top of the 1-2-3 block or tool probe) to the part datum to be found and entered in the Fixture Offset Z. The machine adds the two values together to determine the total tool length offset. A method for doing this is included in Chapter 6.

Figure 4.12: Ways to Set TLO