This algorithm is specifically developed for DMG DMC75V, DMG DMC105V ve DMG DMC100U, DMG DMU80MonoBlock, DMG DMU60MonoBlock CNC machine tools. By the help of the this special algorithm developed, parts that have bigger dimensions than the machine axes limits (dimensions exceed the machine axes limits) can be easily machined without any need to slide or adjust the position of the workpiece on the table manually. The algorithm works as follows:

1. The machine axes limits are embedded on the software for each specific CNC machine tool.

2. The user defines the workpiece reference point (zero point) on ManusPost.

3. The tool lengths can also be defined on ManusPost. If it is defined correctly on CAM software, ManusPost will recognize these defined tool lengths, therefore no need to define it again on ManusPost.

4. Calculating Exact Locations of Machine Components: The major difference of ManusPost than other standard or customized posts is that ManusPost not only calculates the tool relative position with respect to the workpiece, but also calculates (and therefore knows) machine spindle and table exact locations.

5. Knowing the exact locations of the machine components, makes it possible to learn whether or not an overtravel (in any lineer axis) occurs in postprocessing stage.

6. ManusPost will warn the user if an overtravel (axis limit exceeding) occurs. It also tells the user in which operation and in which block this occurs.

7. When this optional feature is added to the system, ManusPost now knows in which operation and block this overtravel occurs. If it is an 3-axis operation, ManusPost will also recognize this, and will solve the problem automatically.

8. The table (C-Axis) is adjusted again to ensure it is 1mm inside the limit and then C-Axis is rotated to the newly adjusted location.

9. Therefore, instead of performing the 3-Axis operations on C-Axis 0 degrees location, ManusPost adjust a new C-Axis location for you automatically.

10. This greatly enhances production times and capabilites, since you no longer will learn whether or not an axis limit occurs after you start machining, and therefore machining will not be interrupted after it is started. You also dont need to do CAM work again, or postprocess the code again, if you rotate the workpiece manually. It is obvious and already has been proved that this optinonal feature will save a lot of time.

This algorithm is developed to find a solution to an axis limit problem for 3+2 axis (indexed) operations and developed for DMG DMC75V, DMG DMC105V ve DMG DMC100U, DMG DMU80MonoBlock, DMG DMU60MonoBlock CNC machine tools.
The algorithm works as follows:

1. Knowing the exact locations of the machine components, makes it possible to learn whether or not an overtravel (in any lineer axis) occurs in postprocessing stage.

2. ManusPost will warn the user if an overtravel (axis limit exceeding) occurs. It also tells the user in which operation and in which block this occurs.

3. When this optional feature is added to the system, ManusPost now knows in which operation and block this overtravel occurs.

4. The alternative postion is tried for A (or B) and C Axes. The new X,Y and Z values are calculated for these alternative A (or B) and C Axes locations. If an overtravel doesn't occur at this alternative location, ManusPost uses this position and adjust the code accordingly.

5. If an overtravel occurs again at this alternative location, the user is warned again, and ManusPost tells the user the operation can not be performed at both actual and alternative locations because of axes limits. While warning, ManusPost also tells the user in in which operation, in which axis this problem occurs.

6. This optional feature also greatly enhances production times and capabilites, since you no longer will learn whether or not an axis limit occurs after you start machining, and therefore machining will not be interrupted after it is started. You also dont need to do CAM work again, or postprocess the code again, if alternative position works and therefore it can be automatically solved by ManusPost. It is obvious and already has been proved that this optinonal feature will save a lot of time.

This algorithm is specifically developed for CNC machine tools that has Heidenhein control units and that supports tool center point control (M128) function. It is always a danger to position the spindle and table rotary axes at the start of operations. The movement that will be observed will totally depends on the machine kinematics, if an option like tool center point control is not available on the CNC control unit. If you are lucky and have a machine simulation software, you can observe if this uncontrollable positioning movement will cause a collision or not. If it is not present, you should check it on machine. This algorithm prevents the spindle to do uncontrollable dangeourous movements while positioning the spindle and table at the start of operations. When this feature is added, the user exactly gets the same movement that is generated on CAM software. This optional feature can be added to any postprocessor that has tool center point control (G41.1, Traori or M128 depending on the control unit) function.

This optional algorithm is developed for Mazak Variaxis 500-5X CNC machine tool and supports CATIA V5 software. This feature can be added to any postprocessor if it is desired and most importantly if it is supported by the CAM software and the control unit.

This algorithm is developed for an old style (1998) Mazak Integrex 200Y CNC machine tool. Almost all the control units today support tool length compensation for different angle orientations of the spindle head. Some of the old ones do not have this functionalty. In these kind of CNC control units, the tool length compensation should be calculated by using sines and cosines. Manualy doing that is of course impossible, since the angular orientation differences not only causes rotary axes values to differ, but also causes the x,y and Z values to change accordingly.