Lesson 13: Wear Offsets

Lesson 13
Wear offsets

This compensation type allows the setup person or operator to deal with minor size
variations as workpieces are machined. While many CNC people (somewhat
inappropriately) use wear offsets to compensate for minor setup imperfections and tool
pressure, the major application for wear offsets is to compensate for tool wear during a tool’s
life.

You know that the tolerances commonly held on CNC turning centers are quite small. It is not unusual to see
at least one overall tolerance of under 0.001 inch (0.254 mm) on turned workpieces.
You also know that each cutting tool has its own program zero assignment – and that there are several ways
to assign program zero. And you know that unless you are using a properly calibrated tool touch off probe,
mistakes with program zero assignment – even minor ones – as well as the effects of tool pressure, make it
difficult to perfectly assign program zero. That is, even after program zero is assigned, there is no guarantee that
every tool will machine the workpiece perfectly – or even within specified tolerances. The tighter the
tolerances you must hold, the greater the potential there will be for sizing problems.
Wear offsets provide a way to make minor adjustments when machined surfaces are not within their tolerance bands – or when
they’re close to a tolerance limit.
There are at least four times when a typical CNC setup person or operator will use wear offsets:
?During setup and after mounting a cutting tool in the turret - After machining with the
new tool, if the setup person discovers that the cutting tool has not machined a
surface within the tolerance band, or if the surface is close to a tolerance limit, they
can change a wear offset to make the needed adjustment.
?When trial machining – Trial machining is done when the setup person or operator is
worried that a cutting tool (that has just been placed in the turret) will not machine
within the tolerance band. Wear offsets are commonly used with which to make trial
machining adjustments (Remember, if you are using a properly calibrated tool touch
off probe, you shouldn’t need to trial machine.)
?When compensating for tool wear – As a cutting tool wears, it will cause the surfaces
it machines to grow or shrink in size. Wear offsets are used to keep cutting tools
machining on-size for their entire lives.
?After a dull tool is replaced – Again, during a cutting tool’s life, tool wear commonly
causes the need for sizing adjustments in wear offsets. When a dull tool is replaced
with a new one, the wear offset must be set back to its initial value – otherwise the
new tool will machine too much material from the workpiece.
In the introduction to Key Concept Four, there is a lengthy presentation about tolerance interpretation. From this
presentation, you know that every dimension has a tolerance. You know that each tolerance will have a high
limit (largest acceptable dimension), a low limit (smallest acceptable dimension), and a mean value (the
dimension right in the middle of the tolerance band.
You also know that each dimension to be machined on a workpiece will have a target value – this is the
dimension you shoot for when an adjustment must be made. Many CNC people use the mean value of the
tolerance band as the target value. That is, when an adjustment must be made, they target the mean value.

TCPO Page 1 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

While there are times when this may not be appropriate (large lot sizes with small tolerances), we’ll use this
technique throughout Lesson Thirteen. That is, for each surface needing an adjustment, we’ll be targeting the
mean value.
You know that the deviation is the amount of needed adjustment. It is the difference between the measured
value and the target value. In all cases, there will be a polarity to the deviation (plus or minus). The current
wear offset value must be either increased or decreased by the amount of the deviation. The polarity is
determined by judging which way the cutting tool must move (plus or minus) in order to bring the dimension
back to the target value. We’ll discuss more abut the deviation and its polarity later in this lesson.
Which dimension do you choose for sizing?
It is very common for a finishing tool to machine several surfaces. One finish turning tool may, for example,
finish three external diameters and faces. Each surface may have its own tolerance specification. And of
course, you program the mean value for each tolerance. In almost all cases, only one wear offset will be used
to control all surfaces machined by each tool, meaning one adjustment will handle all surfaces machined by
the tool.
For example, say a finish turning tool machines three external diameters: a 1.5 inch diameter, a 2.0 inch
diameter, and a 3.0 inch diameter. Unless there is a substantial tool pressure problem, when the 1.5 inch
diameter is coming out correctly (based on a wear offset adjustment in X), so will the 2.0 and 3.0 inch
diameters.
When it comes to making sizing adjustments, you should use the two surfaces (one for diameters and one for
lengths) that have the smallest tolerances. Use them to make sizing adjustment decisions.

How wear offsets are programmed

As you know, wear offsets are invoked by the second two digits of the T word. The command
N140 T0303
for example, indexes the turret to station number three, instates geometry offset number three (the first two
digits) and instates wear offset number three (the second two digits). In almost all applications, you’ll be
making the wear offset number the same as the tool station number (tool one: wear offset one, tool two: wear
offset two, and so on).
What actually happens when a wear offset is instated will vary based upon the CNC control (model and age).
With newer controls (and especially if geometry offsets are used to assign program zero), the T word appears
to simply index the turret. The geometry and wear offsets will not actually be instated (made active) until the
next motion command. But with some older controls – and especially when program zero must be assigned in
the program – the T word indexes the turret and the wear offset will be immediately instated. This will cause
the turret to actually move by the amount of the wear offset.

What if my machine doesn’t have geometry offsets?

It’s much better if the turret remains in position during a turret index, and you can rest assured it will if you’re
assigning program zero with geometry offsets.
If you’re assigning program zero in the program with G50 commands, you may notice that the turret jumps at
each turret index. This motion can be troublesome for two reasons. First, the additional motions will add to
cycle time. The turret may have to move in the plus direction when instating the wear offset. Then it will
have to move in the negative direction when approaching the workpiece. Second, and more importantly, if
the machine’s starting position is close to a plus over travel limit in either axis (and the zero return position
usually is), any large plus wear offset will cause an axis over-travel as soon as the turret index command is
executed.
If you find that your machine’s turret moves by the amount of the wear offset during turret indexes, here’s a
tip that will eliminate the associated motion problems. As you index the turret in your program, do not (yet)
instate the wear offset. The command

TCPO Page 2 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

T0300
for example, indexes the turret to station number three but will not instate a wear offset. In the first approach
motion for the tool, instate the offset. Here is a program segment that eliminates unwanted motion for a
machine that will move by the amount of the wear offset as soon as the offset is instated.
O0003 (Program number)
N005 G28 U0 W0
N010 G50 X8.3432 Z10.2383 (Assign program zero)
N015 T0100 M41 (Index to station one, no wear offset, and select the low range)
N020 G96 S600 M03 (Start the spindle CW at 600 sfm)
N025 G00 X2.2 Z0.005 T0101 M08 (Instate wear offset during the approach movement)
.
.
.
In line N015, the turret is indexed to station one but no wear offset is being instated (yet). During the first
approach movement in line N025, notice the T0101. Since the turret is already indexed to station one, it will
not index – but the wear offset will be instated. The machine will actually consider the current values in wear
offset number one as it makes its approach movement. In essence, the machine will modify the commanded
end point in X and Z by the amounts stored in wear offset number one, and then rapid to the modified
position. Note that this technique will only be required older machines when program zero assignment is
done in the program – and only if the machine moves as soon as a wear offset is instated.

What about wear offset cancellation?

Canceling a wear offset has the inverse effect of instating it. Programmed positions will not be affected by the
values stored in wear offsets once the wear offset is cancelled.
If you’re using geometry offsets to assign program zero, you don’t need to cancel wear offsets (but doing so will have
no adverse affect). If you are assigning program zero in the program with G50 commands, you must cancel
the active wear offset at the end of every tool. The wear offset is canceled during the tool’s return to the tool
change position.
One way to cancel a tool’s offset is to repeat the tool station number in the T command but make the last two
digits zero. The command
N240 T0500
for example, will cancel tool station number five’s wear offset. However, there’s an easier way that will cancel
any tool’s wear offset. The command
T0
will do so.
Here is a program segment that simply faces a workpiece. The technique shown in this program is not
required if you are using geometry offsets to assign program zero. We’re using G50 to assign program zero
(it’s an older machine), so the tool offset must be canceled at the end of the tool.
Sample program that uses G50 to assign program zero:
O0003 (Program number, example when G50 is used to assign program zero)
N003 G28 U0 W0
N005 G50 X8.3432 Z10.2383 (Assign program zero)
N010 T0100 M41 (Index to station one, no wear offset, and select the low range)
N015 G96 S600 M03 (Start the spindle fwd at 600 sfm)

TCPO Page 3 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

N020 G00 X2.2 Z0 T0101 M08 (Invoke offset during the approach movement)
N025 G01 X-0.062 F0.010 (Face workpiece)
N030 G00 Z0.1 (Move away in Z)
N035 G00 X8.3432 Z10.2383 T0 (Move back to tool change position, cancel offset)
N040 M01 (Optional stop)
N045
.
. (Program continues)
.
In line N035, we’re sending the tool back to where it started and canceling the offset with T0.
Once again, remember that programming wear offsets is simpler when geometry offsets are used to assign
program zero. Here is the same program segment modified to use geometry offsets to assign program zero.
O0003 (Program number, example when geometry offsets are used to assign program zero)
N005 T0101 M41 (Index to station one, select wear offset one, and select the low range)
N010 G96 S600 M03 (Start the spindle fwd at 600 sfm)
N015 G00 X2.2 Z0 M08 (Move into approach position, turn on the coolant)
N020 G01 X-0.062 F0.010 (Face workpiece)
N025 G00 Z0.1 (Move away in Z)
N030 G00 X7.0 Z5.0 (Move back to tool change position)
N035 M01 (Optional stop)
N040
.
. (Program continues)
.
Again, geometry offsets make things easier. Notice that program zero assignment values are not in the
program (they’re in the geometry offsets). In line N005, the wear offset can be easily instated right in the
turret index command. And at the end of the tool in line N030, there’s no need to cancel the wear offset
(though doing so won’t hurt anything).
How wear offsets are entered
Figure 4.6 shows the wear offset display screen page.

TCPO Page 4 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

Wear offset display screen page

16T
Offset / Wear
No. X Z R T
1 00.0000 00.0000 0.0000 0
2 00.0000 00.0000 0.0000 0
3 00.0000 00.0000 0.0000 0
4 00.0000 00.0000 0.0000 0
5 00.0000 00.0000 0.0000 0
6 00.0000 2.9735
00.0000 0.0000 0
7 00.0000 00.0000 0.0000 0
8 00.0000 00.0000 0.0000 0
POSITION PROGRAM OFFSET PRG_CHK +

Figure 4.6 – The wear offset display screen page

Wear offsets use only the X and Z registers on this page. The X registers allow adjustments to diameters
(adjustments related to the X axis). The Z registers allow adjustments to lengths (adjustments related to the Z
axis). The R and T registers are related to tool nose radius compensation, and are discussed in Lesson
Fourteen. Notice once again that wear offsets are organized by number (wear offsets one through eight are
shown in Figure 4.6). As you know, you’ll be making the primary wear offset number for a cutting tool the
same as the tool station number. That is, tool number five will use wear offset number five. Tool number ten
will use wear offset number ten. And so on.
The wear offset page shown in Figure 4.6 is blank. That is, none of the wear offsets have been used – they’re
all set to zero. Let’s look at how wear offsets can be entered.
There are two common ways to actually enter a wear offset, with INPUT and with +INPUT. As you begin
typing the value of a wear offset, the soft keys at the bottom of the screen will change. Look at Figure 4.7.
The difference between INPUT and +INPUT

16T
Offset / Wear
No. X Z R T
1 00.0000 00.0000 0.0000 0
2 00.0000 00.0000 0.0000 0
3 00.0000 00.0000 0.0000 0
4 00.0000 00.0000 0.0000 0
5 00.0000 00.0000 0.0000 0
6 00.0000 2.9735
00.0000 0.0000 0
7 00.0000 00.0000 0.0000 0
8 00.0000 00.0000 0.0000 0
0.005 INPUT + INPUT +

Figure 4.7 – INPUT versus +INPUT

Notice that the cursor is currently on the X register of wear offset number two. The operator has just typed
0.005 from the keyboard on the control panel (the entry shows up in the lower-left corner of the display

TCPO Page 5 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

screen. As the operator types the first digit (zero in our case), the soft keys change. While Fanuc control
models vary with regard to what the soft keys show, two of the soft keys will be INPUT and +INPUT. These
two keys are used to enter offset adjustments.
INPUT – This soft key (or the INPUT key on the control panel) will cause the machine to replace the value
that is currently in the offset register with the entered value. For the example in Figure 4.7, if the operator
presses the INPUT soft key, the X register of offset number two will be set to 0.005.
+INPUT – This soft key will cause the machine to modify the value that is currently in the offset register by the
entered value. For the example in Figure 4.7, if the operator presses the +INPUT soft key, the X register of
offset number two will be set to 0.005.
Since the initial value of the offset register is zero, INPUT and +INPUT happen to have the same result in
this example (0.005 being placed in the register). But consider what happens after an initial entry. Figure 4.8
illustrates.
The difference between INPUT and +INPUT

16T
Offset /
No. X Z R T
1 00.0000 00.0000 0.0000 0
2 00.0050 00.0000 0.0000 0
3 00.0000 00.0000 0.0000 0
4 00.0000 00.0000 0.0000 0
5 00.0000 00.0000 0.0000 0
6 00.0000 2.9735
00.0000 0.0000 0
7 00.0000 00.0000 0.0000 0
8 00.0000 00.0000 0.0000 0
0.0003 INPUT + INPUT +

Figure 4.8 – Better example to stress the difference between INPUT and +INPUT
This time, the current value in the offset register is 0.005. The operator has typed the value 0.0003. If they
press the INPUT soft key, the register’s value will change to 0.0003. If they press the +INPUT soft key, the
register’s value will change to 0.0053.
Which is better, INPUT or +INPUT?
In almost all cases, a CNC setup person or operator will need to modify the current value in the offset register
by the amount of the offset entry, meaning the +INPUT soft key will be the offset entry soft key. Think
about it. Whenever a wear offset adjustment is required, you will have calculated the deviation – which is the
difference between the target value and the dimension you have measured on the workpiece. You must
modify the offset’s current setting by the amount of this deviation. The +INPUT soft key will keep you from
having to calculate the resulting offset value – the machine will make this calculation for you.
Remember that the deviation has a polarity. Sometimes it will be negative. The +INPUT soft key is still used.
Say for example, the current value in the offset register is 0.005 (like it is in Figure 4.8). You’ve determined the
deviation – and it is -0.0007. To make the adjustment, you will type -0.0007, and then press the +INPUT key.
After you do, the register will show 0.0043 (when you add 0.005 to -0.0007, the result is 0.0043). Again, the
machine will do the calculation for you when you use the +INPUT soft key.

TCPO Page 6 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

What if my machine doesn’t have a +INPUT soft key?

Older Fanuc controls don’t have a soft key labeled +INPUT. Indeed, they don’t have soft keys. If you have
one of these controls, rest assured that there is still a way to enter the amount of deviation and let the control
do the needed calculation. If your machine doesn’t have a +INPUT soft key, you will use letter addresses X
and Z to cause the control to overwrite the offset (like the INPUT soft key) and U and W to enter modify the
offset (like the +INPUT soft key). In either case, the INPUT key will be used to enter the value.
For example, say the current value of the X offset register is 0.005. If you type X0.0007 and then press the
INPUT key (this INPUT key is on the keyboard), its new value will be 0.0007. But if you type U-0.0007 and
then press the INPUT key, its new value will be 0.0043.
While operation techniques are different, the result is the same. You can enter the amount of deviation and
cause the machine to do the calculation if you use U (for X axis registers) and W (for Z axis registers) when
making offset entries.

Sizing in a tool after it has just been placed in the turret

This example shows the first of four times when wear offsets can be used. While this example doesn’t show
the method we recommend, it should help you understand how wear offsets work. Look at Figure 4.8.
Example stressing the use of wear offsets

Raw material for All tolerances: +/-0.001

second operation
Tool 2

3.0
2.75 1.5

4.0

0.125

2.0 1.0
0.05 stock
(each end) 3.75

Workpiece drawing
Finish face and turn operation

Figure 4.8 – Example to help stress the use of wear offsets

From the drawing on the left side of Figure 4.8, notice that all dimensions have a tolerance specified as +/-
0.001 inch (0.002 overall). On the right side, the finish face and turning operation is about to take place and is
done by tool number two. The roughing operation has already been done.
We’ll say that this is the first workpiece being machined in the job, and during setup, tool number two (the
finish face and turn tool) has just been placed in the turret. The setup person has done their best to measure
program zero assignment values and enter them into geometry offsets. The X and Z wear offset registers for
this tool are currently set to zero.
Notice that tool number two will be machining the 1.5 inch diameter – and it is this diameter we’ll concentrate
on for this example.
After tool number two runs – machining the 1.5 diameter – the setup person stops the cycle and measures the
1.5 inch diameter. Say they find that this diameter is currently 1.5024. It is, of course, oversize – larger than
the high limit for the tolerance band (1.501). An adjustment must be made.

TCPO Page 7 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

Since we’re targeting the mean value, the adjustment must bring the diameter to 1.5 inches. The amount of
the adjustment – the deviation – will be the difference between the target dimension and our measured
dimension of 1.5024 (this comes out to 0.0024). Since the measured diameter is larger than the target diameter,
the deviation will be negative. And since this is a diameter deviation, we must modify the X register of the
offset (not the Z register).
So we must modify the current value of wear offset number two’s X axis register by -0.0024. After bringing
the cursor to the X register of offset number two, we type -0.0024 and press the soft key under +INPUT.
After doing so, the value in this register will be -0.0024 (remember that it started at zero). The next time tool
number two machines a workpiece, this diameter will come out 0.0024 smaller – and right at our target value
of 1.5 inches.
In the scenario just given, we got lucky. Since the 1.5 inch external diameter is oversize, there is still a little
stock to be removed. After making the offset adjustment, the setup person can re-run tool number two on
the same workpiece. After tool number two runs the second time, the 1.5 diameter will be within its tolerance
band (though it may not be exactly 1.5 since the amount of material being removed now is only 0.0024).
Consider the other possibility. After machining with tool number two for first time, maybe the setup person
measures the 1.5 inch diameter and finds it to be 1.4975. Now the diameter is undersize – smaller than the low
limit. Since there is no (feasible) way t put material back on this diameter, the workpiece is scrap. The
deviation in this case is (positive) 0.0025, and the X register of wear offset number two must be modified by
this amount before the next workpiece can be machined.
We call the technique just shown sizing after the fact. While it may be acceptable for some cutting tools (like
roughing tools), it is not recommended when the cutting tool must machine surfaces having tight tolerances.

Sizing in a new tool with trial machining

This example stresses the second of four times when wear offsets can be held. As you have just seen, when
tight tolerances must be held, there is a fifty-fifty chance that the workpiece will be scrapped when a cutting
tool machines for the first time. You should use trial machining techniques whenever there is any doubt about
whether a cutting tool will machine all surfaces within their tolerance bands.
Trial machining involves five steps:
?Recognizing a workpiece attribute with a tight tolerance
?Making an initial adjustment to machine the surface with some excess stock
?Letting the cutting tool machine under the influence of the trial machining offset
?Measuring the surface and adjusting accordingly
?Making the cutting tool run a second time (this time the surface will be within its
tolerance band)
Consider these five steps to trial machining for the example just shown. In the first step, we know there could
be a problem holding the +/-0.001 tolerance on the 1.5 inch diameter. We doubt whether the initial
geometry offset setting for tool number two is accurate enough to make the tool machine this diameter within
its tolerance band.
In the second step, the trial machining adjustment will be made in the X register of offset number two. To
make this tool leave more material on the diameter, the adjustment must be positive. And usually an amount
of about 0.010 inch (0.25 mm) is an appropriate amount of excess material to leave. So the X register of wear
offset number two must be increased by 0.01 inch (the setup person types 0.01 and presses the soft key under
+INPUT).
In the third step, the setup person lets tool number two run. The 1.5 inch diameter is machined with excess
material.

TCPO Page 8 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

In the fourth step, the setup person measures the 1.5 inch diameter. It will, of course, be oversize. Say they
find it to be 1.5082. The needed adjustment is -0.0082 to bring the diameter back to the target value of 1.5
inch. So the X register of wear offset number two is modified by -0.0082 (setup person types -0.0082 and
presses the soft key under +INPUT). While it may not be important at this time, the X value of wear offset
number two will end up as (positive) 0.0018.
In the fifth step, the setup person reruns tool number two. This time it will machine the 1.5 inch diameter
within its tolerance band – and for the next workpiece to be machined, the 1.5 inch diameter should come out
to precisely to its target value, 1.5 inches.
By the way, in the trial machining example just given, trial machining saved us from machining a scrap
workpiece. After trial machining, the diameter came out to only 0.0082”oversize. Yet we had initially
increased the offset by 0.01”. If we had not used trial machining techniques, the 1.5 inch diameter would have
come out to 1.4982, which is smaller than the low limit – again, this diameter would have been undersize.

What causes the initial deviation?

Before we show an example of the third time when wear offsets can be used, we want to make an important
point. This point will only apply if geometry offsets are being used to assign program zero.
In each example just given, when the (new) finish turning tool machines for the first time, there is a substantial
deviation. That is, the difference between the target value and the measured value is quite large – large enough
to cause the 1.5 inch diameter to be out of its tolerance band. And by the way, unless you have a properly
calibrated tool touch off probe, these are realistic examples. It is not unusual for the initial deviation to be
large enough to cause the surface being machined to be out of its tolerance band.
What is causing such a large deviation? As you know from Lesson Eleven, it could be one of two things, or a
combination of both. First, it is possible that the setup person has made a mistake with the measurement
and/or entry of the program zero assignment values for the finish turning tool. And second, even if these
values are perfectly measured and entered, the difference in tool pressure from when the program zero
assignment values are measured to the actual machining of the workpiece may be causing the initial deviation.
Either way, this initial deviation is more related to incorrect program zero assignment than it is to tool wear. Keep in mind
that you can just as easily make the initial adjustment (including trial machining adjustments) in geometry offsets as
you can in wear offsets. The machine will behave in exactly the same way. The +INPUT key can even be used
to modify the current value of the (geometry) offset.
If you make the initial adjustment in the geometry offset, the wear offset values for the (new) cutting tool will
start out at zero. The benefit of having the wear offset begin at zero with a new cutting edge will become clear
as this presentation continues.

Dealing with deviations caused by tool wear

This is the third time when wear offsets can be used. As you know, when certain cutting tools wear, the
surfaces they machine will change. Single point turning tools and boring bars are prime examples. When a
finish turning tool wears, a small amount of material will be removed from its cutting edge. When this
happens, any external diameter machined by the tool will grow. That is, external diameters will get larger as
turning tools wear. At this point, the cutting tool is not worn out – it is just showing signs of wear.
It is not unusual for as much as 0.002 inch (0.050 mm) or more material to be removed from an insert before
it must be replaced. This means a diameter machined by the finish turning tool will grow by 0.004 inch during
the cutting tool’s life.
The same occurs with boring bars. But an internal diameter will shrink as the boring bar insert wears.
Whether or not this will present a problem holding size depends upon two factors: lot size and the smallest
tolerance machined by the tool.

TCPO Page 9 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

With small lots, it is likely that the production run will be completed before the cutting tools wear enough to
require an adjustment. And with wide open tolerances, it is likely that a new cutting tool can completely wear
out without causing the surfaces being machined to approach tolerance limits.
But with large lots, cutting tools will eventually wear out and will need to be replaced. And if tolerances are
small, surfaces will eventually grow (or shrink) out of their tolerance bands long before the tool is completely
dull. This means adjustments must be made during the tool’s life in order to keep the cutting tool machining
all surfaces within tolerance bands.
In the drawing shown on the left side of Figure 4.8, notice once again that the 1.5 inch diameter has a
tolerance of +/-0.001. The high limit is, of course, 1.501 and the low limit is 1.499. During setup, we’ll say
the setup person uses the trial machining techniques shown in the second example to size in the 1.5 inch
diameter – they use wear offsets to do so. When the production run begins, a value of 0.0018 is in the X
register of wear offset number two and the 1.5 inch diameter is coming out to precisely 1.5 inches.
For this discussion, we’ll say there are thousands of workpieces to produce in this production run. So maybe
the job is turned over to a CNC operator at this point to run out the job. As they begin running workpieces,
the 1.5 inch diameter will continue coming out very close to 1.5 inches. But after fifty workpieces are
machined, the operator notices that the 1.5 inch diameter is 1.5002. The finish turning tool has worn by
0.0001 inch. The diameter is still well within the tolerance band, so the operator simply continues running
workpieces.
After fifty more workpieces, the 1.5 inch diameter comes out to 1.5005. The growth trend is continuing. But
the diameter is still within the tolerance band – and nothing needs to be done (yet).
After fifty more workpieces (one-hundred-fifty total), the 1.5 inch diameter comes out to 1.5008. While this
diameter is still within its tolerance band, it is getting dangerously close to the high limit (1.501). If this trend
continues much longer, the diameter will be larger than the high limit (oversize). So at this point, the operator
decides to make a sizing adjustment.
Since the target value is the mean value of the tolerance band, the operator will target 1.5. Currently the
workpiece is 1.5008. So the operator must modify the current X value of wear offset number two by -0.0008.
To do so, they position the cursor to the X register of wear offset number two (which currently happens to
have a value of 0.0018). Then they type -0.0008 and press the soft key under +INPUT. The machine will
subtract 0.0008 from the current value of the offset.
With the next workpiece machined, the 1.5 inch diameter will come out to precisely 1.5 inches – which is back
at the target value. The operator will be able to run another one-hundred-fifty workpieces or so before
another offset adjustment will be required.
After running one-hundred-forty more workpieces, say they find the 1.5 inch diameter has grown to 1.5008
again. So they must make another adjustment. To do so, they position the cursor to the X register of wear
offset number two (which currently happens to have a value of 0.0010). Then they type -0.0008 and press the
soft key under +INPUT. The machine will subtract 0.0008 from the current value of the offset.
The operator may have to make several such adjustments during a given cutting tool’s life – the smaller the
tolerance, the more adjustments that will have to be made. Eventually, the cutting tool will be completely dull
and in need of replacement.

After a dull tool is replaced

This is the fourth time when wear offsets can be used. While different types of cutting tools vary when it
comes to what must be done to replace them, most single point turning tools used on turning centers (like
turning tools and boring bars) incorporate inserts. With these cutting tools, the task of replacing a dull cutting
tool simply means indexing or replacing the insert.
One advantage of most inserts is that they have more than one cutting edge (some have as many as eight
cutting edges). When one edge of the insert is dull, the operator will remove the insert from the cutting tool

TCPO Page 10 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

holder, rotate it to an unused cutting edge, and replace it in the cutting tool holder. This task is known as
indexing the insert. When all cutting edges on the insert have been used, of course, the insert must be replaced.
The key to insert indexing and replacement is consistency. If you can index or replace the insert in such a way
that the new cutting edge is in exactly the same location as the last cutting edge, the new cutting edge will
machine in exactly the same way as the last cutting edge when it was new. The only problem you’ll have to deal
with is related to the amount of offset change you made during the last cutting edge’s life.
In the previous example, after sizing the first workpiece in during setup with a new cutting edge, the X value
of wear offset number two started out at a value of 0.0018. During this tool’s life, several adjustments are
made. Eventually this cutting edge will be dull and the insert must be indexed or replaced. As long as it can
be perfectly replaced (the new cutting edge is in the same location as the old cutting edge), the operator will set
the X axis register for wear offset number two back to the initial value of 0.0018. This will cause the new
cutting edge to machine the 1.5 diameter precisely to 1.5, just as the last cutting edge did when it was new.
This is one time when the INPUT soft key will be used. Since you know the value you want in the offset
(0.0018 in our case), it will be easier to use than the +INPUT soft key – which would first require a calculation
to be made.
By the way, this is the reason why we recommend making the initial adjustment (including trial machining
adjustments) in geometry offsets. If you do, the wear offset will begin at zero. When cutting tools are replaced,
you won’t have to remember the initial wear offset value (0.0018 in our example). Instead, you can simply set
the wear offset value back to zero.

What if my machine has a tool touch off probe?

One of the advantages of a properly calibrated tool touch off probe is that it can perfectly set the geometry
offset – even allowing for tool pressure. It will also set the wear offset to zero. If, during dull tool
replacement, you use the tool touch off probe (just as you do during setup), you need not be concerned about
resetting the wear offset for the cutting tool. And as previously mentioned, the tool touch off probe will also
eliminate the need for trial machining – even when very small tolerances must be held. While an adjustment
may be required after the next workpiece is run to make the cutting tool machine right at its target value, the
surfaces machined by the new tool will be within their tolerance bands.

Consistently replacing inserts

Unfortunately, inserts used for turning center applications may not be very consistent. That is, the insert itself
may have a rather large tolerance. If inserts vary in size – even by a little bit – it will be impossible to perfectly
replace them.
Consider this specification for a very common 80 degree diamond-shaped insert:
CNMG-432
Each letter and number of an insert’s specification has a special (and universal) meaning. It just so happens
that the third letter in the specification (M in our case), specifies the tolerance for the insert.
?A- Included circle = plus or minus .0002, thickness = plus or minus .001
?B- Included circle = plus or minus .0002, thickness = plus or minus .005
?C- Included circle = plus or minus .0005, thickness = plus or minus .001
?D- Included circle = plus or minus .0005, thickness = plus or minus .005
?E- Included circle = plus or minus .001, thickness = plus or minus .001
?G- Included circle = plus or minus .001, thickness = plus or minus .005
?M Included circle = plus or minus .002, thickness = plus or minus .005
?U- Included circle = plus or minus .005, thickness = plus or minus .005

TCPO Page 11 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

The M specification in CNMG-432 specifies a tolerance for the included circle of 0.004 (+/-0.002). The
tolerance for the insert’s thickness is +/-0.005. While the thickness of an insert isn’t very critical, the size of its
included circle controls the position of the cutting edge, as Figure 4.9 shows.
The tolerance for insert size

Included circle

80 degrees

CNMG-432
With a CNMG-432 insert, the included
circle diameter can vary by 0.004 inch Almost 0.004 inch of potential variance
from one insert to another!

Figure 4.9 – Included circle of an 80 degree insert

A position variance of almost 0.004 inch is possible with a CNMG-432 insert. This can result in as much as
0.008 inch variance when machining a diameter. With this much variation, of course, you will not be able to
change inserts precisely enough to eliminate trial machining or using a tool touch off probe when inserts are
replaced.
Note that the tolerances specified above are maximum variations. In practice, you’ll probably find them to be
much less from insert to insert – especially with inserts coming out of the same package. You can easily
measure the amount of variation from insert to insert with a micrometer. If you find the variance to be under
about 0.0005 inch from insert to insert, you may be able to replace inserts precisely enough to eliminate the
need for trial machining or the need to use the tool touch off probe after insert replacement.

Consistently indexing inserts

As stated, almost all inserts have more than one cutting edge. The CNMG-432, for example, has four cutting
edges. This means after a new insert is placed in the tool holder, it can be indexed three times.
The variation among new inserts will not apply to an insert when it is indexed. If an insert is consistently
placed in a tool holder, there will be no variation from one cutting edge of an insert to another. But the key
word is consistently. In order to eliminate the need for trial machining or the tool touch off probe, you must be
able to index inserts perfectly – the next cutting edge must be in precisely the same location as the last cutting
edge. While it may take a little practice, you can save much time and effort if you can master the ability to
consistently index inserts.
Many inserts used on turning centers incorporate an eccentric pin for clamping and location. This pin can be
turned in either direction to clamp the insert. When it is turned in one direction, the pin will press the insert
against one of the location surfaces of the tool holder. When it is turned in the other direction, the eccentric
pin will press the insert against the other location surface of the tool holder. Figure 4.10 shows this.

TCPO Page 12 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

The use of eccentric pins

If the pin is turned in this direction If the pin is turned in this direction Two inserts are shown in a
the insert will be clamped against the insert will be clamped against superimposed manner to stress
the upper location surface the right location surface the potential for variation

Figure 4.10 – How an eccentric pin locates an insert in a tool holder

When you turn the pin in the direction shown in the left-most illustration of Figure 4.10, the insert will be
pressed against the upper location surface of the tool holder. When you turn the pin in the direction shown in
the middle illustration, the insert will be pressed against the right location surface of the tool holder. The right-
most illustration super-imposes two inserts that are clamped in opposite directions. If the seat in the tool
holder is not perfect, you can see how inconsistently clamped inserts will vary in position.
To determine which way the pin should be turned, consider what the cutting tool is doing. For the tool
shown in Figure 4.10, if the tool will be predominantly facing, turn the eccentric pin in the direction shown in
the left-most illustration. If it will be predominantly turning, turn the eccentric pin in the direction shown in
the middle drawing. Once you determine which way the eccentric pin should be turned, use the same method
every time an insert must be indexed or changed.
The method by which inserts are located in the tool holder affects more than just the position of the cutting
edge. It also affects basic machining practice – especially for tools that perform powerful machining
operations. If an insert is not properly located in the tool holder, it will prematurely fail.

Minimizing the need for trial machining

If inserts vary from one to the next, you will have to trial machine whenever you replace an insert (or you
must use the tool touch off probe). Keep track of the initial wear offset value right after sizing in the new
insert (again, this value will be zero if you use the tool touch off probe – or if you use geometry offsets to trial
machine). When it comes time to index the insert (which you may have to do several times) be sure to do so
consistently. Now you can simply set the wear offset back to its initial value. You will not have to trial
machine of use the tool touch off probe when inserts are indexed.
Going from job to job
You know from Lesson Twelve that if a cutting tool is machining properly at the completion of one job, it will
continue to machine properly in the next job. And you know that many cutting tools are often used from job
to job. Let us expand an example scenario from Lesson Twelve, adding some important points related to
wear offsets.
Say two jobs run consecutively that require a rough turning tool, a finish turning tool, and a threading tool
(stations 1, 2, and 3). When setting up the first job, the three tools must be loaded into the turret (if they’re
not already in place). Program zero assignment values must be measured and entered. We’ll say the work
shift value is being used, so it must also be measured and entered.
When the setup person runs the fist workpiece in the first job, they’ll size in all dimensions – making
adjustments as necessary. For the rough turning tool, they’ll ensure that the appropriate amount of finishing

TCPO Page 13 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

stock is being left for the finish turning tool. For the finish turning tool, they use trial machining techniques to
keep from scrapping the first workpiece. For the threading tool, they’ll use trial machining to ensure that the
thread will be properly machined on the first workpiece.
We’ll say one-hundred-fifty workpieces must now be run. During this time, the CNC operator must make
adjustments to the wear offset for the finish turning tool (wear offset number two). At the completion of the
first job, tool number two is not worn out, but two wear offset adjustments have been made to keep it
machining on size.
When the first job is completed, the second job must be run. Though it may be of a totally different
configuration, it requires the same three tools. In this scenario, there won’t be much work for the setup
person to do – at least related to cutting tools and program zero assignment. Since all three tools are currently
in the turret and in the correct turret stations, there will be no need to remove or mount cutting tools. Since
chuck face is the point of reference for geometry offsets, and since the chuck face position doesn’t change
from job to job, the geometry offsets need not be measured. Only one value – the work shift value – must be
measured and entered – assuming the workpiece in the second job is not of the same length as the workpiece
in the first job.
Additionally, there will be no need for trial machining in the second job. Again, all three cutting tools were
machining properly at the completion of the first job. They will continue to machine properly as the second
job begins.

When do you clear wear offsets?

Clearing a wear offset is the act of setting its registers to zero. In some cases, wear offsets are automatically
cleared. When you use the tool touch off probe, for example, it will perfectly set the tool’s geometry offset and
clear the tool’s wear offset. The same happens when you use the measure function to set geometry offsets.
We make the same recommendation for clearing wear offsets as we do for clearing geometry offsets. Get in
the habit of clearing wear offsets for tools as you remove them from the turret. This way, the offsets (wear
and geometry) will be correct for any tool that is currently in the turret.

A more complex example

At this point, you should have a clear understanding of how wear offsets work. But we’ve only scratched the
surface of how they’re used. We’ve shown the four times when wear offsets can be used for one tool and
only for controlling a diameter (X axis adjustment). Now we’ll show a little more complex example that
stresses the use of wear offsets for three tools – as well as how they can be used to control length-related
dimensions (Z surfaces) as well as diameters. Figure 4.11 shows the application.

TCPO Page 14 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

A more complex example stressing the use of wear offsets

All tolerances: +/-0.001
0.125 Raw material for
second operation

3.0
1.5 2.75

4.0

0.125

1.0 2.0
0.05
3.75 stock
Process:
Tool 1: Rough face and turn, leave 0.08 on all diameters, 0.005 on all faces
Tool 2: Finish face and turn to size (mean value is target)
Tool 3: Neck 0.125 groove to size (with 0.125 wide grooving tool)

Figure 4.11 – Three cutting tools are used to machine this workpiece

This is the same workpiece shown in the previous example, but this time we’re working on the other side.
Notice from the illustration on the left that the workpiece is being held in a three-jaw chuck (in soft jaws) on
the 4.0 inch outside diameter. It is being located in Z against the jaw on the largest face. This exposes the
other end of the workpiece to the turret for machining.
We’ll say that we’re machining one thousand of these workpieces – and that all of the tools have been newly
placed in the turret (though in reality, the rough face and turn tool [tool number one] and the finish face and
turn tool [tool number two] were probably used to machine the other side of this workpiece).
The setup person has measured the program zero assignment values for each tool (without the help of a tool
touch off probe) and entered the related values into geometry offsets. They have also measured and entered
the work shift value.

Running the first workpiece – one tool at a time

Assuming that it is important to make the first workpiece being machined a good one, and assuming that the
program is correct, there is really no excuse for scrapping the first workpiece being machined due to wear
offset settings. That is, there will always be a way to ensure that each tool machines properly when machining
the first workpiece.
The key to making the first workpiece a good one is dealing with each tool as you come to it. Consider what
the tool will be doing. If necessary, use trial machining to ensure that the tool machines the workpiece
properly. Make the tool machine correctly before moving on to the next tool in the program. Do the same
for each tool. With this approach, each tool will machine as it should. When you finish with the last tool in
the program, all tools will have machined properly – and you’ll have a good workpiece.
Tool number one: Rough face and turn tool
Notice that this tool will be leaving 0.080 inch of finishing stock on all diameters (0.040 inch on the side) and
0.005 inch of finishing stock on all faces. While the roughing operation itself is not all that critical (trial
machining is not required for most roughing operations), it is quite important to leave the specified amount of
finishing stock. The amount of finishing stock to be left on all diameters is substantial (again, 0.080 inches on
all diameters). But the amount of finishing stock to be left on all faces is minimal (again, only 0.005 inch).
For the diameters machined by this tool, there is ample material being left for finishing. And if we’re off by a
few thousandths, it won’t affect the way the finishing tool machines. So we will not trial machine for

TCPO Page 15 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

diameters. But to be on the safe side, we’ll trial machine to ensure that this tool truly leaves precisely 0.005 on
all faces of the workpiece for finishing. To do so, we’ll add 0.01 to the Z register of wear offset number one.
(The Z adjustment must be positive in order to leave more material on all faces.)
After running the tool, say we measure the 3.0 inch diameter (while the workpiece is still in the chuck) and
find it to be 3.082. We then measure the 1.0 inch thickness of the flange and find it to be 1.0139.
We’re currently leaving 0.082 inch on all diameters, so we’ll reduce the X register of wear offset number one
by 0.002 inch (type -0.002 and press the soft key under +INPUT). To make this tool leave precisely 0.005
inch on all faces for finishing, we’ll reduce the Z register of wear offset number one by 0.0089 inch (type -
0.0089 and press the soft key under +INPUT).
Now we re-run tool number one. After we do, we measure the 3.0 inch diameter and find it to be 3.0796.
We measure the 1.0 inch flange thickness and find it to be 1.0049 inch.
We’ve made the rough turning tool machine properly. It is now leaving the appropriate amount of finishing
stock for the next tool.
Tool number Two: Finish face and turn tool
We’re now ready to run the second tool. Again, this tool will be machining some rather small tolerances (+/-
0.001), and we’re worried that our program zero assignment may not be precise enough. So we decide to trial
machine in both axes – in X to ensure that the three inch diameter comes out correctly, and in Z to ensure
that the faces are machined correctly.
We increase the X register of wear offset number two by 0.01 inches. In Z, we cannot increase it by such a
large amount (there is only 0.005 left on all faces at this point). So we’ll increase it by a smaller amount – say
0.003. When this tool is actually machining the faces, we must visually confirm that it is truly machining
material from the workpiece (you must see chips being formed). If this tool happens to be perfectly set, it will
only be machining 0.002 inch of material from the faces. If it is off at all in the positive direction, it won’
machine any material at all from the faces.
Now we let the finish turning tool machine the workpiece. And sure enough, during facing we notice some
chips are being formed.
When we measure the 3.0 inch diameter, we find it to be 3.0087. We must reduce the X register of wear
offset number two by 0.0087 (type -0.0087 and press the soft key under +INPUT). And note that if we had
not trial machined, we would have scrapped the workpiece.
When we measure the 1.0 inch flange thickness, we find it to be 1.0023. We must reduce the Z register of
wear offset number two by 0.0023 (type -0.0023 and press the soft key under +INPUT).
At this point, tool number two must be run again. After re-running this tool, we find the 3.0 inch diameter to
be 2.9998. We find the 1.0 inch flange thickness to be 0.9999.
(You might think these dimensions should come out to precisely 3.0 and 1.0 – and in some cases they will.
But there is a tool pressure difference between the first time the tool machines (when trial machining) and the
second time it machines. The first time – it will be removing about 0.07 inch of material from all diameters.
The second time it machines, it will be removing only 0.0087 inches. This difference in material removal will
also cause a difference in tool pressure. When you go on to the next workpiece, you should expect these
dimensions to come out to precisely 3.0 and 1.0.)
We happened to use the 1.0 inch flange thickness to determine whether this tool is machining properly. We
did so only because this workpiece attribute is very easy to measure while the workpiece is still in the chuck.
We could also have chosen the 3.75 inch overall length, but it may not be possible to measure this value while
the workpiece is in the chuck. We could also have used the distance from the right end of the workpiece to
the left side of the flange (a total dimension or 3.0 inches). But again, this might be tougher to measure.
Tool number two is now machining properly. And at this point, we still have a good workpiece. Now it’s
time to move on to tool number three.

TCPO Page 16 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

Tool number Three: 0.125 grooving tool

We’ll trial machine to ensure this tool correctly machines the 2.75 inch diameter. We’ll add 0.01 to the X
register of wear offset number three.
After letting this tool machine, we measure the 2.75 inch diameter and find it to be 2.762. The X register of
wear offset number three must be reduced by 0.012 (type -0.012 and press the soft key under +INPUT).
After this tool is re-run, we measure the 2.75 inch diameter and find it to be precisely 2.75 inches.
We’ve carefully sized in each tool, making it cut properly before going on to the next tool. And now that the
last tool has machined, we still have a good workpiece that will pass inspection. While this is still a rather
simple process, this method can be applied to the most complex processes. Again, there is really no excuse
for scrapping a workpiece for reasons related to wear offset settings.
What about the Z position of the groove?
Notice from the drawing in Figure 4.11 that this groove is supposed to be 0.125 inches from the large flange
face. This may be a difficult (though not necessarily impossible) situation for trial machining. So we just went
for it – hoping the groove would be in the right position. When we can measure this dimension (it may
require removing the workpiece from the chuck), we find the 0.125 dimension to be 0.01258. We’re within
tolerance, but not by much. To put this groove in precisely the correct position for the next workpiece, we’ll
make an adjustment to the Z register of wear offset number two. Since the groove is coming out to the right
(positive side) of where it should be, the adjustment will be negative 0.0008 (type -0.0008 and press the soft
key under +INPUT).
If it is absolutely mandatory that this groove be machined correctly in the first workpiece, you can use a
modified form of trial machining. Once the grooving tool is in position and ready to machine the groove, you
can stop the cycle and measure the distance from the large flange face to the leading edge of the grooving tool
(possibly with feeler gauges). Since you’re doing this before any machining takes place, you can confirm that
the grooving tool is in the correct position before a workpiece is scrapped. If the measurement isn’t precisely
0.125 inches, an adjustment can be made to the Z register of wear offset number three.

Completing the production run

With the first workpiece successfully machined and having passed inspection, the job is turned over to a CNC
operator. Again, 1,000 workpieces must be machined. Let’s consider what will happen to the three tools
during the production run.
Tool number one: Rough face and turn tool
For the rough face and turn tool, say we find that it lasts for about 600 workpieces before the cutting edge is
dull. So it will have to be replaced once during the production run. Throughout its life, tool wear may cause
the diameters machined by this tool to grow (maybe by as much as 0.006 inch or so), but there will be no need
for any kind of sizing adjustments.
This small deviation in finishing stock will not affect the finish turning tool (in most jobs). When the insert for
this roughing tool is indexed or replaced, care must be given to ensure that the new cutting edge is in the same
location as the last cutting edge. If inserts are varying dramatically, it may be necessary to repeat the trial
machining done during the machining of the first workpiece when the insert is changed (not just indexed).
Tool number Two: Finish face and turn tool
We’ll say this tool lasts for about 500 workpieces before it gets dull. But during this time, tool wear will cause
the diameters machined by this tool to vary by as much as 0.005 inch. This means several sizing adjustments
must be done during the tool’s life to ensure that the high limits of tolerances are not exceeded.
When the insert for this tool is indexed, the operator must be careful to get the new cutting edge in the same
location as the previous cutting edge. They must also reset the X register of wear offset number two to its
initial value to keep the tool from machining too much material from the next workpiece.

TCPO Page 17 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

If it is not possible to perfectly index inserts, trial machining must be done every time the insert is indexed.
The same goes for insert replacement. If inserts are varying, trial machining must be done whenever they are
replaced.
Tool number Three: 0.125 grooving tool
We’ll say this tool lasts for 700 workpieces before it gets dull. And during its life, the diameter it machines
doesn’t vary by more than about 0.0005 inch, meaning there will be no need for sizing adjustments. But as
with all insert indexing and replacement, it is critical that the new cutting edge position is in precisely the same
location as the previous cutting edge. This is true whether the insert is indexed of replaced. If there is any
doubt about insert placement, trial machining must be done when indexing or replacing inserts.

A reminder about up-coming jobs

These three tools have now been tweaked-in. They are all machining properly in the current job. When this job
is finished, it is likely that the rough face and turn tool and the finish face and turn tool will be used in the next
job. And remember, if a cutting tool is machining properly in one job, it will continue to do so in the next.
This requires, of course, that the mean value of each dimension is programmed for every coordinate in every
job. It also requires you to use the work shift function with geometry offsets as described in Lessons Seven
and Twelve.
As you go on to the next job you’ll know, for example, that the rough face and turn tool will be leaving the
programmed amount of finishing stock on all diameters and faces. And you’ll know that the finishing tool will
machine the first workpiece in the next job within its tolerances (assuming the next job has similar tolerance
requirements). If the grooving tool is used in the next job, you’ll know it will machine to the programmed
diameter and at the programmed Z position.

A reminder about target values

When adjustments are required, we have been targeting the mean value of each tolerance. And many CNC
people are told to do so. However, targeting the mean value actually doubles the number of sizing adjustments
that must be done during a cutting tool’s life. This means the CNC operator will have to more closely
monitor the CNC cycle.
For the 3.0 inch diameter that is machined by the rough face and turn tool in our example, it might be wiser to
target a value closer to the low limit – say a dimension of 2.9992. This will allow the cutting tool to machine
for twice the amount of time before an adjustment must be made.

Secondary wear offset applications

As stated, most operations require but one wear offset per tool. And we’ve called this offset the tool’s primary
offset. But we do want to prepare you for a few times when you may need two or more wear offsets for a
cutting tool. We call these additional wear offsets secondary offsets.
Whenever you use a secondary offset, be sure to come up with a logical method of selecting secondary offset
numbers. The people setting up and running your programs must be told which offsets are related to each
tool (include this information on the setup sheet). If your machine has a twelve station turret and (at least)
thirty-two offsets, we recommend that you add twenty to the tool’s station number to come up with its secondary offset
number. For example, tool station number five will use wear offset number five as its primary offset and wear
offset number twenty-five as its secondary offset.
Here are some applications for secondary offsets. All but the first should only be necessary if you’re
experiencing problems caused by tool pressure deviations as finishing tools machine workpiece surfaces. This
should be taken as a signal that the rigidity and strength of your setup is marginal.

TCPO Page 18 Copyright 2012, CNC Concepts, Inc.

 Lesson 13: Wear Offsets

Flip jobs
Many companies like to complete the workpiece (both ends) in one operation. The operator will load the
workpiece and activate the cycle to machine one end. In the middle of the program the machine will stop and
the operator will turn the workpiece around. The cycle will be reactivated to run the second end.
In this application, it’s likely that at least some of the cutting tools used to machine one end will be used to
machine the other. If this is the case, it is wise to use different wear offsets on each end. We recommend
using wear offsets one through twelve for tool one through twelve for the first end and wear offsets twenty-
one through thirty-two for tool one through twelve for the second end.

Two or more critical diameters

Unsupported sections of a workpiece are prone to deflection (the tool pushes the workpiece away). If a
workpiece deflects, the diameter machined by the cutting tool will vary. Say for example, you’re holding a
rather long workpiece and using a tailstock to support the right end. In this case, the workpiece will be well
supported at both ends, but not well supported in the middle. It will be less prone to deflection as tools
machine at the ends, but more prone to deflection in the middle. This kind of problem can be difficult (if not
impossible) to handle with only one offset. Given this problem, the primary offset can be used to help the
operator hold size on diameters close to the tailstock or chuck ends (less deflection). A secondary wear offset
can be used to help them hold size on diameters close to the middle of the workpiece (more deflection).

Unwanted taper
In similar fashion, your tools may experience changes in deflection even as they machine one diameter. This
commonly appears as taper in the diameter (one end is larger than the other). A secondary offset can be
instated during the machining of the diameter to induce a reverse tapered movement to counteract the taper
being machined.

Grooving into different areas of the workpiece

Yet another tool pressure problem has to do with grooving. You may be necking two grooves with a
grooving tool. One of the grooves may be close to the tailstock support (good support) and another groove
may be right in the middle of the workpiece (poor support). The grooving tool will cause more deflection in
the middle than at the tailstock end. Two wear offsets (one for the end groove and one for the middle) can be
used to give the setup person and operator individual sizing control for the grooves.

Key points for Lesson Thirteen:

?Wear offsets can be used four times: after tools are first mounted in the turret, when trial machining is
done, to compensate for tool wear, and after dull tools are replaced.
?Wear offsets are specified in the program with the second two digits of the T word.
?The wear offset number for a cutting tool should match the tool station number for the tool.
?There are two ways to enter wear offsets, with the INPUT soft key and the +INPUT soft key. The
+INPUT soft key allows you to modify the value that is currently in the offset register.
?A properly calibrated tool touch off probe eliminates the need for trial machining.
?Trial machining should be done whenever you’re in doubt about whether or not a cutting tool will
machine the first time within tolerance bands.

TCPO Page 19 Copyright 2012, CNC Concepts, Inc.