6410

Access the tool management interface via HMI menu: Diagnosis > Tool Data > Active Tools. Identify the tool number and TO unit specified in alarm parameters %1 and %2.

Check tool offset D value and compare against configured limits in the tool table (TOOL.T file or equivalent database). Verify MD36100 (time limit) and MD36110 (pieces limit) settings match production requirements.

Review actual tool usage via NCK parameter SD42300 (tool life current time) and SD42310 (tool life current pieces). If usage exceeds 80% of limits, schedule tool replacement or recalibrate offset.

Do not ignore this prewarning; continued operation beyond 100% life limit triggers hard alarm 6411.

After tool change, reset tool life counters via Maintenance > Tool Replacement > Reset Tool Life, or execute NC command _RESET_TOOL_LIFE in the part program.

Measure the actual tool dimension (length or diameter) with precision gauge. Compare against the original tool dimension stored in the tool offset table.

Check current D offset value in the Offset table (HMI > Offsets > Tool Offsets). Calculate offset drift by subtracting the programmed initial offset from the current compensated value.

Verify prewarning threshold setting: Access NCK Parameters > Monitoring > MD36120 (wear offset prewarning limit). If threshold is too tight, increase it incrementally (e.g., 2mm to 3mm) and test; if offset drift is genuine tool wear, adjust D offset or replace tool.

Offset adjustments must be made in the Part Program or via HMI; manual edits require machine lock (Jog mode disabled).

If tool wear is confirmed and cannot be compensated further, perform tool change: execute M6 command, update tool offset D to new tool dimension, and verify against workpiece with trial cut.

Check if additive offset mode is enabled: Review part program for DOFS commands or verify MD36500 (enable additive offset) = 1. Confirm AO is active on the specified tool via HMI > Tool Data > Additive Offset Status.

Monitor cumulative AO value during program execution: Use Diagnosis > NCK Variables > TOOL_OFFSET[n].ADDITIVE_OFFSET to track real-time D offset changes. Compare cumulative total against MD36125 prewarning limit.

High additive offset accumulation indicates either excessive tool wear, inaccurate initial offset, or overly aggressive AO adjustment rates.

Reduce additive offset adjustment rate: Edit MD36510 (AO step size) or program parameter P_AO_RATE to lower values, or increase MD36125 prewarning threshold if production margins allow.