Fix milling safety blocks and iTNC execution

Author: MaestroFusion360

CHANGELOG.md

@@ -1,5 +1,14 @@
 # Changelog
 
+## 2.8.1 - 2026-10-18
+
+- Unify built-in rotary profile names as 4 Ax / 5 Ax Head / Table while preserving profile IDs and geometry.
+- Accept spaces in unquoted HEIDENHAIN program names and support M128/TCPM with a single rotary table axis, retaining configured axis directions and existing unsupported-configuration diagnostics.
+- Fix milling safety blocks combining G80 with explicit G00/G01 motion: cancel active drilling cycles and execute the programmed move regardless of code order, while retaining diagnostics for conflicting motion commands.
+- Accept HEIDENHAIN TOOL CALL DL/DR offsets. Apply DR to cutter radius in supported pocket, bore-milling and thread-milling cycles without modifying saved tool geometry; warn that contour compensation retains the base radius and DL is ignored in the tool-tip path.
+- Use a 3-degree plunge angle for HEIDENHAIN pocket insertion when no explicit angle is supplied, with a warning identifying the assumption and no additional tool-library fields.
+- Warn when HEIDENHAIN finishing-only pocket cycles have zero side and floor allowances and therefore generate no cutting passes.
+
 ## 2.8.0 - 2026-10-18
 
 - Add native SINUMERIK POCKET3/POCKET4 roughing and finishing, HOLES1/HOLES2 drilling patterns, CYCLE90 thread milling, and DEF REAL/INT variables. Support documented subsets and diagnose unsupported cycle variants explicitly.

app/gcode/kernel/frontend/heidenhain.py

@@ -108,7 +108,7 @@ def _contour(line):
 
 
 def _boundary(line):
-    match = re.fullmatch(r'(BEGIN|END)\s+PGM\s+("(?:[^"\n]|"")+"|[^\s"]+)(?:\s+(MM|INCH))?', line.body, re.I)
+    match = re.fullmatch(r'(BEGIN|END)\s+PGM\s+("(?:[^"\n]|"")+"|[^"\n]+?)(?:\s+(MM|INCH))?', line.body, re.I)
     if match is None:
         raise HeidenhainParseError("Expected BEGIN/END PGM name MM/INCH", line)
     name = match[2]

app/gcode/kernel/machine/execution.py

@@ -181,6 +181,9 @@ def modal_group_conflicts(gcodes: tuple[int | float, ...], language: str) -> tup
     """Return conflicting supported modal codes grouped by machine dialect."""
     groups = _MILLING_MODAL_GROUPS if language == "fanuc_mill" else _TURNING_MODAL_GROUPS
     numeric_codes = {int(code) if float(code).is_integer() else float(code) for code in gcodes}
+    # Cancellation may accompany an explicit ordinary move in a safety block.
+    if language == "fanuc_mill" and numeric_codes & {0, 1, 2, 3}:
+        numeric_codes.discard(80)
     conflicts = []
     for name, members in groups.items():
         present = tuple(sorted(numeric_codes & members))

app/gcode/kernel/milling/cycles/drilling.py

@@ -316,7 +316,7 @@ def execute_milling_cycle(context: CycleContext, *, emit_geometry: bool = True)
     trial_state = replace(state)
     apply_cycle_outcome(trial_state, CycleOutcome(modal_updates=modal_updates))
 
-    explicit_cycle = bool(cycle_codes)
+    explicit_cycle = bool(cycle_codes) and not (80 in cycle_codes and any(g in context.codes for g in (0, 1, 2, 3)))
     should_expand = emit_geometry and trial_state.cycle != 80 and has_position
     handled = emit_geometry and (explicit_cycle or should_expand)
     if not should_expand:

app/gcode/kernel/milling/heidenhain.py

@@ -80,6 +80,8 @@ class _State:
     spindle_direction: int | None = None
     center: tuple[float, float, float] | None = None
     tolerance_warned: bool = False
+    plunge_angle_warned: bool = False
+    tool_radius_delta: float = 0.0
     arc_tolerance: float = 0.01
     ended: str | None = None
     compensation_mode: int = 40
@@ -139,6 +141,8 @@ def controls(self, syntax, values, block):
             "IB",
             "IC",
         }
+        if syntax.command == "TOOL CALL":
+            unsupported -= {"DL", "DR"}
         if unsupported:
             _unsupported("Unsupported Klartext addresses: " + ", ".join(sorted(unsupported)))
         self.feed_controls(syntax, values, block)
@@ -491,12 +495,39 @@ def tool_call(self, syntax, block):
                 ExecutionEvent("tool_change", block.index, "TOOL CALL", tool=tool, previous_tool=self.tool)
             )
         self.tool = tool
+        values = {
+            word.address: scalar(word.expression, self.parameters)
+            for word in syntax.positioning_words
+            if word.address in {"DL", "DR"}
+        }
+        self.tool_radius_delta = values.get("DR", 0.0) * self.scale
+        if self.tool_radius_delta:
+            self.warning(
+                "HEIDENHAIN_TOOL_RADIUS_DELTA",
+                "TOOL CALL DR is applied to supported cycle geometry; contour compensation uses the base tool radius",
+                block,
+            )
+        if values.get("DL", 0.0):
+            self.warning("HEIDENHAIN_TOOL_LENGTH_DELTA_IGNORED", "TOOL CALL DL is ignored in the tool-tip path", block)
         if syntax.spindle_axis:
             self.tool_axis_declared = True
             self.spindle_axis = syntax.spindle_axis
             self.plane = _PLANES[self.spindle_axis][0]
             self.center = None
 
+    def warning(self, code, message, block):
+        self.diagnostics.append(Diagnostic(code, message, "warning", "unverified", block.index + 1, block.raw))
+
+    def cycle_tool(self):
+        """Apply the current call's radial delta without changing the tool library."""
+        tool = self.tools.get(self.tool)
+        if not tool or not self.tool_radius_delta:
+            return tool
+        diameter = float(tool.get("diameter", 0.0)) + 2 * self.tool_radius_delta
+        if not math.isfinite(diameter) or diameter <= 0:
+            raise SemanticError("INVALID_TOOL", "TOOL CALL DR must leave a positive effective cutter diameter")
+        return {**tool, "diameter": diameter}
+
     def cycle(self, syntax, values, block):
         if syntax.cycle_code in {7, 10} and syntax.command == "CYCL DEF":
             self.coordinate_cycle(syntax, values, block)

app/gcode/kernel/milling/heidenhain_cycles.py

@@ -145,7 +145,7 @@ def back_boring(self):
     def bore_milling(self, surface, depth, safety, returned, feed):
         axis = self.axis
         plane, axes = {2: (17, (0, 1)), 1: (18, (0, 2)), 0: (19, (1, 2))}[axis]
-        tool = self.state.tools.get(self.state.tool, {})
+        tool = self.state.cycle_tool() or {}
         diameter = self.q(335) * self.state.scale
         tool_diameter = float(tool.get("diameter", 0))
         radius = (diameter - tool_diameter) / 2

app/gcode/kernel/milling/heidenhain_pockets.py

@@ -151,7 +151,7 @@ def _plan(state, block):
     if q["Q201"] > 0:
         _error("Positive depth depends on the OEM MP7441 policy", unsupported=True)
     _check_parameters(q)
-    tool = _tool_radius(state.tools.get(state.tool))
+    tool = _tool_radius(state.cycle_tool())
     if tool is None:
         _error("Supply a milling cutter diameter through milling_tools/tool_resolver", unsupported=True)
     if state.spindle_direction not in {3, 4}:
@@ -163,7 +163,14 @@ def _plan(state, block):
 
 def _plunge_angle(state):
     tool = state.tools.get(state.tool, {})
-    value = tool.get("ANGLE", tool.get("plunge_angle"))
+    value = tool.get("ANGLE", tool.get("plunge_angle", 3.0))
+    if "ANGLE" not in tool and "plunge_angle" not in tool and not state.plunge_angle_warned:
+        state.warning(
+            "HEIDENHAIN_DEFAULT_PLUNGE_ANGLE",
+            "Pocket insertion uses an assumed plunge angle of 3 degrees",
+            state.program.blocks[state.pc],
+        )
+        state.plunge_angle_warned = True
     try:
         angle = float(value)
     except (TypeError, ValueError):
@@ -231,6 +238,11 @@ def execute_pocket(state, block):
     if state.parameters.get("Q201") == 0:
         return
     if state.parameters.get("Q215") == 2 and state.parameters.get("Q368") == state.parameters.get("Q369") == 0:
+        state.warning(
+            "HEIDENHAIN_POCKET_NO_FINISHING_ALLOWANCE",
+            "Finishing-only pocket has Q368=Q369=0; no cutting passes are generated",
+            block,
+        )
         return
     pocket = _plan(state, block)
     q, scale = pocket.q, state.scale

app/gcode/kernel/milling/heidenhain_rotary.py

@@ -57,9 +57,16 @@ def _capture(state):
 def set_tcp(state, enabled, block):
     if enabled:
         profile = _require_profile(state)
-        if not profile.tcp_table_supported or state.rotary.plane is not None or state.spindle_axis != "Z":
+        single_table = not profile.head_rotary_axes and len(profile.table_rotary_axes) == 1
+        if (
+            not (profile.tcp_table_supported or single_table)
+            or state.rotary.plane is not None
+            or state.spindle_axis != "Z"
+        ):
             raise SemanticError(
-                "UNSUPPORTED_HEIDENHAIN_TCP", "M128/TCPM requires an AC/BC table and PLANE RESET", "unsupported"
+                "UNSUPPORTED_HEIDENHAIN_TCP",
+                "M128/TCPM requires a single rotary table or an AC/BC table, Z tool axis and PLANE RESET",
+                "unsupported",
             )
     if state.rotary.tcp == enabled:
         return

app/gcode/kernel/milling/heidenhain_thread.py

@@ -33,7 +33,7 @@ def thread_plan(state):
     if q["Q351"] not in {-1, 1} or state.spindle_direction not in {3, 4}:
         _unsupported("Specify Q351=+1/-1 and spindle direction M3/M4")
     _check_ranges(q, rapid)
-    tool_radius = _tool_radius(state.tools.get(state.tool))
+    tool_radius = _tool_radius(state.cycle_tool())
     diameter = q["Q335"] * state.scale
     if tool_radius is None:
         _unsupported("Cycle 262 requires a milling cutter diameter from milling_tools/tool_resolver")

app/gcode/kernel/milling/rotary_profiles.json

@@ -3,7 +3,7 @@
   "profiles": [
     {
       "id": "4ax_head_b_negative",
-      "name": "4Ax Head B Negative",
+      "name": "4 Ax Head B Negative",
       "table": [],
       "head": [
         {
@@ -19,7 +19,7 @@
     },
     {
       "id": "4ax_table_b",
-      "name": "4Ax Table B",
+      "name": "4 Ax Table B",
       "table": [
         {
           "address": "B",
@@ -35,7 +35,7 @@
     },
     {
       "id": "4ax_table_a",
-      "name": "4Ax Table A",
+      "name": "4 Ax Table A",
       "table": [
         {
           "address": "A",
@@ -51,7 +51,7 @@
     },
     {
       "id": "5ax_table_ac_angled",
-      "name": "5Ax Table AC Angled",
+      "name": "5 Ax Table AC Angled",
       "table": [
         {
           "address": "A",
@@ -75,7 +75,7 @@
     },
     {
       "id": "5ax_table_bc_angled",
-      "name": "5Ax Table BC Angled",
+      "name": "5 Ax Table BC Angled",
       "table": [
         {
           "address": "B",
@@ -99,7 +99,7 @@
     },
     {
       "id": "5ax_head_ac_angled",
-      "name": "5Ax Head AC Angled",
+      "name": "5 Ax Head AC Angled",
       "table": [],
       "head": [
         {
@@ -123,7 +123,7 @@
     },
     {
       "id": "5ax_head_bc_angled",
-      "name": "5Ax Head BC Angled",
+      "name": "5 Ax Head BC Angled",
       "table": [],
       "head": [
         {
@@ -147,7 +147,7 @@
     },
     {
       "id": "5ax_table_ac",
-      "name": "5Ax Table AC",
+      "name": "5 Ax Table AC",
       "table": [
         {
           "address": "A",
@@ -171,7 +171,7 @@
     },
     {
       "id": "5ax_table_bc",
-      "name": "5Ax Table BC",
+      "name": "5 Ax Table BC",
       "table": [
         {
           "address": "B",
@@ -195,7 +195,7 @@
     },
     {
       "id": "5ax_table_c_head_b_negative",
-      "name": "5Ax Table C Head B Negative",
+      "name": "5 Ax Table C Head B Negative",
       "table": [
         {
           "address": "C",
@@ -220,7 +220,7 @@
     },
     {
       "id": "5ax_head_ac_negative",
-      "name": "5Ax Head AC Negative",
+      "name": "5 Ax Head AC Negative",
       "table": [],
       "head": [
         {
@@ -244,7 +244,7 @@
     },
     {
       "id": "5ax_head_bc_negative",
-      "name": "5Ax Head BC Negative",
+      "name": "5 Ax Head BC Negative",
       "table": [],
       "head": [
         {
@@ -268,7 +268,7 @@
     },
     {
       "id": "5ax_table_c_head_a_negative",
-      "name": "5Ax Table C Head A Negative",
+      "name": "5 Ax Table C Head A Negative",
       "table": [
         {
           "address": "C",
@@ -293,7 +293,7 @@
     },
     {
       "id": "5ax_table_a_head_b",
-      "name": "5Ax Table A Head B",
+      "name": "5 Ax Table A Head B",
       "table": [
         {
           "address": "A",
@@ -318,7 +318,7 @@
     },
     {
       "id": "5ax_table_ab",
-      "name": "5Ax Table AB",
+      "name": "5 Ax Table AB",
       "table": [
         {
           "address": "A",
@@ -342,7 +342,7 @@
     },
     {
       "id": "4ax_table_c",
-      "name": "4-axis Table C",
+      "name": "4 Ax Table C",
       "table": [
         {
           "address": "C",
@@ -358,7 +358,7 @@
     },
     {
       "id": "4ax_head_a",
-      "name": "4-axis Head A",
+      "name": "4 Ax Head A",
       "table": [],
       "head": [
         {
@@ -374,7 +374,7 @@
     },
     {
       "id": "4ax_head_b",
-      "name": "4-axis Head B",
+      "name": "4 Ax Head B",
       "table": [],
       "head": [
         {
@@ -390,7 +390,7 @@
     },
     {
       "id": "4ax_head_c",
-      "name": "4-axis Head C",
+      "name": "4 Ax Head C",
       "table": [],
       "head": [
         {
@@ -406,7 +406,7 @@
     },
     {
       "id": "4ax_table_a_negative",
-      "name": "4-axis Table A Negative",
+      "name": "4 Ax Table A Negative",
       "table": [
         {
           "address": "A",
@@ -422,7 +422,7 @@
     },
     {
       "id": "4ax_table_b_negative",
-      "name": "4-axis Table B Negative",
+      "name": "4 Ax Table B Negative",
       "table": [
         {
           "address": "B",
@@ -438,7 +438,7 @@
     },
     {
       "id": "4ax_table_c_negative",
-      "name": "4-axis Table C Negative",
+      "name": "4 Ax Table C Negative",
       "table": [
         {
           "address": "C",
@@ -454,7 +454,7 @@
     },
     {
       "id": "4ax_head_a_negative",
-      "name": "4-axis Head A Negative",
+      "name": "4 Ax Head A Negative",
       "table": [],
       "head": [
         {
@@ -470,7 +470,7 @@
     },
     {
       "id": "4ax_head_c_negative",
-      "name": "4-axis Head C Negative",
+      "name": "4 Ax Head C Negative",
       "table": [],
       "head": [
         {