CNC Tool Life Management on FANUC Controls

By Nishikant Xalxo | FANUC CNC Expert | Updated: January 10, 2025 | 11 min read

After a tool broke mid-cut and scrapped a ₹50,000 aerospace part, I implemented tool life management on our FANUC 30i-B. Here's how to set up counters, automatic replacements, and preventive scheduling to avoid costly surprises.

Why Tool Life Management Matters

Without tracking, you replace tools too early (wasting money) or too late (scrapping parts). FANUC's tool life management provides:

Automatic tool changes when life expires
Warning before life ends
Data tracking for optimization
Preventive maintenance scheduling

FANUC Tool Life Parameters

On FANUC 30i-B, these parameters control tool life:

Parameter	Function	Typical Value
6800#0	Tool life management enable	1 (enable)
6800#1	Life count type (0=time, 1=count)	1 (count)
6800#2	Warning signal output	1 (enable)
6811	Life count ignore value	0 (don't ignore)

Setting Tool Life Data

On OFFSET page, press [TOOL LIFE] soft key:

Select tool number
Set Life (maximum uses/minutes)
Set Counter (current uses - starts at 0)
Set Warning (when to trigger alarm, e.g., 90% of life)

Example Setup for End Mill:

Tool: T01 (12mm end mill)
Life: 50 parts (typically 4-8 hours of cutting)
Counter: 0 (new tool)
Warning: 45 (trigger at 90%)

System Variables for Tool Life

In macro programs, use these variables:

#3000 = Tool life status (0=normal, 1=warning, 2=expired)
#3001-#3200 = Tool life counters (tools 1-200)
#3201-#3400 = Tool life set values

Macro to Check Tool Life:

O9002 (CHECK TOOL LIFE)
IF [#3001 GE #3201] GOTO 100  ; Tool 1 expired?
    #3000 = 1                  ; Set warning
N100 M99

Automatic Tool Change on Life Expiry

Program example:

O1000 (MAIN PROGRAM)
T01 M06                    ; Load tool 1
G01 X100.0 Y50.0 F500.0
...
IF [#3001 GE #3201] GOTO 900  ; Check life
GOTO 1000

N900 (TOOL LIFE EXPIRED)
M01                        ; Optional stop for tool change
#3001 = 0                  ; Reset counter
T01 M06                    ; Change to new tool

N1000 M30

Preventive Replacement Scheduling

Best practice: Schedule tool changes during planned downtime, not mid-cut.

Review tool life data at end of shift
Replace tools >90% life during setup
Track actual vs predicted life to optimize settings
Keep spare tools ready for automatic changes

Optimizing Tool Life Settings

Start conservative:

Carbide end mill in aluminum: 4-6 hours
Carbide in steel: 2-4 hours
Inserts: 2-3 hours

Then adjust: If tool lasts 110% of life, increase 10%. If breaks at 95%, decrease 15%.

About the Author: Nishikant Xalxo's tool life management reduced part scrapping from 5% to <0.5% in his shop. Contact: nxdecore@gmail.com

Next: Read FANUC Work Offsets Guide