SINUMERIK 840D sl. Service - Functions. Manual (2018-2020)

V2: Preprocessing

25.3 Program call

Program code

Comment

G1 F10 X=VARIABLE*10-56/86EX4+4*SIN(VARIABLE/3)

ENDFOR

; 1 name, only for preprocessing

M17

In order to execute this program normally, the following machine data must specify at least 3

names:

MD28020 $MC_MM_NUM_LUD_NAMES_TOTAL

Six names are required to compile this program after POWER ON.

Preprocessed programs/cycles are stored in the dynamic NC memory. The space required for

each program must be flashed over unmodified as outlined above. Adjustment of the memory

mapping in the static NC memory is required only if bit 6 = 1 is set in the following machine

data:

MD10700 $MN_PREPROCESSING_LEVEL (program processing level)

In this case, the program compilations for which there is insufficient space in the dynamic NC

memory are stored in the static NC memory.

Examples for appropriate machine data settings can be found under "Examples" in the

Subsection "Preprocessing in the dynamic NC memory".

25.3

Program call

Overview

0DLQ SURJUDPV

8VHU F\FOHV

6WDQGDUG F\FOHV

B1B03)B',5

B1B&86B',5

B1B&67B',5

0DLQ SURJUDP

&DOO

&<&/(B63)

$6&,,

ZLWKRXW SUHSURFHVVLQJ

&\FOH

&<&/(

B1B&<&/(B63)

3UHSURFHVVLQJ

&<&/(B&<&

B1B0$,1B63)

&DOO

3UH

ZLWK SUHSURFHVVLQJ

SURFHVVHG

&\FOH

B1B&<&/(B&<&

Special functions

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V2: Preprocessing

25.3 Program call

Figure 25-1

Generation and call of preprocessed cycles without parameters

0DLQ SURJUDPV

8VHU F\FOHV

6WDQGDUG F\FOHV

B1B03)B',5

B1B&86B',5

B1B&67B',5

0DLQ SURJUDP

&DOO

$6&,,

&\FOH

ZLWKRXW SUHSURFHVVLQJ

352& &<&/(

5($/ )):

&<&/(

B1B&<&/( B63)

3UHSURFHVVLQJ

&DOO

3UH

ZLWK SUHSURFHVVLQJ

SURFHVVHG

&\FOH

B1B&<&/( B&<&

Figure 25-2

Generation and call of preprocessed cycles with parameters

Call

● Compiled cycle: A compiled cycle is called in exactly the same way as a normal subroutine.

Example: CYCLE

● Preprocessing is activated: The compiled cycle is called instead of the ASCII cycle.

- If the subroutine is called explicitly with extension _SPF, then the ASCII cycle is called

even if a compilation is available.

Example: CYCLE_SPF; ASCII cycle call

- If the subroutine is called explicitly with extension _CYC, then the preprocessed cycle

is called (assuming that it is available). An error message is output if no compilation is

available.

Example: CYCLE_CYC; calls a precompiled cycle

- If bit 5 is set and a file that is not marked with PREPRO is called explicitly with the

extension _CYC, an error message is issued with Alarm 14011.

● If a subroutine is called without explicit extension, an attempt is first made to load the

program. If this is not possible (not marked with PREPRO), an attempt is made to load the

SPF program.

Special functions

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25.4 Constraints

● The change to an external language mode with G291 is rejected and an alarm issued. When

calling a precompiled cycle, an explicit change is made into the Siemens language mode.

● When the subroutine is called, it is checked whether the compiled file is older than the cycle.

If so, the compile file is deleted and an alarm issued. The user must preprocess the cycles

again.

Note

Only cycles without parameters may be called with the extension _SPF or _CYC.

It is not permissible that PUDs are used in cycles that have been preprocessed. The PUDs

are created in the calling main program. At the time of compilation after POWER ON, this

data is not known to the cycles.

The actual program display shows whether the current ASCII cycle or the compilation has

been called (extension _SPF or _CYC).

Call condition

All cycles in the cycle directories must be compiled before preprocessing is activated. Non-

compiled cycles in _N_CUS_DIR and _N_CST_DIR which were loaded after POWER ON, for

example, can only be called through explicit specification of extension _SPF.

If preprocessing is active and bit 5 is set, all programs that do not start with the PREPRO PROC

instruction are not precompiled.

Syntax check

All program errors, which can be corrected using a correction block, are already identified at

the time of preprocessing. In addition, when the program includes branches and check

structures, a check is made to ensure that the branch destinations are present and that

structures are nested correctly.

Branch destinations and labels must be unique in the program.

After the errors detected during preprocessing have been corrected, preprocessing must be

started again by means of an NC POWER ON.

25.4

Constraints

Availability of the "preprocessing" function

The function is an option ("Program pre-processing"), which must be assigned to the hardware

via the license management.

Language scope

The full vocabulary of the NC language is available in the part program.

Special functions

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25.4 Constraints

There are no restrictions on the calculation of measured process variables and in the reaction

to signals from the process and other channels (override, deletion of distance-to-go, motion-

synchronous actions, channel coordination, interrupt processing, etc.).

Axis name

Part programs are compiled independently of channels. For this reason, the geometry and

channel names set in the following machine data must be identical in all channels if they are

used directly in the precompiled cycles:

MD20060 $MC_AXCONF_GEOAX_NAME_TAB (name of the geometry axis in the channel)

MD20080 $MC_AXCONF_CHANAX_NAME_TAB (name of the channel axis in the channel)

Generally speaking, axis names are not used directly in machining cycles since cycles are

written as follows:

● independently of channels and

● independently of the axis names defined on the machine.

The axes to be traversed are addressed indirectly via machine data or transferred as

parameters:

● Indirect axis programming:

- IF $AA_IM[AXNAME($MC_AXCONF_CHANAX_NAME_TAB[4])] > 5

; This branch will pass through if the actual value of the 5th channel axis

; with reference to the machine coordinate system is greater than 5.

- G1 AX[AXNAME($MC-AXCONF-GEOAX-NAME-TAB[0])] = 10

F1000 G90.

; Traverse the 1st geometry axis to the value 10.

ENDIF

● Transfer of axis to be traversed from the main program:

- Cycle definition

PROC DRILL(AXIS DRILL_AXIS)

WHILE $AA_IW[DRILL_AXIS] > -10

G1 G91 F250 AX[DRILL_AXIS] = -1

ENDWHILE

- Call from the main program

DRILL(Z)

Special functions

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25.5 Examples

25.5

Examples

25.5.1

Preprocessing individual files

Program code

Comment

PROC UP1 PREPRO

; Preprocessing if bit 5 = 1

; in PREPROCESSING_LEVEL

N1000 DEF INT COUNTER

N1010 TARGET: G1 G91 COMPON

N1020 G1 X0.001 Y0.001 Z0.001 F100000

N1030 COUNTER=COUNTER+1

N1040 COUNTER=COUNTER-1

N1050 COUNTER=COUNTER+1

N1060 IF COUNTER<=10 GOTOB TARGET

N1070 M30

PROC UP2

N2000 DEF INT VARIABLE, ARRAY[2]

N2010 IF $AN_NCK_Version < 3.4

N2020 SETAL(61000)

N2030 ENDIF

N2040 START:

N2050 FOR VARIABLE = 1 TO 5

N2060 G1 F1000 X=VARIABLE*10-56/86EX4+4*SIN(VARIABLE/3)

N2070 ENDFOR

N2080 M17

PROC MAIN

N10 G0 X0 Y0 Z0

N20 UP1

N30 G0 X10 Y10 Z10

N40 UP2

N50 G0 X100 Y100

N60 UP3

N70 G0 X10 Y10

N80 M30

Sample constellations:

a) Bit 5 = 1

MD10700 $MN_PREPROCESSING_LEVEL=45 ; bit 0, 2, 3, 5

Subprogram UP1 is pretranslated, and the call description is generated.

Subprogram UP2 is not pretranslated, but the call description is generated.

b) Bit 5 = 0

Special functions

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25.5 Examples

MD10700 $MN_PREPROCESSING_LEVEL=13 ; bit 0, 2, 3,

Both subprograms are pretranslated, and the call description is generated.

c) Example of an invalid subprogram with activated compiling:

Program code

Comment

PROC SUB1 PREPRO

G291

; ← Alarm when compiling, G291 not possible

G0 X0 Y0 Z0

M17

25.5.2

Preprocessing in the dynamic NC memory

Machine data for preprocessing only in the dynamic NC memory with selective selection:

Program code

Comment

; Bit 5 = 1 Selective program selection

; Bit 6 =0 no switch to

; static NC memory if

; dynamic NC memory is full

N30 $MN_MM_DRAM_FILE_MEM_SIZE = 800

; Reserve space

N40 $MN_PREPROCESSING_LEVEL = 63

; Bit 0-5 = 1

M17

Machine data for preprocessing in the dynamic NC memory with the option of using the static

NC memory and selective selection:

Program code

Comment

; Bit 5 = 1 Selective program selection

; Bit 6 = 1 switch to static

; NC memory if dynamic NC

; memory full

N30 $MN_MM_DRAM_FILE_MEM_SIZE = 800

; Reserve space

N40 $MN_PREPROCESSING_LEVEL = 127

; Bit 0-6 = 1

M17

Special functions

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26.1

Function

26.1.1

Introduction

3D circumferential milling and 3D face milling

3D tool radius compensation (3D-TRC) is used to process contours with tools that can be

controlled in their orientation independently of the tool path and shape.

SINUMERIK provides the 3D-TRC in different variants, which are used in combination with

the following manufacturing processes:

● Circumferential milling (Page 902) for structural components

● Face milling (Page 908) for free-form surfaces

Tool orientation

For the 3D-TRC, a distinction must be made between the two scenarios of a tool with a fixed

orientation and a tool with a changeable orientation.

The tool radius compensation with a fixed tool for circumferential milling is designated as a

2½D-TRC. This is the conventional tool radius compensation. Circumferential milling with a

functionality that goes beyond this scope of performance is not possible for the compensation

with a fixed tool. For circumferential milling, there is only a 3D-TRC if the tool orientation is

changeable. This means, in addition to the 3 degrees of freedom for positioning the tool

(generally 3 linear axes), two additional degrees of freedom (2 rotary axes) are also needed

for setting the tool orientation (5-axis machining).

During face milling, the tool orientation can remain constant or be variable. The advantages

of variable orientation are:

● better approximation of the end contour

● increased chip performance

● more freedom in selecting the shape of the tool

● a wider range of surfaces that can be processed (undercuts)

Note

5D-WRK

The 3D-TRC is also called 5D-TRC below, because 5 degrees of freedom are available in this

case for defining the position of the tool in space relative to the workpiece.

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26.1 Function

Parameter assignment

The machine and setting data set for the 2D-TRC are also in effect for the 3D-TRC.

Reference:

Function Manual Basic Functions; Chapter "W1: tool offset"

In addition to this, there is special system data that is only relevant to 3D-TRC. See Chapter

"Parameter assignment (Page 916)" regarding settings of this data.

Activation/deactivation

The selection of the 3D-TRC variant is made in the NC program via G commands of Group 22

(tool offset type). The actual activation and deactivation are done via the G commands of Group

7 (tool radius compensation).

See Chapter "Programming (Page 917)".

26.1.2

Circumferential milling

The 3D circumferential milling is used for machining contours with tools having an orientation

that is not constant during processing. Processing is done using the peripheral surface of the

tool. If the tool is cylindrical, ruled surfaces (e.g. cones, cylinders, etc.) are created during this

processing. Other forms of milling machines can also be used, however (e.g. form cutters).

The tool radius compensation needed for this type of processing is an extension of the

conventional 2½D-TRC.

The ratios for 3D circumferential milling are shown in the following figure:

Special functions

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26.1 Function

)(

;

Z₅

FE:

Milling tool machining point

FS:

Milling tool tip

FH:

Milling tool reference point

Insertion depth

Tool vector

w_r:

Vector from the milling tool reference point to the milling tool machining point with length of

shank radius R

Figure 26-1

Circumferential milling

Insertion depth

The insertion depth of the milling tool is the distance of the milling tool reference point from

the tip of the tool.

The milling tool reference point is the vertical projection of the milling tool machining point on

the programmed path to the longitudinal axis of the tool.

The position of the machining point on the peripheral surface of the tool is set with the insertion

depth.

Via the address ISD (InSertion Depth), the insertion depth of the tool for circumferential milling

and active 3D tool radius compensation can be changed (see Chapter "Programming

(Page 917)").

Special functions

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26.1 Function

26.1.2.2

Behavior at outer corners

At outside corners during circumferential milling with 3D-TRC analogous to the conditions in

the 2½D-TRC, the G commands of Group 18 (corner behavior tool offset) are evaluated:

● G450: Transition circle (tool travels around workpiece corners on a circular path)

Outside corners are treated like circles with a radius of 0, where the circular plane stretches

from the end tangent of the first block and the start tangent of the second block. Thus, an

orientation change during the block transition is also possible. Thus, a block is always

inserted at an outside corner.

In contrast to the solution for the 2½D-TRC, the contour element inserted at an outside

corner is always a circle with a radius of 0, which is affected by the tool radius compensation

like on any other programmed path. It is not possible to insert conical sections in place of

the circles. The address DISC therefore has no relevance in this case and is not evaluated.

● G451: Intersection of equidistant paths (tool backs off from the workpiece corner)

The intersection is determined by extending the offset curves of the two participating blocks

and defining the intersection of the two blocks at the corner in the plane perpendicular to

the tool orientation.

If an intersection is found in the plane perpendicular to the tool, this does not mean that the

curves also intersect in space. Rather the curves in the direction of the tool longitudinal axis

are considered, which are generally a certain distance apart. The positional offset is

eliminated over the entire block length in direction of the tool.

The way this offset is processed in tool direction at outside corners is the same as for inside

corners.

For nearly tangential transitions, the behavior for an active G450 is the same as for G451 (limit

angle can be set via MD20210 $MC_CUTCOM_CORNER_LIMIT). Conversely, if G451 is

active, a circle is also inserted (procedure as for G450) if there is no intersection or if the corner

angle exceeds a specific value (MD20230 $MC_CUTCOM_CURVE_INSERT_LIMIT).

Behavior during orientation changes

The intersection procedure (G451) is not used when at least one block containing a change

to the tool orientation was inserted between the traversing blocks in question. In this case a

circle is always inserted at the corner.

The G commands of Group 27 (too offset for orientation change at outside corners) can be

used to define whether orientation changes, which have been programmed between the two

traversing blocks that form the corner, are executed before the beginning of the inserted circle

set or at the same time.

● ORIC: Orientation changes at outside corners are superimposed on the circle block to be

inserted.

● ORID: Orientation changes are performed before the circle block.

If two or more blocks with orientation changes (e.g. A2=... B2=... C2=...) are programmed

between two traversing blocks and ORIC is active, then the circular block to be inserted is

divided between these intermediate blocks corresponding to the amount of the individual angle

changes. Further programmed intermediate blocks without traversing and orientation motions

are executed at the programmed positions.

If ORID is active, all inserted blocks (both those with and without orientation movement) are

executed at the end of the first of the two traversing blocks. The tangent in the end point of the

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26.1 Function

first traversing block is used for the offset calculation. The circle block with constant orientation

is inserted immediately before the second traversing block.

See also "Example 1: Orientation change at outside corner during 3D circumferential milling

(Page 932)".

Intermediate blocks without relevant traversing information

Intermediate blocks without relevant traversing information (neither tool orientation nor position

of geometry axes are changed) are permissible. The intersection procedure is applied to the

adjacent blocks as if these intermediate blocks did not exist. In the same manner, tool direction

motions in the tool direction may also be programmed in intermediate blocks.

26.1.2.3

Behavior at inside corners

For the 3D-TRC, only adjacent traversing blocks are taken into consideration for the calculation

of the intersecting point.

If the orientation is not changed at the block limit, then the contour need only be considered

in the plane vertical to the tool axis. In this case, the tool cross-section is a circle which touches

the two contours. The geometric relations in this plane are identical to those for 2¹/₂D-TRC.

Behavior during orientation changes

If the orientation changes on a block transition, the tool moves in the inside corner so that it is

constantly in contact with the two blocks forming the corner.

Path segments must be long enough to ensure that the contact points of the tool do not cross

the block limits into other blocks when the orientation changes at an inside corner.

Figure 26-2

Orientation changes at inside corner

When the orientation changes in a block that is one of the two blocks forming the inside corner,

then it is no longer possible to adhere to the programmed relationship between path position

and associated orientation. This is because the orientation must reach its end value even

though the path end position is not reached. This response is identical to the response of

synchronized axes with 2¹/₂ D tool radius compensation.

Special functions

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26.1 Function

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Figure 26-3

Path end position and change in orientation at inside corners

See also "Example 2: Orientation change at inside corner during 3D circumferential milling

(Page 935)".

Change in insertion depth

Generally speaking, the contour elements that form an inside corner are not positioned on the

plane perpendicular to the tool. This means that the contact points between the two blocks

and the tool are at different distances from the tool tip.

This means: The insertion depth (ISD) changes abruptly from the 1st to the 2nd block at an

inside corner.

To ensure that this difference in depth is not an abrupt step change, it is distributed continuously

among the blocks involved during interpolation. The depth-compensating motion is executed

in the current tool direction.

This solution prevents the contour from being violated by cylindrical tools if the length of the

tool prevents the cutter contact point on the lateral surface of the cutter leaving the range in

which machining is possible.

Special functions

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26.1 Function

,6' QHZ

,6' ROG

QG EORFN

VW EORFN

Figure 26-4

Change in insertion depth

26.1.2.4

Monitoring of path curvature

The path curvature is monitored for an unchangeable orientation in the following way:

1. The contour in each block is projected on the plane that is orthogonal to the tool orientation.

2. Then the curvature of the projection is analyzed. Areas with too much curvature (tool does

not fit in the curve) are cut out.

3. The remaining offset contours overlap each other and thus form the global offset contour.

26.1.3

Face milling

Face milling is used to process curved surfaces of any kind. In this case, the longitudinal axis

of the tool and the surface normal vector are more or less parallel. In contrast, the longitudinal

axis of the tool and the surface normal vector of the surface to be machined in a 3D

circumferential milling operation are at right angles to one another.

Information about the surface to be machined is absolutely essential for face milling operations,

i.e. a description of the linear path in space is not sufficient. The tool shape must also be known

in order to implement the tool offset (the term "Tool radius compensation" is not appropriate

in this case).

The conditions for face milling are shown in the following figure:

Special functions

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26.1 Function

Q₎

)(

FE:

Milling tool machining point

FS:

Milling tool tip

n_F:

Surface normal vector

Tool vector

Shaft radius

Corner radius

Difference between the shank radius R and corner radius r

Figure 26-5

Face milling with a torus cutter

26.1.3.1

Tool shapes and tool data for face milling

An overview of the tool shapes, which may be used for face milling operations and relevant

tool data are listed in the following. The shape of the tool shaft is not taken into account.

Therefore, the tool types 120 and 155, for example, have an identical effect.

%DOO HQG PLOO

&\OLQGULFDO

(QG PLOO

(QG PLOO ZLWK

%HYHO FXWWHU

7DSHUHG

GLH VLQNLQJ

FRUQHU URXQGLQJ

ZLWK FRUQHU URXQGLQJ

GLH VLQNLQJ

PLOOLQJ FXWWHU

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W\SH

= shank radius (tool radius)

= corner radius

= angle between the tool longitudinal axis and upper end of the torus surface

Cutter type

Type No.

Ball end mill

110

> 0

Cylindrical die-sinking milling cutter

111

> 0

> R

End mill, angle head cutter

120, 130

> 0

End mill, angle head cutter with corner rounding

121, 131

> r

> 0

Special functions

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26.1 Function

Cutter type

Type No.

Bevel cutter

155

> 0

Bevel cutter with corner rounding

156

> 0

Tapered die-sinking cutter

157

> 0

- : is not evaluated.

Tool data

Tool parameters

Tool dimensions

Geometry

Wear

$TC_DP6

$TC_DP15

$TC_DP7

$TC_DP16

$TC_DP11

$TC_DP20

Note

If, in the NC program, a type number is specified that differs from that in the diagram, then the

system automatically uses tool type 110 (ball end mill).

Note

An alarm is output if the tool data limit values are violated.

Geometry and wear values of tool data have an additive effect, i.e. the tool form that is actually

used for the offset calculation is always described by the sum values.

In the CUT3DFD function (differential tool), only the wear value is considered as an offset

value. The geometry values are only necessary in this case for describing the tool form.

Tool length offset

The tool tip (intersecting point between the tool longitudinal axis and the workpiece surface)

is considered the reference point for the length offset.

Tool change

A new tool with changed dimensions (R, r, a) or other form can only be specified during the

first activation of the tool offset (i.e. during the transition from G40 to G41 or G42) or for an

already active offset only for new programming of G41 or G42. This rule does not apply to any

other tool data, e.g. tool lengths, so that tools can be loaded without reprogramming G41 or

G42.

26.1.3.2

Face milling with a specified surface normal vector

Expanded options for orientation programming are provided for 3D face milling.

The tool offset for face milling cannot be calculated simply by specifying the path (e.g. of a line

in space). The surface to be machined must also be known. The necessary information about

the surface is provided to the controller with the surface normal vector.

The surface normal vector at the block beginning is programmed with A4, B4, C4, and the

vector at the block end with A5, B5, C5. Components of the surface normal vectors which are

not programmed are set to zero. The length of a vector programmed in this way is irrelevant.

Special functions

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26.1 Function

A vector of zero length (all three components are zero) is ignored, i.e. the direction programmed

beforehand remains valid, no alarm is generated.

If only the start vector is programmed (A4, B4, C4) in a block, then the programmed surface

normal vector remains constant over the entire block. If only the end vector is programmed

(A5, B5, C5), then large-circle interpolation is used to interpolate between the end value of the

preceding block and the programmed end value. If both start and end vectors are programmed,

interpolation according to the large circle principle is also performed between the two

directions. The fact that the start vector may be reprogrammed in a block means that the

direction of the surface normal vector can change irregularly on a block transition. Irregular

transitions of the surface normal vector always occur in cases where there is no tangential

transition between the surfaces (planes) involved, i.e. if they form an edge.

Once a surface normal vector is programmed, it remains valid until a new vector is

programmed. In the basic position, the surface normal vector is set to equal the vector in the

Z direction. This basic setting direction is independent of the active plane (G17 - G19). If

ORIWKS is active, surface normal vectors refer to the active frame, i.e. when the frame is

rotated, the vectors rotate simultaneously. This applies both to programmed orientations and

to those that have been derived from the active plane. If ORIWKS is active, the surface normal

vectors are brought along during a frame change. An orientation modified as the result of frame

rotations is not returned to its original state on switchover from ORIWKS to ORIMKS.

It must be noted that the programmed surface normal vectors may not necessarily be the same

as those used internally. This is always the case if the programmed surface normal vector is

not vertical on the path tangent. A new surface normal vector is then formed, which lies within

the plane spanned by the path tangent and programmed surface normal vector, but which is

vertical on the path tangent vector. This orthogonality is required, because the path tangent

vector and the surface normal vectors (must) always be vertical to one another in a real surface.

However, since the two variables can be programmed independently of one another, they can

contain information that is mutually contradictory. Orthogonalization ensures that the

information contained in the path tangent vector has priority over the data in the surface normal

vector. An alarm is output if the angle between the path tangent vector and the programmed

surface normal vector undershoots the limit value, which is defined in the following machine

data:

MD21084 $MC_CUTCOM_PLANE_PATH_LIMIT (minimal angle between surface normal

vector and path tangent vector)

If a block is shortened (inside corner), then the interpolation range of the surface normal vector

is reduced accordingly, i.e. the end value of the surface normal vector is not reached as it

would be with other interpolation quantities such as, for example, the position of an additional

synchronized axis.

In addition to the usual methods of programming orientation, it is also possible to refer the tool

orientation to the surface normal vector and path tangent vector using the addresses LEAD

(lead or camber angle) and TILT (side angle). The interpretation of the angle data depends on

the setting in MD21094 $MC_ORIPATH_MODE (see Chapter "Path-relative orientation

(ORIPATH, ORIPATHS, ORIROTC) (Page 97)"). The specification of the angle relative to the

surface normal is only an expanded option of orientation programming at the end of the block.

It does not imply that the lead and side angles reach their programmed values before the path

end point is reached.

The resulting tool orientation is determined from the path tangent, surface normal vector, lead

angle and side angle at the end of the block. This orientation is always implemented by the

end of the block, particularly in cases where the block is shortened (at an inside corner). If the

omitted path section is not a straight line in a plane, the lead and side angles generally deviate

Special functions

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26.1 Function

from their programmed values at the path end point. This is because the orientation has

changed relative to the surface normal vector or path tangent vector when the absolute

orientation of the tool is the same as at the original path end point.

26.1.3.3

Compensation on path

A special case must be examined with respect to face milling operations, i.e. that the machining

point on the tool surface moves around. This may be the case on a torus cutter whenever

surface normal vector n_F and tool vector w become collinear (i.e. the tool is at exact right angles

to the surface) since it is not a single point on the tool that corresponds to this direction, but

the entire circular surface on the tool end face. The contact point is therefore not defined for

this orientation. A path point in which tool longitudinal axis and surface normal are parallel is

therefore referred to below as a singular point or a singularity.

The above case is also meaningful in practical terms, e.g. in cases where a convex surface,

which may have a vertical surface normal (e.g. hemisphere), must be machined with a

perpendicular tool (e.g. face milling with constant orientation). The machining point on the

contour remains fixed, but the machine must be moved to bring the machining point from one

side of the tool to the other.

The problem described is only a borderline case (lead angle β = 0 and side angle y = 0). If the

lead angle β = 0 and the side angle y has a low value, then the tool must be moved very rapidly

(in borderline case in steps) to keep the machining point resulting from the milling conditions

close to the arc-line forming the end face (see the following figure).

In principle, it is resolved by the smoothing of the surface normal and the smoothing of the

contour.

6LQJXODU SRLQW

Figure 26-6

Switching of the processing point on the tool surface in the vicinity of a point in which the

surface normal vector and the tool orientation are parallel.

Singularities do not only occur in isolated points, but can also occur over entire curves. This

is the case, for example, if the curve to be interpolated is a plane curve (i.e. a curve with a

constant osculating plane) and the tool is constantly aligned in parallel to the binormal vector

(perpendicular to the osculating plane). A simple example of this is an arc in the X-Y plane,

which is processed with a tool that is aligned parallel to the Z axis. For paths of this type, the

tool offset is reduced to a tool length compensation. I.e. the tool is positioned in such a way

that its tip lies on the programmed path.

For a jump-like transition between singular and non-singular curves, linear blocks must be

inserted, just as in the handling of individual points, so that the processing point on the tool

Special functions

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26.1 Function

can migrate from the tool tip to the periphery (at outside corners or convex surfaces) or the

paths must be shortened to prevent contour violations (at inside corners or concave surfaces).

It is therefore necessary to activate both the smoothing of the contours ("Top Surface" function)

and the smoothing of the surface normal to ensure that the transitions run smoothly.

26.1.3.4

Corners in face milling

Two surfaces that do not tangentially transition into one another form an edge. The paths

defined on the surfaces form a corner. This corner is a point of the edge.

The type of corner (inside or outside corner) is defined by the surface normals of the

participating surfaces and the paths defined on them.

The surface normals of the two surfaces forming the edge may point in opposite directions of

the overall surface (the front edge of one surface is continued on the rear edge of the second

surface), see also the following Figure. Transitions of this type are not allowed and are rejected

with an alarm.

The scalar product of the surface normal vector and (possibly variable) tool orientation on one

corner/path must be positive at each point, i.e. it is not permissible to machine from the rear

face of the surface. If this condition is not fulfilled, an alarm is output. The permissible ranges

of validity of tool orientation for inside and outside corners are illustrated in the following Figure.

These ranges are further restricted by the condition that the angle between the surfaces to be

machined and the "steepest" surface line of the tool surface must not be lower than a particular

machine data setting. The "steepest" surface line is a line at angle a to the tool longitudinal

axis (this line is in the same direction as the tool longitudinal axis on cylindrical tools). This

restriction must be imposed to ensure that the contact point on the tool does not leave the

permissible range.

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Figure 26-7

Corners in face milling

It is possible to insert blocks that contain no motion commands (e.g. auxiliary function outputs)

and/or that include motions of geometry axes not involved in the path between two blocks

which contain a path definition. In particular, orientation changes can also be programmed in

such blocks. The only exception applies to the activation and deactivation of the 3D tool radius

compensation function: Intermediate bocks with orientation changes are not permitted

Special functions

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26.1 Function

between the activation block and the first corrected block or between the last corrected block

and the deactivation block. Other intermediate block are allowed, however.

26.1.3.5

Behavior at outer corners

In face milling, outside corners are treated like circles with a radius of 0, where the circular

plane stretches from the end tangent of the first block and the start tangent of the second block.

Thus, an orientation change during the block transition is also possible. Thus, a circle is always

inserted as a contour element at an outside corner. The intersecting point process is not

available for face milling.

Behavior during orientation changes

The G commands of Group 27 (too offset for orientation change at outside corners) can be

used to define whether orientation changes, which have been programmed between the two

traversing blocks that form the corner, are executed before the beginning of the inserted circle

set or at the same time.

● ORIC: Orientation changes at outside corners are superimposed on the circle block to be

inserted.

● ORID: Orientation changes are performed before the circle block.

If two or more blocks with orientation changes (e.g. A2=... B2=... C2=...) are programmed

between two traversing blocks and ORIC is active, then the circular block to be inserted is

divided between these intermediate blocks corresponding to the amount of the individual angle

changes. Further programmed intermediate blocks without traversing and orientation motions

are executed at the programmed positions.

If ORID is active, all inserted blocks (both those with and without orientation movement) are

executed at the end of the first of the two traversing blocks. The tangent in the end point of the

first traversing block is used for the offset calculation. The circle block with constant orientation

is inserted immediately before the second traversing block.

See also "Example 1: Orientation change at outside corner during 3D circumferential milling

(Page 932)".

26.1.3.6

Behavior at inside corners

The position of the tool in which it is in contact with the two surfaces forming the corner must

be determined at an inside corner. The contact points must be on the paths defined on both

surfaces. It is not usually possible to solve this problem exactly since, when the tool is moved

along the path on the first surface, it normally touches a point on the second surface which is

not on the path.

For this reason, the tool is not moved along the path on the first surface, but deviates from the

path in such a way as to ensure that the distance between the contact points and the relevant

contours in the position in which the tool contacts both surfaces is minimal, see also the

following Figure.

Special functions

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26.1 Function

&RQWDFW SRLQWV

7RRO VXUIDFH

3DWK

RIIVHW S

7RRO

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3DWK RQ VXUIDFH

ERWK VXUIDFHV

Figure 26-8

Inside corner with face milling (view in direction of longitudinal axis of tool)

Note

The amount by which the contact points deviate from the programmed contour will generally

be small since the explanatory example shown in the Figure, in which the machining point

"changes" the cutter side at an inside corner (the value of the angular difference Ψ about the

tool longitudinal axis between the two contact points on the tool surface is approximately 180°)

is more likely to be the exception (see also the following Figure, on the right). The angle Ψ will

normally stay almost constant so that the distance between the contact points on the tool

surface will be relatively small (see also the following Figure, on the left).

Figure 26-9

Machining at inside corners

The difference between the programmed point on the path and the point actually to be

approached (path offset p) is eliminated linearly over the entire block length. Differences

resulting from inside corners at the block start and block end are overlaid. The current

difference in a path point is always perpendicular to the path and in the surface defined by the

surface normal vector.

If the tool orientation at an inside corner is not constant, the change in orientation is

implemented in the same way as described in Subsection "Behavior at inside corners" for 3D

circumferential milling, i.e. the tool is moved in the corner so that it contacts the two adjacent

surfaces at the block start, block end and at two points ¹/₃ and ²/₃ of the change in orientation.

A 3rd-degree polynomial is used to interpolate between these 4 points.

A variable tool orientation in a block that is shortened owing to an inside corner is also treated

in the same way as described in Subsection "Behavior at inside corners" for 3D milling

(Page 906), i.e. the entire change in orientation is executed in the shortened block.

Consequently, the functional relationship between path tangent, surface normal and tool

orientation also changes. This results in new, previously nonexistent singularities or

Special functions

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26.2 Commissioning

impermissible side angles (at points which are virtually singular) occurring in the shortened

block. If this type of situation is detected during processing of an inside corner, the machining

operation is aborted with an alarm. No block division takes place at the singular points since

the compensatory motions this would involve frequently cause contour violations and the

change in machining side on the tool is not generally intended or even foreseen by the user.

The alarm is also output during examination of an inside corner if the singularity occurs in the

second of the two blocks without the transition to the next block being considered. The system

does not therefore detect that a block of this type will form an inside corner in conjunction with

the following block and that the singularity would be eliminated again by the second block

reduction.

Remedy: Create new/different NC program, e.g. with a smaller tolerance.

The surface normal vector n_F is not affected by the reduction of a block. This means that in

contrast to the tool orientation, the change in orientation that may need to be executed for this

vector will not be imaged onto the reduced traversing interval. This is necessary because a

surface other than that programmed would be machined. Unlike the tool orientation, no

problems arise as the result of an abrupt change in the surface normal vector at a block

transition since it does not reflect any axis motions.

Analogously to 3D circumferential milling, (see Section "Behavior at inside corners

(Page 906)"), the two traversing blocks that form an inside corner must contain contact points.

There is no evaluation of several traversing blocks (i.e. no bottleneck detection), CDON/CDOF

are not evaluated. If no contact point can be found, the machining operation is aborted with

an alarm (risk of collision).

26.1.3.7

Monitoring of path curvature

The path curvature is only monitored for circumferential milling. As a rule, it is therefore not

detected for CUT3DF* functions when an attempt is made to process a concave surface which

is so intensively curved that machining is not possible with the tool being used. A possible

exception are blocks that are split owing to a singularity. The transition between the two partial

blocks created after the split is then treated like an inside corner. Apart from these special

cases, it is the responsibility of the user to only use tools that make it possible to process every

part of the contour without contour violation. It could be helpful to use the CUT3DFD function

for this, where the differential tool is only minimally different from the original tool.

26.2

Commissioning

26.2.1

Parameter assignment

Minimal angle between path tangent and tool orientation

For the 3D-TRC, the angle between the path tangent and the tool orientation cannot

undershoot a specific limit angle.

This angle is defined in the machine data:

MD21080 $MC_CUTCOM_PARALLEL_ORI_LIMIT

Special functions

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26.3 Programming

The lower the value of MD21080, the higher the computation effort generally is, which is

needed to check adherence to the cited conditions. Exceptions apply to linear blocks with

constant orientation.

Minimal angle between surface normal vector and tool orientation

In 3D face milling, the following machine data specifies the minimum angle which the surface

normal vector and tool orientation must form in each point of the path if you are working with

a side angle that is not equal to zero and the tool is not a cherry:

MD21082 $MC_CUTCOM_PLANE_ORI_LIMIT

If this value is undershot, processing is canceled with an alarm.

The lower the value of MD21082, the higher the computation effort generally is, which is

needed to check adherence to the cited conditions.

MD21082 has no effect in linear blocks with constant orientation. In this case, angles of any

size are permitted, even if the side angle is not equal to zero.

Minimal angle between surface normal vector and path tangent vector

During 3D face milling, the following machine data specifies the minimum angle which the

surface normal vector and path tangent vector must form in each point of the path:

MD21084 $MC_CUTCOM_PLANE_PATH_LIMIT

If this value is undershot, processing is canceled with an alarm.

The lower the value of MD21084, the higher the computation effort generally is, which is

needed to check adherence to the cited conditions.

Interpolation of the surface normals via polynomials

In order to use smoothing of the surface normal in 3D face milling, the function "Interpolation

of the surface normal via polynomials" must be enabled:

MD28291 $MC_MM_SMOOTH_SURFACE_NORMALS = TRUE

If MD28291 is not set, processing is canceled with an alarm.

26.3

Programming

26.3.1

Selecting 3D tool radius compensation for 3D circumferential milling (CUT3DC,

CUT3DCD, ISD)

The 3D tool radius compensation (3D TRC) for the 3D circumferential milling without taking

limitation surfaces into account is selected with the modally effective G command CUT3DC or

CUT3DCD.

The actual activation is performed with G41 or G42 The tool radius compensation is

deactivated with G40.

Special functions

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26.3 Programming

Syntax

G41/G42 ORIC/ORID ISD=... CUT3DC/CUT3DCD CDOF2 X... Y... Z...

G40 X... Y... Z...

Meaning

CUT3DC:

3D TRC for circumferential milling (only when 5-axis transforma-

tion is active)

CUT3DCD:

3D TRC for circumferential milling referred to a differential tool

(only when 5-axis transformation is active)

The radius difference is specified by the tool parameter

$TC_DP15.

G41/G42 X... Y... Z... :

Activate tool radius compensation

G41:

Tool radius compensation left of the contour

G42:

Tool radius compensation right of the contour

Note:

The activation must be performed in a linear block (G0/G1).

CDOF2:

Deactivate collision detection for 3D circumferential milling

ORIC/ORID:

The behavior for orientation changes at outside corners is speci-

fied via the G commands ORIC and ORID.

ORIC:

Orientation changes at outside corners are superim-

posed on the circle block to be inserted.

ORID:

Orientation changes at outside corners are executed

before the circle block to be inserted.

ISD=<Value>:

With the ISD address, the insertion depth of the tool can be

changed for circumferential milling and active 3D tool radius com-

pensation.

<Value>:

Length of the insertion depth

G40 X... Y... Z... :

Deactivate tool radius compensation

Note:

The deactivation must be performed in a linear block (G0/G1) with

geometry axis movements.

Note

The G commands for selecting the 3D TRC are evaluated in the approach block, i.e. typically

in the block that contains G41 or G42.

G41 or G42 can also be programmed in blocks without traversing movement in geometry axes

relevant for the compensation. In this case, the approach block is the first traversing block

following such a block.

A change of the 3D TRC variant with active tool radius compensation is ignored without alarm.

Special functions

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26.3 Programming

Example

Program code

Comment

; Definition of tool D1:

$TC_DP1[1,1]=120

; Type (end mill)

$TC_DP3[1,1]=20

; Length compensation vector

$TC_DP6[1,1]=8

; Radius

N10 X0 Y0 Z0 T1 D1 F12000

; Selection of the tool.

N20 TRAORI(1)

; Activation of the transformation.

N30 G42 ORIC ISD=10 CUT3DC G64 X30

; Activation of the 3D circumferential milling,

; continuous orientation changes at outside corners,

; insertion depth: 10 mm

N40 ORIWKS A30 B15

; Orientation change at a corner through specification of axis po-

sitions.

N50 Y20 A3=1 C3=1

; Traversing block with orientation change,

; specification of the orientation with direction vector.

N60 X50 Y30

; Traversing block with constant orientation.

N70 Y50 A3=0.5 B3=1 C3=5

; Traversing block with orientation change.

N80 M63

; Block without traversing information.

N90 X0 ISD=20

; Traversing block with change of the insertion depth.

N100 G40 Y0

; Deactivation of the tool radius compensation.

N110 M30

Further information

Path and orientation

The type of circumferential milling used here is implemented by defining a path (guide line)

and the associated orientation. In this type of machining, the shape of the tool on the path is

not relevant. Only the radius at the tool intervention point is decisive.

;

Special functions

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26.3 Programming

Figure 26-10

Circumferential milling

Approach behavior

The approach behavior is always NORM for the 3D variant of the tool radius compensation.

Behavior at outside corners

The G commands of group 18 (corner behavior, tool offset) are evaluated at the outside corners

for circumferential milling with 3D TRC in the same way as for the conditions for the 2½D TRC:

● G450: Transition circle (tool travels round workpiece corners on a circular path)

In contrast to the solution for the 2½D TRC, the inserted contour element at an outside

corner is always a circle with a 0 radius, on which the tool radius compensation acts in the

same way as on any other programmed path. It is not possible to insert conics instead of

circles. In this case, the DISC address has no significance and is therefore not evaluated.

● G451: Intersection of equidistant paths (tool backs off from the workpiece corner)

The intersection is determined by extending the offset curves of the two participating blocks

and defining the intersection of the two blocks at the corner in the plane perpendicular to

the tool orientation.

The intersection procedure (G451) is not used when at least one block containing a change

to the tool orientation was inserted between the relevant traversing blocks. In this case, a circle

is always inserted at the corner.

Behavior for changes in orientation at outside corners

The ORIC and ORID G commands are used to determine whether changes in orientation

programmed between two blocks forming the corner are executed before the inserted circle

block (ORID) is processed or at the same time (ORIC).

Insertion depth

The insertion depth of the milling tool is the distance of the milling tool reference point from

the tip of the tool.

The milling tool reference point is the vertical projection of the milling tool machining point on

the programmed path to the longitudinal axis of the tool.

The position of the machining point on the peripheral surface of the tool is set with the insertion

depth.

Special functions

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26.3 Programming

① Programmed path

② Milling tool machining point

③ Milling tool reference point

④ Milling tool tip

ISD

Insertion depth (InSertion Depth)

Figure 26-11

Insertion depth

Tool radius compensation referred to a differential tool

3D TRC for circumferential milling referred to a differential tool is activated via the CUT3DCD

command. It should be applied if the programmed contour refers to the center-point path of a

standard tool, and a tool other than a differential tool is used for machining. When calculating

the 3D tool radius compensation, only the wear value of the radius of the active tool

($TC_DP15) and any programmed tool offsets OFFN and TOFFR are taken into account. The

basic radius ($TC_DP6) of the active tool is not taken into account.

Pocket milling with inclined side walls for circumferential milling with CUT3DC

In this 3D tool radius compensation, a deviation of the mill radius is compensated by infeed

toward the surface normals to be machined. The plane, in which the milling tool face is located,

remains unchanged if the insertion depth ISD has remained the same. For example, a milling

tool with a smaller radius than a standard tool would not reach the pocket base, which is also

the limitation surface. For automatic tool infeed, this limitation surface must be known to the

control, see Section "3D circumferential milling taking into account a limitation surface

(CUT3DCC, CUT3DCCD) (Page 927)".

Special functions

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26.3 Programming

Advanced Surface / Top Surface

Note

When applying tool radius compensation CUT3DCD in combination with the "Advanced

Surface" or "Top Surface" option (requiring a license), the setting recommendations regarding

"Advanced Surface" / "Top Surface" must be observed.

Special test programs are provided in the SIOS portal for checking the set data:

● Test programs for Advanced Surface (https://support.industry.siemens.com/cs/ww/en/view/

78956392)

● Test programs for Top Surface (https://support.industry.siemens.com/cs/ww/en/view/

109738423)

26.3.2

Selecting 3D tool radius compensation for the 3D face milling (CUT3DF,

CUT3DFS, CUT3DFF, CUT3DFD)

The 3D tool radius compensation (3D TRC) for the 3D face milling is selected with the modally

effective G command CUT3DF, CUT3DFS, CUT3DFF or CUT3DFD.

The actual activation is performed with G41 or G42

With 3D face milling, the surface normals of the plane to be machined must be defined in order

to calculate the tool radius compensation. This must be performed in the block with G41 or

G42 via the A4, B4, C4 and A5, B5, C5 addresses.

The tool radius compensation is deactivated with G40.

Syntax

G41/G42 ORIC/ORID CUT3DF/CUT3DFS/CUT3DFF/CUT3DFD X... Y... Z... A4=... B4=...

C4=... A5=... B5=... C5=

G40 X... Y... Z...

Meaning

CUT3DFS:

3D TRC for face milling with constant orientation. The tool

orientation is defined by G17 - G19 and is not influenced by

frames.

CUT3DFF:

3D TRC for face milling with constant orientation. The tool

orientation is the direction defined by G17 - G19 and, in some

case, rotated by a frame.

CUT3DF:

3D TRC for face milling with orientation change (only with

active 5-axes transformation)

Special functions

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26.3 Programming

CUT3DFD:

3D TRC for face milling with orientation change referred to a

differential tool (only with active 5-axis transformation)

The radius difference is specified by the tool parameter

$TC_DP15.

Note:

CUT3DFD is only possible in combination with "Smoothing

of surface normals in 3D face milling". This is activated by

calling the "Top Surface" function (requires as license) via

CYCLE832(...).

G41/G42 X... Y... Z... :

Activate tool offset

The behavior with G41 and with G42 is identical for 3D face

milling.

Note:

The activation must be performed in a linear block (G0/G1).

A4/5=... B4/5=... C4/5=...:

Definition of the surface normals of the plane to be machined

A4=... B4=... C4=...:

Definition at start of block

A5=... B5=... C5=...:

Definition at end of block

ORIC/ORID:

The behavior for orientation changes at outside corners is

specified via the G commands ORIC and ORID.

ORIC:

Orientation changes at outside corners are su-

perimposed on the circle block to be inserted.

ORID:

Orientation changes are performed before the

circle block.

G40 X... Y... Z... :

Deactivate tool radius compensation

Note:

The deactivation must be performed in a linear block (G0/G1)

with geometry axis movements.

Note

G41 or G42 can also be programmed in blocks without traversing movement in geometry axes

relevant for the compensation. In this case, the approach block is the first traversing block

following such a block.

A change of the 3D TRC variant with active tool radius compensation is ignored without alarm.

Examples

Example 1: 3D face milling with CUT3DF

Program code

Comment

N10

; Definition of tool D1:

N20 $TC_DP1[1,1]=121

; Tool type (toroidal miller)

N30 $TC_DP3[1,1]=20

; Length compensation

N40 $TC_DP6[1,1]=5

; Radius

N50 $TC_DP7[1,1]=3

; Rounding radius

N60

N70

Special functions

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26.3 Programming

Program code

Comment

N80 X0 Y0 Z0 A0 B0 C0 G17 T1 D1 F12000

; Selection of the tool.

N90 TRAORI(1)

; Select orientation transformation.

N100 B4=-1 C4=1

; Definition of the plane.

N110 G41 ORID CUT3DF G64 X10 Y0 Z0

; Activate tool offset.

N120 X30

N130 Y20 A4=1 C4=1

; Outside corner, new plane definition.

N140 B3=1 C3=5

; Change in orientation with ORID.

N150 B3=1 C3=1

; Change in orientation with ORID.

N160 X-10 A5=1 C5=2 ORIC

N170 A3=-2 C3=1

; Change in orientation with ORIC.

N180 A3=-1 C3=1

; Change in orientation with ORIC.

N190 Y-10 A4=-1 C4=3

; New plane definition.

N200 X-20 Y-20 Z10

; Inside corner with previous block.

N210 X-30 Y10 A4=1 C4=1

; Inside corner, new plane definition.

N220 A3=1 B3=0.5 C3=1.7

; Change in orientation with ORIC.

N230 X-20 Y30 A4=1 B4=-2 C4=3 ORID

N240 A3 = 0.5 B3=-0.5 C3=1

; Change in orientation.

N250 X0 Y30 C4=1

; Path movement, new plane,

; orientation with relative programming.

N260 BSPLINE X20 Z15

; Spline begin, relative programming of the orien-

tation

N270 X30 Y25 Z18

; remains active during spline.

N280 X40 Y20 Z13

N290 X45 Y0 PW=2 Z8

N300 Y-20

N310 G2 ORIMKS A30 B45 I-20 X25 Y-40 Z0

; Helix, orientation with axis programming.

N320 G1 X0 A3=-0.123 B3=0.456 C3=2.789 B4=-1 C4=5

; Path movement, orientation, non-constant plane.

B5=-1 C5=2

N330 X-20 G40

; Deactivation of the tool radius compensation.

N340 M30

Example 2: NC program (section) generated from a CAD system with CUT3DFD

Program code

Comment

N01 G710

N03 T="12"

N06 S5305 M03

N07 G642

; Approaching the starting position in the MCS taking the tool length into account.

G00 G90 X-250.62787 Y-38.37944 A=DC(253.12719)

B-12.49543

G00 G90 Z251.80052

; End of positioning in the MCS.

;

Special functions

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26.3 Programming

Program code

Comment

TRAORI(1)

; Select orientation transformation.

G500

CYCLE832(0.01, _TOP_SURFACE_SMOOTH_ON + _ORI_FIN-

; Call CYCLE832 with:

ISH, 1)

; Contour tolerance = 0.01 mm,

; Processing type: Top Surface with smoothing,

; Finishing with input of an orientation toler-

ance,

; Orientation tolerance = 1 degree

CUT3DFD

N08 G90 G94

N09 G00 X-269.21195 Y128.32027 Z1.18577

; The blocks N09 to N10 are the fast portion of

A3=-.216361688 B3=.934284397 C3=-.283373051

the approach movement to the workpiece with con-

stant orientation.

N10 G00 X-251.90301 Y53.57752 Z23.85561

N11 G01 X-247.57578 Y34.89183 Z29.52308 F50000.00000

; In the blocks N11 to N21, the slow portion of

the approach movement is realized. The tool is

already close to the workpiece; furthermore, the

mold making settings (e.g. COMPSURF) from the CY-

CLE832 are now active (due to active G01). The

path of this so-called transient phase for the

mold-making behavior should be about 1000 times

the contour tolerance (10 mm in this example).

N12 X-247.69126 Y33.82182 Z24.78219 F1061.00000

N13 X-247.76560 Y33.13299 Z21.73022

N14 X-247.82755 Y32.55897 Z19.18691

N15 X-247.87918 Y32.08062 Z17.06748

N16 X-247.92220 Y31.68200 Z15.30129

N17 X-247.95805 Y31.34981 Z13.82947

A3=-.216361686 B3=.934284391 C3=-.283373071

N18 X-247.98792 Y31.07299 Z12.60295

A3=-.216360662 B3=.934280801 C3=-.283385691

N19 X-248.01282 Y30.84230 Z11.58085

A3=-.216336015 B3=.934194446 C3=-.283689030

N20 X-248.03357 Y30.65006 Z10.72910

A3=-.216233089 B3=.933833626 C3=-.284952647

N21 X-248.05086 Y30.48986 Z10.01931

A5=-.060687572 B5=.974940255 C5=-.214029243

A3=-.215712821 B3=.932005189 C3=-.291263295

N22 G41 X-248.06237 Y30.32400 Z9.36695

; From N22, the surface normal is completely de-

A5=-.060431854 B5=.973045457 C5=-.222554556

fined over the entire block for the first time

A3=-.214974689 B3=.929398552 C3=-.300007025

(i.e. surface normal at the end of the previous

F1061.03295

block N21 is present, thus the surface normal at

the beginning of the block N22 and the surface

normal at the end of the block N22). Thus the

prerequisite for switching on the tool offset

with G41/G42 is fulfilled.

Special functions

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26.3 Programming

Program code

Comment

N23 X-248.07130 Y30.15119 Z8.71082

A5=-.060165696 B5=.971048883 C5=-.231179920

A3=-.214177198 B3=.926684940 C3=-.308841625

N24 X-248.07829 Y29.97126 Z8.05094

A5=-.059884286 B5=.968941717 C5=-.239928784

A3=-.213318480 B3=.923853466 C3=-.317789237

N25 X-248.08317 Y29.78487 Z7.38844

A5=-.059584206 B5=.966718449 C5=-.248807482

A3=-.212397895 B3=.920898045 C3=-.326854594

N26 X-248.08578 Y29.59254 Z6.72679

A5=-.059263963 B5=.964380907 C5=-.257793037

A3=-.211418355 B3=.917822366 C3=-.336012474

Note

For 3D face milling with CUT3DFD, the definition of the surface normal is required for activating

the tool offset with G41/G42. Programming of G41/G42 without definition of the surface

normals leads to the output of an alarm.

Further information

3D face milling

For this type of 3D milling, you require the line-by-line description of the 3D paths on the

workpiece surface. The tool shape and dimensions are taken into account in the calculations,

which are normally performed in CAM. The postprocessor writes to the part program - in

addition to NC blocks - the tool orientations (for active 5-axis transformation) and the G

command for the required 3D tool offset. This means that the machine operator has the

possibility of using tools that are slightly smaller - deviating from the tool used to calculate the

NC paths.

Figure 26-12

Face milling

Approach behavior

The approach behavior is always NORM for the 3D variant of the tool radius compensation.

Special functions

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26.3 Programming

Behavior at outside corners

Outside corners are treated as circles with radius 0 for face milling, whereby the circle plane

extends from the end tangent of the first block to the start tangent of the second block. In this

way, the orientation can be changed during block transition. A circle is therefore always

inserted as contour element at an outside corner. The intersection procedure is not available

with face milling.

Behavior for changes in orientation at outside corners

The ORIC and ORID G commands are used to determine whether changes in orientation

programmed between two blocks forming the corner are executed before the inserted circle

block (ORID) is processed or at the same time (ORIC).

Tool radius compensation referred to a differential tool

3D tool radius compensation referring to a differential tool is selected using the CUT3DFD

command. It should be applied if the programmed contour refers to the center-point path of a

standard tool, and a tool other than a differential tool is used for machining. When calculating

the 3D tool radius compensation, only the wear value of the radius of the active tool

($TC_DP15) and any programmed tool offsets OFFN and TOFFR are taken into account. The

basic radius ($TC_DP6) of the active tool is not taken into account.

3D face milling with CUT3DFD is only possible in combination with "Smoothing of surface

normals in 3D face milling". This is activated by calling the "Top Surface" function (requires as

license) via CYCLE832(...). Activation must take place before the tool offset is activated with

G41/G42; not directly before tool intervention, but rather one path length before that, which

corresponds to approx. 1000 times the contour tolerance (e.g. 1000 x 0.01 mm = 10 mm).

Deactivation must be executed in reverse order: First switch off the tool offset with G40, then

deactivate with e.g. CUT2D (or similar) after a path length which corresponds with

approximately 1000 time the contour tolerance.

In order to be able to use the "Smoothing of surface normals in 3D face milling", the

"Interpolation of surface normals via polynomials" function must also be enabled:

MD28291 $MC_MM_SMOOTH_SURFACE_NORMALS = TRUE

Note

For 3D face milling with CUT3DFD in combination with "Top Surface", the setting

recommendations regarding "Top Surface" must be observed.

Special test programs are provided (https://support.industry.siemens.com/cs/ww/en/view/

109738423) in the SIOS portal for checking the set data.

26.3.3

3D circumferential milling taking into account a limitation surface (CUT3DCC,

CUT3DCCD)

In 3D circumferential milling with a continuous or constant change in tool orientation, the tool

center-point path is frequently programmed for a defined standard tool. Because in practice

suitable standard tools are often not available, a tool that does not deviate too much from a

standard tool (≤ 5%) can be used.

Special functions

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26.3 Programming

CUT3DCCD takes account of a limitation surface for a real differential tool that the programmed

standard tool would define. The NC program defines the center-point path of a standard tool.

CUT3DCC with the use of cylindrical tools takes account of a limitation surface that the

programmed standard tool would have reached. The NC program defines the contour on the

machining surface.

The surface normal vector of the limitation surface is specified with A4, B4, C4 and A5, B5,

C5 for 3D face milling.

Syntax

G41/G42 CUT3DCCD/CUT3DCC CDOF2 X... Y... Z... A4=... B4=... C4=... A5=... B5=...

C5=

G40 X... Y... Z...

Meaning

CUT3DCCD:

3D TRC for the circumferential milling taking into account a limitation

surface with a differential tool on the tool center-point path: Infeed

to the limitation surface

CUT3DCC:

3D TRC for the circumferential milling taking into account a limitation

surface with 3D radius compensation: Contour on the machining

surface

G41/G42 X... Y... Z... :

Activate tool radius compensation

G41:

Tool radius compensation left of the contour

G42:

Tool radius compensation right of the contour

Note:

The activation must be performed in a linear block (G0/G1).

CDOF2:

Deactivate collision detection for 3D circumferential milling

A4/5=... B4/5=...

Definition of the surface normals of the limitation surface

C4/5=...:

A4=... B4=... C4=...:

Definition at start of block

A5=... B5=... C5=...:

Definition at end of block

G40 X... Y... Z... :

Deactivate tool radius compensation

Note:

The deactivation must be performed in a linear block (G0/G1) with

geometry axis movements.

Note

The G commands for selecting the 3D TRC are evaluated in the approach block, i.e. typically

in the block that contains G41 or G42.

G41 or G42 can also be programmed in blocks without traversing movement in geometry axes

relevant for the compensation. In this case, the approach block is the first traversing block

following such a block.

A change of the 3D TRC variant with active tool radius compensation is ignored without alarm.

Special functions

928

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26.3 Programming

Example

Program code

Comment

N10 $TC_DP1[1,1]=120

; Cylindrical milling tool

N20 $TC_DP6[1,1]=10

N30 $TC_DP15[1,1]=-3

; Processing with cylindrical milling tool and CUT3DCCD

N110 TRAORI

; Activation of the transformation.

N120 A4=0 B4=0 C4=1

; Definition of the surface normal of the

limitation surface at the start of the

block.

N130 X0 Y0 Z0 A0 C0 T1 D1 F20000

N140 X10 Y0 Z0 G41 CUT3DCCD CDOF2 G64

; Activate 3D circumferential milling,

taking into account the limitation sur-

face + switching off collision detection.

N150 X20

N160 X30 A45

; Obtuse angle ==> no infeed

N170 X40 A-45

; Acute angle ==> infeed

N180 X55

N190 Y10 Z10

; Movement in the tool direction.

N200 Y20

N210 C45

; Pure change in orientation.

N220 Y30 C90

N230 A5=-1 B5=0 C5=2 Y40

; Change of the surface.

N240 Y50 G40

; Deactivation of the tool radius compen-

sation.

Further information

Tool type

The tool type (tool parameter $TC_DP1) is evaluated. Only milling tools with cylindrical shank

(cylinder or end mill, toroidal miller and, in the limit case, cylindrical die mill) are permitted. This

corresponds to the tool types 1 - 399, with the exception of the numbers 111 and 155 to 157.

Standard tools with corner rounding

Corner rounding with a standard tool is defined by the tool parameter $TC_DP7. Tool

parameter $TC_DP16 describes the deviation of the corner rounding of the real tool compared

with the standard tool.

Special functions

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W5: 3D tool radius compensation - 840D sl only

26.3 Programming

Example: Toroidal miller with reduced radius compared to the standard tool

Tool type

Shaft radius (R)

Corner radius (r)

Standard tool with corner rounding

R = $TC_DP6

r = $TC_DP7

Real tool with corner rounding

R' = $TC_DP6 + $TC_DP15 +

r' = $TC_DP7 + $TC_DP16

OFFN

Tool types 121 and 131 toroidal

miller

(end mill with corner rounding)

In this example, both $TC_DP15 + OFFN and $TC_DP16 are negative.

3D TRC with CUT3DCCD: Tool center-point path with infeed up to the limitation surface

If a tool with a smaller radius than the appropriate standard tool is used, machining is continued

using a milling tool, which is fed in in the longitudinal direction until it reaches the bottom (base)

of the pocket. The tool removes as much material from the corner formed by the machining

surface and limitation surface. This involves a machining type combining circumferential and

face milling. Analogous to a tool with reduced radius, for a tool with increased radius, the infeed

is in the opposite direction.

① Standard tool

② Tool with smaller radius infeed up to the limitation surface

③ Limitation surface

④ Machining surface

Contrary to all other tool offsets of G group 22, tool parameter $TC_DP6 specified for

CUT3DCCD has no relevance for the tool radius and does not influence the resulting

compensation. The compensation offset results from the sum of the wear value of the tool

radius (tool parameter $TC_DP15) and a tool offset OFFN programmed to calculate the

perpendicular offset to the limitation surface.

The generated part program does not specify whether the surface to be machined is to the

right or left of the path. It is therefore assumed that the radius is a positive value and the wear

value of the original tool is a negative value. A negative wear value always describes a tool

with a reduced diameter.

Special functions

930

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W5: 3D tool radius compensation - 840D sl only

26.3 Programming

Using cylindrical tools

When cylindrical tools are used, infeed is only necessary if the machining surface and the

surface of limitation form an acute angle (less than 90 degrees). If a toroidal miller (end mill

with corner rounding) is used, tool infeed in the longitudinal direction is required for both acute

and obtuse angles.

3D TRC with CUT3DCC: Contour on the machining surface

If CUT3DCC is active with a toroidal miller, the programmed path refers to a fictitious cylindrical

milling tool having the same diameter. The resulting path reference point is shown in the

following diagram for a toroidal miller.

① Toroidal miller

② Limitation surface

③ Path reference point

④ Machining surface

Shaft radius (tool radius)

The angle between the machining and limitation surfaces may change from an acute to an

obtuse angle and vice versa even within the same block.

The tool actually being used may either be larger or smaller than the standard tool. However,

the resulting corner radius must not be negative and the sign of the resulting tool radius must

be kept.

For CUT3DCC, the NC part program refers to the contour on the machining surface. As for

conventional tool radius compensation, the total tool radius is used that comprises the following

components:

● Tool radius (tool parameter $TC_DP6)

● Wear value (tool parameter $TC_DP15)

● A tool offset OFFN programmed to calculate the perpendicular offset to the limitation surface

The position of the limitation surface is defined from the following difference:

Dimensions of the standard tool - tool radius (tool parameter $TC_DP6)

Special functions

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26.5 Examples

Advanced Surface / Top Surface

Note

When applying tool radius compensation CUT3DCC / CUT3DCCD in combination with the

"Advanced Surface" or "Top Surface" function (requiring a license), the setting

recommendations regarding "Advanced Surface" / "Top Surface" must be observed.

Special test programs are provided in the SIOS portal for checking the set data:

● Test programs for Advanced Surface (https://support.industry.siemens.com/cs/ww/en/view/

78956392)

● Test programs for Top Surface (https://support.industry.siemens.com/cs/ww/en/view/

109738423)

26.4

Constraints

Boundary conditions for face milling

Functions with high-order geometry information

Functions with high-order geometry information (e.g. polynomials or spline interpolation)

cannot be used.

Top Surface

3D face milling with CUT3DFD is only possible in conjunction with the "Top Surface" function,

which requires a license.

Bottleneck detection

A "bottleneck detection" is not possible, and therefore the user is solely responsible.

Traversing movements in the orientation direction of the tool

For traversing motion in the orientation direction of the tool, and alarm is displayed and

machining stopped.

26.5

Examples

26.5.1

Example 1: Orientation change at outside corner during 3D circumferential milling

Orientation change at outside corner with ORIC active

Program code

Comment

N10 A0 B0 X0 Y0 Z0 F5000

Special functions

932

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W5: 3D tool radius compensation - 840D sl only

26.5 Examples

Program code

Comment

N20 T1 D1

; Selection of the tool (radius=5).

N30 TRAORI(1)

; Activation of transformation.

N40 CUT3DC

; Selection of 3D TRC for circumferential milling.

N50 ORIC

; Orientation changes at outside corners are super-

imposed on the circle block to be inserted.

N60 G42 X10 Y10

; Activation of TRC.

N70 X60

N80 A3=1 B3=0 C3=1

; change in orientation of external corner gener-

ated from N70 and N90

N90 Y60

N100 X10

N110 G40 X0 Y0

; Deactivation of TRC.

N120 M30

The circular motion and change in orientation are executed in parallel in block N80 (ORIC

active):

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RULHQWDWLRQ LQVHUWHG EORFN QRW

SURJUDPPHG

7RRO LQFOLQHG

2XWVLGH FRUQHU ZLWK FRQVWDQW

RULHQWDWLRQ LQVHUWHG EORFN QRW

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;

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Figure 26-13

ORIC: Change in orientation and path movement in parallel

Special case:

Intermediate blocks without traversing and orientation motions are executed at the

programmed positions, e.g. auxiliary functions.

Example:

Program code

Comment

N70 X60

Special functions

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W5: 3D tool radius compensation - 840D sl only

26.5 Examples

Program code

Comment

N75 M20

; auxiliary function call

N80 A3=1 B3=0 C3=1

; change in orientation of external corner gener-

ated from N70 and N90

N90 Y60

Blocks N75 and N80 are executed after N70. The circle block is then executed with the current

orientation.

Orientation change at outside corner with ORID active

Program code

Comment

N10 A0 B0 X0 Y0 Z0 F5000

N20 T1 D1

; Selection of the tool (radius=5).

N30 TRAORI(1)

; Activation of transformation.

N40 CUT3DC

; Selection of 3D TRC for circumferential milling.

N50 ORID

; Orientation changes at outside corners are per-

formed on the circle block to be inserted.

N60 G42 X10 Y10

; Activation of TRC.

N70 X60

N80 A3=1 B3=0 C3=1

; change in orientation of external corner gener-

ated from N70 and N90

N90 Y60

N100 X10

N110 G40 X0 Y0

; Deactivation of TRC.

N120 M30

Special functions

934

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W5: 3D tool radius compensation - 840D sl only

26.5 Examples

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RULHQWDWLRQ LQVHUWHG EORFN QRW

SURJUDPPHG

7RRO LQFOLQHG

7RRO DW VWDUW SRLQW RI 1

;

7RRO DW HQG RI 1

7RRO YHUWLFDO

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VXFK D ZD\ WKDW WKH WRRO DOZD\V

7RRO DW HQG RI 1

WRXFKHV WKH

HQGSRLQW RI 1

Figure 26-14

ORID: Change in orientation and path movement consecutively

26.5.2

Example 2: Orientation change at inside corner during 3D circumferential milling

Program code

Comment

N10 A0 B0 X0 Y0 Z0 F5000

N20 T1 D1

; Selection of the tool (radius=5).

N30 TRAORI(1)

; Activation of transformation.

N40 CUT3DC

; Selection of 3D TRC for circumferential milling.

N50 ORID

N60 G42 X10 Y10 G451

; Activation of TRC.

N70 Y60

N80 A3=1 B3=0 C3=1

; change in orientation of inside corner generated

from N70 and N90.

N90 X60 Y90

N100 G40 X... Y...

N190 CDOF

N200 M30

Special functions

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26.6 Data lists

26.6.2

Channelspecific machine data

Number

Identifier: $MC_

Description

20110

RESET_MODE_MASK

Definition of the control basic setting after power-up and

RESET / part program end

20120

TOOL_RESET_VALUE

Definition of the tool from which the tool length compen-

sation is selected during run-up and upon RESET or part

program end, dependent upon MD 20110.

20130

CUTTING_EDGE_RESET_VALUE

Definition of tool cutting edge for which tool length com-

pensation is selected during power-up or on reset or

parts program end as a function of MD20110

20140

TRAFO_RESET_VALUE

Definition of transformation block which is selected dur-

ing power-up and or RESET or parts program end as a

function of MD20110

20210

CUTCOM_CORNER_LIMIT

Max. angle for intersection calculation with tool radius

compensation

20220

CUTCOM_MAX_DISC

Behavior of the TRC at outside corners

20230

CUTCOM_CURVE_INSERT_LIMIT

Minimum value for intersection calculation with tool ra-

dius compensation

20240

CUTCOM_MAXNUM_CHECK_BLOCKS

Blocks for predictive contour calculation with tool radius

compensation

20250

CUTCOM_MAXNUM_DUMMY_BLOCKS

Number of blocks without traversing motion for tool ra-

dius compensation

20270

CUTTING_EDGE_DEFAULT

Selected cutting edge after tool change

20610

ADD_MOVE_ACCEL_RESERVE

Acceleration reserve for overlaid motions

21080

CUTCOM_PARALLEL_ORI_LIMIT

Minimal angle between path tangent and tool orientation

for 3D-TRC

21082

CUTCOM_PLANE_ORI_LIMIT

Minimal angle between surface normal vector and tool

orientation (for 3D face milling)

21084

CUTCOM_PLANE_PATH_LIMIT

Minimal angle between surface normal vector and path

tangent vector (for 3D face milling)

22550

TOOL_CHANGE_MODE

New tool offset with M function

22560

TOOL_CHANGE_M_CODE

M function for tool change

28291

MM_SMOOTH_SURFACE_NORMALS

Interpolation of the surface normals via polynomials (for

3D face milling)

Special functions

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W6: Path length evaluation - 840D sl only

27.1

Brief description

Function

With the "Path length evaluation" function, the NC specific machine axis data is made available

as the system and OPI variables, with whose help it is possible to assess the strain on the

machine axes and thereby make an evaluation on the state of the machine's maintenance.

Recorded data

The following data is recorded:

● Total traverse path

● Total travel time

● Total travel count

● Total traverse path at high axis speeds

● Total travel time at high axis speeds

● Travel count at high axis speeds

● Total sum of jerks

● Axis travel time with jerk

● Travel count with jerk

Evaluation

When the function is activated, the selected control data is automatically sent and made

available via the system and OPI variables for evaluation in the part program or synchronized

actions, as with user-specified HMI functions.

Meaning

The data remains saved in the control, so that it may continue to be used after POWER OFF /

ON. Consequently, the actual value of a data item represents the sum of all measured values

since the function was activated.

Special functions

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27.3 Parameterization

27.2

Data

The following data is available:

System variable ¹⁾

OPI variable

Meaning

$AA_TRAVEL_DIST

aaTravelDist

Total traverse path:

sum of all set position changes in MCS ²⁾ in [mm] or [deg.].

$AA_TRAVEL_TIME

aaTravelTime

Total travel time:

sum of IPO clock cycles from set position changes in MCS ²⁾ in [s]

(solution: 1 IPO clock cycle)

$AA_TRAVEL_COUNT

aaTravelCount

Total travel count:

a complete machine axis trip is defined by the following succession of

states, as based on set position: standstill > traversing > standstill

$AA_TRAVEL_DIST_HS

aaTravelDistHS

Total traversing distance at high axis velocities ³⁾

$AA_TRAVEL_TIME_HS

aaTravelTimeHS

Total traversing time at high axis velocities ³⁾

$AA_TRAVEL_COUNT_HS

aaTravelCountHS

Total number of traversing operations at high axis velocities ³⁾

$AA_JERK_TOT

aaJerkTotal

Total sum of axis jerks:

Sum of all jerk setpoints in [m/s³] or [deg./ s³].

$AA_JERK_TIME

aaJerkTime

Total travel time with jerk:

sum of IPO clock cycles from jerk setpoint changes in [s] (solution: 1

IPO clock cycle)

$AA_JERK_COUNT

aaJerkCount

Total number of traversing operations with jerk

¹⁾ System variables can be read from part programs and synchronized actions

²) MCS: Machine coordinate system

³⁾ Actual machine axis velocity ≥ 80% of the maximum parameterized axis velocity (MD32000 MAX_AX_VELO)

27.3

Parameterization

27.3.1

General activation

The function is generally activated via the NC-specific machine data:

MD18860 $MN_MM_MAINTENANCE_MON (Activate recording of maintenance data)

27.3.2

Data groups

The data has been collected into data groups.

The data groups are activated via the axis-specific machine data:

Special functions

940

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W6: Path length evaluation - 840D sl only

27.4 Examples

MD33060 $MA_MAINTENANCE_DATA (configuration to record maintenance data)

Bit

Value

Activation of the following data: System variable / OPI variable

● Total traverse path: $AA_TRAVEL_DIST / aaTravelDist

● Total travel time: $AA_TRAVEL_TIME / aaTravelTime

● Total travel count: $AA_TRAVEL_COUNT / aaTravelCount

● Total traversing distance for high velocities:

$AA_TRAVEL_DIST_HS / aaTravelDistHS

● Total traversing time for high velocities:

$AA_TRAVEL_TIME_HS / aaTravelTimeHS

● Total number of traversing operations at high velocities:

$AA_TRAVEL_COUNT_HS / aaTravelCountHS

● Total sum of jerks: $AA_JERK_TOT / aaJerkTotal

● Travel time with jerk: $AA_JERK_TIME / aaJerkTime

● Total travel count with jerk:

$AA_JERK_COUNT / aaJerkCount

27.4

Examples

27.4.1

Traversal per part program

Three geometry axes AX1, AX2 and AX3 exist in a machine. For geometry axis AX1, the part

program-driven total traverse path, total travel time and travel count should be calculated.

Parameter assignment

Activation of the overall function:

MD18860 $MN_MM_MAINTENANCE_MON = TRUE

Group activation: "Total travel distance, total travel time and number of travel operations" for

geometry axis AX1:

MD33060 $MA_MAINTENANCE_DATA[AX1] = 1

Programming

To determine the values referred to the part program, the actual value of the system variables

at the beginning of the part program must be saved in a calculation variable. The difference is

acquired at the end of the part program.

Part program (extract):

Program code

Comment

; Current values:

Special functions

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27.5 Data lists

Program code

Comment

R10=$AA_TRAVEL_DIST[AX1]

; Total traversing distance AX1

R11=$AA_TRAVEL_TIME[AX1]

; Total traversing time AX1

R12=$AA_TRAVEL_COUNT[AX1]

; Number of traversing operations AX1

; Traversing motion of axes

; Generating the difference:

R10=R10-$AA_TRAVEL_DIST[AX1]

; Traversing distance AX1 in the part pro-

gram

R11=R11-$AA_TRAVEL_TIME[AX1]

; Traversing time AX1 in the part program

R12=R12-$AA_TRAVEL_COUNT[AX1]

; Number of traversing operations AX1 in

the part program

27.5

Data lists

27.5.1

Machine data

27.5.1.1

NC-specific machine data

Number

Identifier: $MN_

Description

18860

MM_MAINTENANCE_MON

Activate recording of maintenance data

27.5.1.2

Axis/spindlespecific machine data

Number

Identifier: $MA_

Description

33060

MAINTENANCE_DATA

Configuration, recording maintenance data

Special functions

942

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Appendix

A.1

List of abbreviations

Output

ADI4

(Analog drive interface for 4 axes)

Adaptive Control

ALM

Active Line Module

ARM

Rotating induction motor

Automation system

ASCII

American Standard Code for Information Interchange: American coding standard for

the exchange of information

ASIC

Application-Specific Integrated Circuit: User switching circuit

ASUB

Asynchronous subprogram

AUXFU

Auxiliary function: Auxiliary function

STL

Statement List

User Program

Operating Mode

BAG

Mode group

BCD

Binary Coded Decimals: Decimal numbers encoded in binary code

BERO

Contact-less proximity switch

Binector Input

BICO

Binector Connector

BIN

BINary files: Binary files

BIOS

Basic Input Output System

BCS

Basic Coordinate System

Binector Output

OPI

Operator Panel Interface

CAD

Computer-Aided Design

CAM

Computer-Aided Manufacturing

Compile Cycle: Compile cycles

CEC

Cross Error Compensation

Connector Input

CF Card

Compact Flash Card

Special functions

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945

Appendix

A.1 List of abbreviations

CNC

Computerized Numerical Control: Computer-Supported Numerical Control

Connector Output

CoL

Certificate of License

COM

Communication

CPA

Compiler Projecting Data: Configuring data of the compiler

CRT

Cathode Ray Tube: picture tube

CSB

Central Service Board: PLC module

Control Unit

Communication Processor

CPU

Central Processing Unit: Central processing unit

Carriage Return

CTS

Clear To Send: Ready to send signal for serial data interfaces

CUTCOM

Cutter radius Compensation: Tool radius compensation

DAC

Digital-to-Analog Converter

Data Block (PLC)

DBB

Data Block Byte (PLC)

DBD

Data Block Double word (PLC)

DBW

Data Block Word (PLC)

DBX

Data block bit (PLC)

DDE

Dynamic Data Exchange

DDS

Drive Data Set: Drive data set

DIN

Deutsche Industrie Norm

DIO

Data Input/Output: Data transfer display

DIR

Directory: Directory

DLL

Dynamic Link Library

Drive Object

DPM

Dual Port Memory

DPR

Dual Port RAM

DRAM

Dynamic memory (non-buffered)

DRF

Differential Resolver Function: Differential revolver function (handwheel)

DRIVE-CLiQ

Drive Component Link with IQ

DRY

Dry Run: Dry run feedrate

DSB

Decoding Single Block: Decoding single block

DSC

Dynamic Servo Control / Dynamic Stiffness Control

Data Word

DWORD

Double Word (currently 32 bits)

Special functions

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Appendix

A.1 List of abbreviations

Input

EES

Execution from External Storage

I/O

Input/Output

ENC

Encoder: Actual value encoder

EFP

Compact I/O module (PLC I/O module)

ESD

Electrostatic Sensitive Devices

EMC

ElectroMagnetic Compatibility

European standard

ENC

Encoder: Actual value encoder

EnDat

Encoder interface

EPROM

Erasable Programmable Read Only Memory: Erasable, electrically programmable

read-only memory

ePS Network Services

Services for Internet-based remote machine maintenance

EQN

Designation for an absolute encoder with 2048 sine signals per revolution

Engineering System

ESR

Extended Stop and Retract

ETC

ETC key ">"; softkey bar extension in the same menu

Function Block (PLC)

Function Call: Function Block (PLC)

FEPROM

Flash EPROM: Read and write memory

FIFO

First In First Out: Memory that works without address specification and whose data is

read in the same order in which they was stored

FIPO

Fine interpolator

FPU

Floating Point Unit: Floating Point Unit

CRC

Cutter Radius Compensation

FST

Feed Stop: Feedrate stop

FBD

Function Block Diagram (PLC programming method)

Firmware

Global Control (PROFIBUS: Broadcast telegram)

GDIR

Global part program memory

GEO

Geometry, e.g. geometry axis

GIA

Gear Interpolation dAta: Gear interpolation data

GND

Signal Ground

Basic program (PLC)

Gear Stage

GSD

Device master file for describing a PROFIBUS slave

Special functions

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947

Appendix

A.1 List of abbreviations

GSDML

Generic Station Description Markup Language: XML-based description language for

creating a GSD file

GUD

Global User Data: Global user data

HEX

Abbreviation for hexadecimal number

AuxF

Auxiliary function

HLA

Hydraulic linear drive

HMI

Human Machine Interface: SINUMERIK user interface

MSD

Main Spindle Drive

Hardware

IBN

Commissioning

ICA

Interpolatory compensation

Interface Module: Interconnection module

IMR

Interface Module Receive: Interface module for receiving data

IMS

Interface Module Send: Interface module for sending data

INC

Increment: Increment

INI

Initializing Data: Initializing data

IPO

Interpolator

ISA

Industry Standard Architecture

ISO

International Standardization Organization

JOG

Jogging: Setup mode

K_V

Gain factor of control loop

K_p

Proportional gain

K_Ü

Transformation ratio

LAD

Ladder Diagram (PLC programming method)

LAI

Logic Machine Axis Image: Logical machine axes image

LAN

Local Area Network

LCD

Liquid Crystal Display: Liquid crystal display

LED

Light Emitting Diode: Light-emitting diode

Line Feed

Special functions

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Appendix

A.1 List of abbreviations

PMS

Position Measuring System

Position controller

LSB

Least Significant Bit: Least significant bit

LUD

Local User Data: User data (local)

MAC

Media Access Control

MAIN

Main program: Main program (OB1, PLC)

Megabyte

MCI

Motion Control Interface

MCIS

Motion Control Information System

MCP

Machine Control Panel: Machine control panel

Machine Data

MDA

Manual Data Automatic: Manual input

MDS

Motor Data Set: Motor data set

MSGW

Message Word

MCS

Machine Coordinate System

Motor Module

MPF

Main Program File: Main program (NC)

MCP

Machine control panel

Numerical Control: Numerical control with block preparation, traversing range, etc.

NCU

Numerical Control Unit: NC hardware unit

NRK

Name for the operating system of the NC

Interface Signal

NURBS

Non-Uniform Rational B-Spline

Work Offset

Numerical Extension: Axis expansion board

Organization block in the PLC

OEM

Original Equipment Manufacturer

Operator Panel: Operating equipment

OPI

Operator Panel Interface: Interface for connection to the operator panel

OPT

Options: Options

OLP

Optical Link Plug: Fiber optic bus connector

OSI

Open Systems Interconnection: Standard for computer communications

Special functions

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949

Appendix

A.1 List of abbreviations

PIQ

Process Image Output

PII

Process Image Input

Personal Computer

PCIN

Name of the SW for data exchange with the control

PCMCIA

Personal Computer Memory Card International Association:

Plug-in memory card standardization

PCU

PC Unit: PC box (computer unit)

Programming device

PKE

Parameter identification: Part of a PIV

PIV

Parameter identification: Value (parameterizing part of a PPO)

PLC

Programmable Logic Control: Adaptation control

PROFINET

PNO

PROFIBUS user organization

POWER ON

POU

Program Organization Unit

POS

Position/positioning

POSMO A

Positioning Motor Actuator: Positioning motor

POSMO CA

Positioning Motor Compact AC: Complete drive unit with integrated power and control

module as well as positioning unit and program memory; AC infeed

POSMO CD

Positioning Motor Compact DC: Like CA but with DC infeed

POSMO SI

Positioning Motor Servo Integrated: Positioning motor, DC infeed

PPO

Parameter Process data Object: Cyclic data telegram for PROFIBUS DP transmission

and "Variable speed drives" profile

PPU

Panel Processing Unit (central hardware for a panel-based CNC, e.g SINUMERIK

828D)

PROFIBUS

Process Field Bus: Serial data bus

PRT

Program Test

PSW

Program control word

PTP

Point-To-Point: Point-To-Point

PUD

Program global User Data: Program-global user variables

PZD

Process data: Process data part of a PPO

QEC

Quadrant Error Compensation

RAM

Random Access Memory: Read/write memory

REF

REFerence point approach function

REPOS

REPOSition function

RISC

Reduced Instruction Set Computer: Type of processor with small instruction set and

ability to process instructions at high speed

ROV

Rapid Override: Input correction

Special functions

950

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Appendix

A.1 List of abbreviations

R Parameter, arithmetic parameter, predefined user variable

RPA

R Parameter Active: Memory area in the NC for R parameter numbers

RPY

Roll Pitch Yaw: Rotation type of a coordinate system

RTLI

Rapid Traverse Linear Interpolation: Linear interpolation during rapid traverse motion

RTS

Request To Send: Control signal of serial data interfaces

RTCP

Real Time Control Protocol

Synchronized Action

SBC

Safe Brake Control: Safe Brake Control

SBL

Single Block: Single block

SBR

Subroutine: Subprogram (PLC)

Setting Data

SDB

System Data Block

SEA

Setting Data Active: Identifier (file type) for setting data

SERUPRO

SEarch RUn by PROgram test: Block search, program test

SFB

System Function Block

SFC

System Function Call

SGE

Safety-related input

SGA

Safety-related output

Safe standstill

SIM

Single in Line Module

Softkey

SKP

Skip: Function for skipping a part program block

SLM

Synchronous Linear Motor

Stepper Motor

SMC

Sensor Module Cabinet Mounted

SME

Sensor Module Externally Mounted

SMI

Sensor Module Integrated

SPF

Sub Routine File: Subprogram (NC)

PLC

Programmable Logic Controller

SRAM

Static RAM (non-volatile)

TNRC

Tool Nose Radius Compensation

SRM

Synchronous Rotary Motor

LEC

Leadscrew Error Compensation

SSI

Serial Synchronous Interface: Synchronous serial interface

SSL

Block search

STW

Control word

GWPS

Grinding Wheel Peripheral Speed

Software

SYF

System Files: System files

SYNACT

SYNchronized ACTion: Synchronized Action

Special functions

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951

Appendix

A.1 List of abbreviations

Terminal Board (SINAMICS)

TCP

Tool Center Point: Tool tip

TCP/IP

Transport Control Protocol / Internet Protocol

TCU

Thin Client Unit

TEA

Testing Data Active: Identifier for machine data

TIA

Totally Integrated Automation

Terminal Module (SINAMICS)

Tool Offset: Tool offset

TOA

Tool Offset Active: Identifier (file type) for tool offsets

TRANSMIT

Transform Milling Into Turning: Coordination transformation for milling operations on

a lathe

TTL

Transistor-Transistor Logic (interface type)

Technology cycle

UFR

User Frame: Work offset

Subprogram

USB

Universal Serial Bus

UPS

Uninterruptible Power Supply

VDI

Internal communication interface between NC and PLC

VDI

Verein Deutscher Ingenieure [Association of German Engineers]

VDE

Verband Deutscher Elektrotechniker [Association of German Electrical Engineers]

Voltage Input

Voltage Output

FDD

Feed Drive

SAR

Smooth Approach and Retraction

WCS

Workpiece Coordinate System

Tool

TLC

Tool Length Compensation

WOP

Workshop-Oriented Programming

WPD

Workpiece Directory: Workpiece directory

TRC

Tool Radius Compensation

Tool

Tool Offset

Tool Management

Tool change

Special functions

952

Function Manual, 12/2018, A5E40874099B AB

Appendix

A.2 Overview

A.2

Overview

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Special functions

954

Function Manual, 12/2018, A5E40874099B AB

Glossary

Absolute dimensions

A destination for an axis motion is defined by a dimension that refers to the origin of the currently

valid coordinate system. See → Incremental dimension

Acceleration with jerk limitation

In order to optimize the acceleration response of the machine whilst simultaneously protecting

the mechanical components, it is possible to switch over in the machining program between

abrupt acceleration and continuous (jerk-free) acceleration.

Address

An address is the identifier for a certain operand or operand range, e.g. input, output, etc.

Alarms

All → messages and alarms are displayed on the operator panel in plain text with date and time

and the corresponding symbol for the deletion criterion. Alarms and messages are displayed

separately.

1. Alarms and messages in the part program:

Alarms and messages can be displayed in plain text directly from the part program.

2. Alarms and messages from the PLC:

Alarms and messages for the machine can be displayed in plain text from the PLC program.

No additional function block packages are required for this purpose.

Archiving

Reading out of files and/or directories on an external memory device.

Asynchronous subprogram

Part program that can be started asynchronously to (independently of) the current program

status using an interrupt signal (e.g. "Rapid NC input" signal).

Automatic

Operating mode of the controller (block sequence operation according to DIN): Operating

mode for NC systems in which a → subprogram is selected and executed continuously.

Special functions

Function Manual, 12/2018, A5E40874099B AB

955

Glossary

Auxiliary functions

Auxiliary functions enable → part programs to transfer → parameters to the → PLC, which then

trigger reactions defined by the machine manufacturer.

Axes

In accordance with their functional scope, the CNC axes are subdivided into:

● Axes: Interpolating path axes

● Auxiliary axes: Non-interpolating feed and positioning axes with an axis-specific feedrate.

Auxiliary axes are not involved in actual machining, e.g. tool feeder, tool magazine.

Axis address

See → Axis name

Axis name

To ensure clear identification, all channel and → machine axes of the control system must be

designated with unique names in the channel and control system. The → geometry axes are

called X, Y, Z. The rotary axes rotating around the geometry axes → are called A, B, C.

Backlash compensation

Compensation for a mechanical machine backlash, e.g. backlash on reversal for ball screws.

Backlash compensation can be entered separately for each axis.

Backup battery

The backup battery ensures that the → user program in the → CPU is stored so that it is safe

from power failure and so that specified data areas and bit memory, timers and counters are

stored retentively.

Basic axis

Axis whose setpoint or actual value position forms the basis of the calculation of a

compensation value.

Basic Coordinate System

Cartesian coordinate system which is mapped by transformation onto the machine coordinate

system.

The programmer uses axis names of the basic coordinate system in the → part program. The

basic coordinate system exists parallel to the → machine coordinate system if no

→ transformation is active. The difference lies in the → axis names.

Special functions

956

Function Manual, 12/2018, A5E40874099B AB

Glossary

Baud rate

Rate of data transfer (bits/s).

Blank

Workpiece as it is before it is machined.

Block

"Block" is the term given to any files required for creating and processing programs.

Block search

For debugging purposes or following a program abort, the "Block search" function can be used

to select any location in the part program at which the program is to be started or resumed.

Booting

Loading the system program after power ON.

C axis

Axis around which the tool spindle describes a controlled rotational and positioning motion.

C spline

The C spline is the most well-known and widely used spline. The transitions at the interpolation

points are continuous, both tangentially and in terms of curvature. 3rd order polynomials are

used.

Channel

A channel is characterized by the fact that it can process a → part program independently of

other channels. A channel exclusively controls the axes and spindles assigned to it. Part

program runs of different channels can be coordinated through → synchronization.

Circular interpolation

The → tool moves on a circle between specified points on the contour at a given feedrate, and

the workpiece is thereby machined.

CNC

See → NC

Computerized Numerical Control: includes the components → NC, → PLC, HMI, → COM.

Special functions

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957

Glossary

CNC

See → NC

Computerized Numerical Control: includes the components → NC, → PLC, HMI, → COM.

COM

Component of the NC for the implementation and coordination of communication.

Compensation axis

Axis with a setpoint or actual value modified by the compensation value

Compensation table

Table containing interpolation points. It provides the compensation values of the compensation

axis for selected positions on the basic axis.

Compensation value

Difference between the axis position measured by the encoder and the desired, programmed

axis position.

Continuous-path mode

The objective of continuous-path mode is to avoid substantial deceleration of the → path axes

at the part program block boundaries and to change to the next block at as close to the same

path velocity as possible.

Contour

Contour of the → workpiece

Contour monitoring

The following error is monitored within a definable tolerance band as a measure of contour

accuracy. An unacceptably high following error can cause the drive to become overloaded, for

example. In such cases, an alarm is output and the axes are stopped.

Coordinate system

See → Machine coordinate system, → Workpiece coordinate system

CPU

Central processing unit, see → PLC

Special functions

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Function Manual, 12/2018, A5E40874099B AB

Glossary

Transformation ratio

Curvature

The curvature k of a contour is the inverse of radius r of the nestling circle in a contour point

(k = 1/r).

Cycles

Protected subprograms for execution of repetitive machining operations on the → workpiece.

Data block

1. Data unit of the → PLC that → HIGHSTEP programs can access.

2. Data unit of the → NC: Data blocks contain data definitions for global user data. This data

can be initialized directly when it is defined.

Data word

Two-byte data unit within a → data block.

Diagnostics

1. Operating area of the control.

2. The control has a self-diagnostics program as well as test functions for servicing purposes:

status, alarm, and service displays

Dimensions specification, metric and inches

Position and pitch values can be programmed in inches in the machining program. Irrespective

of the programmable dimensions (G70/G71), the control is set to a basic system.

DRF

Differential Resolver Function: NC function which generates an incremental work offset in

Automatic mode in conjunction with an electronic handwheel.

Drive

The drive is the unit of the CNC that performs the speed and torque control based on the

settings of the NC.

Special functions

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959

Glossary

Dynamic feedforward control

Inaccuracies in the → contour due to following errors can be practically eliminated using

dynamic, acceleration-dependent feedforward control. This results in excellent machining

accuracy even at high → path velocities. Feedforward control can be selected and deselected

on an axis-specific basis via the → part program.

Editor

The editor makes it possible to create, edit, extend, join, and import programs / texts / program

blocks.

Exact stop

When an exact stop statement is programmed, the position specified in a block is approached

exactly and, if necessary, very slowly. To reduce the approach time, → exact stop limits are

defined for rapid traverse and feed.

Exact stop limit

When all path axes reach their exact stop limits, the control responds as if it had reached its

precise destination point. A block advance of the → part program occurs.

External work offset

Work offset specified by the → PLC.

Fast retraction from the contour

When an interrupt occurs, a motion can be initiated via the CNC machining program, enabling

the tool to be quickly retracted from the workpiece contour that is currently being machined.

The retraction angle and the distance retracted can also be parameterized. An interrupt routine

can also be executed following the fast retraction.

Feed override

The programmed velocity is overriden by the current velocity setting made via the → machine

control panel or from the → PLC (0 to 200%). The feedrate can also be corrected by a

programmable percentage factor (1 to 200%) in the machining program.

Finished-part contour

Contour of the finished workpiece. See → Raw part.

Fixed machine point

Point that is uniquely defined by the machine tool, e.g. machine reference point.

Special functions

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Glossary

Fixed-point approach

Machine tools can approach fixed points such as a tool change point, loading point, pallet

change point, etc. in a defined way. The coordinates of these points are stored in the control.

The control moves the relevant axes in → rapid traverse, whenever possible.

Frame

A frame is an arithmetic rule that transforms one Cartesian coordinate system into another

Cartesian coordinate system. A frame contains the following components: → work offset,

→ rotation, → scaling, → mirroring.

Geometry

Description of a → workpiece in the → workpiece coordinate system.

Geometry axis

The geometry axes form the 2 or 3-dimensional → workpiece coordinate system in which, in

→ part programs, the geometry of the workpiece is programmed.

Ground

Ground is taken as the total of all linked inactive parts of a device which will not become live

with a dangerous contact voltage even in the event of a malfunction.

Helical interpolation

The helical interpolation function is ideal for machining internal and external threads using form

milling cutters and for milling lubrication grooves.

The helix comprises two motions:

● Circular motion in one plane

● A linear motion perpendicular to this plane

High-level CNC language

The high-level language is used to write NC programs, → synchronized actions, and → cycles.

It provides: control structures → user-defined variables, → system variables, → macro

programming.

High-speed digital inputs/outputs

The digital inputs can be used for example to start fast CNC program routines (interrupt

routines). High-speed, program-driven switching functions can be initiated via the digital CNC

outputs

Special functions

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961

Glossary

HIGHSTEP

Summary of programming options for → PLCs of the AS300/AS400 system.

HW Config

SIMATIC S7 tool for the configuration and parameterization of hardware components within

an S7 project

Identifier

In accordance with DIN 66025, words are supplemented using identifiers (names) for variables

(arithmetic variables, system variables, user variables), subprograms, key words, and words

with multiple address letters. These supplements have the same meaning as the words with

respect to block format. Identifiers must be unique. It is not permissible to use the same

identifier for different objects.

Inch measuring system

Measuring system which defines distances in inches and fractions of inches.

Inclined surface machining

Drilling and milling operations on workpiece surfaces that do not lie in the coordinate planes

of the machine can be performed easily using the function "inclined-surface machining".

Increment

Travel path length specification based on number of increments. The number of increments

can be stored as → setting data or be selected by means of a suitably labeled key (i.e. 10, 100,

1000, 10000).

Incremental dimension

Incremental dimension: A destination for axis traversal is defined by a distance to be covered

and a direction referenced to a point already reached. See → Absolute dimension.

Intermediate blocks

Motions with selected → tool offset (G41/G42) may be interrupted by a limited number of

intermediate blocks (blocks without axis motions in the offset plane), whereby the tool offset

can still be correctly compensated for. The permissible number of intermediate blocks which

the controller reads ahead can be set in system parameters.

Interpolator

Logic unit of the → NC that defines intermediate values for the motion to be carried out in

individual axes based on information on the end positions specified in the part program.

Special functions

962

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SINUMERIK 840D sl. Service - Functions. Manual (2018-2020) - page 74