SINUMERIK 840D sl. Training. Operate - Turning (2016-2020)

Example 1: Longitudinal guide

6.5 Creating drill holes and position repetitions

Press "Accept" to apply the values entered. After accepting the values, you will see the linking of

the work steps in the work step editor.

Figure 6-29

Linking of work steps

Select the Drilling Reaming softkey.

Open the tool list. Use the cursor key to select the DRILL 10 tool.

Accept the tool into your program. After accepting the tool, enter the following values:

Field

Value

Toggle field

Notes

150 mm/min

35 m/min

Shank/tip

Shank

20 inc

Figure 6-30

10mm drill holes

Press "Accept" to apply the values entered.

Last, repeat the positions 001 and 002 for the 10mm drill.

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Example 1: Longitudinal guide

6.5 Creating drill holes and position repetitions

Figure 6-31

Repeat the positions 001 and 002 in the work step editor.

Call the simulation for checking.

Figure 6-32

3D simulation

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Example 2: Injection mold

7.1

Overview

Learning objectives

In this section you will learn the following new functions. You will learn how to...

• specify straight lines and circular paths using polar coordinates;

• create rectangular pockets;

• apply circular pockets to position patterns.

Task

Figure 7-1

Workshop drawing - Example 2:

Figure 7-2

Workpiece - Example 2:

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Example 2: Injection mold

7.1 Overview

Preparation

Perform the following steps without help:

1. Create a new workpiece with the name 'EXAMPLE2'.

2. Create a new step sequence program with the name 'INJECTION_FORM' .

3. Specify the blank dimensions (for the procedure, see example 1).

Note

Observe the new zero position.

4. Switch to the 20mm milling cutter (F = 80 m/min).

5. Position the tool to the point X-12/ X-12/ Z-5 at rapid traverse.

6. Define the starting point of the contour on X5; Y5. The starting point is approached along a

straight line (F 100 mm/min, cutter radius compensation left). After you have entered the

traversing blocks, your process plan should look like this:

Figure 7-3

Machining step program

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

7.2

Straight lines and circular paths by way of polar coordinates

Operating sequences

Before you start entering the contour, observe the following note:

Note

You can describe the end point of a traversing block not only by way of its X and Y coordinates,

but if necessary also via its polar reference point.

X and Y are not known in our example. However, you can determine the point indirectly: It lies

20 mm away from the center of the circular pocket which highlights the pole here. The polar

angle 176° results from the calculation 180° - 4° (see workshop drawing).

(QG SRLQW

;" <"

3ROH

;

6WDUWLQJ

SRLQW

;

Figure 7-4

Determination of end point and polar angle

Proceed as follows to enter the contour:

Select the Polar softkey.

Select the Pole softkey.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

30 abs

75 abs

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-5

Specifying the pole

Press "Accept" to apply the values entered.

Select the Straight line / polar softkey.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

The length L specifies the

distance of the end point

of the straight line from

the pole.

176

The polar angle specifies

how far the length L must

be rotated around the pole

to reach the end point of

the straight line.

You may specify the polar

angle either in the coun-

terclockwise (176°) or also

in the clockwise direction

(-184°).

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-6

Specifying the straight line using polar coordinates

Press "Accept" to apply the values entered.

Select the Circle / polar softkey.

A circular path can also be specified using polar coordinates.

Enter the following value in the interactive screenform:

Field

Value

Toggle field

Notes

90 abs

Since the pole applies

both for the circular path

and for the straight line, it

need not be entered once

more.

The polar angle is 90° in

this case.

(See illustration below)

(QG SRLQW

6WDUWLQJ

SRLQW

3ROH

;

Figure 7-7

Pole starting / end points

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-8

Specifying the circular path

Press "Accept" to apply the values entered.

Select the Back softkey.

Select the Straight line softkey.

Since the end point of the straight line is known unambiguously, you may here use the Straight

line function.

Enter the following value in the interactive screenform:

Field

Value

Toggle field

Notes

120 abs

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-9

Specifying a straight line

Press "Accept" to apply the values entered.

Select the Polar softkey.

Select the Pole softkey.

Since the end point of the next circular path is not known, you must here work with

polar coordinates again.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

120 abs

The pole of the circular

path is known from the

75 abs

drawing.

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-10

Specifying the pole for the circular path

Press "Accept" to apply the values entered.

Select the Circle / polar softkey.

Enter the following value in the interactive screenform:

Field

Value

Toggle field

Notes

4 abs

The polar angle is also

known because of the

symmetry.

Figure 7-11

Specifying the circular path using polar coordinates

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Press "Accept" to apply the values entered.

Select the Back softkey.

Select the Straight line softkey.

The end point of the straight line is known so that you can enter it directly.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

145 abs

5 abs

Figure 7-12

Specifying a straight line

Press "Accept" to apply the values entered.

Select the Straight line softkey.

The whole contour has been milled once with the last straight line.

Enter the following value in the interactive screenform:

Field

Value

Toggle field

Notes

-20 abs

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-13

Specifying a straight line

Press "Accept" to apply the values entered.

Select the Straight line softkey.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

-12 abs

Radius compensation

off

The last motion is travers-

ing to the safety clear-

ance, disabling the radius

compensation.

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Example 2: Injection mold

7.2 Straight lines and circular paths by way of polar coordinates

Figure 7-14

Specifying a straight line - Safety clearance

Press "Accept" to apply the values entered.

The following simulation shows the manufacturing sequence for you to check before

manufacturing the workpiece.

Figure 7-15

Simulation - Top view

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Example 2: Injection mold

7.3 Rectangular pocket

7.3

Rectangular pocket

Operating sequences

Proceed as follows to enter the rectangular pocket:

Figure 7-17

Rectangular pocket - Example 2

Select the Milling softkey.

Select the Pocket softkey.

Select the Rectangular pocket softkey.

Open the tool list and select CUTTER 10.

Accept the tool into your program.

After accepting the tool, enter the following values:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Reference point

Center

Machining

Roughing

Ensure that the toggle

field stands on Single posi-

tion.

Specify the geometrical

data for the rectangular

pocket in these fields:

Position, width and

length, ...

α0

-15 abs

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Example 2: Injection mold

7.3 Rectangular pocket

Field

Value

Toggle field

Notes

DXY

80%

The max. infeed in the

plane (DXY) specifies at

which width the material

is removed. This can be

specified either as a per-

centage of the milling di-

ameter or directly in mm.

The maximum infeed in

the lane is specified in %

here.

2.5

UXY

0.3

Insertion

Helical

Select "helical insertion" if

not yet set (see below In-

sertion).

2 mm/rev

Figure 7-18

Roughing a rectangular pocket

Press "Accept" to apply the values entered.

Select the Pocket softkey.

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Example 2: Injection mold

7.3 Rectangular pocket

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

Machining

Finishing

Margin and base are finish-

ed using these settings. Al-

ternatively, you may also

only finish the margin or

chamfer the pocket.

Figure 7-19

Finishing a rectangular pocket

Press "Accept" to apply the values entered.

Insertion

Helical insertion

Vertical insertion

Oscillating insertion

EP = insertion pitch

EW = insertion angle

ER = insertion radius

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Example 2: Injection mold

7.4 Circular pockets on a position pattern

7.4

Circular pockets on a position pattern

Operating sequences

Proceed as follows to enter the rectangular pockets:

Figure 7-20

Rectangular pocket - Example 2

Select the Milling softkey.

Select the Pocket softkey.

Select the Circular pocket softkey.

Open the tool list and select CUTTER 10.

Accept the tool into your program.

After accepting the tool, enter the following values:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Machining

Roughing

Position pattern

Similar to drilling, you can

also apply a position pat-

tern to pockets.

∅

-10 abs

DXY

80%

Specify the maximum in-

feed in the plane in %.

UXY

0.3

Insertion

Helical

2 mm/rev

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Example 2: Injection mold

7.4 Circular pockets on a position pattern

Field

Value

Toggle field

Notes

Solid machining

Complete ma-

chining

Figure 7-21

Roughing a circular pocket

Press "Accept" to apply the values entered.

Select the Pocket softkey.

Select the Circular pocket softkey.

Enter the following values:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

Machining

Finishing

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Example 2: Injection mold

7.4 Circular pockets on a position pattern

Figure 7-22

Finishing a circular pocket

Press "Accept" to apply the values entered.

Select the Drilling softkey.

Select the Positions softkey.

Select the position grid softkey.

Note

Position patterns are described in the Drilling menu with the Positions submenu (independent

of the machining method).

Enter the following values:

Field

Value

Toggle field

Notes

α0

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Example 2: Injection mold

7.4 Circular pockets on a position pattern

Figure 7-23

Positions of the circular pockets

Press "Accept" to apply the values entered.

Start simulation.

Figure 7-24

Simulation - Cut active

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Example 3: Mold plate

8.1

Overview

Learning objectives

In this section you will learn the following new functions, in particular the contour calculator.

You will learn how to...

• mill open contours;

• remove contour pockets from the solid, machine residual material and finish;

• apply machining methods on several planes;

• take into account obstacles.

Task

Figure 8-1

Workshop drawing - Example 3:

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101

Example 3: Mold plate

8.1 Overview

Figure 8-2

Workpiece - Example 3:

Preparation

Perform the following steps without help:

1. Create a new workpiece with the name 'Example3'.

2. Create a new process plan with the name 'MOLD_PLATE' .

3. Specify the blank dimensions (for the procedure, see example 1).

Note

Observe the new zero position.

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Example 3: Mold plate

8.2 Path milling of open contours

8.2

Path milling of open contours

Contour calculator

With the contour calculator integrated into ShopMill for entering complex contours, you can

enter even the most complicated contours easily.

With the graphical contour calculator, you can en-

ter the contours faster and more easily than with

conventional programming - and even without

any mathematical knowledge.

Operating sequences

Proceed as follows to enter the contour:

Select the Contour milling softkey.

Select the New contour softkey. Type the name MOLD_PLATE_Outside for the contour.

Each contour is assigned its own name. This provides for better legibility of the programs.

Figure 8-3

Creating the 'MOLD_PLATE_Outside' contour

Press "Accept" to apply your input.

In the interactive screenform, enter the following values for the starting point of the contour line:

Field

Value

Toggle field

Notes

-35

The starting point for con-

struction is also the start-

-100

ing point for later machin-

ing of the contour.

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Example 3: Mold plate

8.2 Path milling of open contours

Figure 8-4

Specifying the starting point

Note

Here you only describe the workpiece contour; the approach and retraction travels will only be

defined later.

Press "Accept" to apply the values entered.

Enter the following values for the straight line in the interactive screenform:

Field

Value

Toggle field

Notes

35 abs

The first contour element

is a vertical straight line

with the end point at

Y=20.

You can specify the subse-

quent circle contour very

easily in this dialog - as a

transition element to the

next straight line. There-

fore, the theoretical end

point of the straight line

lies at Y=35.

Transition to next element

Radius

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Example 3: Mold plate

8.2 Path milling of open contours

Figure 8-5

Specifying the vertical contour straight line

Press "Accept" to apply the values entered.

Enter the following values for the horizontal straight line in the interactive screenform:

Field

Value

Toggle field

Notes

35 abs

Transition to next element

Radius

The radius is entered as a

rounding again.

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Example 3: Mold plate

8.2 Path milling of open contours

Figure 8-6

Specifying the horizontal contour straight line

Press "Accept" to apply the values entered.

Enter the following values for the vertical straight line in the interactive screenform:

Field

Value

Toggle field

Notes

-100 abs

Figure 8-7

Specifying the vertical contour straight line

"Apply" the set values.

Accept the contour into your process plan.

To be able to machine the created contour, you must now create the following work steps. To this

end, proceed as follows:

Select the Path milling softkey.

Open the tool list and select CUTTER 32.

Accept the tool into your program.

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Example 3: Mold plate

8.2 Path milling of open contours

Enter the following values for roughing in the interactive screenform:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Machining

Roughing

With ShopMill V6.4 and

forward

higher, you may also mill

reverse against the engi-

neering direction.

Radius compensation

Left

The tool is to traverse to

the left of the contour.

10 inc

Switch the depth Z1 to

"inc". This provides the ad-

vantage that in all cases

only the actual depth of

the pocket can be entered.

This makes input easier for

you, in particular with nes-

ted pockets.

0.3

UXY

0.3

Approach

Straight line

Approaching can be per-

formed either along a

quarter, semicircle, verti-

cally or along a straight

line.

In this case, it is reasona-

ble to approach the con-

tour tangentially along a

straight line.

The cutter radius need not

be taken into account in

the approach length L1; it

is calculated by ShopMill

automatically.

0.1 mm/tooth

Retraction

Straight line

Lift mode

To retraction

plane

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Example 3: Mold plate

8.2 Path milling of open contours

Figure 8-8

Roughing the contour

Press "Accept" to apply the values entered.

Enter the following values for finishing in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

Machining

Finishing

Figure 8-9

Finishing the contour

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Example 3: Mold plate

8.2 Path milling of open contours

Press "Accept" to apply the values entered.

The two machining steps are linked in the work step editor.

Figure 8-10

Linking of the work steps in the process plan

The following simulation shows the manufacturing sequence for you to check before

manufacturing the workpiece.

Figure 8-11

Simulation - External contour

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

8.3

Solid machining and residual material; finishing of contour pockets

Operating sequences

Proceed as follows to enter the pocket contour: Remove the pocket from the solid and finish.

Figure 8-12

Pocket contour

Select the Contour milling softkey.

Select the New contour softkey. Type the name 'MOLD_PLATE_Inside' for the contour.

Figure 8-13

Creating the 'MOLD_PLATE_Inside' contour

Press "Accept" to apply your input.

Enter the following values for the starting point in the interactive screenform:

Field

Value

Toggle field

Notes

-90

Figure 8-14

Specifying the starting point

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Press "Accept" to apply the values entered.

Enter the following values for the horizontal straight line in the interactive screenform:

Field

Value

Toggle field

Notes

25 abs

Within the framework of

this exercise, do not speci-

fy the arc as a rounding,

but as a separate element.

Therefore, design the

straight line only up to

X25.

Figure 8-15

Specifying the horizontal contour straight line

Press "Accept" to apply the values entered.

Enter the following values for the arc in the interactive screenform:

Field

Value

Toggle field

Notes

Direction of rotation

Left

30 abs

-85 abs

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Figure 8-16

Arc contour (bottom right)

Two design solutions result after entering the Y end point. Select the desired solution using the

Select dialog softkey. Subsequently, the selected solutions turns to orange, and the alternative

solution is displayed with black points.

Accept your selection. The geometry processor automatically detects that the programmed arc

is connected tangentially to the straight line. The Tangent to prec.elem. is displayed inversely

(i.e. held down).

Figure 8-17

Arc contour - after selection

Press "Accept" to apply the values entered.

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Enter the following values for the straight line in the interactive screenform:

Field

Value

Toggle field

Notes

-20 abs

Enter the end point of the

straight line. The transi-

Transition to next element

Radius

tion to R36 is rounded

with R5.

Figure 8-18

Specifying the vertical contour straight line

Press "Accept" to apply the values entered.

Enter the following values for the arc in the interactive screenform:

Field

Value

Toggle field

Notes

Direction of rotation

Clockwise

-30 abs

-20 abs

Transition to next element

Radius

Specify the radius R5 as a

rounding.

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Figure 8-19

Specifying the contour arc

Press "Accept" to apply the values entered.

Enter the following values for the straight line in the interactive screenform:

Field

Value

Toggle field

Notes

-90 abs

Transition to next element

Radius

Specify the radius R5 as a

rounding.

Figure 8-20

Specifying the vertical contour straight line

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Press "Accept" to apply the values entered.

Close the contour. Thus, the pocket contour is described completely.

Figure 8-21

Closing the contour

Accept the contour into your process plan.

Select the Pocket softkey.

Open the tool list and select CUTTER 20.

Accept the tool into your program.

Note

The manufacturing direction of the pocket has already been defined in the program header. The

"Synchronous" setting was selected in this case.

Enter the following values for roughing in the interactive screenform:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Machining

Roughing

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Field

Value

Toggle field

Notes

15 inc

If you specify the machin-

ing depth with incremen-

tal , you must specify a

positive value for the

depth.

DXY

50%

UXY

0.3

Starting point

Automatic

If you select the Autom set-

ting for the starting point

(insertion), the starting

point is specified by Shop-

Mill.

Insertion

Helical

Set insertion to Helical

with 2mm for both pitch

2 mm/rev

and radius.

Lift mode

To retraction

plane

Figure 8-22

Roughing a pocket

Press "Accept" to apply the values entered.

Select the Pocket Resid.mat. softkey. As the 20mm cutter cannot machine R5 radii, material will

remain in the corners. Use the Pocket Resid. mat. to remove areas not yet machined by

roughing with pinpoint accuracy.

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Open the tool list and select CUTTER 10.

Accept the tool into your program.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

0.1 mm/tooth

120 m/min

Machining

Roughing

DXY

50%

The maximum infeed in

the plane must be 50 %.

Figure 8-23

Machining residual material of the pocket

Press "Accept" to apply the values entered.

Select the Pocket softkey.

Open the tool list and select CUTTER 10.

Accept the tool into your program.

Enter the following values for the reworking the pocket in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Field

Value

Toggle field

Notes

Machining

Base

UXY

The allowance which you

have previously entered

for roughing must remain

set for the values in the

"Finishing allowance fields

in the plane (UXY)" and

"Finishing allowance in

the depth (UZ)" fields. This

value is important for au-

tomatic calculation of the

distances to be trav-

ersed.

Figure 8-24

Finishing a pocket

Press "Accept" to apply the values entered.

Select the Pocket softkey.

In the interactive screenform, specify the following value for removing the residual material of

the contour:

Field

Value

Toggle field

Notes

Machining

Edge

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Example 3: Mold plate

8.3 Solid machining and residual material; finishing of contour pockets

Figure 8-25

Finishing the edge

Press "Accept" to apply the values entered.

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Example 3: Mold plate

8.4 Machining on several planes

8.4

Machining on several planes

Operating sequences

Mill a 60mm circular pocket in two work steps as described in the example 'INJECTION_FORM' .

Figure 8-26

Circular pocket

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Example 3: Mold plate

8.4 Machining on several planes

1. In the first work step, the pocket is machined by roughing up to -9.7 mm using a 20 mm cutter.

Figure 8-27

Roughing a circular pocket

2. In the second work step, the pocket is finished using the same tool.

Figure 8-28

Finishing a circular pocket

To specify how the inside circular pocket is machined, proceed as follows: Machine the circular

pocket down to a depth of -20 mm.

Note

Now the starting depth is no longer at 0 mm, but at -10 mm.

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Example 3: Mold plate

8.4 Machining on several planes

Figure 8-29

Inside circular pocket

Select the Milling softkey.

Select the Pocket softkey.

Enter the following values for machining of the circular pocket in the interactive screenform:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Machining

Roughing

-10

∅

-20 abs

DXY

50%

UXY

0.3

Insertion

Vertical

0.1 mm/tooth

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Example 3: Mold plate

8.4 Machining on several planes

Figure 8-30

Roughing the inside circular pocket

Press "Accept" to apply the values entered.

Select the Milling softkey.

Select the Pocket softkey.

Enter the following values for machining of the circular pocket in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

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Example 3: Mold plate

8.4 Machining on several planes

Figure 8-31

Finishing the inside circular pocket

Press "Accept" to apply the values entered.

Start simulation.

Figure 8-32

Simulation in 3D display

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Example 3: Mold plate

8.5 Taking into account obstacles

8.5

Taking into account obstacles

Operating sequences

As you have already seen in example 1, different drill patterns can also be interlinked in the case

of this workpiece. However, you should take into account that one or several obstacles must be

bypassed - depending on the sequence of machining. Traverse either to safety clearance or to

the machining plane between the drill holes - depending on the settings you have made.

First create the work steps 'Centering' and 'Drilling' as done in example 1.

1. Centering

Figure 8-33

Work step 'Centering'

2. Drilling

Figure 8-34

Work step 'Drilling'

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Example 3: Mold plate

8.5 Taking into account obstacles

Proceed as follows to enter the relevant drilling positions:

Select the Positions softkey.

First create the left line of holes in the sequence from bottom to top.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

-10

-42.5

-92.5

α0

Figure 8-35

Specifying the line of holes

Press "Accept" to apply the values entered.

Select the Positions softkey.

Use the "Obstacle" function to specify a distance of 1 mm to be traversed, as the right-hand line

of holes must also be drilled from bottom to top for the purposes of an exercise. The obstacle

only needs to be entered if you have first switched the "Retraction position pattern" toggle field

to "Optimized".

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Example 3: Mold plate

8.5 Taking into account obstacles

Figure 8-36

Specifying an obstacle

Press "Accept" to apply the values entered.

Select the Positions softkey.

Enter the following values for the second line of holes in the interactive screenform:

Field

Value

Toggle field

Notes

-10

42.5

-92.5

α0

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Example 3: Mold plate

8.5 Taking into account obstacles

Figure 8-37

Specifying the line of holes

Press "Accept" to apply the values entered.

Select the Positions softkey.

To get to the next drill pattern - the circle of holes -, another obstacle must be bypassed. Enter

Z=1.

Press "Accept" to apply the value entered.

Select the Positions softkey.

In the interactive screenform, enter the following values for the 6 drill holes in the full circle:

Field

Value

Toggle field

Notes

-10

α0

22.5

Positioning

Straight line

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Example 3: Mold plate

8.5 Taking into account obstacles

Figure 8-38

Specifying the drill holes in the full circle

Press "Accept" to apply the values entered.

Select the Positions softkey.

To make the last drill hole, another obstacle must be bypassed. Enter Z=1.

Press "Accept" to apply the value entered.

Select the Positions softkey.

Enter the following values for the last drilling positions in the interactive screenform:

Note

If necessary delete any existing positions using the DEL key.

Field

Value

Toggle field

Notes

Pattern

Rectangular

-10

42.5

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Example 3: Mold plate

8.5 Taking into account obstacles

Figure 8-39

Specifying the drilling positions

Press "Accept" to apply the values entered.

Note

This programming example is intended to familiarize you with the "Obstacle" function. There are

naturally more elegant methods of programming drilling positions, including only one obstacle.

Try out different strategies and decide which is the best for you.

Start simulation.

Figure 8-40

Simulation - Top view

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Example 4: Lever

9.1

Overview

Learning objectives

In this section you will learn the following new functions. You will learn how to...

• perform face milling;

• create edges (auxiliary pockets) for removing material from the solid around islands;

• create and copy circular islands;

• work with the work step editor and machine islands;

• perform deep-hole drilling, helix milling, boring and thread milling;

• Programming a contour using polar coordinates.

Task

Figure 9-1

Workshop drawing - Example 4:

Figure 9-2

Workpiece - Example 4:

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Example 4: Lever

9.1 Overview

Preparation

Perform the following steps without help:

1. Create a new workpiece with the name 'Example4'.

2. Create a new process plan with the name 'LEVER' .

3. Specify the blank dimensions (for the procedure, see example 1).

Note

The thickness of the blank will be 25 mm; therefore, it is imperative to set ZA to 5 mm.

After input of the data, the program header should look as in the screen below.

Figure 9-3

Workpiece dimensions as in the program header

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Example 4: Lever

9.2 Face milling

9.2

Face milling

Operating sequences

Select the Milling softkey.

Select the Face milling softkey.

Open the tool list and select FACEMILL 63.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Toggle field

Notes

0.1 mm/tooth

120 m/min

Machining

Roughing

Direction

Alternating

-40

-70

110 abs

30 abs

0 abs

DXY

30%

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Example 4: Lever

9.2 Face milling

Figure 9-4

Roughing a surface

Press "Accept" to apply the values entered.

Select the Face milling softkey.

Enter the following values for finishing in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

Machining

Finishing

Note

The values for the finishing allowance must be identical for both roughing and finishing, as this

value specifies the allowance for the subsequent machining by finishing, and then when

finishing, the thickness of the material to be removed is meant.

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Example 4: Lever

9.3 Creating an edge for the lever island

9.3

Creating an edge for the lever island

Operating sequences

Note

Islands are described - like pockets - as a contour in the graphical contour calculator. They only

become islands through linking in the process plan. The first contour in the process plan always

describes the pocket. One or several of the subsequent contours are interpreted as islands.

Since no pocket exists in the case of the 'LEVER' example, you must create a fictitious auxiliary

pocket around the external contour. This serves as a necessary outside boundary for the

traversing paths and thus forms a frame in which the tool motions take place.

Select the Contour milling softkey.

Create a new contour with the name 'LEVER_Rectangular_Area'.

Figure 9-6

Creating the contour

Create the following contour without help. Round the corners with R15. Select such values that

the workpiece corners are covered by the pocket.

Figure 9-7

Edge for the lever island

Compare your contour with the screen below.

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Example 4: Lever

9.4 Machining the lever

9.4

Machining the lever

Operating sequences

Proceed as follows to enter the contour:

Figure 9-9

Lever contour

Select the Contour milling softkey.

Create a new contour with the name 'LEVER_Lever'.

Figure 9-10

Creating the contour

In the interactive screenform, enter the following values for the starting point of the contour line:

Field

Value

Toggle field

Notes

-24 abs

0 abs

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Example 4: Lever

9.4 Machining the lever

Figure 9-11

Specifying the starting point

Press "Accept" to apply the values entered.

Enter the following values for the first arc in the interactive screenform:

Field

Value

Toggle field

Notes

Direction of rotation

Clockwise

Radius and center point

are known.

Figure 9-12

Arc contour

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Example 4: Lever

9.4 Machining the lever

Press "Accept" to apply the values entered.

Create the inclined straight line connected tangentially to the preceding element.

Select the Tangent to prec.elem. softkey.

Figure 9-13

Inclined straight line contour

Press "Accept" to apply your input.

Enter the arc connected tangentially.

Select the Tangent to prec.elem. softkey.

Enter the following values for the arc in the interactive screenform:

Field

Value

Toggle field

Notes

Direction of rotation

Clockwise

Radius, center point and

end point are known.

85 abs

-8 abs

85 abs

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Example 4: Lever

9.4 Machining the lever

Figure 9-14

Arc contour

Press ENTER to confirm the suggested contour.

Press "Accept" to apply the values entered.

Enter the following values for the horizontal straight line up to end point X30 in the interactive

screenform:

Field

Value

Toggle field

Notes

30 abs

Transition to next element

Radius

Enter 40 mm for the radius

to the subsequent ele-

ment.

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Example 4: Lever

9.4 Machining the lever

Figure 9-15

Horizontal straight line contour

Press "Accept" to apply the values entered.

Observe the following note for the next inclined straight line:

Note

The tangential transition is always only referred to the main element, i.e. in this case, the straight

is not connected tangentially (see screenform below).

0DLQ HOHPHQW

QRW WDQJHQWLDO

5RXQGLQJ

0DLQ HOHPHQW

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Example 4: Lever

9.4 Machining the lever

Figure 9-16

Inclined straight line contour

Press "Accept" to apply your input.

Enter the arc connected tangentially.

Select the Tangent to prec.elem. softkey.

Select the All parameters softkey.

Use the All parameters function to display detailed information on the arc. This can serve to

check the entered values, for example (e.g.: Does the arc end vertically ...?).

Enter the following values for the arc in the interactive screenform:

Field

Value

Toggle field

Notes

Direction of rotation

Clockwise

-58 abs

0 abs

-58 abs

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Example 4: Lever

9.4 Machining the lever

Figure 9-17

Arc contour

Select the desired contour suggestion.

Press ENTER to confirm the suggested contour.

Press "Accept" to apply your input.

Specify the vertical straight line (automatically tangential) up to the end point Y-27.

Select the Tangent to prec.elem. softkey.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

-27 abs

Transition to next element

Radius

Round the transition to

the subsequent straight

line using R18.

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Example 4: Lever

9.4 Machining the lever

Figure 9-18

Vertical straight line contour

Press "Accept" to apply the values entered.

Specify the inclined straight line.

Figure 9-19

Inclined straight line contour

Press "Accept" to apply your input.

Close the contour to the starting point with an arc.

Select the Tangent to prec.elem. softkey.

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Example 4: Lever

9.4 Machining the lever

In the interactive screenform, enter the following values for the starting point of the contour line:

Field

Value

Toggle field

Notes

-24

Figure 9-20

Arc contour

Press "Accept" to apply the values entered.

Accept the contour.

Proceed as follows to rough and finish the pocket taking into account the lever contour:

Figure 9-21

Roughing and finishing around the lever

Select the Pocket softkey.

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SINUMERIK 840D sl. Training. Operate - Turning (2016-2020) - page 5