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

Example 4: Lever

9.4 Machining the lever

Open the tool list and select CUTTER 20.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Toggle field

Notes

0.15 mm/tooth

120 m/min

Machining

Roughing

6 inc

DXY

50%

Specify the maximum in-

feed in the plane in %.

UXY

0.3

Starting point

Automatic

Insertion

Vertical

0.15 mm/tooth

Lift mode

To RP

Figure 9-22

Roughing the contour

Press "Accept" to apply the values entered.

Select the Pocket softkey.

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Example 4: Lever

9.4 Machining the lever

Enter the following values for finishing in the interactive screenform:

Field

Value

Toggle field

Notes

0.08 mm/tooth

150 m/min

Machining

Finishing the

base

6 inc

DXY

50%

Specify the maximum in-

feed in the plane in %.

UXY

0.3

Starting point

Manual

-40

Insertion

Vertical

0.15 mm/tooth

Lift mode

To RP

Figure 9-23

Finishing the base

Press "Accept" to apply the values entered.

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Example 4: Lever

9.5 Creating an edge for the circular island

9.5

Creating an edge for the circular island

Operating sequences

Create an edge for boundary when milling without help. Mill down to a depth of -3.

Figure 9-24

Edge contour for the circular islands

Note

The values R36 and R26 result from the corresponding island radius + cutter diameter (here: 20

mm + 1 mm allowance).

The radii R5 and R15 are selected freely.

Select the Contour milling softkey.

Create a new contour with the name 'LEVER_Lever_Area'.

Figure 9-25

Creating the contour

Design the boundary for the traversing paths around the workpiece contour as described above

such that the 20mm milling cutter fits everywhere between the boundary and the islands. Enter

this boundary contour in the same way as the lever contour.

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Example 4: Lever

9.6 Creating a 30mm circular island

9.6

Creating a 30mm circular island

Operating sequences

To create the 30mm circular island, I will proceed as follows:

Figure 9-28

30mm circular island

Select the Contour milling softkey.

Create a new contour with the name 'LEVER_Circle_R15'.

Figure 9-29

Creating the contour

Create a circular contour without help (see illustration below). The starting point of the circular

construction lies at X-15; Y0.

Note

Ensure that various values must be dimensioned incrementally.

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Example 4: Lever

9.7 Creating a 10mm circular island

9.7

Creating a 10mm circular island

Operating sequences

To create the 10mm circular island, proceed as follows:

Figure 9-31

10mm circular island

Select the Contour milling softkey.

Create a new contour with the name 'LEVER_Circle_R5_A'.

Figure 9-32

Creating the contour

Create a circular contour without help (see illustration below). The starting point of the circular

construction lies at X80; Y0.

Note

Since this circular island will be copied in the next step, you must specify the contour

incrementally so that you only need to change the starting point when copying.

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Example 4: Lever

9.8 Copying the 10mm circular island

9.8

Copying the 10mm circular island

Operating sequences

To copy the circular island created in the previous step, proceed as follows:

Figure 9-35

10mm circular island

Navigate and copy the 'LEVER_Circle_R5_A' contour.

Figure 9-36

Copying the contour

Paste the copied contour and give it the name 'LEVER_Circle_R5_B'.

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Example 4: Lever

9.8 Copying the 10mm circular island

Figure 9-37

Specifying the name for the copied contour

Press "Accept" to apply your input.

After accepting the values, your process plan should look like this:

Figure 9-38

Pasted contour in the work step editor

Now you must only change the starting point, as you have specified the contour incrementally.

Open the contour. This key can then also be used in the open contour to open the selected

geometry element for changing.

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Example 4: Lever

9.9 Machining the circular island using the editor

9.9

Machining the circular island using the editor

Operating sequences

To machine the three circular islands, proceed as follows: When machining the circular islands,

you will learn further functions of the work step editor, helping you understand how to use parts

of the process plans several times and how to manage the process plan (see Functions of the

work step editor).

The following contour serves the boundary of the traversing path during manufacturing.

Figure 9-40

Boundary of the traversing path

Your process plan will look as follows:

Figure 9-41

Process plan

Highlight the two work steps for roughing and finishing of the pocket.

Copy the highlighted work steps.

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Example 4: Lever

9.9 Machining the circular island using the editor

Figure 9-42

Highlighted machining steps

Paste the work steps beneath the contours. This will link the technologies for removing material

from the solid with the contours.

Figure 9-43

Pasted machining steps

Now you must only adapt the technologies solid 'roughing' and 'finishing' for removing material

from the solid to the new machining depth:

Open the work step for roughing.

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Example 4: Lever

9.9 Machining the circular island using the editor

Enter the following values for roughing in the interactive screenform:

Field

Value

Toggle field

Notes

3 inc

Starting point

Manual

-10

Figure 9-44

Adaptations for roughing

Press "Accept" to apply the values entered.

Open the work step for finishing. Change the values similar to roughing.

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Example 4: Lever

9.9 Machining the circular island using the editor

Figure 9-45

Adaptations for finishing

Press "Accept" to apply the values entered.

The screenform above shows which geometries are used in finishing (process plan graphic).

Figure 9-46

Broken-line graphics

Check your intermediate result by way of simulation.

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Example 4: Lever

9.9 Machining the circular island using the editor

Figure 9-47

Simulation - Top view

Functions of the work step editor

The following information provides you with an overview of the functions of the work step

editor.

Use this softkey to search for texts in the program.

Use this softkey to select several work steps for further processing (e.g.,

"Copy" or "Cut").

Use this softkey to copy work steps to the clipboard.

Use this softkey to paste work steps from the clipboard to the process plan.

The copied step is always inserted after the currently highlighted step.

Use this softkey to copy work steps to the clipboard; at the same time, it is

deleted at its origin. This softkey can also be used for "pure" deletion.

Use this softkey to switch to the extended menu.

Use this softkey to switch to the broken-line graphics.

Use this softkey to renumber the work steps.

Use this softkey to open the "Settings" dialog. Here you can specify, e.g.

automatic numbering or whether you wish the end of the block to be

represented as a symbol.

Use this softkey to return to the previous menu.

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Example 4: Lever

9.10 Deep hole drilling

9.10

Deep hole drilling

Operating sequences

Proceed as follows for rough-boring:

Figure 9-48

Deep hole drilling

Select the Drilling softkey.

Select the Drilling Reaming softkey.

Open the tool list and select PREDRILL 30.

Accept the tool into your program.

Enter the following values for deep hole drilling in the interactive screenform:

Field

Value

Toggle field

Notes

0.1 mm/rev

120 m/min

Depth reference

Tip

-21 abs

0 s

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Example 4: Lever

9.11 Milling a helix

9.11

Milling a helix

Operating sequences

Proceed as follows to remove the residual material of the circular ring remaining after the drilling

by way of a helical motion ("helix"):

Figure 9-51

Milling a helix

Select the Straight line Circle softkey.

Open the tool list and select CUTTER 20 .

Accept the tool into your program. Enter the following value in the interactive screenform:

Field

Value

Toggle field

Notes

120 m/min

Figure 9-52

Milling a helix

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Example 4: Lever

9.11 Milling a helix

Press "Accept" to apply your input.

Select the Straight line softkey.

Select the Rapid traverse softkey.

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

Note

Since milling is performed without cutter radius compensation here, you must position the

cutter with its circumference to the tap hole diameter (here: 45.84 mm) minus finishing

allowance.

Field

Value

Toggle field

Notes

82 abs

-40 abs

-5 abs

Radius compensation

off

Figure 9-53

Positioning

Press "Accept" to apply the values entered.

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Example 4: Lever

9.11 Milling a helix

Select the Helix softkey. Enter the following values for the helix in the interactive screenform:

Field

Value

Toggle field

Notes

70 abs

-40 abs

3 mm/rev

The pitch of the helix is 3.

-23 abs

0.1 mm/tooth

Note

Since the tool traverses along an inclined path, 6 revolutions are created here to avoid that no

residual material remains (even though the final depth is already reached after 5 revolutions).

Figure 9-54

Specifying the helix

Press "Accept" to apply the values entered.

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Example 4: Lever

9.12 Boring

9.12

Boring

Operating sequences

Proceed as follows to machine the circular pocket to the required dimensions using a boring tool:

Figure 9-55

Boring a circular pocket

Select the Drilling softkey.

Select the Boring softkey.

Open the tool list and select the boring tool DRILL_TOOL.

Accept the tool into your program.

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

Field

Value

Toggle field

Notes

0.08 mm/rev

500 rpm

15 inc

0 s

SPOS

Lift mode

Lifting

The Lift option withdraws

the tool from the contour

before it retracts from the

drill hole. This option may

only be used with single-

edge tools.

0.5

Note

The angular position of the tool during lifting is specified by the machine manufacturer.

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Example 4: Lever

9.12 Boring

Figure 9-56

Boring

Press "Accept" to apply the values entered.

Position the tool to the drill hole center. The dimension 45.84 mm is specified by the set tool

diameter. Instead of entering the position, you can also use the Repeat position function here.

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

Field

Value

Toggle field

Notes

-6

-40

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Example 4: Lever

9.13 Thread milling

9.13

Thread milling

Operating sequences

Figure 9-58

Thread milling

Select the Milling softkey.

Select the Thread milling softkey.

Open the tool list and select THREAD CUTTER .

Accept the tool into your program.

Mill the thread from the top to the bottom. To this end, use the THREAD CUTTER (F = 0.08 mm/

tooth, v = 150 m/min and a pitch of 2 mm). A rectangular thread is to be milled absolutely to

Z-23. Due to the overtravel of 3 mm, the thread is always milled cleanly down to the workpiece

lower edge even if the lowest tooth is slightly worn.

The help displays are very useful for your inputs.

Compare your inputs with the screen below.

Figure 9-59

Thread milling

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Example 4: Lever

9.13 Thread milling

Press "Accept" to apply the values entered.

Specify the position for the thread.

Enter the following values in the interactive screenform:

Field

Value

Toggle field

Notes

-6

-40

Figure 9-60

Entering the position

Press "Accept" to apply the values entered.

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Example 4: Lever

9.14 Programming a contour using polar coordinates

9.14

Programming a contour using polar coordinates

Programming with polar coordinates

Contour elements in workpiece drawings often refer to a pole. In this case, you do not know the

Cartesian coordinates (X/Y), but the polar coordinates, i.e. the distance and the angle to this

pole.

Now we will slightly modify the lever as a further exercise: The lower "lever arm" no longer lies

vertically to zero at X0, but is rotated CW by 10°.

In this example you will learn how this is programmed graphically without using the pocket

calculator or any auxiliary constructions.

Figure 9-61

Programming the lever using polar coordinates

Operating sequences

Move the cursor first to the arc to redimension its center (see screenform below).

Figure 9-62

Positioning the cursor on the arc

Extend the menu.

Position the cursor on the element in front of the arc and paste the pole at this point. Apply the

pole to the zero point.

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Example 4: Lever

9.14 Programming a contour using polar coordinates

Subsequently, change the values matching the arc:

1. In the arc dialog box, delete the values Y-58, I0 and J-58 which are no longer valid.

Figure 9-64

Deleting the values

2. To be able to specify the center point, switch the coordinates from "Cartesian" to "Polar". Enter

the distance to the pole and specify the polar angle (see screenform below).

Figure 9-65

Entering the distance to the pole and specifying the polar angle

Press "Accept" to apply your input.

Apply the change.

The broken-line graphics shows that the auxiliary pocket LEVER_Lever_Area and the circular

island LEVER_Circle_R5_B must also be adapted in the same way.

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Example 4: Lever

9.14 Programming a contour using polar coordinates

Figure 9-66

Broken-line graphics after shifting

Change these two contours without help. Note the following:

Note

As far as the auxiliary pocket is concerned, you may naturally proceed a bit "rougher" and

approach the center of the arc R26 dimensioned with polar coordinates to Cartesian

dimensioning (X-10/Y-57). Then, the contour can be continued directly with a vertical line.

The starting point for the circular island is already dimensioned with polar coordinates. Only the

center point of the full-circle arc must be changed.

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Example 5: Flange

10.1

Overview

Learning objectives

In this chapter you will learn how to ...

• create a subroutine;

• mirror work steps;

• chamfer any contours, and

• create longitudinal and circular grooves.

Task

Figure 10-1

Workshop drawing - Example 5:

Figure 10-2

Workpiece - Example 5:

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Example 5: Flange

10.1 Overview

Note

All work steps were explained in the previous examples and nearly all softkeys / keys to be

selected / pressed were indicated. In the following example, the whole sequence of inputs will

no longer be specified, but instead only essential information and the most important softkeys

and keys to be pressed.

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Example 5: Flange

10.2 Creating a subroutine

10.2

Creating a subroutine

Operating sequences

The creation and functioning of subroutines will be explained taking the example of the

workpiece CORNER_MACHINING.

The four corners will be machined by way of the following steps using a subroutine and the

"Mirror" function.

Figure 10-3

Contour of the four corners

Create a new step sequence program with the name CORNER_MACHINING. Later you will embed

this program as a subroutine.

Figure 10-4

Creating a subroutine

Enter the following data for the program header. The blank dimensions will be specified later

centrally in the main program.

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Example 5: Flange

10.2 Creating a subroutine

Figure 10-5

Entering the data for the subroutine program header

Press "Accept" to apply the values entered.

Select the Contour milling softkey.

Create a new contour with the name CORNER_M_SURFACE .

Figure 10-6

Creating the contour

Specify the starting point. The top right corner, for example, will be designed.

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Example 5: Flange

10.2 Creating a subroutine

Figure 10-7

Specifying the starting point

Press "Accept" to apply the values entered.

Create the contour. After entering the two contour elements, your screen should look like this:

Accept the contour into your process plan.

Figure 10-8

Contour subroutine, top right corner

The contour is to be roughed using an R20 milling cutter (F = 0.15 mm/tooth and v = 120 m/min).

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Example 5: Flange

10.2 Creating a subroutine

Figure 10-9

Roughing the contour

The approach and retract paths are approached along a straight line. The length values are the

distances between the cutter edge and the workpiece.

Figure 10-10

Approach and retract paths along a straight line

Press "Accept" to apply the values entered.

The contour is to be finished using the same milling cutter (F = 0.08 mm/tooth and v = 150 m/

min).

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Example 5: Flange

10.2 Creating a subroutine

Figure 10-11

Finishing the contour

Press "Accept" to apply the values entered.

In the next few steps, the corner of the blank cuboid is to be rounded using R5:

Select the Contour milling softkey.

Create a new contour with the name CORNER_M_ARC .

Figure 10-12

Creating the contour

Specify the starting point.

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Example 5: Flange

10.3 Mirroring work steps

10.3

Mirroring work steps

Task

When you have finished the subroutine, create the main program. You may use the subroutine

for all workpiece corners using the "Mirror" function in the "Transformation" menu.

Mirroring can be performed in two different ways:

• New:

Mirroring is performed from the point at which the 1st processing operation was performed.

• Additive:

Mirroring is performed from the point last machined.

The sequence of processing with the setting New is shown below in the form of drawings:

1. Processing (see subroutine)

2. Processing: Mirroring the X axis

(the X values are mirrored here)

3. Processing: Mirroring the X and Y axes

4. Processing: Mirroring the Y axis

(the X and Y values are mirrored here)

(the Y values are mirrored here)

Operating sequences

Create the main program with the name FLANGE .

Figure 10-18

Creating the main program

Enter the program header.

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10.3 Mirroring work steps

Accept your selection. After acceptance, your work step program looks like this:

Figure 10-21

Subroutine pasted into the main program

The Transformation softkey can be used to shift, rotate, etc. the axes.

Preparing the 2nd processing: Mirror the X values.

Figure 10-22

Mirroring

Press "Accept" to apply your input.

To mirror the remaining processing operations, proceed as follows:

Copy the subroutine after the "Mirror" work step. The 2nd processing follows.

Then you must repeat the processes Mirror and Subroutine call for the two other corners.

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10.3 Mirroring work steps

Figure 10-23

Copying the subroutine

The help display illustrating this procedure will help you. After you have entered all 4 processing

operations, disable mirroring for all three axes.

Figure 10-24

Mirroring help display

Your process plan will look as follows:

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Example 5: Flange

10.5 Rotation of pockets

10.5

Rotation of pockets

Operating sequences

To program the contour and the processing for the pocket highlighted yellow, proceed as

described in the following.

By rotating the coordinate system, subsequently the other two pockets are created.

Select the Contour milling softkey.

Create a new contour with the name 'FLANGE_NODULE' .

Figure 10-31

Creating a new contour

Specify the starting point.

Figure 10-32

Specifying the starting point

Press "Accept" to apply the values entered.

Select the Arc softkey.

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Example 5: Flange

10.5 Rotation of pockets

Select the All parameters softkey.

The arc R42 is described unambiguously, e.g. via the radius, the center point in X and the runout

angle. Design in the counterclockwise direction to ensure that the pocket can also be finished by

synchronized milling.

Figure 10-33

Specifying the arc

Press "Accept" to apply the values entered.

Select the Diagonal softkey.

Select the All parameters softkey.

Create the diagonal straight line.

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10.5 Rotation of pockets

Press "Accept" to apply the values entered.

Select the Diagonal softkey.

Select the All parameters softkey.

Create the 2nd diagonal straight line.

Figure 10-36

Specifying the diagonal

Press "Accept" to apply the values entered.

Select the Arc softkey.

Create the final arc.

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10.5 Rotation of pockets

Figure 10-39

Finishing the pocket base

Figure 10-40

Finishing the pocket edge

To copy the created work step sequence for the machining of the three pockets, proceed as

follows:

Now highlight the complete work step sequence describing machining of the pocket in the work

step editor.

Copy the work step sequence to the clipboard.

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Example 5: Flange

10.6 Chamfering contours

10.6

Chamfering contours

Operating sequences

Chamfer the circular pocket last machined without help.

For chamfering, you will need a tool type which allows entering of an acute angle, in the

example CENTERDRILL12.

Figure 10-47

Center drill

Select Chamfering for machining. The machining of the chamfer is programmed via the chamfer

width (FS) and the insertion depth of the tool tip (ZFS).

Figure 10-48

Chamfering

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Example 5: Flange

10.7 Longitudinal and circular grooves

10.7

Longitudinal and circular grooves

Operating sequences

Finally, program the grooves. They will be positioned to the correct point by way of Position

pattern and Positioning to full circle.

Figure 10-51

Longitudinal and circular grooves

Select the Milling softkey.

Select the Groove softkey.

Use the tool CUTTER 6 (F = 0.08 mm/tooth and v = 120 m/min) for the roughing of the

longitudinal grooves.

Figure 10-52

Roughing a longitudinal groove

Press "Accept" to apply the values entered.

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Example 5: Flange

10.7 Longitudinal and circular grooves

Use the same tool (F = 0.05 mm/tooth and v = 150 m/min) for finishing.

Figure 10-53

Finishing a longitudinal groove

Press "Accept" to apply the values entered.

Select the Drilling softkey.

Subsequently, specify the positions of the longitudinal grooves. The reference point lies in the

groove center.

Figure 10-54

Specifying the positions for the longitudinal groove

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Example 5: Flange

10.7 Longitudinal and circular grooves

Press "Accept" to apply the values entered.

Select the Milling softkey.

Select the Groove softkey.

Use the tool CUTTER 6 (F = 0.08 mm/tooth, FZ = 0.08 mm/tooth and v = 120 m/min) for the

roughing of the circular grooves.

Thanks to the Full circle option, the circular grooves are positioned to each other automatically

at the same distance. The reference point in X/Y/Z refers to the center point of the circular

grooves.

Figure 10-55

Roughing a circular groove

Press "Accept" to apply the values entered.

Select the Groove softkey.

Use the same tool (F = 0.05 mm/tooth,FZ = 0.05 mm/tooth and v = 150 m/min) for finishing.

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And now you can start manufacturing!

After you have acquired well-founded knowledge of the creation of process plans in ShopMill by

working with the examples, we will now machine workpieces.

To machine a workpiece, proceed as follows:

Approaching reference point

After turning on the control system and before traversing the axes according to the process plans

or traversing manually, you will have to approach the reference point of the machine. In this way,

ShopMill will find the start for counting in the position measuring system of the machine.

Since approaching of the reference point is different depending on machine type and

manufacturer, only a few hints can be given here for orientation:

1. If necessary traverse the tool to a free point in the work space from which traversing is

possible in all directions without collision. Make sure that the tool is then not beyond the

reference point of the corresponding axis (since reference point approach is only performed

in one direction for each axis; otherwise, this point cannot be reached).

2. Perform the reference point approach exactly according to the specifications of the machine

manufacturer.

Clamping the workpiece

To guarantee machining in accordance with the specified dimensions and, naturally, also for

your own safety, it is imperative to clamp the workpiece tightly. As a rule, machine jaw vices or

clamps are used.

Setting the workpiece zero

Since ShopMill cannot guess where in the work space the workpiece is located, you must

determine the workpiece zero.

In the plane, the workpiece zero is set in most cases

• using either a 3D probe or

• an edge probe

through sampling.

In the tool axis, the workpiece zero is set in most cases

• using the 3D probe through sampling or

• using a tool through sampling

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And now you can start manufacturing!

Note

When working with the measuring devices and measuring cycles, observe the manufacturer

specifications.

Executing the process plan

Now the machine is prepared, the workpiece is set up, and the tools are gauged. At last we can

start!

First select the program you want to execute in the Program Manager, e.g. INJECTION_FORM.

Figure 11-1

Selecting the program

Open the program.

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And now you can start manufacturing!

Figure 11-2

Opening the process plan

Select the NC selection softkey.

Figure 11-3

Executing

Due to the fact that the process plan has not yet been executed with control, turn the feedrate

potentiometer to zero position to ensure that you keep everything under control from the

beginning.

If you also want to see a simulation during machining, select the Drawing softkey before

starting. Only then are all traversing paths and their effects are displayed.

Easy milling with ShopMill

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