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

How fit are you in ShopMill?

12.2 Exercise 1

12.2

Exercise 1

Will you manage this task using ShopMill within 15 minutes?

Figure 12-1

Workshop drawing DIYS1

Notes

The rotated rectangular pocket shown above has been designed in the original coordinate

system. The starting point lies first on zero. Subsequently, an auxiliary straight line is

programmed at an angle of 15° to the edge of the pocket. The coordinates of this end point are

the starting point for the actual construction. The auxiliary straight line must be deleted.

ShopMill also provides other paths to the objective, e.g. with the "Rotation" function or the

"Rectangular spigot" cycle. Test how you achieve the objective fastest and with which method

you achieve the shortest machining time.

Model

Easy milling with ShopMill

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How fit are you in ShopMill?

12.3 Exercise 2

12.3

Exercise 2

Will you manage this task using ShopMill within 20 minutes?

Figure 12-4

Workshop drawing COMPLEX_POCKET

Notes

Even though it looks complex: This contour is no problem with ShopMill. And automatic removal

of residual material can here be applied optimally. Compare the machining times if you were to

use CUTTER10 for stock removal.

Notes regarding the contour:

• Design the contour in the counterclockwise direction.

• The aperture angle of the top left arc is 115°.

Easy milling with ShopMill

220

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How fit are you in ShopMill?

12.4 Exercise 3

12.4

Exercise 3

Will you manage this task using ShopMill within 30 minutes?

Figure 12-7

Workshop drawing PLATE

Notes

In this sample process plan, the area around the island has first been premilled roughly using the

"Rectangular spigot" cycle from the "Milling" menu. The rectangle described in this cycle is

approached along a circle and will reach the contour at the point described by the length and

angle of rotation. The rectangle is traveled completely once and left at the same point again

along a circle. Approach and retraction radii result from the geometry of the residual spigot.

Easy milling with ShopMill

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How fit are you in ShopMill?

12.5 Exercise 4

12.5

Exercise 4

Will you manage this task using ShopMill within 30 minutes?

Figure 12-10

Workshop drawing WING

Notes

In this sample process plan, the circular outside contour is milled using the "Circular spigot" cycle.

The functioning corresponds mainly to that of the rectangular spigot (see Sample Pattern

Process Plan for Exercise 3). The common center point of the two arcs R45 and R50 (= starting

point for the actual construction) is specified using polar coordinates (25 mm at 65° referred to

the pole point at X0/Y0).

With software version V6.4 and higher, the "Milling" menu also provides a flexible "Engraving"

cycle.

Easy milling with ShopMill

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Introduction

Content

Introduction

Page

Basic information

1.1

Introduction

1.2

SINUMERIK MDynamics milling technology packages

1.3

SINUMERIK Operate user interface

1.3.1

Operating and setup functions

1.3.2

SINUMERIK Operate - Multitouch

1.4

Requirements for milling

1.5

Linear axes, rotary axes and kinematics

1.5.1

Axes and programming

1.5.2

Kinematics of 5-axis machining centers

1.6

Surface quality, velocity, accuracy

1.7

Additional software

1.7.1

SinuTrain

1.7.2

VNC Viewer - remote control on an external PC

1.7.3

Analyze MyWorkpiece /Toolpath additional software

General information on workpiece production

2.1

Process chain for producing 3- to 5-axis workpieces

2.2

CAM systems

2.2.1

Tolerance and accuracy

2.3

Program structure for milling

2.4

Programs, data transfer and editor

2.4.1

Program manager

2.4.2

External storage media - data transfer

2.4.3

EES - Execution from External Storage (NC Extend)

2.4.4

Graphic and file formats in the program manager

2.4.5

Program editor - useful functions

2.5

JOG mode, zeros, tools

2.5.1

Zero offsets

2.5.2

Tool management

2.5.3

Manual retraction - return

2.6

Fundamentals, measuring in JOG and AUTOMATIC

2.6.1

Measurement logs in JOG

2.6.2

Measurement logs in AUTOMATIC

2.7

Measuring workpiece/tool in JOG

2.7.1

Workpiece measuring in JOG

2.7.2

Workpiece measuring functions in JOG

2.7.3

Example for measuring a workpiece in JOG

2.7.4

Measure tool in JOG

Introduction

Content

Page

2.7.5

Tool reference point

2.7.6

Example: Measure tool in JOG

2.8

Measure workpiece/tool in AUTOMATIC - process measuring

2.8.1

Measure workpiece in AUTOMATIC

2.8.2

Workpiece measuring cycles in AUTOMATIC

2.8.3

Example for measuring a workpiece in AUTOMATIC

2.8.4

Tool measuring in AUTOMATIC - process measuring

2.8.5

Example for measuring tools in the AUTOMATIC mode

2.9

Checking and measuring machine/spindle

2.9.1

Spindle 3D angular deviation CYCLE995

2.9.2

Checking/measuring the machine with the kinematics measuring

cycle CYCLE996

2.9.3

CYCLE9960 measure kinematics completely

2.10

Workpiece visualization

2.10.1 Simulation

2.10.2 Quick viewer for mold-making

2.10.3 Simultaneous recording

2.11

Executing programs (AUTOMATIC)

2.11.1 Display all relevant mold-making functions

2.11.2 Program running time

2.11.3 Handwheel override

2.11.4 Block search

2.12

Collision avoidance

Important functions for 3- to 5-axis machining

3.1

Introduction

3.2

Explanation of the terms: swivel, frames and TRAORI

3.3

Transforming coordinate systems - Frames

3.4

Swivel - CYCLE800

3.5

TRAORI 5-axis transformation

3.5.1

Basics of simultaneous 5-axis machining

3.5.2

The TRAORI command

3.5.3

Programming the tool orientation

3.5.4

Orientation interpolation and orientation reference

3.5.5

Example application involving TRAORI and frames

100

3.5.6

Useful NC commands for active TRAORI

101

3.6

High Speed Settings - CYCLE832

102

3.6.1

Parameters for CYCLE832

103

3.6.2

CYCLE832 and CUST_832

109

Content

3.7

Advanced Surface and Top Surface

110

3.7.1

Compressor (COMPCAD, COMPSURF)

112

3.7.2

Continuous-path mode, Look Ahead - G64, G645

113

3.7.3

Feedforward control and jerk limitation - FFWON, SOFT,

115

3.7.4

Smoothing tolerance CTOL, OTOL, ATOL

116

3.7.5

Path reference UPATH/SPATH

116

3.7.6

Smoothing the orientation characteristic (ORISON, ORISOF)

117

3.7.7

Technology G groups

118

3.7.8

Pre-processing memory control FIFOCTRL

119

3.8

Milling radius compensation 2D/3D-WRK

120

3.8.1

3D-WRK cutter radius compensation for circumferential and face milling

120

3.8.2

CUT3DC/CUT3DCD circumferential milling

121

3.8.3

CUT3DF/CUT3DFD face milling

122

3.8.4

Circumferential milling with limiting surfaces (CUT3DCC/CUT3DCCD)

126

3.8.5

Overview of the tool types for the 3D compensations

127

3.8.6

Explanation of the commands

127

3.8.7

Programming example for circumferential milling

129

3.9

Volumetric Compensation System (VCS)

130

3.10

VNCK - virtual machine

131

Aerospace, structural parts

133

4.1

Special functions for structural parts

134

4.2

Programming example for the pocket on a structural part

135

Engine and turbine components

139

5.1

Special functions for engine and turbine components

140

5.2

Example: Turbine blade

141

Complex free-form surfaces

145

6.1

Special functions for free-form surfaces

146

6.2

Example: Milling a manta ray

147

Difference between 3, 3+2 and 5 axes

151

7.1

5-axis simultaneous or 3+2-axes

152

7.2

Example workpiece milled by 3 to 3+2 axes

153

7.3

Example with 3 axes milled

155

7.4

Example with 3+1 axes milled

156

7.5

Example with 3+2 axes milled

157

7.6

Comparison of the three variants

158

Basic information

1.1

Introduction

With mold-making, the main objectives are to achieve perfect surface quality, precision, and

velocity without any need for remachining. Within this context, workflow is typically characterized

by the CAD-CAM-CNC process chain. From the CAD system right through to the control,

Siemens can offer an integrated solution for these requirements in the form of its SINUMERIK

products.

SINUMERIK controls have powerful, highly-developed functions which, if intelligently used,

significantly simplify the complete operation involving programming and milling, and at the same

time the production result is improved.

This manual is a compact resource aimed at experts working in machining environments who

need to get acquainted with the most important basic principles of milling. Based on this, it also

provides machine users with practical tips so that they can organize their work efficiently and

provides programmers with an insight into the functions of the control and the CAD/CAM system.

As regards the various application areas of machining, the dedicated functions that have been

specifically developed for each area are briefly introduced and considered in context.

Although, many aspects cannot be covered in depth by this manual, additional information can

be found in the appropriate SINUMERIK documentation and relevant literature, See "Further

information/documentation" on page 170.

Range of

milling

Blow mold for plastic bottles

Turbine impeller

Basic information

1.2

SINUMERIK MDynamics milling technology

packages

SINUMERIK MDynamics bundles SINUMERIK CNC hardware, intelligent CNC functions and our

unique CAD/CAM/CNC process chain in technology packages for 3-axis and 5-axis milling. The

SINUMERIK MDynamics 3/3+2 or 5-axis milling packages are available for the SINUMERIK

828D and SINUMERIK 840D sl CNC systems.

SINUMERIK 828D

SINUMERIK 828D integrates the milling

package for 3 axes. The basic scope can be

expanded via optional functions (see also the

3-axis milling package for SINUMERIK 840D

sl)

Basic scope, 3/3+2 axes (excerpt):

Advanced Surface

User memory expansion on the user's CF

card

Additional options, 3/3+2 axes (excerpt):

Top Surface

DXF reader

EES

ShopMill machining step programming

3D simulation

SINUMERIK 840D sl

For SINUMERIK 840D sl, you can choose

between two milling packages for 3-axis and

5-axis machining. The basic scope of the

packages includes all the functions needed for

the associated machining tasks and can be

expanded.

Basic scope, 3/3+2 axes (excerpt):

Advanced Surface

Spline interpolation

Transmit and peripheral surface

transformation

AUTOMATIC measuring cycles

3D simulation

Residual material identification

ShopMill machining step programming...

Additional options (excerpt):

The 5-axis package additionally includes:

Top Surface

5-axis machining package TRAORI

DXF reader

3D tool radius compensation

EES

Measure kinematics CYCLE996/9960

Basic information

1.3

SINUMERIK Operate user interface

The new SINUMERIK Operate user interface is well laid out and easy to use. It combines the

known features of HMI Advanced, ShopMill and ShopTurn in a seamlessly integrated, innovative

user and programming interface. This allows machining step programming to be combined with

high-level language programming, resulting in rational and intuitive NC programming and

production planning.

1.3.1

Operating and setup functions

The machine setup display is clear and manageable thanks to graphical support. Complex

workpieces can be quickly and easily machined in one clamping operation. Various kinematics

can be easily set up thanks to the cycle support.

Wide range of setup functions

Support for many kinematics

Animated elements clarify the parameters, for example during programming

Using animated elements, the SINUMERIK CNC achieves a unique level of user friendliness for

operating and programming - even for technological cycles.

Cycle multi-edge in the programGUIDE

Animated elements - Moving image sequence

Basic information

1.3

1.3.2

SINUMERIK Operate - Multitouch

SmartOperation permits an intelligent CNC operation in SINUMERIK Operate using current

technologies, such as multitouch and widescreen displays. The Display Manager permits you to

see a lot of information at a glance.

Multitouch operation

SINUMERIK Operate provides additional operator functions for multitouch panels.

Extended control elements via the function key block

Gesture operation (e.g. wiping, moving and zoom functions)

The selected functions can be activated directly via the function key block. These are, for

example, undo changes or restore and activate the virtual keyboard

or of the calculator

Basic information

1.3

SINUMERIK Operate expansion using a sidescreen

Widescreen format panels offer the option of using the additional area for the faster display of

additional elements and operating. Using the navigation bar

the so-called sidescreen is

shown and hidden

You can display the following elements via the navigation bar:

Machine function direct selection

e.g. machine, tool list, zero offsets or program.

Displaying (widgets)

Standard widgets are for example, zeros, alarms, tool service life and program run time.

Virtual keys (pages)

Activate the ABC keyboard

or of the machine control panel

Basic information

1.4

Requirements for milling

Free-form surfaces

Design standards in all application areas are

Mold-making

becoming increasingly demanding.

Expectations in terms of ergonomics, the air

drag coefficient (CW value) or simply aesthetic

appeal are creating a need for more complex

surface geometries to be achieved quicker

and with greatest precision. The design prima-

rily comes from CAD systems, the machining

programs from CAM systems.

Engine and turbine

With SINUMERIK, Siemens can provide CNC

components

systems that are perfectly suited to the

e.g. impellers

demands of 3- to 5-axis machining as well as

HSC (High Speed Cutting) and HPC (High

Performance Cutting) applications:

Simple to operate

User-friendly programming at the machine

Optimum performance throughout the

CAD-CAM-CNC process chain

Optimized 5-axis functions

Structural parts

Depending on the application, the

Aviation industry

requirements imposed on the control will vary

and a whole range of different functions may

be demanded.

Within this context, milling can be broken

down into three broad areas:

Free-form surfaces (mold-making)

Turbine and engine components

(impellers, blisks)

Structural parts (aviation industry)

SINUMERIK can provide optimum support for

each of these areas.

Basic information

1.5

Linear axes, rotary axes and kinematics

1.5.1

Axes and programming

Tool tip motion

3-axis area

The tool position is approached in space using

linear axes X, Y and Z. This enables the tool

center point to adopt any position.

With 3-axis machining, you program the three

linear axes to achieve the desired machining

operations. The contour is milled line-by-line

by moving the three linear axes.

If the tool also has to be set at an angle, you

will need rotary axes as well.

Setting the tool at an

5(3+2)-axis area

angle

The inclination of the tool (i.e. the tool

orientation) is changed using two axes of

rotation, e.g. B and C.

This is necessary, for example, if the tool

needs to be angled in relation to the

machining surface or if you want to mill a

pocket with inclined walls within the context of

circumferential milling.

Using three linear axes and two rotary axes,

theoretically any point in space can be

approached with any tool orientation. This is

the basis of 5-axis machining.

Linear and rotary axes

5-axis simultaneous

To accommodate machining scenarios

involving tools set at an angle or in order to

mill undercuts or geometries located

anywhere in space, the three linear axes X, Y

and Z are required along with two of the rotary

axes A, B or C. It must be possible to control

the axes simultaneously.

Basic information

1.5

CNC programming options in the 5-axis area

Programming rotary

For the purpose of 5-axis machining, the

axes

orientation of the tool needs to be defined in

addition to the position setpoint of the

machining point. The position setpoint is

defined in the CNC program by means of the

coordinate axes X, Y, and Z.

The tool orientation can be specified on the

basis of the rotary axis positions. This enables

the position setpoint and tool orientation to be

defined in a unique manner.

The example below shows the tool tip in the

position (0,0,0), and the tool shank is the

diagonal of a cube (35.26° relative to the X-Y

plane).

N100 G1 X0 Y0 Z0 B=54.73561 C=45

Programming direction

When describing the tool orientation, it also

vector

makes sense to specify the direction vectors

A3, B3, and C3 so that the orientation can be

programmed independently of the machine

kinematics.

The programming of the example above would

look like the following after specifying the

rotary axis positions:

N100 G1 X0 Y0 Z0 A3=1 B3=1 C3=1

In addition to programming based on the direction vector and rotary axis positions, there are also

other forms of angle programming. These include, for example, Euler or RPY angles. Further

information regarding this topic can be found in Section "Programming the tool orientation" on

page 86.

Basic information

1.5

1.5.2

Kinematics of 5-axis machining centers

A 5-axis machine can control tool motion in five axes. These are the three linear axes (with which

you will already be familiar) and two additional rotary axes. There are different kinematic

solutions for the two rotary axes. We will present the most common of these schematically. With

SINUMERIK controls, even special kinematics can be controlled on the basis of the integrated,

kinematic transformation feature. Special cases such as hexapods, etc. will not be explored in

further detail here.

Two rotary axes in the head

Fork head

Head kinematics nutated *

Two rotary axes in the table

Rotary/swiveling table

Rotary/swiveling table nutated *

*: If the axis of rotation is not perpendicular to a linear axis, then this is known as a "nutated" axis.

Mixed kinematics

Basic information

1.6

Surface quality, velocity, accuracy

Special attention must be paid to the CAD -> CAM -> (postprocessor) -> CNC process chain

when machining three-dimensional geometries, e.g. free-form surfaces. CAM systems generate

NC programs for free-form surface machining. The CAM system receives the workpiece

geometry from a CAD system. The CNC machine has to process the NC data generated and

convert it into axis movements.

In CAD systems, surfaces

of higher orders

are constructed (free-form surfaces).

For example, in order to be able to mill an

entire surface - or for collision checking - the

CAM system generally converts the CAD free-

form surface into a polyhedron.

This means that the smooth design surface is

approximated

by a number of individual

small planes.

This produces deviations from the original

free-form surface.

The CAM programmer overlays this

polyhedron with tool paths. From these, the

postprocessor generates NC blocks within the

specified error tolerances. These usually

comprise many short straight line elements,

G1 X Y Z.

Thus, the machining result is no longer a free-

form surface, but a polyhedron. The small

planes of the polyhedron can be visibly

mapped on the surface.

This can result in undesirable remachining.

Basic information

1.6

SINUMERIK controls offer various functions so that remachining can be avoided:

Compressor function

(COMPCAD/COMPSURF)

At the block transitions, the interpolation leads

to step changes in velocity in the machine

axes, which in turn can cause resonance in

the machine elements and can ultimately be

detected as a beveled pattern

or as the

effects of vibrations

on the workpiece sur-

face.

In accordance with the specified tolerance

band, the compressor

takes a sequence of

NC commands, 2 combines them and

compresses them into a spline

, which can

be directly executed by the control.

The compressor generates smooth paths and

paths with constant curvature. The constant

curvature results in a steady velocity and

acceleration characteristic. The surface quality

is improved and the machine can run at higher

velocities, thereby increasing productivity.

Programmable smoothing (G645)

Discontinuous block transitions can be

blended using the smoothing function to

create steady characteristics. This involves

inserting geometrical elements

at the

corners (block transitions).

The tolerance of these geometrical elements

can be adjusted (see also 3.6).

Basic information

1.7

Additional software

1.7.1

SinuTrain

SinuTrain provides for SINUMERIK controls an intuitive PC-based solution that consists of

control-identical software. SinuTrain allows practical offline programming at a PC; these NC

programs can be transferred directly to the CNC. Using SINUMERIK Operate and the original

SINUMERIK CNC kernel, all operating and programming operations can be used and CNC

programs executed, without any restrictions.

Advantages at a glance

Almost 100-percent offline verification/evaluation of the NC programs thanks to the original

CNC kernel.

Use as optimum programming station by adaptation to the real machine (e. g. by the machine

manufacturer).

Perfectly tailored packages for training and production planning.

Operating, programming and simulating exactly as for the real SINUMERIK.

Basic information

1.7

1.7.2

VNC Viewer - remote control on an external PC

In SINUMERIK Operate, a VNC (Virtual Network Computing) Viewer can be integrated in the

operating area to access a remote PC located in the network of the control. This access allows

applications on the PC to be operated directly from the control. For example, missing information

can be fetched from a CAD/CAM system or from the production planning, or process participants

informed about changed production parameters.

After a one-off configuration of the connection, a switch can be made to the remote connected

PC by pressing a key.

Access to an application

of the external computer

VNC area configuration on the user interface

Remote access to a PC in the

network is possible via the inter-

faces, e.g. X130.

The configuration is performed

in SINUMERIK Operate.

Further information can be

found in the manuals with the

keyword VNC or obtained from

the machine manufacturer.

Basic information

1.7

1.7.3

Analyze MyWorkpiece /Toolpath additional

software

After the processing, the Analyze MyWorkpiece /Toolpath 3D visualization tool allows the

completed geometry from the CAD system, the NC program as well as the recording of the tool

path to be represented concurrently in three dimensions and compared with each other. Filters

and color assignments highlight any potentially problematic areas. They shows immediately

whether the errors are in the NC program or were caused by the machine kinematics or the

clamping.

Optimizations and compensations are possible even before production of a workpiece. For

example, any discrepancies in the NC program caused by an irregular distribution of points,

differences for the travel velocities of neighboring milling paths or tool paths not appropriate for

fine machining are shown.

Missing points in the curvature path

4D evaluation:

Color switching in the curvature path

The capability to measure points with micrometer accuracy makes it possible to evaluate

whether errors are surface-relevant. This saves valuable machine time for the production of

faulty parts because corrective work is reduced to a minimum.

General information on workpiece

production

Content

Page

2.1

Process chain for producing 3- to 5-axis workpieces

2.2

CAM systems

2.3

Program structure for milling

2.4

Programs, data transfer and editor

2.5

JOG mode, zeros, tools

2.6

Fundamentals, measuring in JOG and AUTOMATIC

2.7

Measuring workpiece/tool in JOG

2.8

Measure workpiece/tool in AUTOMATIC - process

measuring

2.9

Checking and measuring machine/spindle

2.10

Workpiece visualization

2.11

Executing programs (AUTOMATIC)

2.12

Collision avoidance

General information on workpiece production

2.1

Process chain for producing 3- to 5-axis workpieces

The production process chain generally starts with workpiece design. The data generated at this

stage provides the basis for further processing and, ultimately, for production.

CAD/CAM

Production

Creating a CAD model

CAD model

Use of the CAM-internal strategies and methods to

CAM strategies

generate the individual machining steps and calculate

Calculation

the paths.

of tool paths

Simulation of the calculated tool paths with collision

Simulation

checking.

of tool paths

Generation of the NC code in the postprocessor.

Postprocessor

Generally, the path at the tool tip (TTP) is output in NC

code.

Data transfer of the NC programs and setting up of the

tool and workpiece. If required, creation of a main

Setting up the machine

program that calls the generated geometry programs.

Specification of the high-speed settings, e.g. in

CYCLE832, if this is not already taken into account by the

Quality

postprocessor. These are tolerance, compressor, path

control, smoothing, jerk and velocity.

Manufacture of the workpiece on the machine.

Machining

General information on workpiece production

2.2

CAM systems

Within the context of the process chain, it is the CAM system that is responsible for the key task

of generating the NC programs. The quality of this data plays a decisive role in determining the

results of workpiece production.

This section outlines the procedure for generating the NC programs. Given the diverse range of

systems available on the market, only a brief summary can be provided.

Tool definition

Plane roughing strategy

Procedure when working with a CAM system:

X CAD data

Fetch CAD data into the CAM system. When reading the data in, a check should be

performed to ensure that the surface geometries are free from defects, i.e. that there are no

steps or jumps. Flaws in the data such as these will manifest themselves on the surface of

the finished workpiece.

X Clamping situation

Define the clamping situation and the geometry that can be freely machined in a clamping

device. Define geometries such as a zero.

X Specify tools

Define the necessary tools on the basis of the machining task at hand and enter the technol-

ogy data. As a general rule, CAM systems are able to read the data in from tool databases.

Amongst other things, the tools determine which subsequent machining strategies can be

used, e.g. whether plunge cutting is possible with the tool.

X Specify machining strategies

Define the machining process for the various workpiece geometries using the appropriate

strategies. First of all, roughing strategies are applied, e.g. roughing in the Z plane or equidis-

tant from the surface geometry. CAM systems offer various options from 2 1/2-axis to 5-axis

machining.

The tool paths can be generated automatically or defined manually; these include, for exam-

ple, approach and retract strategies or special milling strategies such as trochoidal milling.

The machining strategies are gradually introduced in stages as part of this procedure and are

supported by automatic residual material detection, for example.

General information on workpiece production

2.2

X Calculation and simulation

When simulating the calculated tool paths / machine movements, different levels of quality

can be used. From straightforward simulation of the tool paths through to complete simulation

of the G and M codes that takes account of all machine-specific and control-specific data.

Here, potential collisions can be detected and avoided, for example, and the machine's maxi-

mum axis traversing ranges can be taken into account.

X Output of the NC code with the postprocessor

The postprocessor converts the sequences into NC programs taking into account the control-

specific syntax and the control's special functions. For this purpose, CAM systems make use

of universal postprocessors or special postprocessors that have been optimized for the

SINUMERIK system. Manufacturer-specific functions such as separate coolant strategies

must be implemented in the postprocessor in consultation with the machine manufacturer.

2.2.1

Tolerance and accuracy

When working with CAD/CAM systems, certain tolerances and levels of accuracy that will have

an impact on subsequent machining must be observed.

Tolerance The CAM system uses the CAD surface (spline) to generate a contour consisting of linear

traversing blocks (straight line elements). The extent to which the linear contour deviates from

the real contour from the CAD system is known as the chord error or chord tolerance. This

tolerance depends on the strategy and on the workpiece. The tolerance for roughing strategies is

greater than for finishing strategies. When the NC programs are executed on the machine, the

tolerance is specified by the CAM system in CYCLE832 so that optimum results can be achieved

in terms of surface quality and contour accuracy.

Tolerance guide values

Technology

Recommended values

Roughing

Tolerance 0.05 - 0.1 mm - with 5-axes OTOL = 0.3

Semi-finishing

Tolerance 0.01 - 0.05 mm - with 5 axes OTOL = 0.15

Finishing

Tolerance 0.002 mm - max. point separation 0.3 - 0.5 mm

with 5-axes OTOL = 0.01 - 0.1

Accuracy When outputting the NC blocks from the CAM system, you can specify the number of decimal

places. The required level of accuracy is dependent on the type of interpolation.

Accuracy guide values

Axes interpolation

Recommended values

Linear axes

for 3-axis programs, at least 4 decimal places

(X Y Z)

Rotary axis positions

for 5-axis programs, at least 6 decimal places in linear and rotary axes

(A B C)

for optimum surface quality

Direction vector

4 decimal places in linear axes and at least 7 decimal places for

(A3 B3 C3)

direction vectors

General information on workpiece production

2.3

Program structure for milling

CYCLE832 can be programmed in the main program or in thesubprogram for the geometry

data. Both versions are briefly described.

CYCLE832 in the main For machining purposes, a main program is generated

that includes all technology data. The

program main program calls one or more subprograms

that contain only the pure geometric data

of the workpiece. The tool change defines how the content is divided into subprograms.

MAINPROGRAM.MPF

Main program

N10

T1 D1

N20

; Tool change

N30

S10000 M3

N40

G54

N50

CYCLE832 (0.1,_ROUGH,1)

; High Speed Settings

N60

EXTCALL "CAM_rough"

; Call subprogram

N65

CYCLE832(0,_OFF,1)

; Deselect CYCLE832

N70

T2 D1

N80

; Tool change

N90

S15000 M3

N100

G54

N110

TRAORI

; Only for 5-axis

N120

ORIWKS ORIAXES

; Orientation reference and orientation;

N130

; interpolation, switched optionally in CYCLE832

N140

CYCLE832(0.005,_ORI_FINISH,0.5)

; High Speed Settings

N150

ORISON

; Orientation smoothing activation

N160

; switched optionally already in CYCLE832

N170

EXTCALL "CAM_finish"

; Call subprogram

N180

; Deselect CYCLE832

CYCLE832(0,_OFF,1)

N190

; End of program

M30

Subprogram

CAM_rough.SPF subprogram

N10

G0 X0 Y0 Z10

N20

G1 Z0 F500

N30

G1 X-1.45345 Y0.67878 F10000

G1 Z-2.13247 Y=0.34202 F800

N5046

N5047

M17

N6580

Subprogram

CAM_finish.SPF subprogram

N10

G0 X0 Y0 Z10 A3=0 B3=0 C3=0

N20

G1 Z0 F500

N5050

G1 X7.60978 Y3.55541 A3=0.34202 B3=0 C3=-0.9396

N5060

G0 Z50 A3=0.34202 B3=0 C3=0.93969

N6570

TRAFOOF

N6580

M17

General information on workpiece production

2.3

Main program: The main program includes the two key functions for milling, CYCLE832

and

subprogram call (e.g. with EXTCALL)

CYCLE832

: CYCLE832 was specifically adapted for the program structure shown, where

technology data and geometry data are separated. It brings together all the key commands and

activates control functions. The machining technology for milling is defined in CYCLE832. For the

roughing program "CAM_rough" using T1, the parameters in CYCLE832 were set towards

achieving a high velocity. For the finishing program "CAM_Finish", the parameters were set

towards achieving high surface quality and accuracy. CYCLE832 is deselected at the end of the

geometry blocks. More information is available on the individual parameters in Section

CYCLE832 (See "High Speed Settings - CYCLE832" on page 102.)

The call syntax changes if the Top Surface option is active.

EXTCALL

: CAM programs are generally extremely large, which is why they are stored in an

external memory. The EXTCALL command is used to call the subprograms from various

locations, including external memories. All programs should be located in the same directory. If

this is not the case, the paths must also be specified during the call.

If option EES is active, then the subprogram call is made without EXTCALL. (See "EES -

Execution from External Storage (NC Extend)" on page 35.)

ORISON (only for Advanced Surface COMPCAD)

: The NC command ORISON is a vector

smoothing function that has been specially developed for the 5-axis area. This function can be

used to smooth fluctuating orientation across several blocks. The aim is to achieve a smooth

characteristic for the orientation and a more harmonious movement of the axes. As of SW 4.5,

this command can be part of CYCLE832 (_ORI_ROUGH, _ORI_SEMIFIN, _ORI_FINISH). With

older software versions, it is recommended that ORISON is programmed after CYCLE832.

The OTOL command can be used to define the orientation tolerance for vector smoothing with

ORISON. The value is entered in degrees. The set value depends on the component.

Subprogram: The subprogram contains the geometry blocks. In our example, these initially take

the form of blocks for 3-axis milling, which are then followed by the blocks for 5-axis

simultaneous

milling. These are designated A3, B3, and C3.

General information on workpiece production

2.3

CYCLE832 in the For machining purposes, a main program is generated

, which only serves as call program for

subprogram the individual subprograms. The main program calls one or more subprograms

which

contain all the technological and geometric data for the production of the workpiece.

This program structure is suitable for the use of CAM systems whose postprocessors support the

SINUMERIK cycles, output these completely with the cycle call and deselect them during the

program generation. The descriptions for 4 to

are identical (see page 30).

MAINPROGRAM.MPF

Main program

N10

CYCLE800(4,"TABLE",200000,57,0,0,0,0,0,0,0,0,0,1,,1)

; Swivel basic position

N20

CYCLE800()

; Deselect swivel

N30

WORKPIECE(,,,"CYLINDER",0,0,-32,-80,46)

; Define blank

N40

EXTCALL "CF_CARD:/PROG/CAM_ROUGH.SPF"

; Call subprogram

N50

STOPRE

; Stop preprocessing

N60

EXTCALL "CF_CARD:/PROG/CAM_FINISH.SPF"

; Call subprogram

N65

STOPRE

; Deselect CYCLE832

N70

; Further subprograms

N200

M30

; End of program

Subprogram

CAM_ROUGH.SPF subprogram

N10

T1 D1

; Tool call

N20

; Tool change

N30

S10000 M3

; Technological data

N40

G54

; Zero offset

N50

CYCLE832 (0.1,_ROUGH,1)

; CYCLE832 roughing

N60

G0 X0 Y0 Z10

; 3-axis

N70

G1 Z0 F500

N80

G1 X-1.45345 Y0.67878 F10000

N90

N6000

CYCLE832(0,_OFF,1)

; Deselect CYCLE832

N6010

M17

; End of subprogram

Subprogram

CAM_FINISH.SPF subprogram

N10

T2 D1

; Tool call

N20

; tool replacement

N30

S15000 M3

; technological data

N40

TRAORI

; TRAORI for 5-axis On

N50

ORIWKS

; Orientation reference

N60

ORIAXES

; Orientation interpolation, switched optionally already in CYCLE832

N70

G54

; Zero offset

N80

CYCLE832(0.005,_ORI_FINISH,0.5)

; CYCLE832 5-axis finishing

N90

ORISON

; Orientation smoothing activation

N95

; switched optionally already in CYCLE832

N100

G0 X0 Y0 Z10 A3=0 B3=0 C3=0

N110

G1 Z0 F500

N120

G1 X7.60978 Y3.55541 A3=0.34202 B3=0 C3=-0.9396

N130

G0 Z50 A3=0.34202 B3=0 C3=0.93969

N140

N6000

TRAFOOF

; TRAORI Off

N6010

CYCLE832(0,_OFF,1)

; Deselect CYCLE832

N6020

M17

; End of subprogram

CYCLE832 guidelines When CYCLE832 is used, the sequence of the NC commands in the program must be observed.

General information on workpiece production

2.3

Whereby:

CYLCE832 must be called immediately before the mold-making program.

After selection of CYCLE832, only motion commands (G0, G1, G2, G3) should be

programmed.

Manufacturer-specific subprograms, e.g. for tool change or swivel, can overwrite settings of

the CYCLE832 and must be programmed outside the CYCLE832 selection and deselection.

Programming overview

Description

T1 D1 M6

Tool change

CYCLE800(4,"HEAD",200000,57,0,0,0,0,0,0,0,0,0,1,,1)

Settings,

e.g. swivel

CYCLE832 (0.1,_ROUGH,1)

Select CYCLE832

...G1 X-1.45345 Y0.67878 F10000...

Mold-making program

CYCLE832(0,_OFF,1)

Deselect CYCLE832

CYCLE800()

Deselect CYCLE800

Example, NC commands in the 5-axis program sequence

CYCLE800()

TRAFOOF

T="CUTTER_10"

S15061 M3

CYCLE800(0,"TABLE",100000,27,0,0,0,288.079,0,-10.196,0,0,0,-1,0,1)

G00 X-13.532 Y-24.856 M03

TRAORI

ORIWKS ORIAXES

G54

TOFFL=0

TOFFR=0

CYCLE800()

CYCLE832(0.05,_TOP_SURFACE_SMOOTH_ON+_ORI_SEMIFIN,1)

General information on workpiece production

2.4

Programs, data transfer and editor

2.4.1

Program manager

The program manager offers an optimum overview of the directories and programs, and very

easy-to-use file handling. It supports plain names of up to 24 characters for directories and files.

Subdirectories can also be managed on external storage media such as CF cards, USB sticks

and on the NC.

All storage media including the network drives are displayed in the program manager. The part

programs can be edited in all media. You can create, paste, copy, delete and cut programs via

the horizontal softkey bar.

In the program manager, you can use standard Windows short-cuts such as CTRL+C,

CTRL+X, and CTRL+V.

Possible storage locations for programs are:

1. NC

2. Local drive (CompactFlash card or hard drive)

3. USB drives

4. Network drives

General information on workpiece production

2.4

2.4.2

External storage media - data transfer

NC programs are stored in the control, if required, downloaded to the working memory, and

executed on the machine.

Mold-making programs are often too large for the NC memory or they cannot be processed.

Therefore these are swapped to an external memory and processed successively. In the main

program, an EXTCALL command is programmed, which calls up the program according to the

network path on the server, the USB interface, hard drive, etc.

Procedure when calling the geometry program with EXTCALL/CALL

X Program the geometry program call, e.g. SAMPLE in the main program. The call differs

depending on the control and where the data is stored.

Subprogram is on the HMI user memory (NC)

CALL "SAMPLE"

Subprogram is in the directory on the CompactFlash card

EXTCALL "CF_CARD:/PROGRAMS/SAMPLE.SPF"

Subprogram is on a local drive

EXTCALL "LOCAL_DRIVE:/PROGRAMS/SAMPLE.SPF"

Subprogram is on a USB stick

EXTCALL "USB:/MOLD_DIE/CAM_ROUGH.SPF"

Network connected with Ethernet and path in the machine data SD 42700, e.g. on a server

"//R4711/workpieces/subprograms". The default setting is optional. The directory can first

be specified when making the call with EXTCALL.

EXTCALL "SAMPLE.SPF"

Processing of USB flash drive / CF card

On the control, there is a USB port on the front, and on the SINUMERIK 828D, there is a USB

port on the front and on the rear. The slot for a CompactFlash card on the SINUMERIK 828D is

on the front.

Storage media can be inserted or removed during operation, i.e. the machine does not have

to be restarted in order for the storage medium to be recognized

Loading, editing and executing of part programs from the storage medium.

When executing part programs from a storage medium there is no loss of velocity (DNC

operation), in which case executing from a CF card is recommended.

No special software is necessary for reading from or writing to the storage medium on the

PC.

Direct execution from a USB FlashDrive is not recommended. Disconnecting during

operation will stop machining and, under certain circumstances, cause damage to the

workpiece.

General information on workpiece production

2.4

2.4.3

EES - Execution from External Storage (NC Extend)

Using function EES - Execution from External Storage (as of SW 4.7 SP2) you can call and

execute part programs by the NC directly from all connected data storage devices (e.g. local

drive, PCU50, USB global and at the TCU, network). The behavior is the same as that for

processing from the NC part program memory without the restrictions that apply to "processing

external".

With this function, there is practically no longer a restriction regarding the part program size. This

is only limited by the capacity of the external data storage. There is a standard syntax for all

subprogram calls, independent of where the subprogram is archived. Program compensation for

NC stop is possible.

The EES function makes EXTCALL calls superfluous. If required, existing EXTCALL calls

can be converted.

Syntax example for a call with/without option EES

Without EES

With EES

Call subprogram in another folder in the local drive

EXTCALL "//LOCAL_DRIVE: /CAM_PRG/ROUGH_01.SPF"

CALL "//LOCAL_DRIVE: /CAM_PRG/ROUGH_01.SPF"

Subprogram call from the main program in the local drive (main and subprogram in the same folder)

EXTCALL "ROUGH_01.SPF"

CALL "ROUGH_01.SPF"

EXTCALL "ROUGH_01.SPF"

ROUGH_01.SPF

General information on workpiece production

2.4

2.4.4

Graphic and file formats in the program manager

In addition to the standard NC formats (*.mpf, *.spf), the program manager also directly displays

additional graphic and file formats at the control. This means that you can archive and

display, for example, production documentation as PDFs, photographs of the clamping situation

or also CAD drawings (DXF). This means that you have all information in the production

environment directly available at the control - a paperless production environment.

An existing DXF file can be read into the contour editor as contour (DXF reader option).

Syntax documents TXT, PDF

Pixel files BMP, PNG, GIF, JPG

Vector graphic DXF

General information on workpiece production

2.4

2.4.5

Program editor - useful functions

In the program editor, you can conveniently open larger mold-making programs yourself; you can

also edit these and this, independent of the archiving location (NC, CF card, USB stick...). In

addition to standard functions, it offers additional helpful functions such as cut out, copy, paste

and renumber for effectively programming and displaying large programs.

Program editor supplementary functions

Dual editor - two programs can be simultaneously opened next to one another

Structuring large programs by creating blocks (blocks are opened and closed)

Scalable display, changing the font size

Syntax highlighting, color coding NC functions

Determine machining times through simulation and display block-by-block/non-modally

Subprogram calls, including path information, directly using the Various softkey

Dual editor and syntax

highlighting

Subprogram call with

transfer of the complete path

General information on workpiece production

2.5

JOG mode, zeros, tools

2.5.1

Zero offsets

After reference point approach, the actual value display for the axis coordinates is based on the

machine zero (M) of the machine coordinate system (MCS). The program for machining the

workpiece, however, is based on the workpiece zero (W) of the workpiece coordinate system

(WCS). The machine zero and workpiece zero are not necessarily identical. The distance

between the machine zero and the workpiece zero depends on the workpiece type and how it is

clamped. This zero offset is taken into account during the program execution and can be a

combination of different offsets.

When setting up the workpiece, set the workpiece zero as zero offset, e.g. G54. Using the Zero

offsets softkey, open the list where you can select various views using the vertical softkeys.

Active

zero offsets, for which active offsets are included or for which values, settable zero offsets

and total zero offset are entered

Overview

The active offsets or system offsets are displayed for all set-up axes. In addition to the offset

(course and fine), the rotation, scaling and mirroring defined using this are also displayed.

Base

The defined channel-specific and global base offsets, divided into coarse and fine offsets, are

displayed for all set-up axes.

G54..G57

All of the settable offsets, divided into coarse and fine offsets, are displayed along with

rotations, scaling and mirroring.

General information on workpiece production

2.5

2.5.2

Tool management

For tool management, SINUMERIK Operate provides you with the tool list

, the tool wear list

and the magazine

displays. All of the relevant tool data is displayed in the tool list. Using

softkey

you can create, delete, load or unload tools and directly load them into the program.

With the tool catalog

, which is displayed when new tools are created, you can quickly create

tools with the aid of pre-defined tool types.

For the milling technology, schematic diagrams of the tools are displayed above the tool list. The

display can be configured. You can switch this on and off via the >> > Settings expanded

softkey bar (not for multitasking machines).

For automatic tool monitoring, you can define the wear limits and service life. Providing a new

tool or the disabling of a worn tool is done automatically, based on the specified wear values.

Magazine-related data is displayed in the magazine. For example, you can disable locations or

assign tools to locations.

General information on workpiece production

2.5

2.5.3

Manual retraction - return

After an interruption of a tapping operation (G33/G331/G332) or a general drilling operation

(tools 200 to 299) due to power loss or a RESET at the machine control panel, you have the

possibility to retract the tool in the JOG mode in the tool direction without damaging the tool or

the workpiece.

The retraction function is especially useful when the coordinate system is swiveled, i.e. the infeed

axis is not perpendicular.

An active CYCLE800 and TRAORI are taken into account, and for tapping, the spindle is

interpolated in the Z axis for return movement.

Procedure

X After a power failure, switch on the machine again and select the JOG operating MODE.

X Press the menu forward key.

and then return

X Select the WCS coordinate system at the machine control panel and traverse the tool

corresponding to the return axis displayed in window Return tool (e.g. Z+).

General information on workpiece production

2.6

Fundamentals, measuring in JOG and AUTOMATIC

Measuring in JOG

When measuring in JOG (setup), the machine is prepared for machining. This involves

determining the dimensions of the workpiece and the tool which are still unknown.

Manual measurement is used to prepare the machine for machining.

Manual measurement is used to determine unknown workpiece or tool geometries.

The operator interacts with the machine during manual mode in order to perform the

measurement.

The reference point for programming a workpiece is always the workpiece zero. When setting-up

a clamped workpiece its workpiece zero is determined. The workpiece elements - edge, corner,

pocket/hole, lug, plane - can be used when setting-up. When completed, the workpiece zero is

defined as the result of the linear and rotary compensations of the coordinate system that have

been determined.

Measuring in AUTOMATIC (process measuring)

In process measuring, workpiece tolerances are determined within the production process and

tool parameters are monitored. The nominal dimensions of the tool and workpiece are already

known.

Process measuring is performed to check that the workpiece measurements conform to

specifications.

Process measuring is performed to correct known workpiece and tool geometries.

The measurement is performed by calling a measuring cycle in the machining program.

Measuring cycles/functions for all measuring tasks

The SINUMERIK features an extensive

Examples of measuring

pool of practical measuring cycles/

cycles/functions

functions for measuring tasks in JOG

and AUTOMATIC modes. These

measuring cycles/functions enable you

to measure workpieces and tools using

a graphically supported process.

The measuring tasks are performed

with switching probes and

dynamometers or laser measuring

systems.

When measuring in JOG, the

measuring functions can also be used

with edge probes or tools with known

dimensions. During the measurement,

the measuring points are manually

approached and the current position is

saved in the measuring function via a

softkey.

General information on workpiece production

2.6

2.6.1

Measurement logs in JOG

When measuring the workpiece zero and the tool, you can save the values determined in a

standard log. For a standard log, you can first configure the log format (TXT, CSV), log data,

archive location and the names.

After the measurement has been performed, the Measurement log softkey

becomes active,

and you can save the measured values. Measurement logs can be generated only when using

switching probes or dynamometers.

General information on workpiece production

2.6

2.6.2

Measurement logs in AUTOMATIC

As of SW 4.7 SP2, standard logs can be used to save measurement results. Standard logs

display the results from measuring cycles in a clear log structure. The output is possible in text or

tabular format. Contents and structure are predefined.

The call of the control CYCLE150 is always at the start of the program. You can then optionally

create user-defined texts and program the various measuring cycle calls.

In comparison to the standard log in JOG, additional data is captured:

Name of the part program from which the measuring function was called

Workpiece number

Measuring point, measuring variant and time of measurement

Procedure

X Select the display and display mode of the measurement result screen

X Switch on logging

and select the standard log

X Select the format (TXT, CSV)

X Configure whether the log should be recreated after each measurement or the

measurements should be saved consecutively in the same file.

X Select the storage location (NC, USB...)

and the name of the log file

X Parameterize the measuring functions and supplement optional user data with

S_PROTTXT[.].

General information on workpiece production

2.6

X If you have supplemented the standard log to include user data, you must program

CYCLE160 so that the user data is written to the log file.

G code program example with call and a measurement function

N50 CYCLE150(10,1001,"MEAS_PROTOCOL.TXT")

N51 S_PROTTXT[0]=REP("") ; field, delete all data

N52 S_PROTTXT[1]=" Measure workpiece 1234" ; write user data

N70 CYCLE160 ; write user data to the log

N80 CYCLE997(109,1,1,10,1,5,0,45,0,0,0,5,5,5,10,10,10,0,1,,0,)

The standard logs can be saved as CSV or text file.

You can use CYCLE150, also without measuring functions, for example, to display texts

for the operator on the complete screen.

General information on workpiece production

2.7

Measuring workpiece/tool in JOG

2.7.1

Workpiece measuring in JOG

Once the machine has been powered up and the reference point approached, the axis positions

relate to the machine coordinate system. The zero offset signals to the control the position of the

workpiece in the machine coordinate system.

2.7.2

Workpiece measuring functions in JOG

Using the semi-automatic "Measuring in JOG", the required measuring function is selected on the

control using the appropriate softkeys. The displayed input screens are used for assigning the

function parameters. You must bring the tool or probe into a permissible starting position for the

measurement task concerned, e.g. using the traversing keys or handwheel (manual traversing).

The measuring functions permit the following functions:

Calibrating a probe

Detecting dimensions and position of workpiece geometries, e.g. in order to set up the

workpiece.

Requirements for using measuring functions

The probe is calibrated and active; the tool compensation is activated.

Practical measuring functions are provided to facilitate measurements

Measuring functions in

JOG

→ Calibrate probe

→ Measure edge

→ Aligning an edge

→ Measure corner

→ Measure pocket/hole

→ Measure spigot/hole

→ Align plane

→ Back (exit measuring in

JOG)

The measuring functions can be selected directly via the softkeys. The softkeys can be freely

assigned as of the third softkey and the assignments are based on the last selected cycles. After

selecting a measuring function, you can select additional measuring functions via a selection list

(see figure on the right).

General information on workpiece production

2.7

2.7.3

Example for measuring a workpiece in JOG

The workpiece should be setup with the Right-angled corner measuring function. The

compensation should be made in zero offset G54.

X Select the Right-angled corner softkey. You can also select the cycle from the selection list

X Traverse the probe to measuring point P1.

X Select the zero offset, e.g. G54

X When you press "NC Start", the associated measuring points P1, P2, and P3 3 are

automatically approached starting from the manually assumed preliminary position. This

means that the probe approaches the workpiece, is triggered and then returns to the start

position.

X After each measuring process, the measured values can be saved in a measurement log

the measurement log can be configured in advance.

X Once all measuring points have been approached, press Set zero offset

X The corner point now corresponds to the setpoint position. The calculated offset is stored in

the zero offset.

General information on workpiece production

2.7

2.7.4

Measure tool in JOG

When executing a program, the various tool geometries must be taken into account. These are

stored as tool compensation data in the tool list. When the tool is called, the control considers the

tool compensation data.

You can determine the tool compensation data (i.e. the length and radius or diameter) either via

special tool pre-setting devices or with the aid of the measuring functions on the machine.

2.7.5

Tool reference point

The CAM system usually takes into account

the tool diameter when the geometry program

Taper base2

is being created. The calculated tool path

usually refers to the miller center point and the

tool tip (TTP) (center point path).

This means that to measure the length of the

tool, you must use the same reference point

(TTP) as the CAM system. For the purpose of

determining the tool length, always remember

TTP

to check the reference point the CAM

programmer used to measure L1. The TTP is

on the tool tip. The TCP (Tool Center Point)

can be further up in the milling tool - e.g. for

TTP = Tool Tip Point

radius end mills at the center of the radius.

The tool magazine is equipped as usual. The

tool numbers (T1...) or the plain text name

(MILLING_12...) of the tools

are entered

into the tool table and the tools are assigned a

tool compensation D

, consisting of radius

"R" and length "L1".

The typical milling tools are available for

selection in the tool catalog. You only have to

insert these and enter the necessary

compensation data.

CAM systems define the position of the reference point differently depending on the tool

shape. Generally it is assumed that the output tool path refers to the tip of the milling

cutter (TTP). If the CAM system specifies a different reference point, then this difference

must be taken into account when specifying the tool length. You can perform this, for

example, via the TOFFL command in the NC program.

General information on workpiece production

2.7

Ball end mill

Cylindrical die- End mill

End mill with

Specify additional tool data depending on the

Type 110

sinking cutter

Types 120,

corner rounding

Type 111

Types 121, 131

tool type (e.g. conical tools).

In an NC program, the control uses this data

and path compensations G41, G42 - defined

in the program - to execute the necessary path

and length compensations.

Bevel cutter

Bevel cutter with

Tapered

Type 155

corner rounding

die-sinking

Type 156

cutter

Programmable tool compensation (TOFFL, TOFFR)

The TOFFL/TOFF or TOFFR commands can be used to change the effective tool length

(TOFFL/TOFF) or the effective radius (TOFFR) in the NC program without changing the tool

compensations. Additional information on this topic is provided in the Programming Manuals.

Tool length offset:

TOFFL=<value>

Tool radius offset:

TOFFR=<value>

General information on workpiece production

2.7

2.7.6

Example: Measure tool in JOG

Function

You can execute the following functions with "Measure tool":

Calibrate a dynamometer

Determine the tool length or the radius of milling tools or the tool length of drills, and enter this

data into the tool compensation memory.

Requirements for using measuring functions

The tool must have been loaded.

The dynamometer is calibrated and active.

Procedure

X In JOG mode, select the Measure tool softkey

. In the horizontal softkey bar, select

whether you want to measure automatically or manually.

X Click the associated Radius/diameter auto softkey

or Length auto

and enter the

offset, especially for tools with rounded cuts, for example.

X As of SW 4.5, you can specifically measure individual teeth of the tool in order, for example,

to identify a broken cutting edge. The single cutting edge measurement

can be used for

remeasuring and initial measuring. A check is made as to whether the measured values of all

cutting edges are within a defined tolerance range.

X As of SW 4.7, a tool offset

can be specified in the +/- direction. When measuring the tool

in automatic mode, a measurement log

can be created after each measuring process.

X Click NC Start to initiate the measuring process; the tool compensations for radius and length

1 will be entered in the active tool compensation data.

Measuring function: Measure tool in JOG

General information on workpiece production

2.8

Measure workpiece/tool in AUTOMATIC - process

measuring

2.8.1

Measure workpiece in AUTOMATIC

For process measuring in Automatic mode, measuring cycles are specifically parameterized for

the measuring task. The input screens of the program editor are used for parameter assignment.

The measuring points to be approached and the measuring task are automatically implemented

in accordance with the measuring program.

The workpiece is measured to determine workpiece tolerances in the production process.

Depending on the measuring cycle used, you can select the following options as the result of

workpiece measurement:

Measurement only without compensations (actual value is measured)

Zero offset compensation (setpoint - actual value deviation)

Tool data compensation (setpoint - actual value deviation)

2.8.2

Workpiece measuring cycles in AUTOMATIC

Practical measuring cycles are provided to facilitate process measuring.

X You can select the measuring cycles within the NC program using the Measure mill >

Measure workpiece softkeys.

Calibrate probe

Edge,

measure

Measure corner

Measure hole

Measure spigot

Measure plane,

angle deviation

kinematics

General information on workpiece production

2.8

2.8.3

Example for measuring a workpiece in AUTOMATIC

The procedure is illustrated on the basis of the Measure pocket function. The cycle

automatically measures the right-angled pocket and enters the values in the zero offset.

Requirements for using cycles

The probe is calibrated and active; the tool compensation is activated.

Determining zero offset via Measure right-angled pocket:

X Create a new program for measuring the workpiece or edit an existing one.

X In the expanded softkey bar, select the Measure workpiece > Hole > Right-angled pocket

softkeys.

X Select the tool (3D probe), specify the measuring technique and enter the starting point of the

measurement.

X You can define whether the result of the measurement should be a compensation or merely a

measuring process

Compensation in the zero offset with specification of the zero offset

Compensation in the tool compensation data

Measurement only

As you are setting up the workpiece here, the compensation is made in the zero offset.

X Enter the setpoints of the right-angled pocket and parameterize additional cycle parameters

After the measurement, the measured values are compensated in the active zero offset

frame.

General information on workpiece production

2.8

2.8.4

Tool measuring in AUTOMATIC - process measuring

A practical measuring cycle is provided to facilitate the process measuring of tools. The cycle

determines the length and the diameter of the tool using a calibrated dynamometer.

X You can access the measuring cycles in the NC program by selecting the Measure mill >

Measure tool softkeys from the expanded softkey bar.

Requirements

The dynamometer is calibrated

The tool is clamped

In automatic mode, you can automatically measure the tool data or enter it as tool compensation.

2.8.5

Example for measuring tools in the AUTOMATIC

mode

In the following example, you will generate a program that determines the tool length and the

radius and enters this data into the tool compensation.

Determining the tool length:

X Create a new program for measuring the tool.

X Select Measure tool measuring cycle.

X The measuring process is performed with stationary spindle and the measured values are

entered into the tool geometry component

X Select the length as measured value

. Each tooth can be individually measured to check

for tool breakage.

X Assign parameters to the measuring process

General information on workpiece production

2.8

Determining the tool radius:

X The measuring process is performed with rotating spindle and the setpoint - actual value

deviation is entered optionally into the radius wear

X Select the radius as measured value

. Each tooth can be individually measured to check

for tool breakage.

X Assign parameters to the measuring process

Single cutting edge measurement (as of SW 4.5)

The single cutting edge measurement

can be used for

remeasuring (compensation in the wear) and initial

measuring (compensation in the geometry). Milling tools

with up to 100 cutting edges can be measured.

The cycle checks whether the measured values of all cutting

edges are within a defined tolerance range. If the measured

values are outside the tolerance range, an alarm is output.

If the measured value of the longest cutting edge is within

the tolerance range, this is entered in the tool management.

General information on workpiece production

2.9

Checking and measuring machine/spindle

2.9.1

Spindle 3D angular deviation CYCLE995

With this measuring variant, the angularity (parallelism) of a spindle to the machine tool is

measured on a calibration ball. The measurement is performed by combining the sphere

CYCLE997 and outer circle segment CYCLE979 measuring variants.

Based on the measured values, the angular deviation of the spindle to the axis of the plane is

calculated. With the measured angular deviations, the spindle can be mechanically aligned

parallel to the tool axis or the corresponding tables for sag compensation can be updated.

If there are rotary axes, the determined angular data can be used to align the rotary axis. To do

this, the result parameter (_OVR) of CYCLE995 must be used.

Checking the 3D angular deviation with CYCLE995

X Select the appropriate machining plane

and the measuring parameters

The 1st measurement of the calibration ball is performed with CYCLE997 and the

measurement is repeated. From two measuring points along the circumference and one

measuring point at the "north pole" of the sphere (highest point), the center point (position of

the ball) is determined. In addition, the diameter of the calibration ball can be determined.

The second measurement is performed with CYCLE979 at the shank of the probe at a

distance of DZ. The center point of the probe shaft in the plane is determined. The angular

deviation in XY is calculated from the results of the two center points in XY and the distance

between the two measurements in Z (for G17).

General information on workpiece production

2.9

2.9.2

Checking/measuring the machine with the

kinematics measuring cycle CYCLE996

The requirements associated with 5-axis machining can only be met by means of high-precision

machines. As regard to the kinematic transformation, this means that the centers of rotation and

the vectors for NC-controlled or manually alignable rotary axes must be determined and entered

into the control. CYCLE996 is a special measuring cycle that has been designed specifically for

this purpose. It uses a calibration sphere and a calibrated probe to measure the rotary axis

vectors automatically. In practical applications, the cycle makes control easier and improves the

quality of the process, as compensations of the rotary axis vectors (due, for example, to

temperature fluctuations, or other influential factors) can be checked automatically.

For measurement purposes, a calibration sphere is mounted on the table. The sphere is

measured with the probe at three separate swivel positions of the rotary axis and the values

obtained are recorded. CYCLE996 must be called three times for each rotary axis using different

rotary axis positions. The kinematics calculation is performed in full once all the rotary axes have

been measured.

General information on workpiece production

2.9

Checking the machine with CYCLE996:

X Create a new program to measure the kinematics.

X In the part program editor, select the >> MEASURE MILL > MEASURE WORKPIECE > 3D

> KINEMATICS softkeys in the Programs operating area.

X Create a new swivel data record (where the rotary axis is swiveled)

. Ideally, the swivel

positions should create an equilateral triangle, i.e. each one should involve a swivel of 120°.

X Select the rotary axis to be measured

X Assign parameters to the measuring process

for measurements 1 to 3

Press the Calculate softkey once all rotary axes have been measured

After pressing the softkey, the Calculate kinematics dialog opens. The following options are

available in terms of how you then utilize the measurement results:

Measure only (measure and calculate vectors)

Enter (measure, calculate vectors, and enter vectors in swivel data record for compensation

purposes)

1st measurement

2nd measurement

3rd measurement

Please take care when modifying the swivel data. This affects the kinematics directly and

if an error is made with regard to the compensation value, this can result in damage to the

machine during operation.

General information on workpiece production

2.9

2.9.3

CYCLE9960 measure kinematics completely

CYCLE9960 corrects or checks the geometric vectors for defining the kinematic 5-axis

transformation

based on kinematic chains and the tool carrier (classically via $TC_CARR).

With only one call of the cycle, the kinematics are measured, and the determined values and

deviations are represented in the measurement result screen.

For the measurement, up to twelve positions of a measuring sphere on each rotary axis are

sensed using workpiece probes. The sphere positions are defined in a specified rotary axis area

in accordance with the geometric ratios on the machine

. The sphere position is set via the

automatic repositioning of each rotary axis to be measured.

With CYCLE9960, it is also possible to measure the deviation on the tool tip (TCP) with active

transformation for various rotary axis positions, after the measurement and compensation of the

kinematics. These deviations can be compensated with VCS (Volumetric Compensation

System).

Possible fields of application

Check and correct the machine kinematics, e.g. during the machining process or for collision.

Measure and adapt the reference, e.g. for kinematics with changeable heads.

Measure and correct interpolation points, e.g. for compensation of the TCP via VCS Rotary.

General information on workpiece production

2.10

Workpiece visualization

2.10.1 Simulation

You can detect any programming errors even before production by means of the finished part

simulation in the form of a 3D volume model or as a 3-plane view. Using the complete 3D

simulation, you simulate the programs before production, even on swiveled planes and by means

of 5-axis simultaneous simulation.

Opening a simulation:

X Open the NC program in the program editor.

X Press the Simulation softkey. The execution of the NC program is simulated.

X During simulation, you can change, turn and zoom the display. For a better display, you can

place the cuts in the workpiece.

X Via the shortcuts SHIFT+[cursor keys], you can move or rotate the display or move the cutout

and control the override using CTRL+[cursor keys].

→ Start simulation

→ Reset

→ Top view

→ 3D view

→ Side views

→ Zoom, magnify,

turn, cut

→ Override, single

block

→ Display tool paths

5-axis simultaneous simulation

3-axis workpiece simulation

General information on workpiece production

2.10

2.10.2 Quick viewer for mold-making

The mold-making quick view allows the visualization of the processing paths of large part

programs, e.g. from CAM systems. By means of the quick view, you can get a quick overview of

the program, e.g. the shape of the workpiece or traversing errors or check approach and

retraction paths.

The mold-making view supports such blocks as those with G0, G1, G2 and G3, as well as the

display of vectors as rotary axis or vector programming. Non-interpretable NC blocks are skipped

and not displayed in the graphic.

Opening the mold-making view:

X Open the NC program in the program editor.

X Press the >> softkeys and then mold-making view. The NC program and the graphic are

displayed in parallel.

X By pressing the NC blocks or Graphic softkeys

, you can display and hide the views.

→ Display NC

blocks

→ Display graphic

→ Hide G1, G2, G3

→ Hide G0

→ Hide points

→ Zoom and cutout

→ Select program

block

Zoom and cutout:

X Press the Details softkey

and then Zoom+ or Zoom- to zoom the views.

X Press the Details softkey

and then Magnify+ or Magnify- to enlarge or shrink the cutout.

Using the cursor keys, you can move the cutout.

Select erroneous NC block:

If there are errors in the graphic, you can directly select the NC block in the program.

X Press the >> softkey

and then Select point.

X Using the cursor keys, move the displayed cross-hairs to the appropriate position in the

graphic.

X Press the "Select NC block" softkey. The erroneous NC block is highlighted in the editor.

General information on workpiece production

2.10

Hide G0, G1, G2, G3 lines:

X With the softkeys

you can hide G0, G1, G2, G3 or points so that the graphic lines are

shown clearly. In the example, the rapid traverse movements G0 are hidden.

Lines G0, G1, G2, G3 shown

Hide G0 lines

Display vectors, surfaces and curvature:

In addition to the classic view, for mold-making programs, you can also display the rotary axis

vectors and grid mesh (surface, mesh), for example.

X Press the >> softkey

and then Vectors or Surface or curvature. The appropriate view is

displayed.

Vectors

Surface (mesh)

SINUMERIK 840D sl. Training. Operate - Turning (2016-2020) - page 7