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

Appendix

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The operational SinuTrain machine is shut down.

Training and Programming

106

A5E43899500, 01/2018

Preface

________________

Introduction

________________

System overview

CNC operation with

SINUMERIK

INUMERIK Operate_____

mode (JOG)

SINUMERIK 828D

SINUMERIK 840D sl

Tool management______

SINUMERIK Operate - Turning

Data memory_________

Control system overview

Data transfer_________

for machine tools' sales people

CNC operation in automatic__

mode (AUTO)

CNC funtionalities______

________________

CNC programming methods

________________

Workpiece visualization

________________

CNC technology cycles

________________

Complete machining

________________

Multi-channel machining

SINUMERIK Integrate Run__

MyRobot

________________

Tools and information

________________

Safety functions

________________

Summary of unique features

Valid for:

Controls

SINUMERIK 828D / SINUMERIK 840D sl

Software

CNC software version 4.7

2017

A5E41992653B AA

Table of contents

Preface

Introduction

System overview

2.1

SINUMERIK 828D

2.2

SINUMERIK 840D sl

2.2.1

Panels

2.2.2

Operator panel equipment

CNC operation with SINUMERIK Operate

3.1

Animated Elements

3.2

Onboard documentation

3.3

Multitouch operation

3.4

Shortcuts

CNC operation in manual mode (JOG)

4.1

TSM universal cycle

4.2

Work offsets

4.3

Measure workpiece

4.4

Measure tool

4.5

Logging measurement results in JOG

4.6

Stock removal cycle

4.7

Positioning cycle

4.8

Manual machine

Tool management

5.1

Tool table

5.2

Monitoring of tool life and workpiece count

5.3

Replacement tools

5.4

Setup data

Data memory

6.1

Data storage - SINUMERIK 828D

6.2

Data storage - SINUMERIK 840D sl

Data transfer

7.1

Program manager

7.2

Ethernet networking

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Table of contents

CNC operation in automatic mode (AUTO)

8.1

Block search

8.2

Program control

8.3

Execution from external storage devices

8.4

Basic block display

8.5

Simultaneous recording

8.6

Logging measurement results in automatic operation

CNC funtionalities

9.1

80-bit NANO floating-point accuracy

9.2

Block change times

9.2.1

SINUMERIK 828D

9.2.2

SINUMERIK 840D sl

9.3

Jerk limitation

9.4

Dynamic feedforward control

CNC programming methods

10.1

programGUIDE DIN/ISO and SINUMERIK high-level language

10.1.1

Introduction

10.1.2

Program editor

10.1.3

Languages

10.1.4

programGUIDE input support

10.2

ShopTurn machining step programming

10.2.1

Introduction

10.2.2

Sequence editor

10.2.3

Interlinking of sequences

10.2.4

Graphical view

Workpiece visualization

11.1

2D simulation

11.2

3D simulation

CNC technology cycles

12.1

CNC technology cycles for programGuide and ShopTurn

12.2

Highlights of machining cycles

12.2.1

Stock removal along contour with blank contour

12.2.2

Engraving cycle

12.2.3

Counterspindle cycle

12.3

Residual material detection for contour cycles

12.3.1

Residual material detection during turning

12.3.2

Residual material detection during milling

12.4

In-process measuring for workpieces and tools

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Table of contents

Complete machining

13.1

End face machining (TRANSMIT)

13.2

Peripheral surface machining (TRACYL)

Multi-channel machining

14.1

Overview

14.2

programSYNC job list

14.3

Double editor

14.4

Multi-channel stock removal cycle

14.5

Simulation

SINUMERIK Integrate Run MyRobot

15.1

SINUMERIK Integrate Run MyRobot / EasyConnect

15.2

SINUMERIK Integrate Run MyRobot / Handling

Tools and information

16.1

DXF reader

16.2

SinuTrain for SINUMERIK Operate

16.3

CNC4you

Safety functions

17.1

SINUMERIK Safety Integrated

17.2

Collision avoidance

Summary of unique features

18.1

SINUMERIK 828D

18.2

SINUMERIK 840D sl

Index

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Introduction

SINUMERIK 828D and SINUMERIK 840D sl controls, and the easily understandable and

intuitive SINUMERIK Operate programming interface provide a tailored solution for all CNC

turning machines used worldwide.

SINUMERIK Operate

Characteristic features of SINUMERIK Operate include…

● HMI-Advanced, ShopMill and ShopTurn combined under one interface

● Intuitive and clear operation and programming, including Animated Elements

● Display in the modern Windows style

● New powerful functions around setting up, programming, tool and program management

● New functions for complete machining (single-chuck machining)

Two options are available for the programming:

● DIN-ISO programming with programGuide (CNC text editor with programGuide cycle

support, and DIN-ISO and readable CNC high-level language commands) for mid-sized

and large series

● ShopTurn machining step programming with graphical interactive CNC machining step

editor and CNC programming without DIN-ISO knowledge for small series

programSYNC - Efficient programming for multi-channel machines

Turning-milling centers with several saddles are considered to be the high-end machines in

this segment. The individual tool carriers are distributed and managed by SINUMERIK in

different channels. Programs must be created for each channel that then run simultaneously

later during the machining. With the uniform SINUMERIK Operate user interface, Siemens

provides a standard user interface which enables programs for two channels to be created

simultaneously by means of a double editor and to align them with the programSYNC

function. In this way, efficient programming is possible directly on the control.

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System overview

2.1

SINUMERIK 828D

Alongside three high-performance CNC variants of SINUMERIK 828D, SINUMERIK 828D

BASIC is a low-cost starter model in the compact class. SINUMERIK 828 therefore fits the

performance requirements of standard machine concepts perfectly.

• Panel-based compact CNC

• Technologies: Turning, milling, G-Tech

• Up to 10 axes/spindles and 2 help axes

• Up to 2 machining channels

•

10.4" color display / 15.6" touch display

• SIMATIC S7-200 PLC-based

You can find further information in catalog NC 82

Benefits

● Maximum robustness and low maintenance

● Reliable CNC, even in a harsh environment

● Improved efficiency thanks to state-of-the-art operating technologies and functions

● Scalable solutions thanks to tailored hardware and software for the compact class

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System overview

2.1 SINUMERIK 828D

SINUMERIK 828D BASIC PPU 24x.3

The SINUMERIK 828D BASIC is an operator-panel CNC that combines all the components

of a CNC in a single unit:

● CNC, PLC, HMI

●

10.4" TFT color display

● Full CNC keyboard

●

1 machining channel

● Closed-loop control for up to 5 axes/spindles

SINUMERIK 828D BASIC PPU 240.3, horizontal

SINUMERIK 828D PPU 28x.3

The SINUMERIK 828D PPU 28x.3 is an operator-panel CNC that combines all the

components of a CNC in a single unit:

● CNC, PLC, HMI

●

10.4" TFT color display

● Full CNC keyboard

●

1 machining channel

● Closed-loop control for up to 8 axes/spindles

Note: Use with 26x or 28x software variant

SINUMERIK 828D PPU 280.3, horizontal

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System overview

2.1 SINUMERIK 828D

SINUMERIK 828D ADVANCED PPU 290.3

The SINUMERIK 828D ADVANCED PPU 290.3 is an operator-panel CNC that combines all

the components of a CNC in a single unit:

● CNC, PLC, HMI

●

15.6" multitouch display in 16:9 format

● Full CNC keyboard

● Up to 2 machining channels

● Closed-loop control for up to 10 axes/spindles, depending on the software used

Note: Use with 26x, 28x or 28xA software variant

SINUMERIK 828D PPU 290.3

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System overview

2.2 SINUMERIK 840D sl

2.2

SINUMERIK 840D sl

SINUMERIK 840D sl is an open CNC for modular premium machine concepts. With

powerful, innovative system functions, the SINUMERIK 840D sl opens up a boundless range

of technologies. SINUMERIK 840D sl is leading the way in exploiting global machining

trends; this makes it the preferred CNC in the industries of the future.

• Drive-based modular CNC

• Multi-technology CNC

• Up to 93 axes/spindles

• Up to 30 machining channels

• Modular panel concept up to 19" color

display

• SIMATIC S7-300 PLC

You can find further information in catalog NC 62

Benefits

● Increased productivity of the machines thanks to faster controls and innovative machine

concepts

● Improved efficiency for operation thanks to state-of-the-art operating technologies and

functions

● Improved quality by perfectly adapting the control to the machine behavior

● Simplified engineering thanks to additional system support for configuring, testing and

optimizing

● Future-oriented expanded functionality for digitalization and integration in Industry 4.0

automation concepts

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System overview

2.2 SINUMERIK 840D sl

2.2.1

Panels

SINUMERIK OP 08T

• Operator panel 191 mm wide,

7.5" TFT display

(resolution 640 × 480 pixels)

• Integrated 75-key CNC keyboard (layout

as for the SINUMERIK full CNC keyboard)

• With USB interface at the front

• Version with membrane keys

SINUMERIK OP 010

• Operator panel 483 mm wide,

10.4" TFT display

(resolution 640 × 480 pixels)

• Integrated CNC keyboard

• With USB interface for a memory stick at

the front

• Version with membrane keys

• Separate machine control panel

SINUMERIK OP 010S

• Operator panel 310 mm wide,

10.4" TFT display

(resolution 640 × 480 pixels)

• Mechanical keys

• With USB interface for a memory stick at

the front

• Separate CNC keyboard and machine

control panel

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System overview

2.2 SINUMERIK 840D sl

OP 010C

• Operator panel 483 mm wide,

10.4" TFT display

(resolution 640 × 480 pixels)

• Integrated CNC keyboard

• With USB interface for a memory stick at

the front

• Version with mechanical keys

• Separate machine control panel

OP 012

• Operator panel 483 mm wide,

12" TFT display

(resolution 800 × 600 pixels)

• Membrane keys

• Integrated mouse

• Touchpad

• With USB interface for a memory stick at

the front

SINUMERIK OP 015A

• Operator panel 380 mm wide,

15" TFT display

(resolution 1024 × 768 pixels)

• Version with membrane keyboard with 62

keys

• With USB interface at the front

• Integrated mouse

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System overview

2.2 SINUMERIK 840D sl

SINUMERIK OP 015 black

• Operator panel 396 mm wide,

15.6" TFT display

(resolution 1366 × 768 pixels)

• Capacitive keyboard with 64 keys

• Capacitive display area for gesture

operation (touch operation)

Note: see also Chapter AUTOHOTSPOT

SINUMERIK OP 019

• Operator panel 483 mm wide,

19" TFT display

(resolution 1280 × 1024 pixels)

• Version with membrane keys, gloved

operation also possible

• Capacitive sensor equipment for fast key

operation

• Integrated key disable as protection

against incorrect operation

• USB 2.0 connector socket for console

installation

• Separate CNC keyboard and machine

control panel

SINUMERIK OP 019 black

• Operator panel 46.99 cm wide,

18.5" TFT display

(resolution 1366 × 768 pixels)

• Permits the distributed installation of the

operator panel front and the controller

• Capacitive display area for gesture

operation

Note: see also Chapter AUTOHOTSPOT

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System overview

2.2 SINUMERIK 840D sl

SIMATIC Industrial Thin Client

• Touch operation

• Connection via Ethernet

Versions:

SIMATIC ITC 1200, 12" widescreen TFT dis-

play

(resolution 1280 x 800 pixels)

SIMATIC ITC 1500, 15" widescreen TFT dis-

play

(resolution 1280 x 800 pixels)

SIMATIC ITC 1900, 19" widescreen TFT dis-

play

(resolution 1366 x 768 pixels)

Note: see also Chapter AUTOHOTSPOT

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System overview

2.2 SINUMERIK 840D sl

2.2.2

Operator panel equipment

PCU 50

We offer the PCU 50.x for customers who specify a hard disk and/or supplementary

Windows-based software.

● Windows 7 operating system

● Up to 40 GB for data (part programs, documentation, other data)

● Additional PCI slots

● Additional CF card slot

● DVI interface

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CNC operation with SINUMERIK Operate

3.1

Animated Elements

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

To illustrate which parameters affect what in machining operations, SINUMERIK Operate

offers a new input support function with animated element sequences.

Benefits

● Process reliability during the setup

● Increased reliability at program input by easily understood depiction of selection options

● This results in improved efficiency and so increased availability of the machine

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CNC operation with SINUMERIK Operate

3.2 Onboard documentation

3.2

Onboard documentation

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

For each input field in the operating screens, SINUMERIK Operate automatically displays

help in the form of a "cursor text". Further information is provided in the form of a complete

context-sensitive help system with many useful details and graphics.

Benefits

● Programming on the machine without a handbook

● Help button to toggle between the editor and help screens

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CNC operation with SINUMERIK Operate

3.3 Multitouch operation

3.3

Multitouch operation

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

With the appropriate operator panel fronts, SINUMERIK Operate can also be operated with

multitouch gestures. Multitouch operation is possible for the SINUMERIK 840D sl with the

operator panel fronts SINUMERIK OP 015 black line or SINUMERIK OP 019 black line and

for the SINUMERIK 828D PPU 290.3, vertical.

• Intelligent gesture operation with

touchpanels, also with work gloves

• Capacitive touch for industrial use

• Palm detection

• Detection of liquids and contaminations

Extract from the multitouch operation gestures:

Tap with two fin-

Tap and hold

Pan

Flick with three

Spread

gers

fingers

Open object to be

Move graphic

Zoom out graphic

Call the shortcut

changed, e.g. NC

contents, e.g.

Scroll to the start

contents, e.g.

menu, e.g. copy,

block

simulation, mold

or end of lists or

simulation, mold

paste

making view

files

making view

Benefit

● Modern and efficient gesture operation of SINUMERIK Operate - rugged and reliable,

even in harsh industrial environments

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CNC operation with SINUMERIK Operate

3.4 Shortcuts

3.4

Shortcuts

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Shortcuts are available for many menu operations in SINUMERIK Operate. A small extract

follows:

Select all (editor functionality)

Copy

Paste

Cut

Calculation of the time from/to line/block

Language selection

Maximum simulation speed

For screenshots

(Storage location: commissioning (keyword) → System data → HMI data →

Logs → Screenshots)

Benefit

● Shortcuts in SINUMERIK Operate avoid the need for complicated menu operations and

provide functions not previously expected from a CNC

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CNC operation in manual mode (JOG)

4.1

TSM universal cycle

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

A universal cycle is available in the setup for the most commonly used machine functions:

● Tool change, also involving sister tools, with direct access via the tool table (T)

● Spindle speed and direction (S)

● M functions (M)

● Activation of work offsets

● Definition of the gearbox stage

Benefit

● Take over and change in tools directly from the tool table

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CNC operation in manual mode (JOG)

4.2 Work offsets

4.2

Work offsets

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The following work offsets are possible:

● Settable work offsets:

It is possible to enter as many as 100 work offsets (G54 to G57, G505 to G599), offset

coordinates, angles and scaling factors.

● Programmable work offsets:

The programmable work offsets allow you, for example, to work with different work offsets

for repetitive machining operations at different positions on the workpiece.

● External work offsets:

Axis-related linear work offsets can also be activated via the PLC user software.

Benefits

● Flexible machining thanks to a large number of settable work offsets

● User-friendly understandable display of the number of work offsets

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CNC operation in manual mode (JOG)

4.3 Measure workpiece

4.3

Measure workpiece

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The workpieces can be measured as follows:

● Reference tool

Benefit

● Time saving due to user-friendly determination of the workpiece zero

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CNC operation in manual mode (JOG)

4.4 Measure tool

4.4

Measure tool

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The tool compensation value can be directly determined in the machine set-up.

The following variants are supported:

● Touch chuck

● Determine lengths via reference diameter

● Tool measuring probe (tooleye) or magnifier

The measurement results can be output in a measurement report (see Logging

measurement results in JOG (Page 29)).

Benefit

● User-friendly functions for determining the tool dimensions directly in the machine

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CNC operation in manual mode (JOG)

4.5 Logging measurement results in JOG

4.5

Logging measurement results in JOG

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The results for measuring in JOG can be logged. The standard log contains the

measurement results of the most recently performed measuring method.

The function is available as turning technology for the tool measurement.

Text format or table format can be selected for the output format

The measuring log comprises the following data:

● Date and time when the log was written

● Log name with path details

● Measuring method

● Correction target

● Setpoints, measured values and differences

Benefit

● Simple logging of measured values in log files

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CNC operation in manual mode (JOG)

4.6 Stock removal cycle

4.6

Stock removal cycle

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

A comfortable stock removal cycle is available in the set-up mode. Soft collet chucks can, for

example, be turned with this cycle.

The following parameters can be specified:

● Roughing or finishing

● Undercut for soft collet chucks

Benefit

● Preparation of workpiece or collet chuck without having to create a part program

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CNC operation in manual mode (JOG)

4.7 Positioning cycle

4.7

Positioning cycle

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The machine axes can be positioned directly via input screens in the setup:

● Linear axes / spindles

● Feedrate / rapid traverse

Benefit

● Simple axis positioning without manual input, directly over the dialog screen

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CNC operation in manual mode (JOG)

4.8 Manual machine

4.8

Manual machine

SINUMERIK 828D

BASIC

ADVANCED

Option: P17

SINUMERIK 840D sl

BASIC

Option: P17

The "Manual machine" function is part of the Shopmill/Shopturn option package. This allows

you to perform all important machining operations in the manual machine operating area

without needing to create a specific part program.

The following functions are available:

● Measuring a tool

● Traversing axes

● Setting the work offset

● Setting the endstop

● Turning a straight line / circle

● Drilling, including centering, deep-hole drilling, tapping

● Milling, including face milling, pocket, multiple edge spigot

Benefit

● Simple and intuitive operation of cycle-controlled turning machines

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Tool management

5.1

Tool table

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Tools with their complete operating data can be managed in the tool list.

● Tools are assigned to the desired magazine locations with the load function.

● For each tool, you can store the following data:

- Tool type (rougher, finisher, engraver, drilling and milling tools

)

- Tool name in plaintext (ex.: "ROUGHING_80DEGREES")

- Max. of 9 cutting edges per tool

- Tool length and cutting plate geometry

- Nose angle for drills or number of teeth for milling tools

- Direction of spindle rotation and coolant (level 1 and 2)

● Direct transfer of the tool from the list in the program or for measurement

● Using the settings, for example, you can activate the graphic magazine display

● Reading tools from a file or archiving to a file

Benefits

● All tool data at a glance

● Simple and secure handling via unmistakable tool names

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Tool management

5.2 Monitoring of tool life and workpiece count

5.2

Monitoring of tool life and workpiece count

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

You can use SINUMERIK Operate to monitor the service life of your tools and the number of

exchanges. You can give your tools meaningful names instead of cryptic numbers. You will

come to appreciate this convenience when you read the CNC program, if not before.

● Monitor cutting time (T) in minutes or number of exchanges (C)

● Prewarning limit for timely preparation of new tools

Benefits

● Reduction of machine standstill times via tool monitoring

● Support of tool life monitoring or job time monitoring as standard

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Tool management

5.3 Replacement tools

5.3

Replacement tools

SINUMERIK 828D

BASIC

ADVANCED

Option: M78

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

If needed, you can also manage replacement tools with SINUMERIK Operate. Tools with the

same name are created as replacement tools. The replacement tools are identified with an

incrementing number in the ST column.

Benefit

● Automatic exchange of identical tools for unmanned operation

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Tool management

5.4 Setup data

5.4

Setup data

SINUMERIK 828D

BASIC

ADVANCED

Option: P16

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Part programs can be saved complete with set-up data like tool data and zero points.

Benefit

● Time savings when you save the part programs

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Data memory

6.1

Data storage - SINUMERIK 828D

Internal memory

External storage

Execution from external

storage (EES)

828D

(option P75)

BASIC

ADVANCED

Network, USB storage me-

USB / CF card can be used for data transport or

dia, compact flashcard

for execution with EXTCALL

Option P77

100 MB

3 MB

5 - 10 MB

Execution from the CNC

expanded user memory

(option P77)

Internal memory can be expanded via option P77 → 100 MB

External storage via

option P75 → can be ex-

panded almost without limit

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Data memory

6.2 Data storage - SINUMERIK 840D sl

6.2

Data storage - SINUMERIK 840D sl

Internal memory

External storage

Execution from external

storage devices (EES, op-

NCU

NCU +

tion P75)

PCU

Network, USB storage me-

Option P77 +

up to

dia, compact flashcard

PCU

40 GB

Option P77 +

up to 6 GB

option P12 ¹⁾

Option P77

100 MB

CNC user

NCU 710.3B: 2 to 16 MB

Execution from the CNC

memory

expanded user memory

NCU 720.3B and NCU 730.3B: 2 to 22 MB

(option D00)

(option P77)

Internal memory can be expanded via option P77 + PCU →

External storage via

40 GB

option P75 → can be ex-

panded almost without limit

Internal memory can be expanded via option P77 + P12 → 6 GB

Internal memory can be expanded via option P77 → 100 MB

1) HMI user memory, alternative to PCU

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Data transfer

7.1

Program manager

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

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

very easy-to-use file handling similar to Windows Explorer.

● Plain text names with as many as 24 characters for directories and files

● Manage subdirectories on external storage media, local drives and on the NC

● Store and display files of any type (e.g. *.png, *.pdf, *.dxf, *.xml)

● Manage and open DXF files

● Display all storage media in the program manager (with details of the storage capacity),

including the network drives.

● Part programs can be edited on all media

Benefits

● Easy and open exchange of data between the various storage media and the network

● User-friendly data handling in typical PC style with copy, paste, rename, etc.

● Preview window permits quick identification of programs without having to open them

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Data transfer

7.2 Ethernet networking

7.2

Ethernet networking

SINUMERIK 828D

BASIC

ADVANCED

Option: P01

SINUMERIK 840D sl

BASIC

Option: P17

The SINUMERIK controls are prepared for networking via Ethernet (TCP/IP) (RJ45

connection).

● The data transfer rate is 10/100 Mbit/s.

● Remote access to the control via the RCS Commander, e.g. for commissioning and

remote diagnostics

● Access to the network drives is available directly from the program manager. No

additional software is required on the server.

Benefits

● Cost-effective and simple connection via Ethernet (TCP/IP) to Windows PCs

● No software required on the servers

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CNC operation in automatic mode (AUTO)

8.1

Block search

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

A block search may be executed in machine status RESET, e.g. after a program interruption

or to specifically return to machining. The program data is prepared in such a way that all

relevant parameters (tool, work offsets, M functions, etc.) are available when accessing the

program.

The following search variants are available:

● selectively to the point of interruption, still possible after Power Off for G code program

● to arbitrary CNC blocks in DIN/ISO programs

● in arbitrary subprogram levels for DIN/ISO programs

● in ShopTurn machining step programs

● in position patterns for machining step programming

You can individually configure the block search:

● with calculation/without calculation

● with approach/without approach

Benefits

● Time-saving and secure restart at any program point, as no editing of the part program is

required

● An extremely quick block search is also available for large part programs through the

"External block search without calculation" function; overstore, if necessary

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CNC operation in automatic mode (AUTO)

8.2 Program control

8.2

Program control

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

You can influence the program sequence in the AUTO and MDI modes. The following

options are available to do this:

● PRT - No axis motion

The program is completely executed with the axes stationary, e.g. for the program test.

● DRY - Dry run feedrate

The traversing velocities programmed in conjunction with G1, G2, G3, CIP and CT are

replaced by a defined dry run feedrate.

● RG0 - Reduced rapid traverse

You define the reduced rapid traverse in the settings for automatic operation.

● M01 - Programmed stop 1

The processing of the program stops at every block in which supplementary function M01

is programmed. In this way you can check the intermediate result

when machining a workpiece.

● SKP - Skip block

Skip blocks are skipped during machining.

● MRD - Displaying measurement result

The display of the measurement result can be enabled or disabled during program

execution.

Benefits

● Secure positioning of new part programs

● Continue machining quickly after interruptions

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CNC operation in automatic mode (AUTO)

8.3 Execution from external storage devices

8.3

Execution from external storage devices

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

You can select, edit and execute part programs directly on the CF card, USB stick, hard disk

or via the network.

SINUMERIK 828D

BASIC

ADVANCED

Option: P75

SINUMERIK 840D sl

BASIC

Option: P75

The "Execution from external storage (EES)" option provides the following advantages over

the basic configuration:

● Uniform syntax for the subprogram call, independent of the storage location of the

subprogram. This reduces syntax errors for the subprogram call.

● Part programs can be edited without NC reset.

● The size of the memory available on the machine can be expanded economically with

external media. The size of the part programs is limited only by the capacity of the

external data storage.

Benefit

● Quick and easy access to part programs on external storage media

● Block search for large programs on external storage media

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CNC operation in automatic mode (AUTO)

8.4 Basic block display

8.4

Basic block display

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The individual traversing blocks are displayed as DIN/ISO commands during execution of

machining steps or machining cycles.

The basic block display guarantees an especially high process security while running-in

programs in single block mode.

This function is available for programGUIDE (screenshot on left) and also for ShopTurn

(screenshot on right).

Benefit

● Optimal control of the program execution, even in complex sequences or machining

cycles, especially in single block mode

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CNC operation in automatic mode (AUTO)

8.5 Simultaneous recording

8.5

Simultaneous recording

SINUMERIK 828D

BASIC

ADVANCED

Option: P22

SINUMERIK 840D sl

BASIC

Option: P22

During machining, the tool paths can be simultaneously recorded on the display of the

controller in side view, front view, two window view or in 3D view. Workpiece depiction and

views correspond to the graphic simulation.

Benefit

● Machining can also be monitored in a complex machine room

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CNC operation in automatic mode (AUTO)

8.6 Logging measurement results in automatic operation

8.6

Logging measurement results in automatic operation

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

In automatic operation, you can output the measurement results as measuring log. You can

configure the output. The following settings are some of those possible:

● Display mode: autom. 8 s, NC start, for alarm

● Log type: standard log, user log

● Log format: text format (*.txt), table format (*.csv)

● Log data: new (discard old log data), append (append to old log data)

● Log storage: storage directory (complete path)

You can then open the measuring log in the program management at the configured storage

path. The measuring log contains data that includes:

● Date and time when the log was written

● Measuring method

● Correction target

● Setpoints, measured values and differences

Note: Irrespective of the user interface language, the measuring logs are output in English.

Benefit

● Simple logging of measured values in log files

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CNC funtionalities

9.1

80-bit NANO floating-point accuracy

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The accuracy of the workpiece is determined by more factors than just the mechanical

characteristics of the machine. The CNC also contributes to a critical degree towards the

precision of the workpieces. SINUMERIK Operate offers many CNC functions for this

purpose.

The SINUMERIK controls and the SINAMICS drive calculate with 80-bit NANO floating-point

accuracy. This enables a calculation accuracy much less than a nanometer. This exactness

is available not only for closed loop position control but also for closed-loop power and speed

control and also for sensor evaluation of the drive.

Benefit

● Maximum precision in the workpiece results based on extremely high calculation

accuracy

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CNC funtionalities

9.2 Block change times

9.2

Block change times

9.2.1

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

The following table shows typical block change times depending on the deployed PPU:

PPU 241.3/240.3

PPU 281.3/280.3

PPU 290.3

SW24

SW26

SW28

~3 ms

~2 ms

~1 ms

Benefit

● Minimum block change times for the associated performance versions

9.2.2

SINUMERIK 840D sl

BASIC

Basic configuration

The following table shows typical block change times depending on the deployed NCU:

NCU 710.3B PN

NCU 720.3B PN

NCU 730.3B PN

1.2 ms

0.5 ms

0.3 ms

Benefit

● Minimum block change times for the associated performance versions

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CNC funtionalities

9.3 Jerk limitation

9.3

Jerk limitation

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The control calculates a steady acceleration profile instead of jumps in acceleration. This

enables jerk-free speed characteristics for the involved path axes. The jerk limitation can

also be directly activated in the part program with the »SOFT« NC language command.

Benefits

● Longer machine lifespan through protection of the mechanical components

● Higher path accuracy through softer acceleration

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CNC funtionalities

9.4 Dynamic feedforward control

9.4

Dynamic feedforward control

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Inaccuracies in the resulting workpiece contour due to following errors can practically be

eliminated using dynamic feedforward control FFWON. The result is excellent machining

precision even at high path speeds. This is clarified with a circularity test on the machine.

Example:

Benefit

● Higher path accuracy through compensation of contouring errors

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CNC programming methods

SINUMERIK Operate provides the following programming methods for selection:

DIN-ISO programming with programGUIDE

CNC text editor with programGuide cycle support, and DIN-ISO and readable CNC high-

level language commands for mid-sized and large series

The wide choice of technology cycles and the ease of parameterization allows you to reduce

the programming time.

ShopTurn - Machining step programming

with graphical interactive CNC machining step editor and CNC programming without DIN-

ISO knowledge for small series.

Machining operations such as stock removal, grooving or thread cutting are shown in

ShopTurn in the form of worksteps. In this way CNC programs - even for complex machining

operations - are very compact and easily read. Associated sequences are automatically

interlinked and can be assigned any position patterns.

ShopTurn offers you the shortest programming times even for highly demanding machining

tasks. The parameter input is supported by Animated Elements.

Benefit

● Whether you use programGUIDE or ShopTurn - in either case the full range of

technological cycles, position patterns and geometries is available to you

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CNC programming methods

10.1 programGUIDE DIN/ISO and SINUMERIK high-level language

10.1

programGUIDE DIN/ISO and SINUMERIK high-level language

10.1.1

Introduction

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Below is an overview of the characteristic functions of programGUIDE and SINUMERIK CNC

programming. This includes:

● DIN/ISO editor

● Languages

● programGUIDE input support

These functions belong to the basic configuration of SINUMERIK Operate.

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CNC programming methods

10.1 programGUIDE DIN/ISO and SINUMERIK high-level language

10.1.2

Program editor

A line-oriented program editor is available to you for DIN/ISO programming. The editor ena-

bles you to input CNC language commands directly or to edit them. Thereby, the complete

range of CNC functions are available for the most complex machining.

The following functions are included in the

program editor:

• Contour calculator

• Tool selection directly from tool list

• Support screens for standard machining

and measuring cycles

• "Copy", "Insert" and "Cut" key group

• "Find", "Replace" and "Replace All"

character string

• The syntax is highlighted in various colors

(comments, NC blocks, etc.)

• Renumbering a program

• Direct execution from any NC program

block (block search)

• Jump to program start or program end

Benefits

● Time saving by using a powerful editor when programming

● Even large part programs allow extremely fast editing in MB size

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CNC programming methods

10.1 programGUIDE DIN/ISO and SINUMERIK high-level language

10.1.3

Languages

The CNC Interpreter of the SINUMERIK 828D and the SINUMERIK 840D sl can also

process more complex CNC commands, in addition to DIN 66025 standard commands. The

commands are presented in clearly readable form.

The following commands are available:

●

G-code

G-code in accordance with DIN 66025 and in ISO dialect mode

●

G functions

G0, G1, G2, G71 ...

●

Language commands (extended G functions)

CIP, SOFT, BRISK, FFWON ...

●

Frame operations (programmable work offsets)

The workpiece coordinate system can be shifted, scaled, mirrored or rotated with the

commands TRANS, SCALE, MIRROR, ROT.

●

R parameters (arithmetic parameters)

300 predefined R parameters are available as arithmetic parameters (floating-point

format).

●

User variables

Users can define their own variables by name and type.

●

System variables

System variables can be read/written in all programs. They enable access to work offsets,

tool offsets, axis positions, measurement values, control conditions etc.

●

Arithmetic operations

The following arithmetic operations are available to combine the variables:

arithmetic operations + - * / sin, cos, exp, etc.

logical operations == <> >=, etc.

●

Program control structures

BASIC-style language commands are available for flexible programming of the user

cycles: IF-ELSE-ENDIF, FOR, CASE ...

Benefits

●

Established programming according to DIN 66025

●

Unbeatable range of commands for flexibility and time saving while programming

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CNC programming methods

10.1 programGUIDE DIN/ISO and SINUMERIK high-level language

10.1.4

programGUIDE input support

The cycle support is an extension of the highly flexible DIN/ISO programming. The input

screens are based on the ShopTurn cycles input screens, so as to ensure optimum

continuity.

The calls for tool, feedrate and spindle speed can of course also be input in the DIN/ISO

editor.

Benefits

● Existing DIN/ISO part programs with cycles can continue to be used

● Minimum learning requirements due to the continuity of the input support

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CNC programming methods

10.2 ShopTurn machining step programming

10.2

ShopTurn machining step programming

10.2.1

Introduction

SINUMERIK 828D

BASIC

ADVANCED

Option: P17

SINUMERIK 840D sl

BASIC

Option: P17

The following information provides you with an overview of the characteristic functions of

ShopTurn. This includes:

● Sequence editor

● Interlinking of sequences

● Graphic view (broken-line graphics)

These functions are part of the machining step programming options package in ShopTurn.

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CNC programming methods

10.2 ShopTurn machining step programming

10.2.2

Sequence editor

The graphical programming is performed via a graphic interactive sequence editor. Each

program line represents a technological sequence (such as: face turning, centering, drilling,

tapping) or geometric data required for the sequences (position patterns or contours). Graph-

ical programming offers, in comparison to DIN/ISO programming, a compact and compre-

hensible program overview.

Entering individual sequences requires no

knowledge of DIN/ISO. All required technical

and geometric parameters are entered in

screen forms. Simple, intuitive programming

with sequences can always be expanded very

flexibly by inputting DIN/ISO blocks and con-

trol functions.

Benefits

● Intuitive program input, without knowledge of DIN/ISO or Operating Manual

● Compact, clearly arranged machining programs

● Reducing the programming time by graphical input screens and copying / inserting

machining steps

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CNC programming methods

10.2 ShopTurn machining step programming

10.2.3

Interlinking of sequences

In ShopTurn, associated sequences are interlinked with each other. The interlinked

sequences are performed consecutively at the appropriate contours or pattern positions.

In the following example, the sequences centering, drilling and tapping are applied to 4 holes

on the pitch circle pattern position.

Benefit

● Reduced programming time due to linking of machining steps

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CNC programming methods

10.2 ShopTurn machining step programming

10.2.4

Graphical view

While programming, the previously entered sequences will be continuously displayed to

scale. A simulation is not required for this. The switching between the machining step

program and the broken-line graphics is performed with the "Graphics View" softkey or the

"Ctrl+G" shortcut.

● Turning view

● Front face and peripheral side

Benefit

● Increased reliability at program input by quickly checking the contour, without having to

start a simulation run

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Workpiece visualization

11.1

2D simulation

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

SINUMERIK Operate offers with 2D simulation the facility to make optimum and reliable

preparations for machining workpieces, such as by detecting collisions. Calculating the

machining time also supports optimum calculation of tooling costs.

● Use of the real geometry values of the tools mounted in the machine

● Simulation in side view, front view or two window view

● Simulation can be interrupted at any time, and the speed is controllable

Benefits

● Maximum process reliability through simulation using real geometry values

● Perfect clarity by showing the workpiece dimensions with a scale

● Parallel simulation (backg11round simulation) is possible in conjunction with the NCU 720

and NCU 730, i.e. simulating a part program while another part program is being

simultaneously machined.

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Workpiece visualization

11.2 3D simulation

11.2

3D simulation

SINUMERIK 828D

BASIC

ADVANCED

Option: P25

SINUMERIK 840D sl

BASIC

Option: P25

SINUMERIK 3D workpiece simulation offers you optimum assistance and reliability in

programming and in quotation costing.

● Reliability:

realistic 3D volume model, with zoom to details and free rotation of the viewing angle

● Support:

- Simulation speed controllable

- Single block operation and start / stop available at any time

● Checking:

Automatic calculation of machining time

Benefits

● Particularly realistic simulation through representation of the tool

● Optimum help and reliability in programming and in quotation costing

● Parallel simulation (backg11round simulation) is possible in conjunction with the NCU 720

and NCU 730, i.e. simulating a part program while another part program is being

simultaneously machined.

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CNC technology cycles

12.1

CNC technology cycles for programGuide and ShopTurn

Irrespective of whether you use programGUIDE or ShopTurn - in either case the full range of

technological cycles, position patterns and geometries is available to you.

Benefits

● Significant simplification of programming, even for complex jobs, using CNC technology

cycles

● Continuity of cycles for programGuide and ShopTurn

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CNC technology cycles

12.2 Highlights of machining cycles

12.2

Highlights of machining cycles

12.2.1

Stock removal along contour with blank contour

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

With the intelligent contour stock removal cycle, free contours can be processed in a variety

of ways:

● Processing any contour calculator geometry

● Cylindrical blank, freely-defined blank, blank as allowance of finished-part contour

● Longitudinal / face / contour-parallel roughing on outside and inside

● Processing sloping contours (relief cuts)

● Consideration of tool's setting and plate angle

● Grooving any contours on outside, inside or end face

● ...

Benefits

● Effective processing through orientation to the actually existing material

● Lower risk of accident and better chip disposal through feed interruption

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CNC technology cycles

12.2 Highlights of machining cycles

12.2.2

Engraving cycle

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The engraving cycle is used to engrave a text on a workpiece along a line or arc. You can

enter the text as fixed text or assign it via a variable as variable text.

Examples of variable texts:

● Date and time

The values for the date and time are read from the CNC.

● Quantity

The "Quantity" variable is available as a pre-defined user variable

● Numbers

When outputting numbers (e.g. measurement results), you can select the output format

(digits before and after the point) of the number to be engraved.

● Text

Instead of entering a fixed text in the engraving text field, you can specify the text to be

engraved via a text variable (e.g., _VAR_TEXT="ABC123").

Benefits

● Reduction of set-up times by complete machining on one machine

● Simple program input of engraving

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CNC technology cycles

12.2 Highlights of machining cycles

12.2.3

Counterspindle cycle

SINUMERIK 828D

BASIC

ADVANCED

not available

Option: M75 (SW 28x) ¹⁾

Option: M75 ¹⁾

SINUMERIK 840D sl

BASIC

Basic configuration ¹⁾

1) The function is only available in conjunction with ShopTurn/ShopMill machining step

programming (option: P17).

SINUMERIK Operate enables the use of a fully-functional counterspindle. The main spindle

and counterspindle can be operated under conditions of angular synchronism.

DIN/ISO programming

The commands for spindle synchronization and the axis movements for workpiece transfer

can be programmed as DIN/ISO language commands.

Machining step programming

A user-friendly counterspindle cycle is conveniently available for spindle synchronization and

axis movements for workpiece transfer.

Benefits

● Simple and secure programming of all counterspindle functions

● High quality of workpieces by workpiece transfer in synchronous spindle mode

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CNC technology cycles

12.3 Residual material detection for contour cycles

12.3

Residual material detection for contour cycles

12.3.1

Residual material detection during turning

SINUMERIK 828D

BASIC

ADVANCED

Option: P13

SINUMERIK 840D sl

BASIC

Option: P13

Contour areas which do not permit machining by tools with large plate angles are

automatically recognized in the stock removal cycle. The operator can rework these areas

using a suitable tool with a smaller plate angle.

Benefit

● Time saving through avoiding idle cuts during residual stock removal

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CNC technology cycles

12.3 Residual material detection for contour cycles

12.3.2

Residual material detection during milling

SINUMERIK 828D

BASIC

ADVANCED

Option: P13

SINUMERIK 840D sl

BASIC

Option: P13

Contour ranges which do not permit milling with large diameters are automatically identified

in the cycle for contour pockets and contour pins. These areas can be selectively machined

with a suitable smaller tool, rather than having to use this tool for the entire contour pocket or

pin.

If you mill several pockets and wish to avoid unnecessary tool changeovers, remove stock

from all the pockets first and then remove the residual material. In this case, you must enter

the tool used for removing the residual material from the pocket in the "TR reference tool"

parameter.

Benefits

● Shorter machining times through the use of a large tool for the substantial part of the

stock removal and a smaller tool for the remaining residual material

● Avoidance of non-cutting movements while achieving extremely simple programming

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CNC technology cycles

12.4 In-process measuring for workpieces and tools

12.4

In-process measuring for workpieces and tools

SINUMERIK 828D

BASIC

ADVANCED

Option: P28

SINUMERIK 840D sl

BASIC

Option: P28

For measurement tasks in automatic operation, powerful measuring cycles are available

both within the sequence and in DIN/ISO programming. Input screens with dynamic help

displays are used for convenient entry of the measuring parameters.

The following cycles are available for workpiece measurement:

The following measurement variants are available for tool measurement:

● Calibration of the tool probe

● Determation of the tool length of turning tools and drills

● Determation of length/radius/length and radius of milling tools on a turning machine

The following measuring tasks can be made:

● Automatic value correction for tool geometry or work offset

● Display of measurement results

● Logging of measurement results

Benefits

● Reliable quality of the manufactured parts by automatic measurement in the machine

● Fast programming for complex measuring tasks thanks to input screens with graphic

support

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Complete machining

13.1

End face machining (TRANSMIT)

SINUMERIK 828D

BASIC

ADVANCED

Option: M27

SINUMERIK 840D sl

BASIC

Option: M27

Drilling and milling can be performed on the end face of workpieces in the main and

counterspindle with ShopTurn.

The part program is easily created in a right-angle coordinate system with the end face

transformation TRANSMIT (C axis mode) .

The path movements are conducted with the linear axes

X / Z and the rotary axis C.

Machine without Y axis

• Machining with TRANSMIT

Machine with Y axis

• Machining with Y axis

• Machining with TRANSMIT

Benefit

● Full functional range for drilling and milling on the end face

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Complete machining

13.2 Peripheral surface machining (TRACYL)

13.2

Peripheral surface machining (TRACYL)

SINUMERIK 828D

BASIC

ADVANCED

Option: M27

SINUMERIK 840D sl

BASIC

Option: M27

Using the peripheral surface transformation TRACYL, drilling and milling machining can be

executed on the peripheral surface of workpieces in the main and counterspindle.

Machine without Y axis

• Any drill holes on the peripheral surface

• Any milling without slot wall offset on the peripheral

surface

Machine with Y axis

• Any drill holes on the peripheral surface

• Any milling without slot wall offset on the peripheral

surface

• Any milling with slot wall offset on the peripheral

surface

• Grooving on parallel walls of the peripheral surface

with milling radius correction

Benefits

● Full functional range for drilling and milling on the peripheral surface

● Reduction of set-up times by complete machining on one machine

SINUMERIK Operate - Turning

Control system overview for machine tools' sales people, 2017, A5E41992653B AA

SINUMERIK 840D sl. Training. Operate - Turning (2016-2020) - page 11