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

System overview

2.2 SINUMERIK 840D sl

SINUMERIK OP 015 black

x Operator panel 396 mm wide,

15.6" TFT display

(resolution 1366 × 768 pixels)

x Capacitive keyboard with 64 keys

x Capacitive display area for gesture

operation (touch operation)

Note: see also Chapter Multitouch operation

(Page 27)

SINUMERIK OP 019

x Operator panel 483 mm wide,

19" TFT display

(resolution 1280 × 1024 pixels)

x Version with membrane keys, gloved

operation also possible

x Capacitive sensor equipment for fast key

operation

x Integrated key disable as protection

against incorrect operation

x USB 2.0 connector socket for console

installation

x Separate CNC keyboard and machine

control panel

SINUMERIK OP 019 black

x Operator panel 46.99 cm wide,

18.5" TFT display

(resolution 1366 × 768 pixels)

x Permits the distributed installation of the

operator panel front and the controller

x Capacitive display area for gesture

operation

Note: see also Chapter Multitouch operation

(Page 27)

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2.2 SINUMERIK 840D sl

SIMATIC Industrial Thin Client

x Touch operation

x 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 Multitouch operation

(Page 27)

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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.

Ⴠ Windows 7 operating system

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

Ⴠ Additional PCI slots

Ⴠ Additional CF card slot

Ⴠ DVI interface

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2.2 SINUMERIK 840D sl

SIMATIC IPC

Panel PC variant up to 19" panels for multitouch operation:

Ⴠ Compact and rugged

Ⴠ Solid State Drive (SSD)

Ⴠ Passive cooling

Ⴠ Specific configuration for SINUMERIK

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2.2 SINUMERIK 840D sl

2.2.3

Handheld units

Mini handheld unit

The following mini-handheld unit is suitable for the machine setup:

SINUMERIK HT 2

The SINUMERIK HT 2 handheld terminal is designed to allow machine tools to be operated

manually if you need to remain mobile during operation (e.g. for setup activities). It has been

developed specifically with the focus on easy handling, ruggedness and to address the

actual requirements met in practice.

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2.2 SINUMERIK 840D sl

SINUMERIK HT 8

The mobile SINUMERIK HT 8 handheld ter-

minal combines the functions of an operator

panel and a machine control panel in a single

device.

x Fully graphic 7.5" TFT color display

x Mobility for operator control and monitoring

x Operation via touch screen, membrane

keys and touch pen

x Emergency stop button and 2 enabling

buttons for left-handed and right-handed

operators

x Simple insertion or removal during

operation

x Rugged, compact and ergonomically

designed

Wireless hand-held device Hubitron

For wireless operation, we recommend the Hubitron HBG 800-DP hand-held device.

Further information:

www.hubitron.de www.hubitron.de )

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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. For instance, the

difference between chip breakage and chip removal when drilling or the precise probe

sequence for a corner measurement can be shown.

Benefits

Ⴠ Process reliability during the setup

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

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

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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

Ⴠ Programming on the machine without a handbook

Ⴠ Help button to toggle between the editor and help screens

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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.

x Intelligent gesture operation with

touchpanels, also with work gloves

x Capacitive touch for industrial use

x Palm detection

x 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

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

even in harsh industrial environments

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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) ൺ System data ൺ HMI data ൺ

Logs ൺ Screenshots)

Benefit

Ⴠ 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 setup mode for the most commonly used machine functions.

These include:

Ⴠ Tool change, also replacement tools, with direct access via the tool table (T)

Ⴠ Spindle speed and direction (S)

Ⴠ M functions (M)

Ⴠ Activation of work offsets

Ⴠ Definition of the gearbox stage

Ⴠ Selection of the machining plane

Benefit

Ⴠ User-friendly manual input function with dialog prompting

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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:

Ⴠ 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.

Ⴠ 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.

Ⴠ External work offsets:

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

Benefits

Ⴠ Flexible machining thanks to a large number of adjustable work offsets

Ⴠ User-conform understandable representation of the number of work offsets

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4.3 Measuring a workpiece

4.3

Measuring a workpiece

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The workpieces can be measured as follows:

Ⴠ Edge finder, dial gauge, reference tool

Ⴠ 3D switching probe.

The following measuring cycles are available:

Ⴠ Calibrate probe

Ⴠ Point measurement for edges

Ⴠ Orienting the edge (angle)

Ⴠ Inner/outer corner (3 or 4 points)

Ⴠ Orienting the edge by means of 2 holes/spigots

Ⴠ Rectangular or circular pockets, rectangular or circular spigots

Ⴠ Center point of 3 or 4 holes or spigots

Ⴠ Orienting the plane with three points

The measurement results can be output in a measuring log (see Chapter Logging

measurement results in JOG (Page 33)).

Benefits

Ⴠ Time saving due to user-friendly determination of the workpiece's clamping position

instead of orienting the workpiece by hand.

Ⴠ The measurement results can be output in a measuring log.

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4.4 Measuring a tool

4.4

Measuring a tool

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The tool compensation values can be directly determined in setup mode.

The following variants are supported:

Ⴠ Manual or switching probe

Ⴠ Scratching with tool at known workpiece geometry

The measurement results can be output in a measuring log (see Chapter Logging

measurement results in JOG (Page 33)).

Benefit

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

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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 milling technology for the workpiece and tool measurement.

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

The measuring log comprises the following data:

Ⴠ Date and time when the log was written

Ⴠ Log name with path details

Ⴠ Measuring method

Ⴠ Correction target

Ⴠ Setpoints, measured values and differences

Benefit

Ⴠ Simple logging of measured values in log files

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4.6 Face milling cycle

4.6

Face milling cycle

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

A face milling cycle for preparation of the blank for machining is available directly in setup

mode. You can select the tool directly from the list. Input the feedrate and the spindle speed /

cutting speed.

You can specify the following parameters:

Ⴠ Machining strategy and direction

Ⴠ Machining limitations

The input values are retained even after switching off and on again, so that users can always

restart their face milling operation with minimum effort.

Benefit

Ⴠ Preparation of workpiece without having to create a part program

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4.7 Retract

4.7

Retract

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The Retract function supports the manual retraction of the tool after an interruption. In the

JOG mode, after the interruption, the tool can be retracted from the workpiece in the tool

direction.

Typical applications include machining while deploying the CYCLE800 swivel cycle, 5-axis

machining with TRAORI as well as tapping without compensating chuck.

Benefit

Ⴠ Machining can be continued at the point of interruption

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4.8 Stop and retract (ESR)

4.8

Stop and retract (ESR)

4.8.1

Stop and retract (ESR) - Drive-autonomous

SINUMERIK 828D

BASIC

ADVANCED

Option: M60

SINUMERIK 840D sl

BASIC

Option: M60

The extended stop and retract (ESR) function - drive-autonomous offers the possibility of

flexibly responding when a fault situation occurs, irrespective of the higher-level control (NC):

For this purpose, the following axial functions can be configured in the drive:

Ⴠ Retract

Ⴠ Extended stop

Ⴠ Generator operation

The drive-autonomous responses are automatically initiated in fault situations. The triggering

of the drive-autonomous responses can also be realized user-specific via the part programs

or synchronized actions from the higher-level control. As the stopping and retraction motion

of the drive-autonomous ESR are purely axial, in contrast to the control-controlled ESR,

couplings are not taken into account.

Benefit

Ⴠ Faster, situation-conform stop and retraction of axes after a power failure

Ⴠ Stopping and retraction motions in the drives even when they can no longer be specified

from the control, e.g. as a result of a communication failure

Ⴠ Fast resumption of the part program thanks to the block search at the point of interruption

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4.8 Stop and retract (ESR)

4.8.2

Stop and retract (ESR) - CNC-controlled and drive-autonomous

SINUMERIK 828D

BASIC

ADVANCED

not available

SINUMERIK 840D sl

BASIC

Option: M61

As well as the drive-autonomous stop and retract function, the CNC-controlled stop and

retract function is also available. To permit smooth interpolated retraction on the path or

contour, the path interpolation can be processed further for a definable period following the

triggering event.

The retraction axes are subsequently traversed in synchronism to an absolute or incremental

position as programmed. These functions are primarily used for gearing and grinding

technologies.

Benefit

Ⴠ Faster, situation-conform stop and retraction of axes after a power failure

Ⴠ Safe stopping, also of the safety axes

Ⴠ Fast resumption of the part program thanks to the block search at the point of interruption

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4.9 Swiveling in setup mode

4.9

Swiveling in setup mode

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

You can swivel the machining plane to any angle in setup mode:

Ⴠ Machining inclined surfaces

Ⴠ Measure with inclined tool or table

The plane can be swiveled directly including rotation of coordinates or axial swiveling. Using

the initial setting softkey, you can traverse the rotary axes of the swivel data set to the initial

position. Here, you can select between with and without retraction.

Benefits

Ⴠ Swivel the machining plane in setup mode by dialog

Ⴠ Simple setup of the workpiece for machining with swivel axes

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4.10 Manual machine

4.10

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:

Ⴠ Measuring a tool

Ⴠ Traversing axes

Ⴠ Setting the work offset

Ⴠ Turning a straight line / circle

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

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

Ⴠ Milling contours

Benefit

Ⴠ Simple and intuitive operation of cycle-controlled milling 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.

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

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

- Tool type: e.g. face milling cutter, taps and 3D probes

- Clear tool name in plain text, example: CUTTER_HEAD_63MM

- Max. of 9 cutting edges per tool

- Tool length and diameter

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

- Spindle direction and coolant (level 1 and 2) and up to four additional functions

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

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

Ⴠ Reading tools from a file or archiving to a file

Benefits

Ⴠ All tool data at a glance

Ⴠ 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.

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

Ⴠ Prewarning limit for timely preparation of new tools

Ⴠ Provided the desired tool is not in the magazine, SINUMERIK Operate will request a

manual tool change.

Benefits

Ⴠ Reduction of machine standstill times via tool monitoring

Ⴠ 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. Replacement tools are identified with an

increasing number in the ST column.

Benefit

Ⴠ Automatic exchange of identical tools for unmanned operation

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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 ൺ 100 MB

External storage via

option P75 ൺ 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 ൺ

External storage via

40 GB

option P75 ൺ can be ex-

panded almost without limit

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

Internal memory can be expanded via option P77 ൺ 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.

Ⴠ Plain names with as many as 24 characters for directories and files

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

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

Ⴠ Manage and open DXF files

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

including the network drives.

Ⴠ Edit part programs on all media

Highlights

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

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

Ⴠ 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

Basic configuration

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

connection).

Ⴠ The data transfer rate is 10/100 Mbps.

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

remote diagnostics

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

additional software is required on the server.

Highlight

Ⴠ Easy and economical connection via Ethernet (TCP/IP) to Windows PCs

Ⴠ No software needs to be installed 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:

Ⴠ specifically to the point of interruption, also possible after power off

Ⴠ to any CNC block in DIN/ISO programs

Ⴠ to any subprogram levels in DIN/ISO programs

Ⴠ in ShopMill machining step programs

Ⴠ in position patterns for machining step programming

Ⴠ accelerated block search in large mold making programs

You can individually configure the block search:

Ⴠ with calculation / without calculation

Ⴠ with approach / without approach

Benefits

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

required

Ⴠ 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:

Ⴠ

PRT - no axis motion

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

Ⴠ

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.

Ⴠ

RG0 - reduced rapid traverse

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

Ⴠ

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.

Ⴠ

DRF - handwheel offset

This selection allows you to enter an additional incremental work offset while processing

in automatic mode with an electronic handwheel.

Ⴠ

SKP

Skip blocks are skipped during machining.

Ⴠ

MRD

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

execution.

Benefits

Ⴠ

Secure positioning of new part programs

Ⴠ

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:

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

subprogram. This reduces syntax errors for the subprogram call.

Ⴠ Part programs can be edited without NC reset.

Ⴠ 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

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

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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 to you for programGUIDE (screenshot on left) and also for ShopMill

(screenshot on right).

Benefit

Ⴠ Optimal control of the program execution, also 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

While machining the workpiece the tool paths can be recorded on the screen of the control in

the plan view, 3-side view or in 3D view. Workpiece depiction and views correspond to the

graphic simulation.

Benefit

Ⴠ 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:

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

Ⴠ Log type: standard log, user log

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

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

Ⴠ 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:

Ⴠ Date and time when the log was written

Ⴠ Measuring method

Ⴠ Correction target

Ⴠ Setpoints, measured values and differences

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

Benefit

Ⴠ Simple logging of measured values in log files

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CNC operation in automatic mode (AUTO)

8.7 Handwheel override

8.7

Handwheel override

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

In the AUTOMATIC mode, while executing a program, small corrections and override feed of

the tool in the tool direction are possible using a handwheel. When the orientation of the tool

changes, the handwheel override that has been accumulated is also rotated. The manual

correction acts in the form of override to the traversing motion from the NC program.

Benefit

Ⴠ Small corrections and feeds of the tool in the tool direction are possible using a

handwheel.

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CNC functions

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

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

accuracy

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CNC functions

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

Ⴠ 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

Ⴠ Minimum block change times for the associated performance versions

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CNC functions

9.3 Jerk limiting

9.3

Jerk limiting

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

Ⴠ Longer machine lifespan through protection of the mechanical components

Ⴠ Higher path accuracy through softer acceleration

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CNC functions

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

Ⴠ Higher path accuracy through compensation of contouring errors

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Tool and mold making

10.1

High speed settings

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The high speed settings cycle enables easy parameterization of the optimum motion control

in relation to the machining type and the part program contour tolerance band.

The high-speed setting cycle sets automatically the associated optimum combination of

accuracy, speed and surface quality - for 3-axis and 5-axis machining of free form surfaces.

The cycle is called within the DIN/ISO editor or in ShopMill. Calling this function activates

Advanced Surface and/or Top Surface depending on the options and the configuration. The

best available mold making function is automatically used.

The following settings are possible:

x Machining type

- Roughing

- Rough-finishing

- Finishing

x Tolerance

x Multiple axis program yes/no

x Orientation tolerance and rotary axis

tolerance

Highlight

Ⴠ Simple and easily understandable parameterization of the required machining type

(roughing, pre-finishing or finishing) with an interactive screen

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Tool and mold making

10.2 Advanced Surface and Top Surface

10.2

Advanced Surface and Top Surface

Machining of free-form surfaces involves high requirements regarding speed, precision and

surface quality. The "High Speed Settings" cycle simplifies the parameterization of mold

making applications.

The "Advanced Surface" and "Top Surface" options allow the manufacturing of high-quality

mold making workpieces.

Perfect surface

Conventional CNC

with Advanced Surface

SINUMERIK Operate can even cope with

and Top Surface

inadequate CNC block sequences in mold

making programs: New forward-thinking,

mathematical algorithms perform fully identi-

cal calculations for the movement paths in

forward and reverse directions. This means

that reverse paths on molds yield mirror-finish

workpiece surfaces.

Minimum machining time

In addition, Advanced Surface and Top Sur-

face ensure shortest machining times. A

brand new type of motion control calculates

an ideally smooth surface, for which it keeps

the tool within the optimum speed range at all

times.

One-off optimization

The Advanced Surface and Top Surface algo-

rithms guarantee optimum workpiece surfaces

and shortest machining times after just a sin-

gle optimization of the system.

Highlight

Ⴠ Advanced Surface and Top Surface are synonyms for milling at physical machine limits;

coupled with maximum speed, accuracy and best surface quality, not only for mold

making

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Tool and mold making

10.2 Advanced Surface and Top Surface

10.2.1

Advanced Surface

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Option: S07

With Advanced Surface you can easily parameterize optimum speed control depending on

the machining type (roughing, rough-finishing, finishing).

Enter the following settings for Advanced Sur-

face:

x Tolerance of the machining axes

x Machining type

- Finishing

- Rough-finishing

- Roughing

- Deselection

x Multiple axis program yes/no

Benefit

Ⴠ Advanced Surface permits maximum productivity coupled with simple process

parameterization - from 3-axis multipass milling through to dynamic 5-axis machining

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Tool and mold making

10.2 Advanced Surface and Top Surface

10.2.2

Top Surface

SINUMERIK 828D

BASIC

ADVANCED

not available

Option: S17

SINUMERIK 840D sl

BASIC

Option: S17

The High Speed Settings cycle, Top Surface option ensures a significantly improved

workpiece surface for inclined multipass finishing programs, even for poor data quality and/or

irregular point distribution in NC programs from the CAD/CAM system.

The dynamic response is also optimized:

Ⴠ Improved observance of the acceleration and jerk limits

Ⴠ Lower vibration excitation of the machine

In addition to selecting the machining types

(finishing, rough-finishing, roughing), the fol-

lowing settings are possible:

x Smoothing yes/no

x Multiple axis program yes/no

x Contour and orientation tolerance

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Tool and mold making

10.2 Advanced Surface and Top Surface

The contour tolerance is shown as magnifying

glass.

Standard values:

x Roughing 0.1

x Rough-finishing 0.05

x Finishing 0.01

The smoothing is also shown in the magnify-

ing glass:

x Smoothing adds shine to the surface.

x Without smoothing, high-precision

contours appear perfectly.

Benefits

Ⴠ Perfect surface quality - Correction of irregularities from the CAD/CAM data, direction-

independent identical smoothing of the milling paths

Ⴠ High accuracy

Ⴠ Stable milling machine - significantly smoother machine running, less wear, long-term

availability

Ⴠ Perfect usability - simple and graphical operator screens, optimum surface quality, even

with the default setting, for most programs

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Tool and mold making

10.3 Look Ahead

10.3

Look Ahead

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Option: S07

The Look Ahead function (the function is part of Advanced Surface) achieves an optimum

machining speed by looking ahead over a parameterized number of traversing blocks. With

tangential block transitions, the axis is accelerated and decelerated beyond block

boundaries, so that no drops in speed occur.

Highlight

Ⴠ Shorter machining times through optimum speed control

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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.

ShopMill machining step programming

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

ISO knowledge for small series.

Machining operations such as traversing movements, drilling or pocket milling are shown in

ShopMill in the form of machining steps. This means that CNC programs are very compact

and are easy to generate and read - even for complex machining operations. Associated

sequences are automatically interlinked and can be assigned any position patterns.

Benefit

Ⴠ Whether you use programGUIDE or ShopMill - in either case the full range of

technological cycles, position patterns and geometries is available to you

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CNC programming methods

11.1 programGUIDE DIN/ISO and SINUMERIK high-level language

11.1

programGUIDE DIN/ISO and SINUMERIK high-level language

11.1.1

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:

Ⴠ DIN/ISO editor

Ⴠ Languages

Ⴠ programGUIDE input support

These functions belong to the basic configuration of SINUMERIK Operate.

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CNC programming methods

11.1 programGUIDE DIN/ISO and SINUMERIK high-level language

11.1.2

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 is available for the most complex machining.

The following functions are included in the

program editor:

x Contour calculator

x Tool selection directly from tool list

x Support screens for standard machining

and measuring cycles

x "Copy", "Paste" and "Cut" block

x "Find", "Replace" and "Replace All"

character string

x The syntax is highlighted in various colors

(comments, NC blocks, etc.)

x Renumbering a program

x Direct execution from any NC program

block (block search)

x Jump to program start or program end

Benefits

Ⴠ Time saving by using a powerful editor when programming

Ⴠ Even large part programs (many MB large) can be edited extremely fast

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CNC programming methods

11.1 programGUIDE DIN/ISO and SINUMERIK high-level language

11.1.3

Languages

The CNC interpreter of 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:

Ⴠ

G-code

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

Ⴠ

G functions

G0, G1, G2, G71 ...

Ⴠ

Language commands (extended G functions)

CIP, SOFT, BRISK, FFWON ...

Ⴠ

Frame operations (programmable work offsets)

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

commands TRANS, SCALE, MIRROR, ROT.

Ⴠ

R parameters (arithmetic parameters)

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

format).

Ⴠ

User variables

Users can define their own variables by name and type.

Ⴠ

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.

Ⴠ

Arithmetic operations

The following arithmetic operations are available to combine the variables:

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

logical operations == <> >=, etc.

Ⴠ

Program control structures

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

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

Benefits

Ⴠ

Established programming according to DIN 66025

Ⴠ

Unbeatable range of commands for flexibility and time saving while programming

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CNC programming methods

11.1 programGUIDE DIN/ISO and SINUMERIK high-level language

11.1.4

programGUIDE input support

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

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

consistency.

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

editor.

Benefits

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

Ⴠ Minimum learning requirements due to the consistency of the input support

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CNC programming methods

11.2 ShopMill - machining step programming

11.2

ShopMill - machining step programming

11.2.1

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

ShopMill. This includes:

Ⴠ Sequence editor

Ⴠ Interlinking of sequences

Ⴠ Broken-line graphics

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

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CNC programming methods

11.2 ShopMill - machining step programming

11.2.2

Sequence editor

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

program line represents a technological sequence (such as: face milling, 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 technolog-

ical 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

Ⴠ Intuitive program input, without knowledge of DIN/ISO and the Operating Manual

Ⴠ Compact, clearly arranged machining programs

Ⴠ Reducing the programming time by graphical input masks and copying/pasting machining

steps

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CNC programming methods

11.2 ShopMill - machining step programming

11.2.3

Interlinking of sequences

In ShopMill, 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, deep-hole drilling and tapping are applied

to 6 holes on the pitch circle pattern position.

Benefit

Ⴠ Reduced programming time due to linking of machining steps

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CNC programming methods

11.2 ShopMill - machining step programming

11.2.4

Graphic 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.

Ⴠ Plan view of workpiece

Ⴠ Front view of drilling operations

Benefit

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

start a simulation run

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Workpiece visualization

12.1

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.

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

Ⴠ Simulation in plan view and side view

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

Benefits

Ⴠ Maximum process reliability through simulation using real geometry values

Ⴠ Perfect clarity by showing the workpiece dimensions with a scale

Ⴠ Parallel simulation (backg14round 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

12.2 3D simulation

12.2

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.

Ⴠ Reliability:

3 viewing planes and solid model of the finished part, with zoom to details and free

rotation of the viewing angle

Ⴠ Support:

- Simulation speed controllable by override

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

Ⴠ Checking:

Automatic calculation of machining time

Benefits

Ⴠ Particularly realistic simulation through representation of the tool

Ⴠ Optimum help and reliability in programming and in quotation costing

Ⴠ Parallel simulation (backg14round 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

12.3 Mold making fast view

12.3

Mold making fast view

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

The mold making fast view is available, in particular for large part programs.

Ⴠ Fast view of G0, G1, G2, G3 blocks, VECTORS using the 3D mold building model

Ⴠ Fast identification of part programs where simulation would take a long time

Ⴠ Displaying/hiding G0, G1, G2, G3 lines and points

Ⴠ 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.

Benefit

Ⴠ More safety when handling mold making programs

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CNC technology cycles

13.1

CNC technology cycles for programGUIDE and ShopMill

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

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

Benefits

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

cycles

Ⴠ Consistency of cycles for programGUIDE and ShopMill

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CNC technology cycles

13.2 Highlights of machining cycles

13.2

Highlights of machining cycles

13.2.1

Overview

For frequently repeated machining tasks, machining cycles are available for the drilling,

milling and turning technologies.

Ⴠ Drilling technology:

Drilling/centering, drilling/counterboring, deep-hole drilling, tapping with and without

compensating chuck, boring 1 ... 5, row of holes, circle of holes, grid of holes, machining

on inclined surfaces

Ⴠ Milling technology:

Thread milling, elongated holes in a circle, grooves in a circle, circumferential groove,

rectangular/circular pocket, face milling, path milling, rectangular/circular spigot,

machining on inclined surfaces, high-speed settings for optimized HSC machining,

engraving cycle

Ⴠ Turning technology:

Groove, undercut, cutting with relief cut, thread undercut, thread cutting, chaining of

threads, thread recutting

A selection of machining cycles is explained in more detail below.

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CNC technology cycles

13.2 Highlights of machining cycles

13.2.2

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:

Ⴠ Date and time

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

Ⴠ Quantity

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

Ⴠ 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.

Ⴠ 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

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

Ⴠ Simple program input of engraving

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CNC technology cycles

13.2 Highlights of machining cycles

13.2.3

Trochoidal milling

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Vortex milling (trochoidal milling) of open slots is available as a milling strategy directly on

the controller, i.e. NC programs for path motions do not have to be generated by CAM

systems as previously.

Ⴠ It is the preferred strategy for HSC roughing, the tool is never fully inserted and tool paths

are smooth and round

Ⴠ Simple parameterizing per dialog: Roughing, pre-finishing, finish milling, finishing floor

and edge

Ⴠ You can select as milling direction synchronous operation, reverse rotation, and for

maximum cutting volume during roughing the combination reverse rotation and

synchronous operation

Benefits

Ⴠ Innovative CAM function now available directly on the controller

Ⴠ Reduction in the machining time for slot milling by up to 50%

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CNC technology cycles

13.2 Highlights of machining cycles

13.2.4

Plunge milling

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

For machining deep pockets and slots in thin-walled workpieces, the plunge milling cycle is

available for open slots.

Ⴠ As types of machining you can select roughing, pre-finishing and finishing of the edge

and/or floor

Ⴠ Essentially, forces apply only along the main spindle axis, therefore, hardly any distortion

of the tool occurs.

Benefits

Ⴠ Less vibrations and deeper cutting depth thanks to the new machining strategy plunge

milling

Ⴠ Reduced cutting pressure and distortion enable higher productivity when machining thin-

walled workpieces

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CNC technology cycles

13.2 Highlights of machining cycles

13.2.5

Deep-hole drilling

SINUMERIK 828D

BASIC

ADVANCED

Basic configuration

SINUMERIK 840D sl

BASIC

Basic configuration

Easy-to-use cycles for deep-hole drilling are available in SINUMERIK Operate.

The tool drills at the programmed spindle speed and feedrate to the entered final drilling

depth.

Deep hole drilling is performed with a depth infeed of a maximum definable depth executed

several times, increasing gradually until the final drilling depth is reached.

For example, the drilling machine can be retracted after each infeed depth either to the

piloting depth + safety clearance for chip removal or by the length of the programmed

retraction path for chip breakage.

You can also choose between the following drilling strategies:

x With or without predrilling

x With or without pilot hole

x Soft first cut yes/no

x Chip breaking/removal

x Chip breaking and swarf removal

1 cut - drill in one step to the end

depth

x Swarf removal to the piloting depth /

safety clearance

x Retraction to the piloting depth /

retraction plane

x Position pattern

Benefit

Ⴠ Generate drill holes with more than one feed to any positions

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CNC technology cycles

13.3 Residual material detection for contour cycles

13.3

Residual material detection for contour cycles

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 spigots. These areas can be selectively

machined with a suitable smaller tool, rather than having to use this tool for the entire

contour pocket or spigot.

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

Ⴠ 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

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

SINUMERIK Operate - Milling

Control system overview for machine tools' sales people, 2017, A5E41992599B AA

SINUMERIK 840D sl. Training. Operate - Turning (2016-2020) - page 14