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

Example 3: Guide shaft

8.4 Creating the machined part contour and stock removal

To complete the arc, proceed as follows:

1. Enter center point K-35 (absolute dimension).

Figure 8-15 Specifying the arc contour center point

2. Enter the transition to the next element with R4.

Figure 8-16 Specifying the arc contour radius

You can use the existing contour data and the calculated selection options to construct the

arc and the straight line (with unknown end point).

Accept the contour section.

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Example 3: Guide shaft

8.4 Creating the machined part contour and stock removal

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

Field

Value

Selection via toggle key

Notes

-75 abs

Transition to next element

Radius

Figure 8-17 Specifying the horizontal straight line contour

Accept the entered values.

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Example 3: Guide shaft

8.4 Creating the machined part contour and stock removal

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

Field

Value

Selection via toggle key

Notes

90 abs

-80 abs

Transition to next element

Radius

Figure 8-18 Specifying the inclined straight line contour

Accept the entered values.

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Example 3: Guide shaft

8.4 Creating the machined part contour and stock removal

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

Field

Value

Selection via toggle key

Notes

-90 abs

Transition to next element

Chamfer

To prevent damage to the

chuck, end the

construction at Z-90.

Figure 8-19 Specifying the horizontal straight line contour

Accept the entered values.

Accept the contour into your process plan.

Figure 8-20 Accepting the contour

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Example 3: Guide shaft

8.4 Creating the machined part contour and stock removal

Stock removal

In the following work step you will perform contour stock removal.

To this end, proceed as follows:

Select the Stock removal softkey.

Open the tool list and select the ROUGHING_T80 A tool.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.3

260 m/min

Machining

longitudinal

external

roughing

2.5

0.2

0.0

Contour

The blank description

must be switched to

contour here.

Relief cuts

To ensure that the recess

of radius 23 is not

machined, you must

switch to No.

Set machining area limits

Figure 8-21 Contour stock removal

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Example 3: Guide shaft

8.5 Residual stock removal

Accept the entered values. Both contours and the work step are linked together following

acceptance.

Select the Simulation softkey.

Figure 8-22 Contour stock removal simulation (with display of the traversing paths).

The traversing paths in the simulation clearly indicate how the previously constructed blank

is taken into consideration.

8.5

Residual stock removal

Operating sequences

Proceed as follows to cut the residual material:

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Example 3: Guide shaft

8.5 Residual stock removal

The following illustration shows the process plan up to roughing machining:

Figure 8-23 Process plan including roughing machining

Select the Contour turning softkey.

Select the Residual stock removal softkey.

Open the tool list and select the BUTTON_TOOL_8 tool.

Accept the tool into your program.

Enter the following values for residual stock removal in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.25

240 m/min

Machining

longitudinal

external

roughing

2.0

0.2

0.0

Relief cuts

Yes

Machining with relief cuts

must be switched to Yes

here.

0.2

Set machining area limits

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Example 3: Guide shaft

8.5 Residual stock removal

Start the simulation.

Figure 8-26 Residual stock removal simulation

After roughing the contour, it must then be finished.

Select the Contour turning softkey.

Select the Stock removal softkey.

Open the tool list and select the FINISHING_T35 A tool.

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.12

280 m/min

Machining

longitudinal

external

finishing

Allowance

Relief cuts

Yes

Set machining area limits

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Example 3: Guide shaft

8.6 Groove

8.6

Groove

Operating sequences

Proceed as follows to create a groove:

After residual stock removal, the list of work steps looks like this:

Figure 8-29 Process plan following stock removal

Select the Turning softkey.

Select the Groove softkey.

Select the second groove shape (groove 2).

Open the tool list and select PLUNGE_CUTTER_3 A.

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Example 3: Guide shaft

8.6 Groove

Accept the tool into your program.

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

Field

Value

Selection via toggle key

Notes

0.1 mm/rev

150 m/min

Machining

Roughing +

finishing

Position

see illustration

below

Here, you enter the

position and allowance of

-67

the groove.

4.2

X (field)

4 inc

α1

Here, you enter the flank

angle and rounding at the

α2

corners.

FS1

X (field)

FS4

X (field)

0.2

X (field)

Figure 8-30 Creating a groove

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Example 3: Guide shaft

8.7 Thread

8.7

Thread

Operating sequences

Proceed as follows to create a thread.

Select the Turning softkey.

Select the Thread softkey.

Open the tool list and select THREADING_T1.5.

Accept the tool into your program.

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

Field

Value

Selection via toggle key

Notes

1.5 mm/rev

800 rpm

Machining

Roughing

The thread is created with

the diminishing setting.

Diminishing

This setting causes the

External thread

cutting division to be

reduced for each cut, and

so ensures that the

cutting cross-section

remains constant.

-3

-23 abs

X (field)

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Example 3: Guide shaft

8.8 Drilling

After the thread has been created, the list of work steps looks like this:

Figure 8-36 Process plan following thread creation

Select the Drilling softkey.

Select the Drilling Reaming softkey. The workpiece is drilled directly, i.e. without centering.

Select the Drilling softkey.

Open the tool list and select DRILL_5.

Accept the tool into your program.

Enter the following values for the drill hole in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.06 mm/rev

140 m/min

Face

Shank

The depth reference is

switched to Shank.

10 inc

The hole depth can be

entered as 10mm

incremental or -10mm

absolute.

0 s

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Example 3: Guide shaft

8.8 Drilling

Figure 8-37 Drilling

Accept the entered values. After acceptance, the list of work steps looks like this:

Figure 8-38 Process plan following drilling

During the drilling work step, an open connector appears in the list of work steps. This is

automatically linked to the drilling positions in the next step.

Select the Positions softkey.

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Example 3: Guide shaft

8.8 Drilling

For the purposes of the exercise, the four drill holes are entered as single positions. A

simpler solution here would be to use the position circle.

Figure 8-39 Entering the positions

Accept the entered values. After acceptance, the list of work steps looks like this:

Figure 8-40 Process plan following input of the position pattern

The drill holes are now linked to the drilling positions.

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Example 3: Guide shaft

8.9 Milling the rectangular pocket

8.9

Milling the rectangular pocket

Operating sequences

Proceed as follows to create a rectangular pocket on the front face (C axis or complete

machining sequence).

Select the Milling softkey.

Select the Pocket softkey.

Select the Rectangular pocket softkey.

Open the tool list and select CUTTER_8.

Accept the tool into your program.

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

Field

Value

Selection via toggle key

Notes

0.03 mm/tooth

220 m/min

Face

Machining

Roughing

Single positions

X (field)

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Example 3: Guide shaft

8.9 Milling the rectangular pocket

Field

Value

Selection via toggle key

Notes

α0

3 inc

DXY

75%

1.5

UXY

Insertion

Helical

see insertion below

Figure 8-43 Producing a rectangular pocket

Accept the entered values. After acceptance, the list of work steps looks like this:

Figure 8-44 Process plan following rectangular pocket

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Example 4: Hollow shaft

9.1

Overview

Learning objectives

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

● perform internal machining on workpieces;

● work with the work step editor;

● create an undercut and

● an asymmetrical groove.

Task

Figure 9-1

Workshop drawing - Example 4:

Figure 9-2

Blank contour

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

All non-dimensioned radii R10.

Note

On account of improved clamping, side 1 is manufactured first.

9.2

Creating the first workpiece side

Creating a process plan

Since the workpiece is to be machined from two sides (and produced without

counterspindle), two process plans must be created.

Create the process plan for the left-hand side first ('HOLLOW_SHAFT_SIDE1')

Operating sequences

Create the program 'HOLLOW_SHAFT_SIDE1' without help.

Figure 9-3

Creating a ShopTurn program

Enter the following data in the program header (see illustration).

Figure 9-4

Workpiece dimensions in the program header

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

9.2.1

Face turning

Operating sequences

Proceed as follows to face turn the blank to Z0:

Select the Turning softkey.

Select the Stock removal softkey.

Select the ROUGHING_T80 A tool.

Enter the following values in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.2

240 m/min

Machining

Roughing

Since a large amount of

material (5mm) remains

on the front face, set the

machining to roughing.

Position

(see illustration

below)

Machining direction

Chart

105

-1.6 abs

0 abs

2.5

0.0

0.2

Figure 9-5

Face turning the workpiece

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Accept the entered values. After acceptance, your work step program looks like this:

Figure 9-6

Process plan following face turning

9.2.2

Drilling

Operating sequences

Proceed as follows to drill the workpiece at the center.

Select the Drilling softkey.

Select the Drilling Centric softkey.

Open the tool list and select DRILL_32.

Accept the tool into your program.

Enter the following values for the drill hole in the interactive screenform:

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

9.2.3

Blank contour

Operating sequences

Enter the following blank contour without help. Since the workpiece is only machined on one

side for each process plan, the blank contour only needs to be constructed to Z-65.

Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_BLANK' for the contour.

Figure 9-9

Creating the contour

Create the blank contour in the contour calculator (see illustration below).

Figure 9-10 Creating a blank contour

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

9.2.4

Machined part contour of the first side, external

Operating sequences

Proceed as follows to enter the machined part contour:

Note

The (red) contour of the machined part is intended not to correspond to the drawing. The

machined part contour serves as the roughing machining limit, but more importantly it

specifies the precise traversing path for finishing. Thus, the construction begins here at the

drill hole diameter. This ensures that the end face is finished cleanly. The contour end is an

extension of the chamfer extending outside the blank. The large diameter is produced only in

the second clamping.

Select the Contour turning softkey.

Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE1_E' for the

contour.

Figure 9-11 Creating the contour

Confirm your input.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Set the starting point to X32/Z0.

Figure 9-12 Specifying the contour starting point

Confirm your input.

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

Field

Value

Selection via toggle key

Notes

68 abs

Transition to next element

Chamfer

Figure 9-13 Specifying the vertical straight line contour

Accept the entered values.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

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

Field

Value

Selection via toggle key

Notes

-5 abs

Transition to next element

Chamfer

Figure 9-14 Specifying the horizontal straight line contour

Accept the entered values.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Enter the following values for the next section in the interactive screenform:

Field

Value

Selection via toggle key

Notes

Direction of rotation

Right

68 abs

-25 abs

Transition to next element

Chamfer

Figure 9-15 Specifying the arc contour

Select the desired construction.

Accept your selection.

Accept the contour section.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

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

Field

Value

Selection via toggle key

Notes

-55 abs

Transition to next element

Chamfer

The undercut is inserted

later as an individual

element.

Figure 9-16 Specifying the horizontal straight line contour

Accept the entered values.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

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

Field

Value

Selection via toggle key

Notes

98 abs

Transition to next element

Chamfer

The inclined straight line

remains as chamfer after

the second side has been

machined.

Figure 9-17 Specifying the vertical straight line contour

Accept the entered values.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

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

Field

Value

Selection via toggle key

Notes

106 abs

α1

135

Transition to next element

Chamfer

Figure 9-18 Specifying the inclined straight line contour

Accept the entered values.

Accept the contour into your process plan.

Figure 9-19 Contour in the contour calculator

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

After acceptance, the process plan looks like this. Both contours are automatically linked

together.

Figure 9-20 Process plan following input of the contours

Stock removal, residual stock removal and finishing

In the following work step you will perform contour stock removal.

To this end, proceed as follows:

Select the Stock removal softkey.

Open the tool list and select the ROUGHING_T80 A tool.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.3

260 m/min

Machining

longitudinal

external

roughing

2.0

0.2

0.0

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Field

Value

Selection via toggle key

Notes

Contour

In the blank descriptions

you can choose between

the following settings:

Cylinder:

Blank = cylinder

Contour:

Blank = constructed

contour

Allowance:

Blank = constructed

contour with defined

allowance

Relief cuts

Insertion with the

roughing tool is not

recommended. Therefore,

switch the Relief cuts field

to No.

Set machining area limits

Figure 9-21 Roughing the contour

Accept the entered values.

Select the Residual stock removal softkey.

Open the tool list and select the FINISHING_T35 A tool.

Accept the tool into your program. Before finishing, the residual material is cut in the concave

fillet.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Enter the following values for stock removal of residual material in the interactive

screenform:

Field

Value

Selection via toggle key

Notes

0.2

240 m/min

Machining

longitudinal

external

roughing

2.0

0.2

0.0

Relief cuts

Yes

To ensure that the

concave fillet is taken into

consideration, the Relief

cuts field must be

switched to Yes.

0.2

Set machining area limits

Figure 9-22 Stock removal of residual material contour

Accept the entered values.

Select the Stock removal softkey.

Open the tool list and select the FINISHING_T35 A tool.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.15

280 m/min

Machining

longitudinal

external

finishing

Allowance

Relief cuts

Yes

Switch Relief cuts to Yes

here, too.

Set machining area limits

Figure 9-23 Finishing the contour

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Accept the entered values. After acceptance, your work step program looks like this: The

contours are automatically linked to the stock removal work steps.

Figure 9-24 Process plan following stock removal of the contour

9.2.5

Undercut

You can select from four different types of undercut:

Undercut form E

Undercut form F

Undercut DIN thread

Undercut thread

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Operating sequences

Proceed as follows to create an undercut.

After residual stock removal, the list of work steps looks like this:

Figure 9-25 Process plan following stock removal

Select the Turning softkey.

Select the Undercut softkey.

Select the Undercut form E softkey.

Open the tool list and select the FINISHING_T35 A tool.

Accept the tool into your program.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

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

Field

Value

Selection via toggle key

Notes

0.15

200 m/min

Position

see illustration

below

E 1.0 x 0.4

-55

0 inc

70 abs

Figure 9-26 Specifying the undercut

Accept the entered values. After acceptance, the list of work steps looks like this:

Figure 9-27 Process plan with undercut

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

9.2.6

Machined part contour of the first side, internal

Operating sequences

Proceed as follows to enter the machined part contour:

Select the Contour turning softkey.

Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE1_I' for the

contour.

Figure 9-30 Creating the contour

Confirm your input.

Set the starting point to X50/Z0.

Figure 9-31 Specifying the contour starting point

Confirm your input.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Create the contour without help (see illustration below).

Figure 9-32 Machined part contour of the first side, internal

Stock removal, residual stock removal and finishing

In the following work step you will perform contour stock removal. Enter the geometries into

your process plan as follows.

Figure 9-33 Broken-line graphics

Select the Stock removal softkey.

Open the tool list and select the ROUGHING_T80 I tool.

Accept the tool into your program.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.25

250 m/min

Machining

longitudinal

You must switch the

internal

machining to Inside.

roughing

2.0

0.2

0.0

Cylinder

Since drilling has already

taken place, you do not

need to take a blank

contour into consideration

for internal machining.

Switch to Cylinder.

32 abs

0 inc

Relief cuts

Set machining area limits

Figure 9-34 Roughing the contour

Accept the entered values.

Select the Stock removal softkey.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

Open the tool list and select the FINISHING_T35 I tool.

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.12

280 m/min

Machining

longitudinal

internal

finishing

Allowance

Relief cuts

Set machining area limits

Figure 9-35 Finishing the contour

Accept the entered values.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

9.2.7

The work step editor

Functions of the work step editor

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

editor.

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

Use this softkey to search for texts in the program.

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

"Copy" or "Cut").

Use this softkey to copy work steps to the clipboard.

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

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

step.

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

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

Use this softkey to switch to the extended menu.

Use this softkey to renumber the work steps.

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

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

represented as a symbol.

Use this softkey to return to the previous menu.

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Example 4: Hollow shaft

9.2 Creating the first workpiece side

You will need some of these functions in order to reuse the blank contour of the first side in

the process plan for the second side of the workpiece. The blank contour will be copied to

the clipboard and pasted into the process plan for the second side.

Figure 9-40 Blank contour

9.2.8

Copying the contour

Operating sequence

Proceed as follows to copy the blank contour to the clipboard:

Navigate to the 'HOLLOW_SHAFT_BLANK' contour.

Figure 9-41 Copying the contour to the clipboard.

Copy the blank contour to the clipboard. The contour remains on the clipboard until you copy

another work step to the clipboard or shut down the control system.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

9.3

Creating the second workpiece side

Creating a process plan

Proceed as follows to create a process plan for the second side of the workpiece.

Operating sequences

Create the program 'HOLLOW_SHAFT_SIDE2' without help.

Figure 9-42 Creating a ShopTurn program

Enter the following data in the program header (see illustration).

Figure 9-43 Workpiece dimensions in the program header

9.3.1

Face turning

Operating sequences

Proceed as follows to face turn the blank to X-1.6 and Z0:

Select the Turning softkey.

Select the Stock removal softkey.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Select the ROUGHING_T80 A tool.

Enter the following values in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.2

240 m/min

Machining

Roughing

Since a large amount of

material (5mm) remains

on the front face, set the

machining to roughing.

Position

(see illustration

below)

Machining direction

Chart

105

-1.6 abs

0 abs

2.5

0.0

0.2

Figure 9-44 Face turning the workpiece

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Accept the entered values. After acceptance, your work step program looks like this:

Figure 9-45 Process plan following face turning

9.3.2

Drilling

Operating sequences

Proceed as follows to drill the workpiece at the center.

Select the Drilling softkey.

Select the Drilling Centric softkey.

Open the tool list and select DRILL_32.

Accept the tool into your program.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Enter the following values for the drill hole in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.1 mm/rev

2500 rpm

Chip removal

Tip

-67 abs

Figure 9-46 Hole

"Apply" the set values. After acceptance, the list of work steps looks like this:

Figure 9-47 Process plan following input of the drilling position

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

9.3.3

Specifying a blank contour

Operating sequences

Proceed as follows to paste the blank contour from the clipboard into your process plan:

First, navigate in the process plan to the most recently entered work step (see illustration).

Figure 9-48 Position for inserting the blank contour

Paste the blank contour from the clipboard. After pasting the contour, your process plan

should look like this.

Figure 9-49 Pasting the contour

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

9.3.4

Machined part contour of the second side, external

Operating sequences

Proceed as follows to enter the machined part contour:

Note

The asymmetrical groove is produced later.

Select the Contour turning softkey.

Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE2_E' for the

contour.

"Apply" your input.

Set the starting point to X57/Z0.

Figure 9-50 Specifying the contour starting point

"Apply" your input.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Create the contour up to the end point to Z-65 and X100 without help (see illustration below).

Figure 9-51 Contour in the contour calculator

Accept the contour into your process plan.

Stock removal and finishing

In the following work step you will perform contour stock removal.

To this end, proceed as follows:

Select the Stock removal softkey.

Open the tool list and select the ROUGHING_T80 A tool.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.3

260 m/min

Machining

longitudinal

external

roughing

2.0

0.2

0.0

Contour

Relief cuts

Set machining area limits

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Figure 9-52 Roughing the contour

"Apply" the set values. After acceptance, your work step program looks like this:

Figure 9-53 Process plan following roughing

Select the Stock removal softkey.

Open the tool list and select the FINISHING_T35 A tool.

Accept the tool into your program.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.15

200 m/min

Machining

longitudinal

external

finishing

Allowance

Relief cuts

Set machining area limits

Figure 9-54 Finishing the contour

"Apply" the set values. After acceptance, your work step program looks like this:

Figure 9-55 Process plan following stock removal of the contour

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Start the simulation.

Figure 9-56 Simulation - 3D view

9.3.5

Creating an asymmetrical groove

Operating sequences

Proceed as follows to create an asymmetrical groove.

Select the Turning softkey.

Select the Groove softkey.

Select the Groove 2 softkey.

Open the tool list and select the PLUNGE_CUTTER_3 A tool.

Accept the tool into your program.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

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

Field

Value

Selection via toggle key

Notes

0.08

180 m/min

Machining

Roughing +

finishing

Position

see illustration

below

-55

X (field)

5.5 inc

α1

X (field)

0.2

X (field)

Figure 9-57 Specifying a groove

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

9.3.6

Machined part contour of the second side, internal

Operating sequences

Proceed as follows to enter the machined part contour:

Select the Contour turning softkey.

Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE2_I' for the

contour.

"Apply" your input.

Set the starting point to X57/Z0.

Figure 9-60 Specifying the contour starting point

"Apply" your input.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Create the contour without help (see illustration below).

Figure 9-61 Machined part contour of the second side, internal

Note

When creating the contour, ensure that the arc elements merge tangentially.

Tangential merging applies only to main elements, i.e. the rounding is attached to the main

element.

(See illustration below)

0DLQ HOHPHQWV

5RXQGLQJ

WDQJHQWLDO

QRQ WDQJHQWLDO

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Accept the contour. After accepting the contour, your work step program looks like this.

Figure 9-62 Process plan following input of the contour

Stock removal, residual stock removal and finishing

In the following work step you will perform contour stock removal.

Select the Stock removal softkey.

Open the tool list and select the ROUGHING_T80 I tool.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.25

280 m/min

Machining

longitudinal

You must switch the

internal

machining to Inside.

roughing

2.0

0.2

0.0

Cylinder

Since drilling has already

taken place, you do not

need to take a blank

contour into consideration

for internal machining.

Switch to Cylinder.

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Field

Value

Selection via toggle key

Notes

32 abs

0 abs

Relief cuts

Set machining area limits

Figure 9-63 Roughing the contour

"Apply" the set values.

Select the Residual stock removal softkey.

Open the tool list and select the FINISHING_T35 I tool.

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.2

240 m/min

Machining

longitudinal

internal

finishing

Allowance

Relief cuts

Yes

0.2

Set machining area limits

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Example 4: Hollow shaft

9.3 Creating the second workpiece side

Figure 9-64 Contour residual stock removal

"Apply" the set values.

Select the Stock removal softkey.

Open the tool list and select the FINISHING_T35 I tool.

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.12

280 m/min

Machining

longitudinal

internal

finishing

Allowance

Relief cuts

Yes

Set machining area limits

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Example 5: Plunge-turning

10.2 Plunge-turning

Preparation

Perform the following steps without help:

1. Create a new workpiece with the name 'EXAMPLE5'.

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

3. Fill in the program header (see illustration below).

Figure 10-2 Creating a program header

10.2

Plunge-turning

The achievable level of productivity during turning is limited, among other things, by the

possible number of tools in the revolver and the frequent tool changes required for effective

turning machining. With standard turning tools alone, not all possible contours can be

produced, and residual material machining, therefore, is often performed by means of

plunge-cutting. For the complete machining of a contour, therefore, it is always necessary to

change between standard turning tools and plunge-cutting tools.

The aim of the plunge-turning cycle is to reduce the number of tool changes and to avoid

empty cuts, such as those that occur during the backward movement of the turning tool, for

example.

As a general rule, hardly any empty cuts exist during the plunge-turning cycle, as stock

removal is performed during both forward and backward movement. This must be taken into

account during program creation. ShopTurn offers optimum support for this. As you already

know, you only need to describe the contour of the turning part and during the stock removal

cycle you can select whether you wish to perform stock removal using a conventional

procedure or by means of plunge-cutting or plunge-turning. ShopTurn automatically

calculates the cuts and traversing movements of the tool based on the cycle. This means

that empty cuts are eliminated to a great extent.

During the simulation, you can clearly analyze the calculated traversing movements of the

tool. Even a combination of conventional turning machining and plunge-turning is possible,

i.e. a standard tool is used for roughing, while plunge-turning is used for machining residual

material, meaning that the contour can be thoroughly machined without the risk of damage.

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Example 5: Plunge-turning

10.3 Creating the contour

10.3

Creating the contour

Operating sequences

Create the contour without help.

Select the Contour turning softkey.

Select the New contour softkey. Enter the name 'CONTOUR_E' for the contour.

Confirm your input.

Set the starting point to X48/Z0.

Figure 10-3 Specifying the contour starting point

Create a contour (see illustration below).

Figure 10-4 Contour in the contour calculator

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Example 5: Plunge-turning

10.4 Stock removal with the plunge-turning cycle

10.4

Stock removal with the plunge-turning cycle

Operating sequences

In the following work step you will perform contour stock removal.

To this end, proceed as follows:

Select the Contour turning softkey.

Select the Plunge-turning softkey.

Open the tool list and select the PLUNGE_CUTTER_3 A tool.

Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.2

0.25

150 m/min

Machining

longitudinal

external

roughing

2.5

0.2

0.0

Cylinder

50 abs

0 abs

Set machining area limits

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Example 5: Plunge-turning

10.4 Stock removal with the plunge-turning cycle

Roughing the contour

Accept the entered values.

Select the Plunge-turning softkey.

Open the tool list and select the PLUNGE_CUTTER_3 A tool.

Accept the tool into your program.

Enter the following values for finishing in the interactive screenform:

Field

Value

Selection via toggle key

Notes

0.15

200 m/min

Machining

longitudinal

external

finishing

Allowance

Set machining area limits

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And now you can start manufacturing!

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

ShopTurn by working with the examples, we will now machine workpieces.

To machine a workpiece, proceed as follows:

Approaching reference point

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

plans or traversing manually, you will have to approach the reference point of the machine.

In this way, ShopTurn will find the start of counting in the position measuring system of the

machine.

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

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

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

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

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

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

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

machine manufacturer.

Clamping the workpiece

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

your own safety, it is imperative to clamp the workpiece tightly. A three-block chuck is usually

used for this.

Setting the workpiece zero

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

determine the workpiece zero in Z.

The workpiece zero is usually determined through sampling with a calculated tool in the Z

axis.

Executing the process plan

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

can start!

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And now you can start manufacturing!

11.1 And now you can start manufacturing!

Select the NC selection softkey.

Figure 11-3 Executing

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

feedrate potentiometer to zero position to ensure that you keep everything under control

from the beginning.

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

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

Start machining and check the speed of the tool motions using the feedrate potentiometer.

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How accomplished are you in the use of ShopTurn?

12.1

Exercise 1

Will you manage this task using ShopTurn within 10 minutes?

Figure 12-1 Workshop drawing DIYS1

Notes

In the process plan, the workpiece is milled to size in two work steps (see model below). For

this reason, you can assign the the starting point of the CONTOUR_1 contour to the start of

the first chamfer.

Model

Figure 12-2 Process plan

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How accomplished are you in the use of ShopTurn?

12.4 Exercise 4

12.4

Exercise 4

Will you manage this task using ShopTurn within 15 minutes?

Figure 12-13 Workshop drawing DIYS4

Notes

In the process plan, the end face is roughed and finished first (see model below). Then the

entire external area, including the undercut, is produced. Following this, the internal part of

the contour is machined. The starting point of the internal contour is set to X70/Z0. You can

copy the external and internal machining sequences using the work step editor by means of

cut and paste.

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SINUMERIK 840D sl. Training. Operate - Turning (2016-2020) - page 27