Page 1 Easy Extend (828D only) Service Planner (828D only) Valid for Ladder Viewer and Ladder Control System add-on (828D only) SINUMERIK 840D sl/840DE sl/828D Alarms, error messages, and system alarms Software Version CNC software for 840D sl/ 840DE sl/828D 2.6 SP1 with SINUMERIK Operate for PCU/PC 2.6 SP1...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Preface
● Researching documentation online Information on DOConCD and direct access to the publications in DOConWEB. ● Compiling individual documentation on the basis of Siemens contents with the My Documentation Manager (MDM), refer to http://www.siemens.com/mdm. My Documentation Manager provides you with a range of features for generating your own machine documentation.
Page 4 If you have any technical questions, please contact our hotline: Europe/Africa Phone +49 180 5050 222 +49 180 5050 223 0.14 €/min. from German landlines, max. 0.42 €/min for calls from a mobile phone Internet http://www.siemens.com/automation/support-request Americas Phone +1 423 262 2522 +1 423 262 2200 E-mail mailto:[email protected]...
Page 5 Preface Note Country-specific telephone numbers for technical support are provided under the following Internet address: http://www.automation.siemens.com/partner Questions about the manual If you have any queries (suggestions, corrections) in relation to this documentation, please fax or e-mail us: +49 9131- 98 2176 E-mail mailto:[email protected]...
Page 6 Preface Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...
Page 7: Table Of Contents
Table of contents Preface ..............................3 Introduction.............................. 17 Product overview .........................17 Operator panel fronts ........................18 1.2.1 Overview ............................18 1.2.2 Keys of the operator panel......................20 Machine control panels ........................26 1.3.1 Overview ............................26 1.3.2 Controls on the machine control panel ..................26 User interface..........................29 1.4.1 Screen layout ..........................29 1.4.2...
Page 8 Table of contents 2.5.6 Calibrating the electrical tool probe..................... 68 Measuring the workpiece zero ....................69 2.6.1 Overview ............................. 69 2.6.2 Sequence of operations ......................72 2.6.3 Examples with manual swivel ..................... 73 2.6.4 Calibrating the electronic workpiece probe ................. 74 2.6.5 Setting the edge ..........................
Page 9 Table of contents Starting and stopping machining....................135 Selecting a program........................136 Testing a program........................137 Displaying the current program block ..................138 4.4.1 Current block display .........................138 4.4.2 Displaying a basic block......................139 4.4.3 Display program level ........................140 Correcting a program .........................141 Repositioning axes........................142 Starting machining at a specific point ..................143 4.7.1 Use block search ........................143...
Page 10 Table of contents 5.6.2 Showing and hiding the tool path....................185 Program control during the simulation ..................186 5.7.1 Changing the feedrate....................... 186 5.7.2 Simulating the program block by block ..................187 Changing and adapting a simulation graphic................188 5.8.1 Enlarging or reducing the graphical representation ..............
Page 11 Table of contents Call work offsets.........................233 7.10 Repeating program blocks ......................233 7.11 Specifying the number of workpieces ..................235 7.12 Changing program blocks ......................236 7.13 Changing program settings......................237 7.14 Selection of the cycles via softkey .....................238 7.15 Calling technology functions ......................242 7.15.1 Additional functions in the input screens ...................242 7.15.2...
Page 12 Table of contents 8.3.4 Creating contour elements ......................332 8.3.5 Changing the contour........................ 336 8.3.6 Contour call (CYCLE62) - only for G code program ..............337 8.3.7 Path milling (CYCLE72) ......................338 8.3.8 Contour pocket/contour spigot (CYCLE63/64)................342 8.3.9 Predrilling contour pocket (CYCLE64) ..................344 8.3.10 Milling contour pocket (CYCLE63)....................
Page 13 Table of contents 8.7.14 Obstacle .............................434 Multi-channel view ..........................435 Multi-channel view ........................435 Multi-channel view in the "Machine" operating area ..............435 Setting the multi-channel view ....................438 User variables............................441 10.1 Overview ............................441 10.2 R parameters ..........................442 10.3 Global GUD..........................443 10.4 Channel GUD..........................444 10.5 Local LUD ..........................445...
Page 14 Table of contents 12.6 Tool wear........................... 482 12.6.1 Reactivating a tool........................484 12.7 Tool data OEM .......................... 485 12.8 Magazine........................... 486 12.8.1 Positioning a magazine ......................488 12.8.2 Relocating a tool ........................488 12.9 Sorting tool management lists....................490 12.10 Filtering the tool management lists ...................
Page 15 Table of contents Setting up drives ............................ 531 14.1 Overview ............................531 14.2 Setting up drives ........................532 HT 8............................... 535 15.1 HT 8 overview ..........................535 15.2 Traversing keys..........................538 15.3 Machine control panel menu......................539 15.4 Virtual keyboard .........................540 15.5 Calibrating the touch panel ......................542 Easy Message (828D only)........................
Page 16 Table of contents 19.11 Editing block properties......................570 19.12 Inserting and editing networks ....................570 19.13 Editing network properties......................572 19.14 Displaying and editing symbol tables..................573 19.15 Inserting/deleting a symbol table ....................574 19.16 Searching for operands......................575 19.17 Displaying the network symbol information table..............
Page 17: Introduction
Introduction Product overview The SINUMERIK controller is a CNC (Computerized Numerical Controller) for machine tools. You can use the CNC to implement the following basic functions in conjunction with a machine tool: ● Creation and adaptation of part programs ● Execution of part programs ●...
Page 18: Operator Panel Fronts
Introduction 1.2 Operator panel fronts Operator panel fronts 1.2.1 Overview Introduction The display (screen) and operation (e.g. hardkeys and softkeys) of the SINUMERIK Operate user interface use the operator panel front. In this example, the OP 010 operator panel front is used to illustrate the components that are available for operating the controller and machine tool.
Page 19 Introduction 1.2 Operator panel fronts Operator controls and indicators Status LED: POWER Status LED: TEMP (illuminated LEDs indicate increased wear) Alphabetic key group Numerical key group Softkeys Control key group Hotkey group Cursor key group USB interface Menu select key Menu forward button Machine area button Menu back key...
Page 20: Keys Of The Operator Panel
A more precise description as well as a view of the other operator panel fronts that can be used may be found in the following reference: Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl 1.2.2 Keys of the operator panel The following keys and key combinations are available for operation of the control and the machine tool.
Page 21 Introduction 1.2 Operator panel fronts Function Scrolls downwards by one page in a window. + In the program manager and in the program editor, from the cursor position, selects directories or program blocks up to the end of the window.
Page 22 Introduction 1.2 Operator panel fronts Function  Editing box Moves the cursor into the next upper field.  Navigation – Moves the cursor in a table to the next cell upwards. – Moves the cursor upwards in a menu screen. ...
Page 23 Introduction 1.2 Operator panel fronts Function + Moves the cursor to the last entry. + Moves the cursor to the last entry in the last line of the actual column.  Editing box Deletes a character selected to the left of the cursor. ...
Page 24 Introduction 1.2 Operator panel fronts Function + Reactivates changes that were undone (only in the program editor). + Inserts text from the clipboard:  Pastes the text from the clipboard at the actual cursor position.  Pastes text from the clipboard at the position of a selected text.
Page 25 Introduction 1.2 Operator panel fronts Function  Opens an editing window in the insert mode. Press the key again, exits the window and the entries are undone.  Opens a selection box and shows the selection options.  Completes input of a value in the entry field. ...
Page 26: Machine Control Panels
1.3.1 Overview The machine tool can be equipped with a machine control panel by Siemens or with a specific machine control panel from the machine manufacturer. You use the machine control panel to initiate actions on the machine tool such as traversing an axis or starting the machining of a workpiece.
Page 27 Introduction 1.3 Machine control panels Machine manufacturer For additional responses to pressing the Emergency Stop button, please refer to the machine manufacturer's instructions. Installation locations for control devices (d = 16 mm) RESET Stop processing the current programs.  The NCK control remains synchronized with the machine. It is in its initial state and ready for a new program run.
Page 28 Introduction 1.3 Machine control panels Machine manufacturer A machine data code defines how the increment value is interpreted. Customer keys T1 to T15 Traversal axes with rapid traverse superposition and coordinate exchange Axis keys Selects an axis. Direction keys Select the traversing direction. ...
Page 29: User Interface
Introduction 1.4 User interface User interface 1.4.1 Screen layout Overview Active operating area and mode Alarm/message line Program name Channel state and program control Channel operational messages Axis position display in actual value window Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...
Page 30: Status Display
Introduction 1.4 User interface Display for active tool T  current feedrate F  active spindle with current status (S)  Spindle utilization rate in percent  Operating window with program block display Display of active G functions, all G functions, auxiliary functions and input window for different functions (for example, skip blocks, program control).
Page 31 Introduction 1.4 User interface Display Description "Diagnosis" operating area "Start-up" operating area Active mode or submode "Jog" mode "MDA" mode "Auto" mode "Teach In" submode "Repos" submode "Ref Point" submode Alarms and messages Alarm display The alarm numbers are displayed in white lettering on a red background.
Page 32 Introduction 1.4 User interface Second line Display Description Program path and program name The displays in the second line can be configured. Machine manufacturer Please also refer to the machine manufacturer's instructions. Third line Display Description Display of channel status. If several channels are present on the machine, the channel name is also displayed.
Page 33: Actual Value Window
Introduction 1.4 User interface 1.4.3 Actual value window The actual values of the axes and their positions are displayed. Work/Machine The displayed coordinates are based on either the machine coordinate system or the workpiece coordinate system. The machine coordinate system (Machine), in contrast to the workpiece coordinate system (Work), does not take any work offsets into consideration.
Page 34: T,F,S Window
Introduction 1.4 User interface See also Overview (Page 69) Work offsets (Page 100) 1.4.4 T,F,S window The most important data concerning the current tool, the feedrate (path feed or axis feed in JOG) and the spindle are displayed in the T, F, and S windows. Tool data Display Meaning...
Page 35: Current Block Display
Introduction 1.4 User interface Spindle data Display Meaning Spindle selection, identification with spindle number and main spindle Speed Actual value (when spindle turns, display increases) Setpoint (always displayed, also during positioning) Symbol Spindle status Spindle not enabled Spindle is turning clockwise Spindle is turning counterclockwise Spindle is stationary Override...
Page 36: Operation Via Softkeys And Buttons
Introduction 1.4 User interface 1.4.6 Operation via softkeys and buttons Operating areas/operating modes The user interface consists of different windows featuring eight horizontal and eight vertical softkeys. You operate the softkeys with the keys next to the softkey bars. You can display a new window or execute functions using the softkeys. The operating software is sub-divided into six operating areas (machine, parameter, program, program manager, diagnosis, startup) and five operating modes or submodes (JOG, MDA, AUTO, TEACH IN, REF POINT, REPOS).
Page 37: Entering Or Selecting Parameters
Introduction 1.4 User interface Use the "Return" softkey to close an open window. Use the "Cancel" softkey to exit a window without accepting the entered values and return to the next highest window. When you have entered all the necessary parameters in the parameter screen form correctly, you can close the window and save the parameters using the "Accept"...
Page 38 Introduction 1.4 User interface Press the key. The selection options are displayed in a list. Select the required setting using the and keys. If required, enter a value in the associated input field. Press the key to complete the parameter input. Changing or calculating parameters If you only want to change individual characters in an input field rather than overwriting the entire entry, switch to insertion mode.
Page 39 Introduction 1.4 User interface + Enter the division character using the + keys. Enter bracket expressions using the + <(> and + <)> keys. + <)> Enter "r" or "R" as well as the number x from which you would like to ...
Page 40: Pocket Calculator
Introduction 1.4 User interface 1.4.8 Pocket calculator You can use the pocket calculator to quickly calculate parameter values during programming. If, for example, the diameter of a workpiece is only dimensioned indirectly in the workpiece drawing, i.e., the diameter must be derived from the sum of several other dimension specifications, you can calculate the diameter directly in the input field of this parameter.
Page 41: Context Menu
Introduction 1.4 User interface Press the "Calculate" softkey. - OR - Press the key. The new value is calculated and displayed in the input field of the pocket calculator. Press the "Accept" softkey. The calculated value is accepted and displayed in the input field of the window.
Page 42: Touch Operation
Introduction 1.4 User interface 1.4.10 Touch operation If you have an operator panel with a touch screen, you can perform the following functions with touch operation: Operating area switchover You can display the operating area menu by touching the display symbol for the active operating area in the status display.
Page 43: Entering Asian Characters
Introduction 1.4 User interface Note Changing the language directly on the input screens You can switch between the user interface languages available on the controller directly on the user interface by pressing the key combination . 1.4.12 Entering Asian characters You have the possibility of entering Asian characters.
Page 44 Introduction 1.4 User interface Precondition The control has been set to Chinese or Korean. Procedure Editing characters Open the screen form and position the cursor on the entry field and press the keys. The editor is displayed. Enter the desired phonetic notation. Click the ...
Page 45: Protection Levels
● Work offsets ● Setting data ● Program creation / program editing References For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Softkeys Machine operating area Protection level End user (protection level 3)
Page 46 Introduction 1.4 User interface Diagnostics operating area Protection level Manufacturer (protection level 1) End user (protection level 3) Service (protection level 2) Startup operating area Protection levels End user (protection level 3) Keyswitch 3 (protection level 4) Keyswitch 3 (protection level 4) Key switch 3 (protection level 4) Keyswitch 3...
Page 47: Online Help In Sinumerik Operate
Introduction 1.4 User interface 1.4.14 Online help in SINUMERIK Operate A comprehensive context-sensitive online help is stored in the control system. ● A brief description is provided for each window and, if required, step-by-step instructions for the operating sequences. ● A detailed help is provided in the editor for every entered G code. You can also display all G functions and take over a selected command directly from the help into the editor.
Page 48 Introduction 1.4 User interface Calling a topic in the table of contents Press the "Table of contents" softkey. Depending on which technology you are using, the Operating Manuals "Operator control Milling", "Operator control Turning" or "Operator control Universal" as well as the "Programming" Programming Manual are displayed.
Page 49 Introduction 1.4 User interface Displaying alarm descriptions and machine data If messages or alarms are pending in the "Alarms", "Messages" or "Alarm Log" window, position the cursor at the appropriate display and press the or the key. The associated alarm description is displayed. If you are in the "Startup"...
Page 50 Introduction 1.4 User interface Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...
Page 51: Setting Up The Machine
Setting up the machine Switching on and switching off Start-up When the control starts up, the main screen opens according to the operating mode specified by the machine manufacturer. In general, this is the main screen for the "REF POINT" submode. Machine manufacturer Please also refer to the machine manufacturer's instructions.
Page 52: Approaching A Reference Point
Setting up the machine 2.2 Approaching a reference point Approaching a reference point 2.2.1 Referencing axes Your machine tool can be equipped with an absolute or incremental path measuring system. An axis with incremental path measuring system must be referenced after the control has been switched-on –...
Page 53: User Agreement
Setting up the machine 2.2 Approaching a reference point Select the axis to be traversed. Press the <-> or <+> key. The selected axis moves to the reference point. If you have pressed the wrong direction key, the action is not accepted and the axes do not move.
Page 54 Setting up the machine 2.2 Approaching a reference point Select the axis to be traversed. Press the <-> or <+> key. The selected axis moves to the reference point and stops. The coordinate of the reference point is displayed. The axis is marked with Press the "User enable"...
Page 55: Operating Modes
Setting up the machine 2.3 Operating modes Operating modes 2.3.1 General You can work in three different operating modes. "JOG" mode "JOG" mode is used for the following preparatory actions: ● Approach reference point, i.e. the machine axis is referenced ●...
Page 56 Setting up the machine 2.3 Operating modes Selecting "Repos" Press the key. "MDA" mode (Manual Data Automatic) In "MDA" mode, you can enter and execute G code commands non-modally to set up the machine or to perform a single action. Selecting "MDA"...
Page 57: Modes Groups And Channels
Setting up the machine 2.3 Operating modes 2.3.2 Modes groups and channels Every channel behaves like an independent NC. A maximum of one part program can be processed per channel. ● Control with 1channel One mode group exists. ● Control with several channels Channels can be grouped to form several "mode groups."...
Page 58: Settings For The Machine
Another channel can be selected by pressing one of the other softkeys. References Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Channel switchover via touch operation On the HT 8 and when using a touch screen operating panel, you can switch to the next channel via touch operation in the status display.
Page 59: Switching The Unit Of Measurement
Setting up the machine 2.4 Settings for the machine 2.4.2 Switching the unit of measurement You can set millimeters or inches as the unit of measurement. Switching the unit of measurement always applies to the entire machine. All required information is automatically converted to the new unit of measurement, for example: ●...
Page 60: Setting The Work Offset
Setting up the machine 2.4 Settings for the machine 2.4.3 Setting the work offset You can enter a new position value in the actual value display for individual axes when a settable work offset is active. The difference between the position value in the machine coordinate system MCS and the new position value in the workpiece coordinate system WCS is saved permanently in the currently active work offset (e.g.
Page 61 Setting up the machine 2.4 Settings for the machine Resetting the actual value Press the "Delete active WO" softkey. The offset is deleted permanently. NOTICE Irreversible active work offset The current active work offset is irreversibly deleted by this action. Relative actual value Press the "REL actual values"...
Page 62: Measuring The Tool
Setting up the machine 2.5 Measuring the tool Measuring the tool The geometries of the machining tool must be taken into consideration when executing a part program. These are stored as tool offset data in the tool list. Each time the tool is called, the control considers the tool offset data.
Page 63: Measuring The Tool Length With The Workpiece As Reference Point
Setting up the machine 2.5 Measuring the tool 2.5.2 Measuring the tool length with the workpiece as reference point Procedure Insert the tool you want to measure in the spindle. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" and "Length manual" softkeys. The "Length Manual"...
Page 64: Measuring Radius Or Diameter
Setting up the machine 2.5 Measuring the tool 2.5.3 Measuring radius or diameter Procedure Insert the tool you want to measure in the spindle. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" softkey. Press the "Radius manual" or "Diam. manual" softkey. Select the cutting edge number D and the the number of the replacement tool ST.
Page 65: Fixed Point Calibration
Setting up the machine 2.5 Measuring the tool 2.5.4 Fixed point calibration If you want to use a fixed point as the reference point in manual measurement of the tool length, you must first determine the position of the fixed point relative to the machine zero. Test socket You can use a mechanical test socket as the fixed point, for example.
Page 66: Measuring A Tool With An Electrical Tool Probe
Setting up the machine 2.5 Measuring the tool 2.5.5 Measuring a tool with an electrical tool probe For automatic measurement, you determine the length and radius or diameter of the tool with the aid of a tool probe (table contact system). The control uses the known positions of the toolholder reference point and tool probe to calculate the tool offset data.
Page 67 Setting up the machine 2.5 Measuring the tool Procedure Insert the tool that you want to measure. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" softkey. Press the "Length auto" softkey if you want to measure the length of the tool.
Page 68: Calibrating The Electrical Tool Probe
Setting up the machine 2.5 Measuring the tool 2.5.6 Calibrating the electrical tool probe If you want to measure your tools automatically, you must first determine the position of the tool probe on the machine table with reference to the machine zero. Tool probes are typically shaped like a cube or a cylindrical disk.
Page 69: Measuring The Workpiece Zero
Setting up the machine 2.6 Measuring the workpiece zero Measuring the workpiece zero 2.6.1 Overview The reference point for programming a workpiece is always the workpiece zero. You can determine the workpiece zero on the following workpiece elements: ● Edges, (Page 78) ●...
Page 70 Information on user-specific settings is provided in the Chapter "Measuring in the JOG mode". Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Selecting the measuring plane The measuring plane (G17,18,19) can be selected to flexibly adapt to measuring tasks. If the measuring plane selection is not activated, then the measurement is performed based on the currently active measuring plane.
Page 71 Setting up the machine 2.6 Measuring the workpiece zero Selecting the work offset as basis for the measurement A work offset can be selected as measurement basis to flexibly adapt to the measuring tasks. If the work offset selection as measurement basis is not activated, then the measurement refers to the currently active work offset.
Page 72: Sequence Of Operations
Setting up the machine 2.6 Measuring the workpiece zero You are supported by one or two activation windows when you position the rotary axes (see Corrections after measuring the zero point (Page 98)"). You can only select "Rotary axis " for the "Angle corr." parameter, if your machine has rotary axes.
Page 73: Examples With Manual Swivel
Setting up the machine 2.6 Measuring the workpiece zero 2.6.3 Examples with manual swivel Two typical examples demonstrate the interaction and the use of "Measure workpiece" and "Manual swivel" when measuring and aligning workpieces. First example The following steps are required when remachining a cylinder head with 2 holes on an inclined plane.
Page 74: Calibrating The Electronic Workpiece Probe
Setting up the machine 2.6 Measuring the workpiece zero 3. Manual swivel With "direct" swiveling enter the required rotary axis positions or with "axis by axis" the required rotations (e.g. Y=-90) and . 4. Measure workpiece Apply "Set edge Z": The measured offset in Z is converted and entered as an X value in the chosen work offset.
Page 75 Setting up the machine 2.6 Measuring the workpiece zero When calibrating the length of the workpiece probe in Z0, enter the reference point of the surface based on the active work offset (e.g. of the workpiece or the machine table). When calibrating the probe ball radius, enter a ∅...
Page 76: Setting The Edge
Setting up the machine 2.6 Measuring the workpiece zero 2.6.5 Setting the edge The workpiece lies parallel to the coordinate system on the work table. You measure one reference point in one of the axes (X, Y, Z). Precondition You can insert any tool in the spindle for scratching when measuring the workpiece zero manually.
Page 77 Setting up the machine 2.6 Measuring the workpiece zero Press the "Select WO" softkey to select an adjustable work offset. In the window "Work offset – G54 ... G599", select a work offset, in which the zero point should be saved and press the "In manual" softkey.
Page 78: Edge Measurement
Setting up the machine 2.6 Measuring the workpiece zero 2.6.6 Edge measurement The following options are available to you when measuring an edge: Aligning the edge The workpiece lies in any direction, i.e. not parallel to the coordinate system on the work table.
Page 79 Setting up the machine 2.6 Measuring the workpiece zero - OR - In the selection box, select the desired work offset in which you want to store the zero point. - OR - Press the "Select WO" softkey to select an adjustable work offset. In the window "Work offset –...
Page 80: Measuring A Corner
Setting up the machine 2.6 Measuring the workpiece zero Automatic measurement Prepare the measurement (see steps 1 to 5 above). Traverse the workpiece probe close to the workpiece edge on which you wish to measure and press the key. This starts the automatic measuring process.
Page 81 Setting up the machine 2.6 Measuring the workpiece zero Precondition You can insert any tool in the spindle for scratching when measuring the workpiece zero manually. - OR - An electronic workpiece probe is inserted in the spindle and activated when measuring the workpiece zero automatically.
Page 82 Setting up the machine 2.6 Measuring the workpiece zero Press the "Select WO" softkey to select an adjustable work offset. In the window "Work offset – G54 ... G599", select a work offset, in which the zero point should be saved and press the "In manual" softkey.
Page 83: Measuring A Pocket And Hole
Setting up the machine 2.6 Measuring the workpiece zero Automatic measurement Prepare the measurement (see steps 1 to 6 above). Approach measuring point P1 with the workpiece probe and press the key. This starts the automatic measuring process. The position of measuring point 1 is measured and stored.
Page 84 Setting up the machine 2.6 Measuring the workpiece zero Measuring 3 holes The workpiece with the three holes to be measured is clamped to the work table in any position. 4 points are automatically measured in the three holes and the hole centers are calculated from them.
Page 85 Setting up the machine 2.6 Measuring the workpiece zero Procedure Select the "Machine" operating area and press the key. Press the "Workpiece zero" softkey. Press the "Rectangular pocket" softkey. - OR - Press the "1 hole" softkey. - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired measurement version.
Page 86 Setting up the machine 2.6 Measuring the workpiece zero Repeat steps 6 and 7 to measure and store measuring points P2, P3 and P4. Press the "Calculate" softkey. The length, width, and center point of the rectangular pocket or diameter and center point of the hole are calculated and displayed. - OR - Press the "Set WO"...
Page 87 Setting up the machine 2.6 Measuring the workpiece zero - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired measurement version. Traverse the workpiece probe to approximately the center above the rectangular pocket or the hole or for several, above the first hole to be measured.
Page 88 Setting up the machine 2.6 Measuring the workpiece zero  If you do not make any entry in the entry field "Øhole", then the 3 holes axis moves with the measuring feed from the starting point. If the measuring stroke does not reach the edge of the hole, then the approximate diameter must be entered.
Page 89 Setting up the machine 2.6 Measuring the workpiece zero Press the "Calculate" or "Set WO" softkey. Rectangular The length, width, and center point of the rectangular pocket are pocket calculated and displayed. For "Set WO", the setpoint position of the center point is stored as new zero point.
Page 90: Measuring A Spigot
Setting up the machine 2.6 Measuring the workpiece zero 2.6.9 Measuring a spigot You have the option to measure and align rectangular spigots, and one or more circular spigots. Measuring a rectangular spigot The rectangular spigot should be aligned at right-angles to the coordinate system. By measuring four points at the spigot you can determine the length, width, and center point of the spigot.
Page 91 Setting up the machine 2.6 Measuring the workpiece zero Precondition You can insert any tool in the spindle for scratching when measuring the workpiece zero manually. An electronic workpiece probe is inserted in the spindle and activated when measuring the workpiece zero automatically.
Page 92 Setting up the machine 2.6 Measuring the workpiece zero Press the "Save P1" softkey. The point is measured and stored. Repeat steps 6 and 7 to measure and store measuring points P2, P3 and P4. Press the "Calculate" softkey. The diameter and center point of the spigot are calculated and displayed.
Page 93 Setting up the machine 2.6 Measuring the workpiece zero Press the "4 circular spigots" softkey. - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired measurement version.
Page 94 Setting up the machine 2.6 Measuring the workpiece zero  Enter the approximate diameter of the spigot into "Øspigot". 4 circular spigots  Enter the infeed value in "DZ" to determine the measuring depth.  In "Angle offs.", select entry "Yes" if you want to align using coordinate rotation or select in "Angle offs."...
Page 95: Aligning The Plane
Setting up the machine 2.6 Measuring the workpiece zero 2 spigots The angle between the line connecting the center points and the reference axis is calculated and displayed. For "Set WO", the center point of the first spigot now corresponds to the position setpoint.
Page 96 Setting up the machine 2.6 Measuring the workpiece zero Procedure Select the "Machine" operating area and press the key. Press the "Workpiece zero" and "Align plane" softkeys. The "Align plane" window opens. Select "Measuring only" if you only want to display the measured values.
Page 97: Defining The Measurement Function Selection
Setting up the machine 2.6 Measuring the workpiece zero Then traverse the tool to the second and third measuring point and press the "Save P2" and "Save P3" softkeys. Press the "Set WO" or "Calculate" softkey. Angles α and β are calculated and displayed. For "Set WO"...
Page 98: Corrections After Measurement Of The Zero Point
Setting up the machine 2.6 Measuring the workpiece zero Open the list of measurement versions, select the desired measurement version using the and the keys. - OR - Using the key. Selecting an axis also activates the handwheel (e.g., "X" is assigned to handwheel no. 1 and is activated immediately). Press the "Handwheel"...
Page 113: Mda
Setting up the machine 2.11 MDA 2.11 In "MDA" mode (Manual Data Automatic mode), you can enter G-code commands block-by- block and immediately execute them for setting up the machine. You can load an MDA program straight from the Program Manager into the MDA buffer. You may also store programs which were rendered or changed in the MDA operating window into any directory of the Program Manager.
Page 114: Saving An Mda Program
Setting up the machine 2.11 MDA 2.11.2 Saving an MDA program Proceed as follows Select the "Machine" operating area. Press the key. The MDA editor opens. Create the MDA program by entering the G-code commands using the operator's keyboard. Press the "Store MDA"...
Page 115: Executing An Mda Program
Setting up the machine 2.11 MDA 2.11.3 Executing an MDA program Proceed as follows Select the "Machine" operating area. Press the key. The MDA editor opens. Input the desired G-code commands using the operator’s keyboard. Press the key. The control executes the input blocks.
Page 116: Deleting An Mda Program
Setting up the machine 2.11 MDA 2.11.4 Deleting an MDA program Precondition The MDA editor contains a program that you created in the MDI window or loaded from the program manager. Procedure Press the "Delete blocks" softkey. The program displayed in the program window is deleted. Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...
Page 117: Execution In Manual Mode
Execution in manual mode General Always use "JOG" mode when you want to set up the machine for the execution of a program or to carry out simple traversing movements on the machine: ● Synchronize the measuring system of the controller with the machine (reference point approach) ●...
Page 118 Execution in manual mode 3.2 Selecting a tool and spindle Display Meaning Input of the tool (name or location number) You can select a tool from the tool list using the "Select tool" softkey. Cutting edge number of the tool (1 - 9) Spindle Spindle selection, identification with spindle number Spindle M function...
Page 119: Selecting A Tool
Execution in manual mode 3.2 Selecting a tool and spindle 3.2.2 Selecting a tool Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Enter the name or the number of the tool T in the input field. - OR - Press the "Select tool"...
Page 120: Starting And Stopping A Spindle Manually
Execution in manual mode 3.2 Selecting a tool and spindle 3.2.3 Starting and stopping a spindle manually Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Select the desired spindle (e.g. S1) and enter the desired spindle speed (rpm) in the adjacent input field.
Page 121: Position Spindle
Execution in manual mode 3.2 Selecting a tool and spindle 3.2.4 Position spindle Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Select the "Stop Pos." setting in the "Spindle M function" field. The "Stop Pos." entry field appears. Enter the desired spindle stop position.
Page 122: Traversing Axes
Execution in manual mode 3.3 Traversing axes Traversing axes You can traverse the axes in manual mode via the Increment or Axis keys or handwheels. During a traverse initiated from the keyboard, the selected axis moves at the programmed setup feedrate. During an incremental traverse, the selected axis traverses a specified increment.
Page 123 Execution in manual mode 3.3 Traversing axes Press keys 1, 10, etc. up to 10000 in order to move the axis in a defined increment. The numbers on the keys indicate the traverse path in micrometers or micro-inches. Example: Press the "100" button for a desired increment of 100 μm (= 0.1 mm).
Page 124: Traversing Axes By A Variable Increment
Execution in manual mode 3.3 Traversing axes 3.3.2 Traversing axes by a variable increment Procedure Select the "Machine" operating area. Press the key. Press the "Settings" softkey. The "Settings for manual operation" window is opened. Enter the desired value for the "Variable increment" parameter. Example: Enter 500 for a desired increment of 500 μm (0.5 mm).
Page 125: Positioning Axes
Execution in manual mode 3.4 Positioning axes Positioning axes In manual mode, you can traverse individual or several axes to certain positions in order to implement simple machining sequences. The feedrate / rapid traverse override is active during traversing. Procedure If required, select a tool.
Page 126: Swiveling
Execution in manual mode 3.5 Swiveling Swiveling Manual swivel in the JOG mode provides functions that make it far easier to setup, measure, and machine workpieces with swiveled surfaces. If you want to create or correct an inclined position, the required rotations of the workpiece coordinate system around the geometry axes (X, Y, Z) are automatically converted into suitable positions of the machine kinematics.
Page 127 Execution in manual mode 3.5 Swiveling ● Swivel plane You can start the swivel plane as "new" or "additive" to a swivel plane that is already active. ● Swivel mode Swiveling can be axis by axis or direct. – Axis-by-axis swiveling is based on the coordinate system of the workpiece (X, Y, Z). The coordinate axis sequence can be selected freely.
Page 128 Execution in manual mode 3.5 Swiveling ● Zero plane The zero plane corresponds to the tool plane (G17, G18, G19) including the active work offset (G500, G54, ...). Rotations of the active work offset and the rotary axes are taken into account for manual swiveling.
Page 129 Execution in manual mode 3.5 Swiveling Press the "Basic setting" softkey and the key to move the machine into the initial position. If the actual work offset does not include a rotation, then the rotary axes of the swivel data set are moved to zero. The tool is located vertically to the machining plane.
Page 130: Simple Face Milling Of Workpiece
Execution in manual mode 3.6 Simple face milling of workpiece Parameter Description Unit Direction Preferred direction of rotation for 2 alternatives (swiveling axis-by-axis) +: Larger angle of the axis on the scale of the swivel head / swivel table -: Smaller angle of the axis on the scale of the swivel head / swivel table Tool Correction: The position of the tool tip is maintained during swiveling No correction: The position of the tool tip changes during swiveling...
Page 131 Execution in manual mode 3.6 Simple face milling of workpiece Procedure Select the "Machine" operating area. Press the key. Press the softkey. Press the relevant softkey to specify the lateral limitations of the workpiece. Select the machining type (e.g. roughing) in the "Machining" field. Select the machining direction in the "Direction"...
Page 132 Execution in manual mode 3.6 Simple face milling of workpiece Parameters Description Unit Machining The following machining operations can be selected: ∇ (roughing)  ∇∇∇ (finishing)  Direction Same direction of machining   Alternating direction of machining   Corner point 1 of surface in X direction (abs.
Page 133: Default Settings For Manual Mode
Execution in manual mode 3.7 Default settings for manual mode Default settings for manual mode Specify the configurations for manual mode in the "Settings for manual operation" window. Presettings Settings Description Type of feedrate Here, you select the type of feedrate. G94: Axis feedrate/linear feedrate ...
Page 134 Execution in manual mode 3.7 Default settings for manual mode Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...
Page 135: Machining The Workpiece
Machining the workpiece Starting and stopping machining During execution of a program, the workpiece is machined in accordance with the programming on the machine. After the program is started in automatic mode, workpiece machining is performed automatically. Requirements The following requirements must be met before executing a program: ●...
Page 136: Selecting A Program
Machining the workpiece 4.2 Selecting a program Stopping machining Press the key. Machining stops immediately. Individual program blocks are not executed to the end. On the next start, machining is resumed from the point where it left off. Canceling machining Press the ...
Page 137: Testing A Program
Machining the workpiece 4.3 Testing a program Testing a program When testing a program, the system can interrupt the machining of the workpiece after each program block, which triggers a movement or auxiliary function on the machine. In this way, you can control the machining result block-by-block during the initial execution of a program on the machine.
Page 138: Displaying The Current Program Block
Machining the workpiece 4.4 Displaying the current program block Press the key again, if the machining is not supposed to run block-by-block. The key is deselected again. If you now press the key again, the program is executed to the end without interruption.
Page 139: Displaying A Basic Block
Machining the workpiece 4.4 Displaying the current program block 4.4.2 Displaying a basic block If you want precise information about axis positions and important G functions during testing or program execution, you can call up the basic block display. This is how you can check, when using cycles, for example, whether the machine is actually traversing.
Page 140: Display Program Level
Machining the workpiece 4.4 Displaying the current program block 4.4.3 Display program level You can display the current program level during the execution of a large program with several subprograms. Several program run throughs If you have programmed several program run throughs, i.e. subprograms are run through several times one after the other by specifying the additional parameter P, then during processing, the program runs still to be executed are displayed in the "Program Levels"...
Page 141: Correcting A Program
Machining the workpiece 4.5 Correcting a program Correcting a program As soon as a syntax error in the part program is detected by the controller, program execution is interrupted and the syntax error is displayed in the alarm line. Correction possibilities Depending on the state of the control system, you can make the following corrections using the Program editing function.
Page 142: Repositioning Axes
Machining the workpiece 4.6 Repositioning axes Repositioning axes After a program interruption in automatic mode (e.g. after a tool breaks) you can move the tool away from the contour in manual mode. The coordinates of the interrupt position will be saved. The distances traversed in manual mode are displayed in the actual value window.
Page 143: Starting Machining At A Specific Point
Machining the workpiece 4.7 Starting machining at a specific point Starting machining at a specific point 4.7.1 Use block search If you would only like to perform a certain section of a program on the machine, then you need not start the program from the beginning. You can also start the program from a specified program block.
Page 144 Machining the workpiece 4.7 Starting machining at a specific point Cascaded search You can start another search from the "Search target found" state. The cascading can be continued any number of times after every search target found. Note Another cascaded block search can be started from the stopped program execution only if the search target has been found.
Page 145: Continuing Program From Search Target
Machining the workpiece 4.7 Starting machining at a specific point 4.7.2 Continuing program from search target To continue the program at the desired position, press the key twice. ● The first CYCLE START outputs the auxiliary functions collected during the search. The program is then in the Stop state.
Page 146: Defining An Interruption Point As Search Target
Machining the workpiece 4.7 Starting machining at a specific point 4.7.4 Defining an interruption point as search target Precondition A program was selected in "AUTO" mode and interrupted during execution through CYCLE STOP or RESET. Software option You require the "Extended operator functions" option (only for 828D). Procedure Press the "Block search"...
Page 147: Entering The Search Target Via Search Pointer
Machining the workpiece 4.7 Starting machining at a specific point 4.7.5 Entering the search target via search pointer Enter the program point which you would like to proceed to in the "Search Pointer" window. Software option You require the "Extended operator functions" option for the "Search pointer" function (only for 828D).
Page 148: Parameters For Block Search In The Search Pointer
Machining the workpiece 4.7 Starting machining at a specific point Note Interruption point You can load the interruption point in search pointer mode. 4.7.6 Parameters for block search in the search pointer Parameter Meaning Number of program level Program: The name of the main program is automatically entered Ext: File extension Pass counter...
Page 149: Block Search Mode
Machining the workpiece 4.7 Starting machining at a specific point 4.7.7 Block search mode Set the desired search variant in the "Search Mode" window. The set mode is retained when the the controller is shut down. When you activate the "Search"...
Page 150 Machining the workpiece 4.7 Starting machining at a specific point References For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Procedure Select the "Machine" operating area. Press the key. Press the "Block search" and "Block search mode" softkeys.
Page 151: Intervening In The Program Sequence
Machining the workpiece 4.8 Intervening in the program sequence Intervening in the program sequence 4.8.1 Program control You can change the program sequence in the "AUTO" and "MDA" modes. Abbreviation/program Scope control The program is started and executed with auxiliary function outputs and dwell times. In this mode, the axes are not traversed.
Page 152 Machining the workpiece 4.8 Intervening in the program sequence Activating program control You can control the program sequence however you wish by selecting and clearing the relevant check boxes. Display / response of active program controls: If a program control is activated, the abbreviation of the corresponding function appears in the status display as response.
Page 153: Skip Blocks
Machining the workpiece 4.8 Intervening in the program sequence 4.8.2 Skip blocks It is possible to skip program blocks, which are not to be executed every time the program runs. The skip blocks are identified by placing a "/" (forward slash) or "/x (x = number of skip level) character in front of the block number.
Page 154: Overstore
Machining the workpiece 4.9 Overstore Overstore With overstore, you have the option of executing technological parameters (for example, auxiliary functions, axis feed, spindle speed, programmable instructions, etc.) before the program is actually started. The program instructions act as if they are located in a normal part program.
Page 155 Machining the workpiece 4.9 Overstore Press the key. The blocks you have entered are stored. You can observe execution in the "Overstore" window. After the entered blocks have been executed, you can append blocks again. You cannot change the operating mode while you are in overstore mode.
Page 156: Editing A Program
Machining the workpiece 4.10 Editing a program 4.10 Editing a program With the editor, you are able to render, supplement, or change part programs. Note The maximum block length is 512 characters. Calling the editor ● The editor is started via the "Program correction" function in the "Machine" operating area.
Page 157: Searching In Programs
Machining the workpiece 4.10 Editing a program 4.10.1 Searching in programs You can use the search function to quickly arrive at points where you would like to make changes, e.g. in very large programs. Precondition The desired program is opened in the editor. Procedure Press the "Search"...
Page 158: Replacing Program Text
Machining the workpiece 4.10 Editing a program 4.10.2 Replacing program text You can find and replace text in one step. Requirement The desired program is opened in the editor. Proceed as follows Press the "Search" softkey. A new vertical softkey bar appears. Press the "Find + replace"...
Page 159: Copying/Pasting/Deleting A Program Block
Machining the workpiece 4.10 Editing a program 4.10.3 Copying/pasting/deleting a program block Precondition The program is opened in the editor. Procedure Press the "Mark" softkey. - OR - Press the or key. - OR - Double-click the program. The selected program is opened in the "Program" operating area. Press the "Simulation" softkey. The program execution is displayed graphically on the screen. The machine axes do not move.
Page 181: Simultaneous Recording Before Machining Of The Workpiece
Simulating machining 5.3 Simultaneous recording before machining of the workpiece Simultaneous recording before machining of the workpiece Before machining the workpiece on the machine, you can graphically display the execution of the program on the screen to monitor the result of the programming. Software option You require the option "Simultaneous recording (real-time simulation)"...
Page 182: Simultaneous Recording During Machining Of The Workpiece
Simulating machining 5.4 Simultaneous recording during machining of the workpiece Simultaneous recording during machining of the workpiece If the view of the work space is blocked by coolant, for example, while the workpiece is being machined, you can also track the program execution on the screen. Software option You require the option "Simultaneous recording (real-time simulation)"...
Page 183: Different Views Of A Workpiece
Simulating machining 5.5 Different views of a workpiece Different views of a workpiece In the graphical display, you can choose between different views so that you constantly have the best view of the current workpiece machining, or in order to display details or the overall view of the finished workpiece.
Page 184: Side Views
Simulating machining 5.5 Different views of a workpiece Displaying and moving cutting planes You can display and move cutting planes X, Y, and Z. See also Defining cutting planes (Page 192) 5.5.3 Side views Starting the simulation. Press the "Other views" softkey. Press the "From front"...
Page 185: Editing The Simulation Display
Simulating machining 5.6 Editing the simulation display Editing the simulation display 5.6.1 Entering blank details You have the option of replacing the blank defined in the program or to define a blank for programs in which a blank definition cannot be inserted. Note The unmachined part can only be entered if simulation or simultaneous recording is in the reset state.
Page 186: Program Control During The Simulation
Simulating machining 5.7 Program control during the simulation Program control during the simulation 5.7.1 Changing the feedrate You can change the feedrate at any time during the simulation. You can track the changes in the status line. Note If you are working with the "Simultaneous recording" function, the rotary switch (override) on the control panel is used.
Page 187: Simulating The Program Block By Block
Simulating machining 5.7 Program control during the simulation 5.7.2 Simulating the program block by block You can control the program execution during simulation, i.e. execute a program block by block, as when executing a program. Procedure Simulation is started. Press the "Program control" and "Single block" softkeys. Press the "Back"...
Page 188: Changing And Adapting A Simulation Graphic
Simulating machining 5.8 Changing and adapting a simulation graphic Press the and keys simultaneously to enable and disable the single block mode. Changing and adapting a simulation graphic 5.8.1 Enlarging or reducing the graphical representation Precondition The simulation or the simultaneous recording is started. Procedure Press the <+>...

Page 189: Panning A Graphical Representation
Simulating machining 5.8 Changing and adapting a simulation graphic Press the "Details" and "Auto zoom" softkeys if you wish to automatically adapt the segment to the size of the window. The automatic scaling function "Fit to size" takes account of the largest expansion of the workpiece in the individual axes.

Page 190: Rotating The Graphical Representation
Simulating machining 5.8 Changing and adapting a simulation graphic 5.8.3 Rotating the graphical representation In the 3D view you can rotate the position of the workpiece to view it from all sides. Precondition Simulation has been started and the 3D view is selected. Procedure Press the "Details"...

Page 191: Modifying The Viewport
Simulating machining 5.8 Changing and adapting a simulation graphic 5.8.4 Modifying the viewport If you would like to move, enlarge or decrease the size of the segment of the graphical display, e.g. to view details or display the complete workpiece, use the magnifying glass. Using the magnifying glass, you can define your own segment and then increase or decrease its size.

Page 192: Defining Cutting Planes
Simulating machining 5.8 Changing and adapting a simulation graphic 5.8.5 Defining cutting planes In the 3D view, you have the option of "cutting" the workpiece and therefore displaying certain views in order to show hidden contours. Precondition The simulation or the simultaneous recording is started. Procedure Press the "Details"...

Page 193: Displaying Simulation Alarms
Simulating machining 5.9 Displaying simulation alarms Displaying simulation alarms Alarms might occur during simulation. If an alarm occurs during a simulation run, a window opens in the operating window to display it. The alarm overview contains the following information: ● Date and time ●...

Page 194 Simulating machining 5.9 Displaying simulation alarms Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 195: Creating G Code Program
Creating G code program Graphical programming Functions The following functionality is available: ● Technology-oriented program step selection (cycles) using softkeys ● Input windows for parameter assignment with animated help screens ● Context-sensitive online help for every input window ● Support with contour input (geometry processor) Call and return conditions ●...

Page 196: Program Views
Creating G code program 6.2 Program views Program views You can display a G code program in various ways. ● Program view ● Parameter screen, either with help screen or graphic view Program view The program view in the editor provides an overview of the individual machining steps of a program.

Page 197 Creating G code program 6.2 Program views Parameter screen with help display Press the or the key to open a selected program block or cycle in the program view. The associated parameter screen with help screen is then displayed. Figure 6-2 Parameter screen with help display The animated help displays are always displayed with the correct orientation to the selected...

Page 198 Creating G code program 6.2 Program views Parameter screen with graphic view Using the "Graphic view" softkey, you can toggle between the help screen and the graphic view in the screen. Figure 6-3 Parameter screen with a graphical view of a G code program block Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 199: Program Structure
Creating G code program 6.3 Program structure Program structure G_code programs can always be freely programmed. The most important commands that are included in the rule: ● Set a machining plane ● Call a tool (T and D) ● Call a work offset ●...

Page 200: Basics
Creating G code program 6.4 Basics Basics 6.4.1 Machining planes A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2½-D machining).

Page 201: Programming A Tool (T)
Creating G code program 6.4 Basics ● Milling: G17 (XY) The plane is transferred to the cycles as new parameter. The plane is output in the cycle, i.e. the cycle runs in the entered plane. It is also possible to leave the plane fields empty and thus create a plane-independent program.

Page 202: Generating A G Code Program
Creating G code program 6.5 Generating a G code program Generating a G code program Create a separate program for each new workpiece that you would like to produce. The program contains the individual machining steps that must be performed to produce the workpiece.

Page 203: Blank Input
Creating G code program 6.6 Blank input Blank input Function The blank is used for the simulation and the simultaneous recording. A useful simulation can only be achieved with a blank that is as close as possible to the real blank. Create a separate program for each new workpiece that you would like to produce.

Page 204 Creating G code program 6.6 Blank input Parameter Description Unit Data for Selection of the spindle for blank Main spindle  Counterspindle  Note: If the machine does not have a counterspindle, then the entry field "Data for" is not applicable.

Page 205: Machining Plane, Milling Direction, Retraction Plane, Safe Clearance And Feedrate (Pl, Rp, Sc, F)
Creating G code program 6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP, SC, F) Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP, SC, F) In the program header, cycle input screens have general parameters that are always repeated.

Page 206: Selection Of The Cycles Via Softkey
Creating G code program 6.8 Selection of the cycles via softkey Selection of the cycles via softkey Overview of machining steps The following softkey bars are available to insert machining steps. All of the cycles/functions available in the control are shown in this display. However, at a specific system, only the steps possible corresponding to the selected technology can be selected.

Page 207 Creating G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 208 Creating G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 209 Creating G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 210 Creating G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ See also General (Page 265) Generating a G code program (Page 202) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 211: Calling Technology Functions
These are then generated with the appropriate default values when the cycles are called. For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Cycle support Example Use the softkeys to select whether you want support for programming contours, drilling or milling cycles.

Page 212: Checking Cycle Parameters
Creating G code program 6.9 Calling technology functions 6.9.3 Checking cycle parameters The entered parameters are already checked during the program creation in order to avoid faulty entries. If a parameter is assigned an illegal value, this is indicated in the input screen and is designated as follows: ●...

Page 213: Additional Functions In The Input Screens
Creating G code program 6.9 Calling technology functions 6.9.5 Additional functions in the input screens Selection of units If, for example, the unit can be switched in a field, this is highlighted as soon as the cursor is positioned on the element. In this way, the operator recognizes the dependency.

Page 214: Measuring Cycle Support
The tool geometry that is acquired is entered in the appropriate tool offset data set. References You will find a more detailed description on how to use measuring cycles in: HMI sl / SINUMERIK 840D sl Programming Manual Measuring Cycles Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 215 Creating G code program 6.10 Measuring cycle support Procedure Press the menu forward key. Press the horizontal "Measure mill" softkey. Using a vertical softkey, select the desired measurement function group, e.g. "Calibrate probe". - OR - Measure workpiece - OR - Calibrate workpiece probe - OR - Measure tool...

Page 216 Creating G code program 6.10 Measuring cycle support Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 217: Creating A Shopmill Program
Creating a ShopMill program The program editor offers graphic programming to generate machining step programs that you can directly generate at the machine. Software option You require the "ShopMill/ShopTurn" option to generate ShopMill machining step programs. Functions The following functionality is available: ●...

Page 218: Program Views
Creating a ShopMill program 7.1 Program views Program views You can display a ShopMill program in various views: ● Machining schedule ● Programming graphics ● Parameter screen, either with help display or programming graphics Machining schedule The work plan in the editor provides an overview of the individual machining steps of a program.

Page 219 Creating a ShopMill program 7.1 Program views Programming graphics The programming graphics show the contour of the workpiece as a dynamic graphic with dotted lines. The program block selected in the machining schedule is highlighted in color in the programming graphics. Figure 7-2 Programming graphics of a ShopMill program Parameter screen with help display...

Page 220 Creating a ShopMill program 7.1 Program views Figure 7-3 Parameter screen with help display The animated help displays are always displayed with the correct orientation to the selected coordinate system. The parameters are dynamically displayed in the graphic. The selected parameter is displayed highlighted in the graphic.

Page 221 Creating a ShopMill program 7.1 Program views Parameter screen with programming graphics In the screen, you can toggle between the help display and the program graphics using the "Graphic view". Figure 7-4 Parameter screen with programming graphics Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 222: Program Structure
Creating a ShopMill program 7.2 Program structure Program structure A machining step program is divided into three sub-areas: ● Program header ● Program blocks ● End of program These sub-areas form a work plan. Program header The program header contains parameters that affect the entire program, such as blank dimensions or retraction planes.

Page 223: Basic Information
Creating a ShopMill program 7.3 Basic information Basic information 7.3.1 Machining planes A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2½-D machining).

Page 224: Polar Coordinates
Creating a ShopMill program 7.3 Basic information 7.3.2 Polar coordinates The rectangular coordinate system is suitable in cases where dimensions in the production drawing are orthogonal. For workpieces dimensioned with arcs or angles, it is better to define positions using polar coordinates. This is possible if you are programming a straight line or a circle.

Page 225 Creating a ShopMill program 7.3 Basic information The position data points P1 to P3 in absolute dimensions relative to the zero point are the following: P1: X20 Y35 P2: X50 Y60 P3: X70 Y20 Incremental dimensions In the case of production drawings in which dimensions refer to some other point on the workpiece rather than the zero point, it is possible to enter an incremental dimension.

Page 226: Creating A Shopmill Program
Creating a ShopMill program 7.4 Creating a ShopMill program Creating a ShopMill program Create a separate program for each new workpiece that you would like to produce. The program contains the individual machining steps that must be performed to produce the workpiece.

Page 227: Program Header
Creating a ShopMill program 7.5 Program header Program header In the program header, set the following parameters, which are effective for the complete program. Parameter Description Unit Measurement unit The dimension unit (mm or inch) set in the program header only refers to the position data in the actual program.

Page 228: Generating Program Blocks
Creating a ShopMill program 7.6 Generating program blocks Parameter Description Unit Machining direction When machining a pocket, a longitudinal slot or a spigot, ShopMill takes the machining direction (climbing or conventional) and the spindle direction in the tool list into account. The pocket is then machined in a clockwise or counterclockwise direction.

Page 229: Tool, Offset Value, Feed And Spindle Speed (T, D, F, S, V)
Creating a ShopMill program 7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) - OR - Press the "Tool list" and "New tool" softkeys. Using the softkeys on the vertical softkey bar, select the required tool with the data and press the "To program"...

Page 230 Creating a ShopMill program 7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) Tool length compensation Tool length compensation takes effect as soon as the tool is loaded into the spindle. Different tool offsets can be assigned to each tool with multiple cutting edges. The tool length compensation of the spindle tool remains active even after the program has been executed (RESET).

Page 231: Defining Machine Functions
You have the option of defining machine functions as well as your own texts in the "Machine functions" window. References A description of the configuration options is provided in Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Procedure The ShopMill program to be edited has been created and you are in the editor.

Page 232 Creating a ShopMill program 7.8 Defining machine functions See also Starting and stopping a spindle manually (Page 120) Parameter Description Unit Spindle M function, defines the spindle direction of rotation or spindle position Spindle off  Spindle rotates clockwise  Spindle rotates counterclockwise ...

Page 233: Call Work Offsets
Creating a ShopMill program 7.9 Call work offsets Call work offsets You can call work offsets (G54, etc.) from any program. You define work offsets in work offset lists. You can also view the coordinates of the selected offset here. Procedure Press the "Various", "Transformations"...

Page 234 Creating a ShopMill program 7.10 Repeating program blocks Procedure Position the cursor at the program block, behind which a program block that will be repeated should follow. Press the "Various" softkey. Press the ">>" and "Repeat progr." softkeys. Press the "Set marker" and "Accept" softkeys. A start marker is inserted behind the actual block.

Page 235: Specifying The Number Of Workpieces
Creating a ShopMill program 7.11 Specifying the number of workpieces 7.11 Specifying the number of workpieces If you wish to produce a certain quantity of the same workpiece, then at the end of the program, specify that you wish to repeat the program. Control the numbers of times that the program is repeated using the "Times, counters"...

Page 236: Changing Program Blocks
Creating a ShopMill program 7.12 Changing program blocks 7.12 Changing program blocks You can subsequently optimize the parameters in the programmed blocks or adapt them to new situations, e.g. if you want to increase the feedrate or shift a position. In this case, you can directly change all the parameters in every program block in the associated parameter screen form.

Page 237: Changing Program Settings
Creating a ShopMill program 7.13 Changing program settings 7.13 Changing program settings Function All parameters defined in the program header, with the exception of the dimension unit, can be changed at any location in the program. The settings in the program header are modal, i.e. they remain active until they are changed. Define a new blank, e.g.

Page 238: Selection Of The Cycles Via Softkey
Creating a ShopMill program 7.14 Selection of the cycles via softkey 7.14 Selection of the cycles via softkey Overview of machining steps The following machining steps are available for insertion. All of the cycles/functions available in the control are shown in this display. However, at a specific system, only the steps possible corresponding to the selected technology can be selected.

Page 239 Creating a ShopMill program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 240 Creating a ShopMill program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 241 Creating a ShopMill program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 242: Calling Technology Functions
Creating a ShopMill program 7.15 Calling technology functions ⇒ ⇒ 7.15 Calling technology functions 7.15.1 Additional functions in the input screens Selection of units If, for example, the unit can be switched in a field, this is highlighted as soon as the cursor is positioned on the element.

Page 243: Checking Input Parameters
Setting data for technological functions Technological functions can be influenced and corrected using machine or setting data. For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl 7.15.4 Changing a cycle call You have called the desired cycle via softkey in the program editor, entered the parameters and confirmed with "Accept".

Page 244: Measuring Cycle Support
The tool geometry that is acquired is entered in the appropriate tool offset data set. References You will find a more detailed description on how to use measuring cycles in: HMI sl / SINUMERIK 840D sl Programming Manual Measuring Cycles Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 245 Creating a ShopMill program 7.16 Measuring cycle support Procedure Press the menu forward key. Press the horizontal "Measure mill" softkey. Using a vertical softkey, select the desired measurement function group, e.g. "Calibrate probe". - OR - Measure workpiece - OR - Calibrate workpiece probe - OR - Measure tool...

Page 246: Example, Standard Machining
Creating a ShopMill program 7.17 Example, standard machining 7.17 Example, standard machining General The following example is described in detail as ShopMill program. A G code program is generated in the same way; however, some differences must be observed. If you copy the G code program listed below, read it into the control and open it in the editor, then you can track the individual program steps.

Page 247: Workpiece Drawing
Creating a ShopMill program 7.17 Example, standard machining 7.17.1 Workpiece drawing 7.17.2 Programming 1. Program header Specify the blank. Measurement unit mm Work offset Blank Cuboid -2.5 abs -2.5 abs 182.5 abs 182.5 abs 1 abs Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 248 Creating a ShopMill program 7.17 Example, standard machining -20 abs Machining direction Climbing Retraction position Optimized pattern Press the "Accept" softkey. The work plan is displayed. Program header and end of program are created as program blocks. The end of program is automatically defined. 2.

Page 249 Creating a ShopMill program 7.17 Example, standard machining 3. Outside contour of the workpiece Press the "Milling", "Multi-edge spigot" and "Rectangular spigot" softkeys. Enter the following technology parameters: T MILLER20 F 0.14 mm/tooth V 240 m/min Enter the following parameters: Position of reference Bottom left point...

Page 250 Creating a ShopMill program 7.17 Example, standard machining 4. Outside contour islands To simply machine the entire surface outside the island, define a contour pocket around the blank and then program the island. In this way, the entire surface area is machined and no residual material is left behind.

Page 251 Creating a ShopMill program 7.17 Example, standard machining Outside contour of the island Press the "Contour milling", "Contour" and "New contour" softkeys. The "New Contour" input window opens. Enter the contour name (in this case: Part_4_island). The contour calculated as NC code is written as internal subprogram between a start and an end marker containing the entered name.

Page 252 Creating a ShopMill program 7.17 Example, standard machining 165 abs 95 abs α1 290 degrees 155 abs α1 degr 140 abs α1 225 degrees Press the ">>" and "Close contour" softkeys, to close the contour. Press the "Accept" softkey. Contour milling/solid machining Press the "Contour milling"...

Page 253 Creating a ShopMill program 7.17 Example, standard machining Note  When selecting the milling tool, please make sure that the tool diameter is large enough to cut the intended pocket. A message will be displayed if you make a mistake. ...

Page 254 Creating a ShopMill program 7.17 Example, standard machining 6. Milling a rectangular pocket (small) Press the "Milling", "Pocket" and "Rectangular pocket" softkeys. The "Rectangular Pocket" input window opens. Enter the following technology parameters: T MILLER10 F 0.04 mm/tooth V 260 m/min Enter the following parameters: Reference point Center...

Page 255 Creating a ShopMill program 7.17 Example, standard machining V 230 m/min Enter the following parameters: Machining Roughing (∇) Circular pattern Pitch circle 85 abs 135 abs 0 abs α0 180 degrees α1 180 degrees 3 inc 0 mm Press the "Accept" softkey. 8.

Page 256 Creating a ShopMill program 7.17 Example, standard machining 9. Drilling/reaming Press the "Drilling", "Drilling reaming" and "Drilling" softkeys. The "Drilling" input window opens. Enter the following technology parameters: T DRILL10 F 500 mm/min S 1600 rev/min Enter the following parameters: Diameter/tip -25 abs Press the "Accept"...

Page 257 Creating a ShopMill program 7.17 Example, standard machining 11. Obstacle Press the "Drilling", "Positions", and “Obstacle” softkeys. The "obstacle" input window opens. Enter the following parameters: 2 abs Press the "Accept" softkey. Note If this obstacle cycle is not inserted, the drill will violate the right-hand corner of the island contour.

Page 258 Creating a ShopMill program 7.17 Example, standard machining 13. Milling the circular pocket Press the "Milling", "Pocket" and "Circular pocket" softkeys. The "Circular Pocket" input window opens. Enter the following technology parameters: T MILLER8 F 0.018 mm/tooth V 230 m/min Enter the following parameters: Machining Roughing (∇)

Page 259: Results/Simulation Test
Creating a ShopMill program 7.17 Example, standard machining 7.17.3 Results/simulation test Figure 7-5 Programming graphics Figure 7-6 Machining schedule Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 260 Creating a ShopMill program 7.17 Example, standard machining Program test by means of simulation During simulation, the current program is calculated in its entirety and the result displayed in graphic form. Figure 7-7 3D view Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 261: G Code Machining Program
Creating a ShopMill program 7.17 Example, standard machining 7.17.4 G code machining program G17 G54 G71 WORKPIECE(,,"","BOX",112,1,-20,-100,-2.5,-2.5,182.5,182.5) ;****************Tool change**************** T="FACING TOOL" D1 M6 G95 FZ=0.1 S3000 M3 M8 CYCLE61(50,1,1,0,-2.5,-2.5,185,185,2,80,0,0.1,31,0,1,10) G0 Z200 M9 ;****************Tool change**************** T="MILLER20" D1 M6 G95 FZ=0.14 S3900 M3 M8 CYCLE76(50,0,1,,20,180,180,10,0,0,0,5,0,0,0.14,0.14,0,1,185,185,1,2,2100,1,101) ;CYCLE62(,2,"MA1","MA0") CYCLE62(,2,"E_LAB_A_PART_4_POCKET","E_LAB_E_PART_4_POCKET")

Page 262 Creating a ShopMill program 7.17 Example, standard machining T="MILLER8" D1 M06 G95 FZ=0.018 S12000 M3 M8 POCKET4(50,-10,1,12,30,85,135,5,0,0,0.018,0.01,0,21,40,9,15,2,1,0,1,2,10100,111,111) MCALL POCKET4(50,-10,1,4,16,0,0,5,0,0,0.018,0.018,0,11,40,9,15,0,2,0,1,2,10100,111,111) REPEATB POS_1 ;#SM MCALL G0 Z200 M9 ;****************Tool change**************** ;Contour chamfering T="CENTERING TOOL10" D1 M6 G94 F500 S8000 M3 M8 CYCLE62(,2,"E_LAB_A_PART_4_ISLAND","E_LAB_E_PART_4_ISLAND") CYCLE72("",100,0,1,20,2,0.5,0.5,500,100,305,41,1,0,0.1,1,0,0,0.3,2,101,1011,101) POCKET3(50,0,1,4,70,40,10,90,60,15,4,0,0,500,0.2,0,25,40,8,3,15,2,1,0,0.3,2,11100,11,111) POCKET3(50,-4,1,2,35,20,6,90,60,15,2,0,0,500,0.2,0,35,40,8,3,15,10,2,0,0.3,2,11100,11,111)

Page 263 Creating a ShopMill program 7.17 Example, standard machining Y115 RND=20 ;*GP* X15 Y135 ;*GP* Y155 RND=10 ;*GP* X60 RND=15 ;*GP* Y135 ;*GP* G3 X110 I=AC(85) J=AC(135) ;*GP* G1 Y155 RND=15 ;*GP* X143.162 ;*GP* X165 Y95 ;*GP* X155 Y77.679 RND=28 ;*GP* Y40 ;*GP* X140 Y25 ;*GP* X90 ;*GP*...

Page 264 Creating a ShopMill program 7.17 Example, standard machining Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 265: Programming Technological Functions (Cycles)
Programming technological functions (cycles) Drilling 8.1.1 General General geometry parameters ● Retraction plane RP and reference point Z0 Normally, reference point Z0 and retraction plane RP have different values. The cycle assumes that the retraction plane is in front of the reference point. Note If the values for reference point and retraction planes are identical, a relative depth specification is not permitted.

Page 266: Centering (Cycle81)
Programming technological functions (cycles) 8.1 Drilling Drilling positions The cycle assumes the tested hole coordinates of the plane. The hole centers should therefore be programmed before or after the cycle call as follows (see also Section, Cycles on single position or position pattern (MCALL)): ●...

Page 267 Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Single position Machining ...

Page 268: Drilling (Cycle82)
Programming technological functions (cycles) 8.1 Drilling 8.1.3 Drilling (CYCLE82) Function With the "Drilling" function, the tool drills with the programmed spindle speed and feedrate down to the specified final drilling depth (shank or tip). The tool is retracted after a programmed dwell time has elapsed. Approach/retraction 1.

Page 269: Reaming (Cycle85)
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Shank (drilling depth in relation to the shank) Drilling depth  The drill is inserted into the workpiece until the drill shank reaches the value programmed for Z1. The angle entered in the tool list is taken into account. Tip (drilling depth in relation to the tip) ...

Page 270: Deep-Hole Drilling (Cycle83)
Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev Feedrate mm/min S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Single position...

Page 271 Programming technological functions (cycles) 8.1 Drilling Approach/retraction during chipbreaking 1. The tool moves with G0 to safety clearance of the reference point. 2. The tool drills with the programmed spindle speed and feedrate F = F · FD1 [%] up to the 1st infeed depth.

Page 272 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Single position Machining  position Drill hole at programmed position. (only for G Position pattern  code) Position with MCALL Z0 (only for G Reference point Z code) Stock removal Machining ...

Page 273: Boring (Cycle86)
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Dwell time at drilling depth in seconds DTB - (only for G  code) Dwell time at drilling depth in revolutions  Dwell time at final drilling depth in seconds  Dwell time at final drilling depth in revolutions ...

Page 274 Programming technological functions (cycles) 8.1 Drilling 6. Retraction with G0 to the safety clearance of the reference point. 7. Retraction to retraction plane with G0 to drilling position in the two axes of the plane (coordinates of the hole center point). Procedure The part program or ShopMill program to be processed has been created and you are in the editor.

Page 275: Tapping (Cycle84, 840)
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Retraction distance in the Y direction (incremental) - (for lift-off only, standard) Retraction distance in the Z direction (incremental) - (for lift-off only, standard) Retraction distance (incremental) - (for lift-off only, ShopMill) 8.1.7 Tapping (CYCLE84, 840) Function...

Page 276 Programming technological functions (cycles) 8.1 Drilling Approach/retraction - CYCLE84 - without compensating chuck One cut: 1. Travel with G0 to the safety clearance of the reference point. 2. Spindle is synchronized and started with the programmed speed (dependent on %S). 3.

Page 277 Programming technological functions (cycles) 8.1 Drilling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Thread" and "Tap" softkeys. The "tapping" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 278 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit User input Pitch - (only  machining without Pitch results from the input encoder) Active feedrate  Pitch results from the feedrate (only for G code) Table Thread table selection: Without ...

Page 279 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Retraction distance after each machining step – (only without compensating chuck, chipbreaking and manual retraction) Distance by which the drill is retracted for chipbreaking. V2 = automatic: The tool is retracted by one revolution. DT (only for G Dwell time at final drilling depth in seconds code)

Page 280: Drill And Thread Milling (Cycle78)
Programming technological functions (cycles) 8.1 Drilling 8.1.8 Drill and thread milling (CYCLE78) Function You can use a drill and thread milling cutter to manufacture an internal thread with a specific depth and pitch in one operation. This means that you can use the same tool for drilling and thread milling, a change of tool is superfluous.

Page 281 Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Single position Machining ...

Page 282 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Through boring Remaining drilling depth with drilling feedrate   Residual drilling depth for through boring - ("yes", only for through boring) Drilling feedrate for remaining drilling depth - ("yes", only for through boring) mm/min mm/rev Stock removal...

Page 283: Positioning And Position Patterns
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Climb milling: Mill thread in one cycle. Milling direction  Conventional milling: Mill thread in one cycle.  Climbing - conventional: Mill thread in two cycles: rough cutting is performed by ...

Page 284: Arbitrary Positions (Cycle802)
Programming technological functions (cycles) 8.1 Drilling Tool traverse path ● ShopMill The programmed positions are machined with the previously programmed tool (e.g. center drill). Machining of the positions always starts at the reference point. In the case of a grid, machining is performed first in the direction of the 1st axis and then meandering back and forth.

Page 285: Position Pattern Line (Holes1), Grid Or Frame (Cycle801)
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit X coordinate for 1st position (abs.) Y coordinate for 1st position (abs.) - (only for Polar coordinates, additional. Positions, when selecting "polar" ShopMill) ... L7 Length (abs.) ... C7 Angle (abs.) Degrees ...

Page 286: Circle Position Pattern (Holes2)
Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Repeat jump label for position (only for G code) Machining plane (only for G code) Position pattern Selection option for the following patterns: Line  (only for G code) Grid  Frame ...

Page 287 Programming technological functions (cycles) 8.1 Drilling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Positions" and "Circle" softkeys. The "Position circle" input window opens. Parameter Description Unit...

Page 288: Repeating Positions
Programming technological functions (cycles) 8.1 Drilling 8.1.13 Repeating positions Function If you want to approach positions that you have already programmed again, you can do this quickly with the function "Repeat position". You must specify the number of the position pattern. This cycle automatically assigns this number.

Page 289: Milling
Programming technological functions (cycles) 8.2 Milling Milling 8.2.1 Face milling (CYCLE61) Function You can face mill any workpiece with the "Face milling" cycle. A rectangular surface is always machined. The rectangle results from corner points 1 and 2 that are pre-assigned with the values of the blank part dimensions from the program header. Workpieces with and without limits can be face-milled.

Page 290 Programming technological functions (cycles) 8.2 Milling Machine manufacturer Please refer to the machine manufacturer's specifications. Selecting the machining direction Toggle the machining direction in the "Direction" field until the symbol for the required machining direction appears. ● Same direction of machining ●...

Page 291 Programming technological functions (cycles) 8.2 Milling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Milling direction Cutting edge number Retraction plane Feedrate mm/min mm/rev Safety clearance S / V Spindle speed or constant cutting rate m/min Feedrate mm/min Parameter Description...

Page 292: Rectangular Pocket (Pocket3)
Programming technological functions (cycles) 8.2 Milling 8.2.2 Rectangular pocket (POCKET3) Function You can mill any rectangular pocket with the "rectangular pocket milling" function. The following machining variants are available: ● Mill rectangular pocket from solid material. ● Pre-drill rectangular pocket in the center first if, for example, the milling cutter does not cut in the center (program the drilling, rectangular pocket and position program blocks in succession).

Page 293 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Pocket" and "Rectangular pocket" softkeys. The "Rectangular pocket" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 294 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Corner radius α0 Angle of rotation Degrees Depth referred to Z0 (inc) or pocket depth (abs) - (only for ∇, ∇∇∇ or ∇∇∇ edge) Maximum plane infeed  Maximum plane infeed as a percentage of the milling cutter diameter ...

Page 295: Circular Pocket (Pocket4)
Programming technological functions (cycles) 8.2 Milling 8.2.3 Circular pocket (POCKET4) Function You can mill any circular pocket with the "Circular pocket" cycle. The following machining methods are available: ● Mill circular pocket from solid material. ● Pre-drill circular pocket in the center first if, for example, the milling cutter does not cut in the center (program the drilling, circular pocket and position program blocks in succession).

Page 296 Programming technological functions (cycles) 8.2 Milling Machining type: Plane-by-plane When milling circular pockets, you can select the following machining types: ● Roughing During roughing, the individual planes of the circular pocket are machined one after the other from center point until depth Z1 is reached. ●...

Page 297 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Pocket" and "Circular pocket" softkeys. The "Circular Pocket" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 298 Programming technological functions (cycles) 8.2 Milling Parameters Description Unit Maximum plane infeed  Maximum plane infeed as a percentage of the cutting tool diameter  - (only for ∇ and ∇∇∇) Maximum depth infeed - (only for ∇, ∇∇∇ and ∇∇∇ Rand) Plane finishing allowance - (only for ∇, ∇∇∇...

Page 299: Rectangular Spigot (Cycle76)
Programming technological functions (cycles) 8.2 Milling 8.2.4 Rectangular spigot (CYCLE76) Function You can mill various rectangular spigots with the "Rectangular spigot" cycle. You can select from the following shapes with or without a corner radius: Depending on the dimensions of the rectangular spigot in the workpiece drawing, you can select a corresponding reference point for the rectangular spigot.

Page 300 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Multi-edge spigot" and "Rectangular spigot" softkeys. The "Rectangular Spigot" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 301: Circular Spigot (Cycle77)
Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Corner radius α0 Angle of rotation Degrees Spigot depth (abs) or depth relative to Z0 (inc) - (only for ∇ and ∇∇∇) Maximum depth infeed - (only for ∇ and ∇∇∇) Plane finishing allowance for the length (L) and width (W) of the rectangular spigot.

Page 302 Programming technological functions (cycles) 8.2 Milling Machining type You can select the machining mode for milling the circular spigot as follows: ● Roughing Roughing involves moving round the circular spigot until the programmed finishing allowance has been reached. ● Finishing If you have programmed a finishing allowance, the circular spigot is moved around until depth Z1 is reached.

Page 303: Multi-Edge (Cycle79)
Programming technological functions (cycles) 8.2 Milling Parameter Description Unit The positions refer to the reference point: Reference point X – (for single position only) Reference point Y – (for single position only) Reference point Z – (for single position only) ∅...

Page 304 Programming technological functions (cycles) 8.2 Milling 4. The multi-edge is traversed again in a quadrant. This process is repeated until the depth of the multi-edge has been reached. 5. The tool retracts to the safety clearance at rapid traverse. Note A multi-edge with more than two edges is traversed helically;...

Page 305: Longitudinal Groove (Slot1)
Programming technological functions (cycles) 8.2 Milling Parameter Description Unit The positions refer to the reference point: Reference point X – (for single position only) Reference point Y – (for single position only) Reference point Z – (for single position only) ∅...

Page 306 Programming technological functions (cycles) 8.2 Milling Machining type You can select the machining mode for milling the longitudinal slot as follows: ● Roughing During roughing, the individual planes of the slot are machined one after the other until depth Z1 is reached. ●...

Page 307 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Reference point Position of the reference point: (lefthand edge)  (inside left)  (center)  (inside right)  (righthand edge)  ∇ (roughing) Machining  ∇∇∇ (finishing)  ∇∇∇ edge (edge finishing) ...

Page 308: Circumferential Groove (Slot2)
Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Insertion The following insertion modes can be selected: Predrilled: (only for G code)  Approach of reference point shifted by the amount of the safety clearance with G0. Perpendicular: Insert vertically in longitudinal groove center: ...

Page 309 Programming technological functions (cycles) 8.2 Milling Annular groove To create an annular groove, you must enter the following values for the "Number N" and "Aperture angle α1" parameters: N = 1 α1 = 360° Approach/retraction 1. The tool approaches the center point of the semicircle at the end of the slot at rapid traverse at the height of the retraction plane and adjusts to the safety clearance.

Page 310 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Groove" and "Circumferential groove" softkeys. The "Circumferential Groove" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 311: Open Groove (Cycle899)
Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Groove width Slot depth (abs) or depth relative to Z0 (inc) – (only for ∇, ∇∇∇ and (only for G code) ∇∇∇ edge) (only for Slot depth (abs) or depth relative to Z0 (inc) - (only for ∇, ∇∇∇ and ShopMill) ∇...

Page 312 Programming technological functions (cycles) 8.2 Milling Vortex milling Particularly where hardened materials are concerned, this process is used for roughing and contour machining using coated VHM milling cutters. Vortex milling is the preferred technique for HSC roughing, as it ensures that the tool is never completely inserted.

Page 313 Programming technological functions (cycles) 8.2 Milling Vortex milling: Climbing or conventional Vortex milling: Climbing - conventional milling milling Supplementary conditions for vortex milling ● Roughing 1/2 slot width W – finishing allowance UXY ≤ milling cutter diameter ● Slot width minimum 1.15 x milling cutter diameter + finishing allowance maximum, 2 x milling cutter diameter + 2 x finishing allowance ●...

Page 314 Programming technological functions (cycles) 8.2 Milling Following each insertion, the milling cutter is lifted by the height of the safety clearance at the machining feedrate. As far as possible, this occurs during what is known as the retraction process, i.e. if the milling cutter's wrap angle is less than 180°, it is lifted at a 45- angle from the base in the opposite direction to the bisector of the wrap area.

Page 315 Programming technological functions (cycles) 8.2 Milling Machining type, rough finishing If there is too much residual material on the slot walls, unwanted corners are removed to the finishing dimension. Machining type, finishing: When finishing walls, the milling cutter travels along the slot walls, whereby just like for roughing, it is again fed in the Z direction, increment by increment.

Page 316 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Slot" and "Open slot" softkeys. The "Open slot" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 317: Long Hole (Longhole) - Only For G Code Programs
Programming technological functions (cycles) 8.2 Milling Parameters Description Unit Single position Machining  position Mill a slot at the programmed position (X0, Y0, Z0). Position pattern  Mill slots at a programmed position pattern (e.g. full circle or grid). The positions refer to the reference point: Reference point X –...

Page 318 Programming technological functions (cycles) 8.2 Milling Approach/retraction 1. Using G0, the starting position for the cycle is approached. In both axes of the current plane, the closest end point of the first elongated hole to be machined is approached at the level of the retraction plane in the tool axis and then lowered to the reference point shifted by the amount of the safety clearance.

Page 319: Thread Milling (Cycle70)
Programming technological functions (cycles) 8.2 Milling Parameters Description Unit Reference point Position of the reference point: Single position Machining  position An elongated hole is machined at the programmed position (X0, Y0, Z0). Position pattern  Several elongated holes are machined in the programmed position pattern (e.g. pitch circle, grid, line).

Page 320 Programming technological functions (cycles) 8.2 Milling Approach/retraction when milling internal threads 1. Positioning on retraction plane with rapid traverse. 2. Approach of starting point of the approach circle in the current plane with rapid traverse. 3. Infeed to a starting point in the tool axis calculated internally in the controller with rapid traverse.

Page 321 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Thread milling" softkey. The "thread milling" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...

Page 322 Programming technological functions (cycles) 8.2 Milling Parameters Description Unit Machining position: (only for G code) Single position  Position pattern (MCALL)  The positions refer to the center point: Reference point X – (for single position only) Reference point Y – (for single position only) Reference point Z (only for G code) End point of the thread (abs) or thread length (inc)

Page 323: Engraving (Cycle60)
Programming technological functions (cycles) 8.2 Milling 8.2.12 Engraving (CYCLE60) Function The "Engraving" function is used to engrave a text on a workpiece along a line or arc. You can enter the text directly in the text field as "fixed text" or assign it via a variable as "variable text".

Page 324 Programming technological functions (cycles) 8.2 Milling Press the "Lowercase" softkey to enter lowercase letters. Press it again to enter uppercase letters. Press the "Variable" and "Date" softkeys if you want to engrave the current date. The data is inserted in the European date format (
..).

Page 325 Programming technological functions (cycles) 8.2 Milling  Press the "Variable" and "Number 123.456" softkeys if you want to engrave a any number in a certain format. The format text <#.###,_VAR_NUM> is inserted and you return to the engraving field with the softkey bar. ...

Page 326 Programming technological functions (cycles) 8.2 Milling Note Entering the engraving text Only single-line entries without line break are permissible! Variable texts There are various ways of defining variable text: ● Date and time For example, you can engrave the time and date of manufacture on a workpiece. The values for date and time are read from the NCK.

Page 327 Programming technological functions (cycles) 8.2 Milling Parameters Description Unit Depth infeed rate mm/min (only for G code) Depth infeed rate mm/min (only for ShopMill) mm/tooth (linear alignment) Alignment  (curved alignment)  (curved alignment)  Reference point Position of the reference point bottom left ...

Page 328: Contour Milling
Programming technological functions (cycles) 8.3 Contour milling Contour milling 8.3.1 General Function You can mill simple or complex contours with the "Contour milling" cycle. You can define open contours or closed contours (pockets, islands, spigots). A contour comprises separate contour elements, whereby at least two and up to 250 elements result in a defined contour.

Page 329 Programming technological functions (cycles) 8.3 Contour milling Contour element Symbol Meaning Straight line in any direction Straight line with any gradient Arc right Circle Arc left Circle Pole Straight diagonal or circle in polar coordinates Finish contour End of contour definition The different colors of the symbols indicate their status: Foreground Background...

Page 330: Creating A New Contour
Programming technological functions (cycles) 8.3 Contour milling 8.3.3 Creating a new contour Function For each contour that you want to mill, you must create a new contour. The contours are stored at the end of the program. Note When programming in the G code, it must be ensured that the contours are located after the end of program identifier! The first step in creating a contour is to specify a starting point.

Page 331 Programming technological functions (cycles) 8.3 Contour milling Cartesian starting point Enter the starting point for the contour. Enter any additional commands in G code format, as required. Press the "Accept" softkey. Enter the individual contour elements. Polar starting point Press the "Pole" softkey. Enter the pole position in Cartesian coordinates.

Page 332: Creating Contour Elements
Programming technological functions (cycles) 8.3 Contour milling 8.3.4 Creating contour elements After you have created a new contour and specified the starting point, you can define the individual elements that make up the contour. The following contour elements are available for the definition of a contour: ●...

Page 333 Programming technological functions (cycles) 8.3 Contour milling Additional functions The following additional functions are available for programming a contour: ● Tangent to preceding element You can program the transition to the preceding element as tangent. ● Dialog box selection If two different possible contours result from the parameters entered thus far, one of the options must be selected.

Page 334 Programming technological functions (cycles) 8.3 Contour milling The "Circle" input window opens. - OR The "Pole Input" input window opens. Enter all the data available from the workpiece drawing in the input screen (e.g. length of straight line, target position, transition to next element, angle of lead, etc.).

Page 335 Programming technological functions (cycles) 8.3 Contour milling Contour element "straight line, e.g. Y" Parameter Description Unit End point Y (abs or inc) α1 Starting angle to X axis Degrees Transition to next Type of transition element Radius  Chamfer  Radius Transition to following element - radius Chamfer...

Page 336: Changing The Contour
Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit α2 Angle to the preceding element Degrees β1 End angle to Z axis Degrees β2 Angle of opening Degrees Transition to next Type of transition element Radius  Chamfer  Radius Transition to following element - radius Chamfer...

Page 337: Contour Call (Cycle62) - Only For G Code Program
Programming technological functions (cycles) 8.3 Contour milling Procedure for changing a contour element Open the part program or ShopMill program to be executed. With the cursor, select the program block where you want to change the contour. Open the geometry processor. The individual contour elements are listed.

Page 338: Path Milling (Cycle72)
Programming technological functions (cycles) 8.3 Contour milling Procedure The subprogram to be edited has been created and you are in the editor. Press the "Contour milling" softkey. Press the "Contour" and "Contour call" softkeys. The "Contour Call" input window opens. Assign parameters to the contour selection.

Page 339 Programming technological functions (cycles) 8.3 Contour milling Programming of arbitrary contours The machining of arbitrary open or closed contours is generally programmed as follows: 1. Enter contour You build up the contour gradually from a series of different contour elements. 2.

Page 340 Programming technological functions (cycles) 8.3 Contour milling Path milling along center-point path. A programmed contour can also be machined along the center-point path if the radius correction was switched-out. In this case, approaching and retraction is only possible along a straight line or vertical.

Page 341 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Left (machining to the left of the contour) Radius  compensation Right (machining to the right of the contour)   A programmed contour can also be machined on the center-point path. In this case, approaching and retraction is only possible along a straight line or vertical.

Page 342: Contour Pocket/Contour Spigot (Cycle63/64)
Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Axis by axis Retraction  strategy Spatial (not with perpendicular approach mode)  Retraction radius - (only for "quadrant or semi-circle" retraction) Retraction distance - (only for "straight line" retraction) Lift mode If more than one depth infeed is necessary, specify the retraction height to which the tool retracts between the individual infeeds (at the transition from the end of the contour...

Page 343 Programming technological functions (cycles) 8.3 Contour milling Machining You program the machining of contour pockets with islands/blank contour with spigots e.g. as follows: 1. Enter the pocket contour/blank contour 2. Enter the island/spigot contour 3. Call the contour for pocket contour/blank contour or island/spigot contour (only for G code program) 4.

Page 344: Predrilling Contour Pocket (Cycle64)
Programming technological functions (cycles) 8.3 Contour milling 8.3.9 Predrilling contour pocket (CYCLE64) Function In addition to predrilling, the cycle can be used for centering. The centering or predrilling program generated by the cycle is called for this purpose. If a milling cutter cannot be inserted at the center to remove stock from contour pockets, then it is necessary to predrill first.

Page 345 Programming technological functions (cycles) 8.3 Contour milling Procedure when centering The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Cont. mill.", "Predrilling", and "Centering" softkeys. The "Centering" input window opens. Parameters, G code program Parameters, ShopMill program Name of the program to be generated...

Page 346 Programming technological functions (cycles) 8.3 Contour milling Predrilling procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Cont. mill.", "Predrilling", and "Predrilling" softkeys. The "Predrilling" input window opens. Parameters, G code program Parameters, ShopMill program Name of the program to be generated...

Page 347: Milling Contour Pocket (Cycle63)
Programming technological functions (cycles) 8.3 Contour milling 8.3.10 Milling contour pocket (CYCLE63) Function Before you can machine a pocket with islands, you must enter the contour of the pocket and islands. The first contour you specify is interpreted as the pocket contour and all the others as islands.

Page 348 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Maximum plane infeed  Maximum plane infeed as a percentage of the milling cutter diameter  - (only for ∇ or ∇∇∇ base) Maximum depth infeed – (only for ∇ or ∇∇∇ edge) Plane finishing allowance –...

Page 349: Residual Material Contour Pocket (Cycle63)
Programming technological functions (cycles) 8.3 Contour milling Note When input manually, the starting point can also be located outside the pocket. This can be useful, for example, when machining a pocket which is open on one side. The machining operation then begins without insertion with a linear movement into the open side of the pocket.

Page 350 Programming technological functions (cycles) 8.3 Contour milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Contour milling" and "Pocket Res. Mat." softkeys. The "Pocket Res. Mat." input window opens. For the ShopMill program, press the "All parameters"...

Page 351: Milling Contour Spigot (Cycle63)
Programming technological functions (cycles) 8.3 Contour milling 8.3.12 Milling contour spigot (CYCLE63) Function You can mill any spigot using the "Mill spigot" cycle. Before you mill the spigot, you must first enter a blank contour and then one or more spigot contours.

Page 352 Programming technological functions (cycles) 8.3 Contour milling Parameters, G code program Parameters, ShopMill program Name of the program to be generated Tool name Machining plane Feedrate mm/min mm/rev Climbing Milling direction  Cutting edge number Conventional  Retraction plane Feedrate mm/min mm/rev Safety clearance...

Page 353: Residual Material Contour Spigot (Cycle63)
Programming technological functions (cycles) 8.3 Contour milling 8.3.13 Residual material contour spigot (CYCLE63) Function When you have milled a contour spigot and residual material remains, then this is automatically detected. You can use a suitable tool to remove this residual material without having to machine the whole spigot again, i.e.

Page 354 Programming technological functions (cycles) 8.3 Contour milling Parameters, G code program Parameters, ShopMill program Name of the program to be generated Tool name Machining plane Feedrate mm/min mm/rev Climbing Milling direction  S / V Spindle speed or constant cutting rate m/min Conventional ...

Page 355: Turning - Only For G Code Programs
Programming technological functions (cycles) 8.4 Turning - only for G code programs Turning - only for G code programs 8.4.1 General In all turning cycles apart from contour turning (CYCLE95), in the combined roughing and finishing mode, when finishing it is possible to reduce the feedrate as a percentage. Machine manufacturer Please also refer to the machine manufacturer's specifications.

Page 356 Programming technological functions (cycles) 8.4 Turning - only for G code programs Machine manufacturer Please also refer to the machine manufacturer's instructions. If the tool does not round the corner at the end of the cut, it is raised by the safety distance or a value specified in the machine data at rapid traverse.

Page 357 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Machining ∇ (roughing)  ∇∇∇ (finishing)  Position Stock removal position: Machining Stock removal direction (longitudinal or transverse) in the coordinate system direction Parallel to the Z axis (longitudinal) Parallel to the X axis (transverse) External Internal...

Page 358: Groove (Cycle930)
Programming technological functions (cycles) 8.4 Turning - only for G code programs 8.4.3 Groove (CYCLE930) Function You can use the "Groove" cycle to manufacture symmetrical and asymmetrical grooves on any straight contour elements. You can machine outer or inner grooves in the longitudinal or transverse directions. Use the "Groove width"...

Page 359 Programming technological functions (cycles) 8.4 Turning - only for G code programs Procedure The part program to be executed has been created and you are in the editor. Press the "Turning" softkey. Press the "Groove" softkey. The "Groove" input window opens. Select one of the three groove cycles with the softkey: Simple groove cycle The "Groove 1"...

Page 360: Undercut Form E And F (Cycle940)
Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit α1, α2 Flank angle 1 or flank angle 2 - (only for grooves 2 and 3) Degrees Asymmetric grooves can be described by separate angles. The angles can be between 0 and <...

Page 361 Programming technological functions (cycles) 8.4 Turning - only for G code programs Press the "Undercut" softkey. The "Undercut" input window opens. Select one of the following undercut cycles via the softkeys: Press the "Undercut form E" softkey. The "Undercut form E (DIN 509)" input window opens. - OR Press the "Undercut form F"...

Page 362: Thread Undercut (Cycle940)
Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Position Form F machining position: Undercut size according to DIN table: e.g.: F0.6 x 0.3 (undercut form F) Reference point X ∅ Reference point Z Allowance in X ∅...

Page 363 Programming technological functions (cycles) 8.4 Turning - only for G code programs Procedure The part program to be executed has been created and you are in the editor. Press the "Turning" softkey. Press the "Undercut" softkey. Press the "Thread undercut DIN" softkey. The "Thread Undercut (DIN 76)"...

Page 364 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Cross feed ∅ (abs) or cross feed (inc) - (only for ∇∇∇ and ∇ + ∇∇∇) Maximum depth infeed – (only for ∇ and ∇ + ∇∇∇) U or UX Finishing allowance in X or finishing allowance in X and Z –...

Page 365: Thread Turning (Cycle99)
Programming technological functions (cycles) 8.4 Turning - only for G code programs 8.4.6 Thread turning (CYCLE99) Function You can use the "Longitudinal thread", "Tapered thread" or "Face thread" cycle to turn external or internal threads with a constant or variable pitch. There may be single or multiple threads.

Page 366 Programming technological functions (cycles) 8.4 Turning - only for G code programs Procedure for longitudinal thread, tapered thread, or face thread The part program to be executed has been created and you are in the editor. Press the "Turning" softkey. Press the "Thread"...

Page 367 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Change in thread pitch per revolution - (only for P = mm/rev or in/rev) G = 0: The thread pitch P does not change. G > 0: The thread pitch P increases by the value G per revolution. G <...

Page 368 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit αP Infeed slope as angle – (alternative to infeed slope as flank) Degrees α > 0: Infeed along the rear flank α < 0: Infeed along the front flank α...

Page 369 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Thread pitch in mm/revolution  mm/rev in/rev Thread pitch in inch/revolution  turns/" Thread turns per inch  MODULUS Thread pitch in MODULUS  Change in thread pitch per revolution - (only for P = mm/rev or in/rev) G = 0: The thread pitch P does not change.

Page 370 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Thread run-out (inc) The thread run-out can be used if you wish to retract the tool obliquely at the end of the thread (e.g. lubrication groove on a shaft). Thread depth (inc) Infeed slope as flank (inc) –...

Page 371 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters, G code program (thread, conical) Machining plane Safety clearance Feedrate mm/min Parameters Description Unit Thread pitch in mm/revolution  mm/rev in/rev Thread pitch in inch/revolution  turns/" Thread turns per inch ...

Page 372 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Thread advance (inc) The starting point for the thread is the reference point (X0, Z0) brought forward by the thread advance W. The thread advance can be used if you wish to begin the individual cuts slightly earlier in order to also produce a precise start of thread.

Page 373: Thread Chain (Cycle98)
Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Thread changeover depth (inc) First machine all thread turns sequentially to thread changeover depth DA, then machine all thread turns sequentially to depth 2 · DA, etc.

Page 374 Programming technological functions (cycles) 8.4 Turning - only for G code programs Approach/retraction 1. Approach of the starting point determined in the cycle at the beginning of the run-in path for the first thread with G0 2. Infeed for roughing according to the defined infeed type. 3.

Page 375 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Thread pitch 1 mm/rev in/rev turns/" MODULUS Intermediate point 1 X ∅ (abs) or X1 or X1α  Intermediate point 1 in relation to X0 (inc) or ...

Page 376: Cut-Off (Cycle92)
Programming technological functions (cycles) 8.4 Turning - only for G code programs 8.4.8 Cut-off (CYCLE92) Function The "Cut-off" cycle is used when you want to cut off dynamically balanced parts (e.g. screws, bolts, or pipes). You can program a chamfer or rounding on the edge of the machined part. You can machine at a constant cutting rate V or speed S up to a depth X1, from which point the workpiece is machined at a constant speed.

Page 377 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters Description Unit Direction of spindle rotation Maximum speed limit - (only for constant cutting rate V) rev/min Reference point in X ∅ (abs, always diameter) Reference point in Z (abs) FS or R Chamfer width or rounding radius Depth for speed reduction ∅...

Page 378: Contour Turning - Only For G Code Programs
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Contour turning - only for G code programs 8.5.1 General information Function You can machine simple or complex contours with the "Contour turning" cycle. A contour comprises separate contour elements, whereby at least two and up to 250 elements result in a defined contour.

Page 379: Representation Of The Contour
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 5. Remove residual material (roughing) For G code programming, when removing stock, it must first be decided whether to rough (machine) with residual material detection or not. A suitable tool will allow you to remove this without having to machine the contour again.

Page 380: Creating A New Contour
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Foreground Background Meaning Black Blue Cursor on new element Black Orange Cursor on current element Black White Normal element White Element not currently evaluated (element will only be evaluated when it is selected with the cursor) Graphical display...

Page 381 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Press the "Contour" and "New contour" softkeys. The "New Contour" input window opens. Enter a name for the new contour. The contour name must be unique. Press the "Accept" softkey. The input window for the starting point of the contour appears.

Page 382: Creating Contour Elements
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.4 Creating contour elements Creating contour elements After you have created a new contour and specified the starting point, you can define the individual elements that make up the contour. The following contour elements are available for the definition of a contour: ●...

Page 383 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Additional functions The following additional functions are available for programming a contour: ● Tangent to preceding element You can program the transition to the preceding element as tangent. ●...

Page 384 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs The input screen to enter the contour opens, in which you initially enter a starting point for the contour. This is marked in the lefthand navigation bar using the "+" symbol. Press the "Accept"...

Page 385 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Contour element "Straight line e.g. Z" Parameters Description Unit End point Z (abs or inc) α1 Starting angle to Z axis Degrees α2 Angle to the preceding element Degrees Transition to next Type of transition...

Page 386 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Thread Length Z1 Length Z2 Radius R1 Radius R2 Insertion depth Chamfer Transition to following element - chamfer Grinding allowance Grinding allowance to right of contour ...

Page 387: Changing The Contour
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit β1 End angle to Z axis Degrees β2 Opening angle Degrees Transition to next Type of transition element Radius  Chamfer  Radius Transition to following element - radius Chamfer Transition to following element - chamfer Grinding allowance...

Page 388: Contour Call (Cycle62)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Procedure for changing a contour element Open the part program to be executed. With the cursor, select the program block where you want to change the contour. Open the geometry processor. The individual contour elements are listed.

Page 389 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Procedure The part program to be executed has been created and you are in the editor. Press the "Turning" and "Contour turning" softkeys. Press the "Contour" and "Contour call" softkeys. The "Contour Call"...

Page 390: Stock Removal (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.7 Stock removal (CYCLE952) Function For stock removal, the cycle takes into account a blank that can comprise a cylinder, an allowance on the finished-part contour or any unmachined-part contour. You must define an unmachined-part contour as a separate closed contour in advance of the finished-part contour.

Page 391 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Feedrate interruption To prevent the occurrence of excessively long chips during machining, you can program a feedrate interruption. Parameter DI specifies the distance after which the feedrate interruption should occur.

Page 392 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters, G code program Name of the program to be generated Machining plane Retraction plane Safety clearance Feedrate mm/min Residual With subsequent residual material removal material  ...

Page 393 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Constant cutting depth Alternating cutting depth - (only with align cut segmentation to edge) Maximum depth infeed - (only for position parallel to the contour and UX) UX or U Finishing allowance in X or finishing allowance in X and Z –...

Page 394: Stock Removal Residual (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.8 Stock removal residual (CYCLE952) Function Using the "Stock removal residual" function, you can remove material that has remained for stock removal along the contour. During stock removal along the contour, the cycle automatically detects any residual material and generates an updated blank contour.

Page 395 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit The machining direction depends on the stock removal direction and choice of tool. front Position  back  internal  external  Maximum depth infeed - (only for ∇) 1.

Page 396: Grooving (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.9 Grooving (CYCLE952) Function The "Grooving" function is used to machine grooves of any shape. Before you program the groove, you must define the groove contour. If a groove is wider than the active tool, it is machined in several cuts. The tool is moved by a maximum of 80% of the tool width for each groove.

Page 397 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters, G code program Name of the program to be generated Machining plane Retraction plane - (only for machining direction, longitudinal, internal) Safety clearance Feedrate mm/min Residual With subsequent residual material removal material ...

Page 398: Grooving Residual Material (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit - (only for unmachined part description, cylinder and allowance) For unmachined part description, cylinder  Allowance or cylinder dimension (abs or inc) For unmachined part description, allowance ...

Page 399 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Procedure The part program to be executed has been created and you are in the editor. Press the "Turning" and "Contour turning" softkeys. Press the "Grooving residual material" softkey. The "Grooving residual material"...

Page 400: Plunge Turning (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Allowance Allowance for pre-finishing - (only for ∇∇∇)  U1 contour allowance  Compensation allowance in X and Z direction (inc) – (only for allowance) Positive value: Compensation allowance is kept ...

Page 401 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Machining type You can freely select the machining type (roughing or finishing). For more detailed information, please refer to section "Stock removal". Procedure The part program to be executed has been created and you are in the editor.

Page 402 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Maximum depth infeed - (only for ∇) 1. Grooving limit tool (abs) – (only for face machining direction) 2. Grooving limit tool (abs) – (only for face machining direction) UX or U Finishing allowance in X or finishing allowance in X and Z –...

Page 403: Plunge Turning Residual Material (Cycle952)
Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.12 Plunge turning residual material (CYCLE952) Function The "Plunge turning residual material" function is used when you want to machine the material that remained after plunge turning. For a G code program, select the function in the screen.

Page 404 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Feedrate in X direction mm/rev Feedrate in Z direction mm/rev ∇ (roughing) Machining  ∇∇∇ (finishing)  Face Machining  direction Longitudinal  front Position ...

Page 405 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Set machining area Set machining area limits limits  – XA: 1. Limit XA ∅ – XB: 2. Limit XB ∅ (abs) or 2nd limit referred to XB (inc) –...

Page 406: Further Cycles And Functions
Programming technological functions (cycles) 8.6 Further cycles and functions Further cycles and functions 8.6.1 Swiveling plane/tool (CYCLE800) The CYCLE800 swivel cycle is used to swivel to any surface in order to either machine or measure it. In this cycle, the active workpiece zeros and the work offsets are converted to the inclined surface taking into account the kinematic chain of the machine by calling the appropriate NC functions - and rotary axes (optionally) are positioned.

Page 407 Programming technological functions (cycles) 8.6 Further cycles and functions The definition of the blank (WORKPIECE) always refers to the currently effective work offset. For programs that use "swivel", a swivel to zero must be made before the blank is defined. For ShopMill programs, the blank in the program header is automatically referred to the unswiveled state.

Page 408 Programming technological functions (cycles) 8.6 Further cycles and functions Aligning tools In contrast to "Swivel plane", no rotation is operative in the active frame chain (WCS) in the case of "Swivel tool" or "Align milling tool". Only the offsets calculated by the NC and the corresponding tool orientation are effective.

Page 409 Programming technological functions (cycles) 8.6 Further cycles and functions Swivel plane (only for G code programming) ● New Previous swivel frames and programmed frames are deleted and a new swivel frame is formed according to the values specified in the input screen. Every main program must begin with a swivel cycle with the new swivel plane, in order to ensure that a swivel frame from another program is not active.

Page 410 Programming technological functions (cycles) 8.6 Further cycles and functions When projection angles around YZ and ZY are programmed, the new Y-axis of the swiveled coordinate system lies in the old X-Y plane. ● directly For direct swiveling, the required positions of the rotary axes are specified. The HMI calculates a suitable new coordinate system based on these values.

Page 411 Programming technological functions (cycles) 8.6 Further cycles and functions ● Machine manufacturer has set the direction reference to rotary axis 1 (B) when he commissioned the swivel function. ● A rotation around X (WCS) of 10 degrees is programmed in the swivel cycle. The machine in the basic setting (pole setting) of the kinematics (B = 0 C = 0) is shown in the following diagram.

Page 412 Programming technological functions (cycles) 8.6 Further cycles and functions Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Various" softkey. Press the "Swivel plane" softkey. The "Swivel plane" input window opens. Press the "Basic setting"...

Page 413 Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit - (only for axis sequence) Rotation around X Degrees Rotation around Y Degrees Rotation around Z Degrees Projection Position of the projection in space - (only for swivel mode, projection angle) position Xα, Yα, Zβ...

Page 414: Swiveling Tool (Cycle800)
Programming technological functions (cycles) 8.6 Further cycles and functions 8.6.2 Swiveling tool (CYCLE800) 8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) After "Swivel plane", the tool orientation is always perpendicular on the machining plane. When milling with radial cutters, it can make technological sense to set the tool at an angle to the normal surface vector.

Page 415: Swiveling Tool/Orienting Milling Tools - Only For G Code Program (Cycle800)
Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit Name of the swivel data set No: No retraction before swiveling Retraction  Z: Retraction in the direction of machine axis Z  Z, X, Y: Move machining axis to retraction position before swiveling ...

Page 416: High-Speed Settings (Cycle832)
Programming technological functions (cycles) 8.6 Further cycles and functions Procedure The part program to be executed has been created and you are in the editor. Press the "Various" softkey. Press the "Swivel tool" and "Align milling tool" softkeys. The "Align milling tool" input window opens. Parameter Description Unit...

Page 417 - that are declared in the machine data for the reset state. References For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Machine manufacturer Please refer to the machine manufacturer's specifications.

Page 418: Subroutines
Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit Tolerance Tolerance of the machining axis ∇ (roughing) Machining  ∇∇ (pre-finishing)  ∇∇∇ (finishing)  Deselection  8.6.4 Subroutines If you require the same machining steps when programming different workpieces, you can define these machining steps in a separate subprogram.

Page 419 Programming technological functions (cycles) 8.6 Further cycles and functions Press the "Various" and "Subroutine" softkeys. Enter the path of the subprogram if the desired subprogram is not stored in the same directory as the main program. The subprogram is thus executed in the position pattern. Press the "Accept”...

Page 420: Further Cycles And Functions Shopmill
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill Further cycles and functions ShopMill 8.7.1 Transformations To make programming easier, you can transform the coordinate system. Use this possibility, for example, to rotate the coordinate system. Coordinate transformations only apply in the actual program. You can define shift, rotation, scaling or mirroring.

Page 421: Translation
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.2 Translation For each axis, you can program an offset of the zero point. New offset Additive offset Parameter Description Unit Offset  New offset Additive  Additive offset Offset X Offset Y Offset Z Milling...

Page 422: Rotation
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.3 Rotation You can rotate every axis through a specific angle. A positive angle corresponds to counterclockwise rotation. New rotation Additive rotation Parameter Description Unit Rotation  New rotation Additive ...

Page 423: Scaling
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.4 Scaling You can specify a scale factor for the active machining plane as well as for the tool axis. The programmed coordinates are then multiplied by this factor. New scaling Additive scaling Parameter Description...

Page 424: Mirroring
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.5 Mirroring Furthermore, you can mirror all axes. Enter the axis to be mirrored in each case. Note Travel direction of the milling cutter Note that with mirroring, the travel direction of the cutting tool (conventional/climbing) is also mirrored.

Page 425: Straight Or Circular Machining
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.6 Straight or circular machining When you want to perform straight or circular path movements or machining without defining a complete contour, you can use the functions "Straight line" or "Circle" respectively. General sequence To program simple machining operations, proceed as follows: ●...

Page 426 Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill Procedure The ShopMill program to be edited has been created and you are in the editor. Press the menu forward key and the "Straight Circle" softkey. Press the "Tool" softkey. The parameter screen "Tool"...

Page 427: Programming A Straight Line
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.7 Programming a straight line The tool moves at the programmed feedrate or with rapid traverse from its actual position to the programmed end position. Radius compensation Alternatively, you can implement the straight line with radius compensation. The radius compensation acts modally, therefore you must deactivate the radius compensation again when you want to traverse without radius compensation.

Page 428: Programming A Circle With Known Center Point
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill Parameter Description Unit Machining feedrate mm/rev mm/min mm/tooth Radius compensation Input defining which side of the contour the cutter travels in the programmed direction: Radius compensation to right of contour Radius compensation to left of contour Radius compensation off The previously programmed setting for radius compensation is used.

Page 429: Programming A Circle With Known Radius
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill Parameter Description Unit Target position Y (abs) or target position Y referred to the last programmed position (inc) Distance between circle starting point and center point in X direction (inc.) Distance between circle starting point and center point in Y direction (inc.) Machining feedrate mm/rev...

Page 430: Helix
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill Parameter Description Unit Target position Y (abs) or target position Y referred to the last programmed position (inc) Radius of arc. You can select the arc of your choice by entering a positive or a negative sign. mm/rev mm/min mm/tooth...

Page 431: Polar Coordinates
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.11 Polar coordinates If a workpiece has been dimensioned from a central point (pole) with radius and angles, you will find it helpful to program these as polar coordinates. You can program straight lines and circles as polar coordinates. Defining a pole You must define the pole before you can program a straight line or circle in polar coordinates.

Page 432: Straight Polar
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.12 Straight polar A straight line in the polar coordinate system is defined by a radius (L) and an angle (α). The angle refers to the X axis. The tool moves from its actual position along a straight line to the programmed end point at the machining feedrate or in rapid traverse.

Page 433: Circle Polar
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.13 Circle polar A circle in the polar coordinate system is defined by an angle (α). The angle refers to the X axis. The tool moves from its actual position on a circular path to the programmed end point (angle) at the machining feedrate.

Page 434: Obstacle
Programming technological functions (cycles) 8.7 Further cycles and functions ShopMill 8.7.14 Obstacle Function If there is an obstacle between 2 position patterns, it can be crossed. The height of the obstacle can be programmed absolutely or incrementally. If all positions in the 1st pattern have been machined, the tool axis travels with rapid traverse to a height corresponding to the obstacle height + safety clearance.

Page 435: Multi-Channel View
Multi-channel view Multi-channel view The multi-channel view allows you to simultaneously view two channels in the following operating areas: ● "Machine" operating area ● "Program" operating area Multi-channel view in the "Machine" operating area When a multi-channel machine, you have the option of simultaneously monitoring and influencing the execution of several programs.

Page 436 Multi-channel view 9.2 Multi-channel view in the "Machine" operating area Single channel view If, for your multi-channel machine, you always only wish to monitor one channel, then you can set a permanent single-channel view. Horizontal softkeys ● Block search When selecting the block search, the multi-channel view is kept. The block display is displayed as search window.

Page 437 Multi-channel view 9.2 Multi-channel view in the "Machine" operating area Displaying/hiding a multi-channel view Select the "Machine" operating area Select the operating mode "JOG", "MDA" or "AUTO". Press the menu forward key and the "Settings" softkey. Press the "Multi-channel view" softkey. In the window "Settings for multi-channel view"...

Page 438: Setting The Multi-Channel View
Multi-channel view 9.3 Setting the multi-channel view Setting the multi-channel view Setting Meaning View Here, you define whether one or two channels are displayed. 1 channel  2 channels  Channel selection and Here, you create the channel group, i.e. you specify which channels and sequence in which sequence are displayed in the multi-channel view.

Page 439 Multi-channel view 9.3 Setting the multi-channel view Press the menu forward key and the "Settings" softkey. Press the "Multi-channel view" softkey. The "Settings for multi-channel view" window is opened. Set the multi-channel or single-channel view and define which channels are to be seen in the "Machine" operating area - and in the double editor - in which sequence.

Page 440 Multi-channel view 9.3 Setting the multi-channel view Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 441: User Variables
User variables 10.1 Overview The defined user data may be displayed in lists. The following variables can be defined: ● Data parameters (R parameters) ● Global user data (GUD) is valid in all programs ● Local user data (LUD) is valid in one program ●...

Page 442: R Parameters
User variables 10.2 R parameters 10.2 R parameters R parameters (arithmetic parameters) are channel-specific variables that you can use within a G code program. G code programs can read and write R parameters. These values are retained after the control is switched off. Number of channel-specific R parameters The number of channel-specific R parameters is defined in a machine data element.

Page 443: Global Gud
User variables 10.3 Global GUD 10.3 Global GUD Global user data Global GUDs are NC global user data (Global User Data) that remains available after switching the machine off. GUDs apply in all programs. Definition A GUD variable is defined with the following: ●...

Page 444: Channel Gud
User variables 10.4 Channel GUD Press the "GUD selection" softkey and the "SGUD" to "GUD6" softkeys if you wish to display SGUD, MGUD, UGUD as well as GUD4 to GUD 6 of the global user variables. - OR - Press the "GUD selection" and ">>" softkeys as well as the "GUD7" to "GUD9"...

Page 445: Local Lud
User variables 10.5 Local LUD Procedure Select the "Parameter" operating area. Press the "User variable" softkey. Press the "Channel GUD" and "GUD selection" softkeys. A new vertical softkey bar appears. Press the "SGUD" ... "GUD6" softkeys if you want to display the SGUD, MGUD, UGUD as well as GUD4 to GUD 6 of the channel- specific user variables.

Page 446: Program Pud
User variables 10.6 Program PUD Proceed as follows Select the "Parameter" operating area. Press the "User variable" softkey. Press the "Local LUD" softkey. 10.6 Program PUD Program-global user data PUDs are global part program variables (Program User Data). PUDs are valid in all main programs and subroutines, where they can also be written and read.

Page 447: Searching For User Data
User variables 10.7 Searching for user data 10.7 Searching for user data You can search for R parameters and user data. Procedure Select the "Parameter" operating area. Press the "R parameters", "Global GUD", "Channel GUD", "Local GUD" or "Program PUD" softkeys to select the list in which you would like to search for user data.

Page 448 User variables 10.8 Defining and activating user variables Press the "Open" softkey. - OR - Press the key. - OR - Press the key. The selected file is opened in the editor and can be edited there. Define the desired user data.

Page 449: Teaching In A Program
Teaching in a program 11.1 Overview The "Teach in" function can be used to edit programs in the "AUTO" and "MDA" modes. You can create and modify simple traversing blocks. You traverse the axes manually to specific positions in order to implement simple machining sequences and make them reproducible.

Page 450: Inserting A Block
Teaching in a program 11.3 Inserting a block Operating mode or operating area switchover If you switch to another operating mode or operating area in teach-in mode, the position changes will be canceled and teach-in mode will be cleared. 11.3 Inserting a block You have the option of traversing the axes and writing the current actual values directly to a new position block.

Page 451: Input Parameters For Teach-In Blocks
Teaching in a program 11.3 Inserting a block 11.3.1 Input parameters for teach-in blocks Parameters for teach-in of position and teach-in of G0, G1, and circle end position CIP Parameter Description Approach position in X direction Approach position in Y direction Approach position in Z direction Feedrate (mm/r;...

Page 452: Teach-In Via Window
Teaching in a program 11.4 Teach-in via window Transition behavior at the beginning and end of the spline curve The following motion parameters are offered: Parameter Description Start BAUTO Automatic calculation BNAT Curvature is zero or natural BTAN Tangential EAUTO Automatic calculation ENAT Curvature is zero or natural...

Page 453 Teaching in a program 11.4 Teach-in via window Procedure Select the "Machine" operating area. Press the or key. Press the key. Press the "Teach prog." softkey. Use the cursor and input keys to position the cursor at the desired point in the program.

Page 454: Teach In Rapid Traverse G0
Teaching in a program 11.4 Teach-in via window 11.4.2 Teach in rapid traverse G0 You traverse the axes and teach-in a rapid traverse block with the approached positions. Note Selection of axes and parameters for teach-in You can select the axes to be included in the teach-in block in the "Settings" window. You also specify here whether motion and transition parameters are offered for teach-in.

Page 455: Teach-In A Spline
Teaching in a program 11.4 Teach-in via window 11.4.5 Teach-in A spline For Akima-spline interpolation, you enter interpolation points that are connected by a smooth curve. Enter a starting point and specify a transition at the beginning and end. You teach-in each interpolation point via "Teach in of position". Software option You require the "Spline-Interpolation"...

Page 456: Editing A Block
Teaching in a program 11.5 Editing a block Press the "Accept" softkey. A new program block will be inserted at the cursor position. - OR - Press the "Cancel" softkey to cancel your input. Note Selection of axes and parameters for teach-in You can select the axes to be included in the teach-in block in the "Settings"...

Page 457: Selecting A Block
Teaching in a program 11.6 Selecting a block Press the "Teach prog." softkey. Click the program block to be edited. Press the relevant softkey "Teach position, "Rap. tra. G0", "Straight line G1", or "Circ. interm. pos. CIP", and "Circ. end pos. CIP". The relevant windows with the input fields are displayed.

Page 458: Deleting A Block
Teaching in a program 11.7 Deleting a block 11.7 Deleting a block You have the option of deleting a program block entirely. Requirement "AUTO" mode: The program to be processed is selected. Proceed as follows Select the "Machine" operating area. Press the ...

Page 459 Teaching in a program 11.7 Deleting a block Press the "Teach prog." softkey. Press the ">>" and "Settings" softkeys. The "Settings" window appears. Under "Axes to be taught" and "Parameters to be taught", select the check boxes for the relevant settings and press the "Accept" softkey to confirm the settings.

Page 460 Teaching in a program 11.7 Deleting a block Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 461: Tool Management
Tool management 12.1 Lists for the tool management All tools and also all magazine locations that have been created or configured in the NC are displayed in the lists in the Tool area. All lists display the same tools in the same order. When switching between the lists, the cursor remains on the same tool in the same screen segment.

Page 462: Magazine Management
Tool management 12.2 Magazine management Search functions You have the option of searching through the lists according to the following objects: ● Tool ● Magazine location ● Empty location 12.2 Magazine management Depending on the configuration, the tool lists support a magazine management. Magazine management functions ●...

Page 463: Tool Types
Tool management 12.3 Tool types 12.3 Tool types A number of tool types are available when you create a new tool. The tool type determines which geometry data are required and how they will be computed. Tool types Figure 12-1 Example of Favorites list Figure 12-2 Available tools in the "New tool - milling cutter"...

Page 464 Tool management 12.3 Tool types Figure 12-3 Available tools in the "New tool - drill" window Figure 12-4 Available tools in the "New tool - special tools" window See also Changing a tool type (Page 494) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 465: Tool Dimensioning
Tool management 12.4 Tool dimensioning 12.4 Tool dimensioning This section provides an overview of the dimensioning of tools. Tool types Figure 12-5 End mill (Type 120) Figure 12-6 Face mill (Type 140) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 466 Tool management 12.4 Tool dimensioning Figure 12-7 Angle head cutter (Type 130) Figure 12-8 Drill (Type 200) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 467 Tool management 12.4 Tool dimensioning Figure 12-9 Tap (Type 240) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 468 Tool management 12.4 Tool dimensioning Figure 12-10 3D tool with an example of a cylindrical die-sinking cutter (Type 110) Figure 12-11 3D tool type with an example of a ballhead cutter (Type 111) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 469 Tool management 12.4 Tool dimensioning Figure 12-12 3D tool with an example of an end mill with corner rounding (Type 121) Figure 12-13 3D tool type with an example of a bevel cutter (Type 155) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 470 Tool management 12.4 Tool dimensioning Figure 12-14 3D tool with an example of a bevel cutter with corner rounding (Type 156) Figure 12-15 3D tool with an example of a tapered die-sinking cutter (Type 157) Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 471 Tool management 12.4 Tool dimensioning Figure 12-16 Electronic workpiece probe Machine manufacturer The tool length of the workpiece probe is measured to the center of the ball (length m) or to the ball circumference (length u). Please refer to the machine manufacturer's specifications. Note An electronic workpiece probe must be calibrated before use.

Page 472: Tool List
Tool management 12.5 Tool list 12.5 Tool list All parameters and functions that are required to create and set up the tools are displayed in the tool list. Each tool is uniquely identified by the tool identifier and the replacement tool number. Tool parameters Column heading Meaning...

Page 473 Tool management 12.5 Tool list Column heading Meaning Direction of spindle rotation Spindle not switched on CW spindle rotation CCW spindle rotation Coolant supply 1 and 2 (e.g. internal and external cooling) can be switched on and switched off. The coolant supply at the machine does not necessarily have to be set- M1 - M4 Other tool-specific functions such as additional coolant supply, monitoring functions for speed, tool breakage, etc.

Page 474: Additional Data
Tool management 12.5 Tool list Procedure Select the "Parameter" operating area. Press the "Tool list" softkey. The "Tool list" window is opened. See also Displaying tool details (Page 493) Changing a tool type (Page 494) 12.5.1 Additional data The following tool types require geometry data that is not included in the tool list display. Tools with additional geometry data Tool type Additional parameters...

Page 475: Creating A New Tool
Tool management 12.5 Tool list You can use the configuration file to specify the data to be displayed for specific tool types in the "Additional Data" window. Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure The tool list is opened. In the list, select an appropriate tool, e.g.

Page 476 You can define the following data in this window: ● Names ● Tool location type ● Size of tool References: For a description of configuration options, refer to the Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 477: Measuring The Tool
Tool management 12.5 Tool list 12.5.3 Measuring the tool You can measure the tool offset data for the individual tools directly from the tool list. Note Tool measurement is only possible with an active tool. Procedure The tool list is opened. Select the tool that you want to measure in the tool list and press the "Measure tool"...

Page 478: Delete Tool
Tool management 12.5 Tool list Press the "New cutting edge" softkey. A new data set is stored in the list. The cutting edge number is incremented by one and the offset data is assigned the values of the cutting edge on which the cursor is positioned.

Page 479: Loading And Unloading Tools
Tool management 12.5 Tool list 12.5.6 Loading and unloading tools You can load and unload tools to and from a magazine via the tool list. When a tool is loaded, it is taken to a magazine location. When it is unloaded, it is removed from the magazine and stored in the NC memory.

Page 480: Selecting A Magazine
Tool management 12.5 Tool list Multiple load points If you have configured several loading points for a magazine, then the "Loading Point Selection" window appears after pressing the "Load" softkey. Select the required loading point and confirm with "OK". Unloading tools Place the cursor on the tool that you would like to unload from the magazine and press the "Unload"...

Page 481 The magazine selection behavior with multiple magazines can be configured in different ways. Machine manufacturer Please refer to the machine manufacturer's specifications. References For a description of configuration options, refer to the Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 482: Tool Wear
Tool management 12.6 Tool wear 12.6 Tool wear All parameters and functions that are required during operation are contained in the tool wear list. Tools that are in use for long periods are subject to wear. You can measure this wear and enter it in the tool wear list.

Page 483 Tool management 12.6 Tool wear Column heading Meaning Tool life Tool life Workpiece count Number of workpieces Wear * Tool wear *Parameter depends on selection in TC Setpoint Setpoint for tool life, workpiece count, or wear. Prewarning limit Specification of the tool life, workpiece count or wear at which a warning is displayed.

Page 484: Reactivating A Tool
Tool management 12.6 Tool wear See also Displaying tool details (Page 493) Changing a tool type (Page 494) 12.6.1 Reactivating a tool You can replace disabled tools or make them ready for use again. Preconditions In order to reactivate a tool, the monitoring function must be activated and a setpoint must be stored.

Page 485: Tool Data Oem
Tool management 12.7 Tool data OEM References Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Multiple load points If you have configured several loading points for a magazine, then the "Loading Point Selection" window appears after pressing the "Load" softkey.

Page 486: Magazine
Tool management 12.8 Magazine 12.8 Magazine Tools are displayed with their magazine-related data in the magazine list. Here, you can take specific actions relating to the magazines and the magazine locations. Individual magazine locations can be location-coded or disabled for existing tools. Tool parameters Column heading Meaning...

Page 487 Tool management 12.8 Magazine Magazine list icons Icon/ Meaning Designation Tool type Red "X" The tool is disabled. Yellow triangle pointing The prewarning limit has been reached. downward Yellow triangle pointing The tool is in a special state. upward Place the cursor on the marked tool. A tooltip provides a short description.

Page 488: Positioning A Magazine
Tool management 12.8 Magazine 12.8.1 Positioning a magazine You can position magazine locations directly on the loading point. Procedure The magazine list is opened. Place the cursor on the magazine location that you want to position onto the load point. Press the "Position magazine"...

Page 489 Tool management 12.8 Magazine Procedure The magazine list is opened. Position the cursor on the tool that you wish to relocate to a different magazine location. Press the "Relocate" softkey. The "... relocate from location ... to location ..." window is displayed. The "Location"...

Page 490: Sorting Tool Management Lists
Tool management 12.9 Sorting tool management lists 12.9 Sorting tool management lists When you are working with many tools, with large magazines or several magazines, it is useful to display the tools sorted according to different criteria. Then you will be able to find a specific tool more quickly in the lists.

Page 491: Filtering The Tool Management Lists
Tool management 12.10 Filtering the tool management lists 12.10 Filtering the tool management lists The filter function allows you to filter-out tools with specific properties in the tool management lists. For instance, you have the option of displaying tools during machining that have already reached the pre-alarm limit in order to prepare the corresponding tools to be loaded.

Page 492: Specific Search In The Tool Management Lists
Tool management 12.11 Specific search in the tool management lists 12.11 Specific search in the tool management lists There is a search function in all tool management lists, where you can search for the following objects: ● Tools You enter a tool name. You can narrow down your search by entering a replacement tool number.

Page 493: Displaying Tool Details
Tool management 12.12 Displaying tool details Press the "Magazine location" softkey if you wish to search for a specific magazine location or a specific magazine. - OR - Press the "Empty location" softkey if you wish to search for a specific empty location.

Page 494: Changing A Tool Type
Tool management 12.13 Changing a tool type The "Tool details - all parameters" window is displayed. All of the available tool, cutting edge and monitoring data of the selected tool are displayed in the list. You can view all of the window contents using the horizontal scroll bar.

Page 495: Program Management
Program management 13.1 Overview You can access programs at any time via the Program Manager for execution, editing, copying, or renaming. Programs that you no longer require can be deleted to release their storage space. NOTICE Execution from USB FlashDrive Direct execution from a USB FlashDrive is not recommended.

Page 496 Program management 13.1 Overview Choosing storage locations In the horizontal softkey bar, you can select the storage location that contains the directories and programs that you want to display. In addition to the "NC" softkey, via which the passive file system data can be displayed, additional softkeys can be displayed. The "USB"...

Page 497 Program management 13.1 Overview ● Name The name may be a maximum of 24 characters long Permissible characters include all upper-case letters (without accents), numbers, and underscores. ● Type Directory: WPD Program: MPF Subprogram: SPF Initialization programs: INI Job lists: JOB Tool data: TOA Magazine assignment: TMA Zero points: UFR...

Page 498: Nc Memory
Program management 13.1 Overview 13.1.1 NC memory The complete NC working memory is displayed along with all tools and the main programs and subroutines. You can create further subdirectories here. Proceed as follows Select the "Program manager" operating area. Press the "NC" softkey. 13.1.2 Local drive Workpieces, main and subprograms are displayed that are saved in the user memory of the...

Page 499: Usb Drives
Program management 13.1 Overview Procedure The local drive is selected. Position the cursor on the main directory. Press the "New" and "Directory" softkeys. The "New Directory" window opens. In the "Name" entry field, enter "mpf.dir", "spf.dir" and "wks.dir" and press the "OK" softkey. The directories "Part programs", "Subprograms"...

Page 500: Opening And Closing The Program
Program management 13.2 Opening and closing the program 13.2 Opening and closing the program To view a program in more detail or modify it, open the program in the editor. With programs that are in the NCK memory, navigation is already possible when opening. The program blocks can only be edited when the program has been opened completely.

Page 501: Executing A Program
Program management 13.3 Executing a program Closing the program Press the ">>" and "Exit" softkeys to close the program and editor again. - OR - If you are at the start of the first line of the program, press the key to close the program and the editor.

Page 502 Program management 13.3 Executing a program Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure Select the "Program Manager" operating area. Select the desired storage location and position the cursor on the workpiece/program that you would like to execute. Press the "Select"...

Page 503: Creating A Directory/Program/Job List/Program List
Program management 13.4 Creating a directory/program/job list/program list 13.4 Creating a directory/program/job list/program list 13.4.1 Creating a new directory Directory structures help you to manage your program and data transparently. You can create subdirectories in a directory on the local drive and on USB/network drives. In a subdirectory, in turn, you can create programs and then create program blocks for them.

Page 504: Creating A New Workpiece
Program management 13.4 Creating a directory/program/job list/program list 13.4.2 Creating a new workpiece You can set up various types of files such as main programs, initialization files, tool offsets, etc. in a workpiece. Note Additional workpiece directories cannot be created within a workpiece directory (WPD). Proceed as follows Select the "Program manager"...

Page 505: Creating A New G Code Program
Program management 13.4 Creating a directory/program/job list/program list 13.4.3 Creating a new G code program You can create G code programs and then render G code blocks for them in a directory/workpiece. Procedure Select the "Program Manager" operating area. Select the desired storage location and position the cursor on the folder, in which you would like to store the program.

Page 506: Creating A New Shopmill Program
Program management 13.4 Creating a directory/program/job list/program list 13.4.4 Creating a new ShopMill program In the part program and workpiece directories, you can create ShopMill programs and then subsequently generate the machining steps for them. Procedure Select the "Program Manager" operating area. Select the desired storage location and position the cursor on the folder, in which you would like to store the program.

Page 507: Creating A Joblist
Program management 13.4 Creating a directory/program/job list/program list Procedure Select the "Program manager" operating area. Select the desired storage location and position the cursor on the folder, in which you would like to create the file. Press the "New" and "Any" softkeys. The "Any new program"...

Page 508 Comments are identified in the job list by ";" at the start of the line or by round brackets. Template You can select a template from Siemens or the machine manufacturer when creating a new job list. Executing a workpiece If the "Select"...

Page 509: Creating A Program List
Program management 13.4 Creating a directory/program/job list/program list 13.4.7 Creating a program list You can also enter programs in a program list that are then selected and executed from the PLC. The program list may contain up to 100 entries. Machine manufacturer Please refer to the machine manufacturer's specifications.

Page 510: Creating Templates
Program management 13.5 Creating templates 13.5 Creating templates You can store your own templates to be used for creating part programs and workpieces. These templates provide the basic framework for further editing. You can use them for any part programs or workpieces you have created. Storage location for templates The templates used to create part programs or workpieces are stored in the following directories:...

Page 511: Displaying The Program In The Preview
Program management 13.6 Displaying the program in the Preview. 13.6 Displaying the program in the Preview. You can show the content on a program in a preview before you start editing. Procedure Select the "Program manager" operating area. Select a storage location and place the cursor on the relevant program.

Page 512 Program management 13.7 Selecting several directories/programs The softkey is active. Select the required directories/programs with the cursor keys or mouse. Press the "Select" softkey again to deactivate the cursor keys. Canceling a selection By reselecting an element, the existing selection is canceled. Selecting via keys Key combination Meaning...

Page 513: Copying And Pasting A Directory/Program
Program management 13.8 Copying and pasting a directory/program Selecting with the mouse Key combination Meaning Left mouse Click on element: The element is selected. A previously existing selection is canceled. Left mouse + Expand selection consecutively up to the next click. Pressed Left mouse + Expand selection to individual elements by clicking.

Page 514 Program management 13.8 Copying and pasting a directory/program Example If the name is not changed during the copy procedure, a copy is created automatically: MYPROGRAM.MPF is copied to MYPROGRAM__1.MPF. The next time it is copied, it is changed to MYPROGRAM__2.MPF, etc. If the files MYPROGRAM.MPF, MYPROGRAM__1.MPF, and MYPROGRAM__3.MPF already exist in a directory, MYPROGRAM__2.MPF is created as the next copy of MYPROGRAM.MPF.

Page 515: Deleting A Program/Directory
Program management 13.9 Deleting a program/directory - OR - Enter another name if you want to paste the directory/program under another name and press the "OK" softkey. Note Copying files in the same directory You cannot copy files to the same directory. You must copy the file under a new name. 13.9 Deleting a program/directory 13.9.1...

Page 516: Renaming File And Directory Properties
Program management 13.10 Renaming file and directory properties - OR -. Press the "Cancel" softkey to cancel the process. 13.10 Renaming file and directory properties Information on directories and files can be displayed in the "Properties for ..." window. Information on the creation date is displayed near the file's path and name. You can change names.

Page 517: Extcall
Program management 13.11 EXTCALL 13.11 EXTCALL The EXTCALL command can be used to access files on a local drive, USB data carriers or network drives from a part program. The programmer can set the source directory with the setting data SD $SC42700 EXT_PROG_PATH and then specify the file name of the subprogram to be loaded with the EXTCALL command.

Page 518 Program management 13.11 EXTCALL ● Call of network drive, if SD42700 is empty: e.g. EXTCALL "//computer name/enabled drive/TEST.SPF" - OR - Calls the network drive, if SD $SC42700 "//Computer name/enabled drive" contains: EXTCALL "TEST.SPF" ● Use of the HMI user memory (local drive): –...

Page 519: Backing Up Data
Program management 13.12 Backing up data 13.12 Backing up data 13.12.1 Generating an archive in the Program Manager You have the option of archiving individual files from the NC memory and the local drive. Archive formats You have the option of saving your archive in the binary and punched tape format. Save target The archive folder of the system data in the "Startup"...

Page 520: Generating The Archive Via Series Startup
Program management 13.12 Backing up data Press "OK". The "Generate Archive: Name" window opens. Select the format (e.g. archive ARC (binary format)), enter the desired name and press the "OK" softkey. A message informs you if archiving was successful. 13.12.2 Generating the archive via series startup If you only want to backup specific data, then you can select the desired files directly from the data tree and generate an archive.

Page 521 Program management 13.12 Backing up data Procedure Select the "Start-up" operating area. Press the "System data" softkey. The data tree opens. In the data tree, select the required files from which you want to generate an archive. - OR - If you want to back up several files or directories, press the "Select"...

Page 522: Reading In An Archive
Program management 13.12 Backing up data 13.12.3 Reading in an archive If you want to read in a specific archive, you can select this directly from the data tree. Procedure Select the "Start-up" operating area. Press the "System data" softkey. Below the "Archive"...

Page 523: Setup Data
Program management 13.13 Setup data 13.13 Setup data 13.13.1 Backing up setup data Apart from programs, you can also save tool data and zero point settings. You can use this option, for example, to back up tools and zero point data for a specific machining step program.

Page 524 Program management 13.13 Setup data Data Basic zero points   Directory The directory is displayed, in which the selected program is located. File name Here you have the option of changing the suggested file names. Note Magazine assignment You can only read out the magazine assignments if your system provides support for loading and unloading tool data to and from the magazine.

Page 525: Reading-In Set-Up Data
Program management 13.13 Setup data Note Program selection If a main program as well as an INI file with the same name are in a directory, when selecting the main program, initially, the INI file is automatically started. In this way, unwanted tool data can be changed.

Page 526 Program management 13.13 Setup data Selecting loading point For a magazine, if more than one loading point was set-up, using the "Select loading point" softkey, you have the option of opening a window in which you can assign a loading point to a magazine.

Page 527: V24
Program management 13.14 V24 13.14 13.14.1 Reading-in and reading-out archives You have the option of reading-out and reading-in archives in the "Program Manager" operating area as well as in the "Start-up" operating area via the serial V24 interface. Availability of the serial V24 interface ●...

Page 528 Program management 13.14 V24 Procedure Select the "Program Manager" operating area, and press the "NC" or "Local drive" softkey - OR - Select the "Start-up" operating area and press the "System data" softkey. Reading-out archives Select the directories or the files that you wish to send to V24. Press the ">>"...

Page 529: Setting V24 In The Program Manager
Program management 13.14 V24 13.14.2 Setting V24 in the program manager V24 setting Meaning Protocol The following protocols are supported for transfer via the V24 interface: RTS/CTS (default setting)  Xon/Xoff  Transfer It is also possible to use a secure protocol for data transfer (ZMODEM protocol).

Page 530 Program management 13.14 V24 V24 setting Meaning End of data transfer (hex) Only for punched tape format Stop with end of data transfer character The default setting for the end of data transfer character is (HEX) 1A Time monitoring (sec) Time monitoring For data transfer problems or at the end of data transfer (without end of data transfer character) data transfer is interrupted after the...

Page 531: Setting Up Drives
Setting up drives 14.1 Overview Set up connections Up to 8 connections to so-called logical drives (data carriers) can be configured. These drives can be accessed in the "Program manager" and "Startup" operating areas. The following logical drives can be set up: ●...

Page 532: Setting Up Drives
Setting up drives 14.2 Setting up drives 14.2 Setting up drives The "Set-up drives" window is available in the "Startup" operating area for configuration. File The created configuration data is stored in the "logdrive.ini" file. This file is located in the /user/sinumerik/hmi/cfg directory.

Page 533 Setting up drives 14.2 Setting up drives Entry Meaning sk_usb_front.png Icon file name. Is displayed on the softkey. sk_local_drive.png Icon file name. Is displayed on the softkey. Text file slpmdialog File for softkey dependent on the language. If nothing is specified in the input fields, the text appears on the softkey as Text context SlPmDialog...

Page 534 Setting up drives 14.2 Setting up drives Press the "Activate drive" softkey. The drive is activated. The operating system now checks the entered data and whether the connection is established. An OK message is output in the dialog line if an error is not identified.

Page 535: Ht 8
HT 8 15.1 HT 8 overview The mobile SINUMERIK HT 8 handheld terminal combines the functions of an operator panel and a machine control panel. It is therefore suitable for visualization, operation, teach in, and programming at the machine. Customer keys (user-defined) Traversing keys User menu key Handwheel (optional)

Page 536 References For more information about connection and startup of the HT 8, see the following references: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Customer keys The four customer keys are freely assignable and can be set up customer-specifically by the machine manufacturer.

Page 537 You can display the operating area menu by touching the display symbol for the active operating area. Handwheel The HT 8 is available with a hand wheel. References For information about connecting the hand wheel, refer to: Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 538: Traversing Keys
HT 8 15.2 Traversing keys 15.2 Traversing keys The traversing keys are not labeled. However, you can display a label for the keys in place of the vertical softkey bar. Labeling of the traversing keys is displayed for up to six axes on the touch panel by default. Machine manufacturer Please refer to the machine manufacturer's specifications.

Page 539: Machine Control Panel Menu
HT 8 15.3 Machine control panel menu 15.3 Machine control panel menu Here you select keys from the machine control panel which are reproduced by the software by touch operation of the relevant softkeys. See chapter "Controls on the machine control panel" for a description of the individual keys. Note PLC interface signals that are triggered via the softkeys of the machine control panel menus are edge triggered.

Page 540: Virtual Keyboard
HT 8 15.4 Virtual keyboard Softkeys on the machine control panel menu Available softkeys: "Machine" softkey Select the "Machine" operating area "[VAR]" softkey Select the axis feedrate in the variable increment "1… n CHANNEL" Change the channel softkey "Single Block" Switch single block execution on/off softkey "WCS MCS"...

Page 541 HT 8 15.4 Virtual keyboard Positioning of the virtual keyboard You can position the virtual keyboard anywhere in the window by pressing the empty bar next to the "Close window" icon with your finger or a stylus and moving it back and forth. Special keys on the virtual keyboard Num: Reduces the virtual keyboard to the number block.

Page 542: Calibrating The Touch Panel
HT 8 15.5 Calibrating the touch panel 15.5 Calibrating the touch panel It is necessary to calibrate the touch panel upon first connection to the controller. Note Recalibration If the operation is not exact, then redo the calibration. Procedure Press the back key and the key at the same time to start the TCU service screen.

Page 543: Easy Message (828D Only)
Easy Message (828D only) 16.1 Overview Easy Message enables you to be informed about certain machine states by means of SMS messages via a connected modem: ● For example, you would like to be informed about emergency stop states ● You would like to know when a batch has been completed Control commands ●...

Page 544: Activating Easy Message
Easy Message (828D only) 16.2 Activating Easy Message References Information on the GSM modem can be found in the PPU SINUMERIK 828D Manual Calling the SMS Messenger Select the "Diagnostics" operating area. Press the "Easy Msg." softkey. 16.2 Activating Easy Message To commission the connection to the modem for the SMS Messenger, activate the SIM card at the initial start-up.

Page 545: Creating/Editing A User Profile
Easy Message (828D only) 16.3 Creating/editing a user profile Activating a new SIM card Press the "Easy Msg." softkey. The "SMS Messenger" window appears. "Status" shows that the connection to the modem has been activated. Press the "Settings" softkey. Press the "Delete PIN" softkey to delete the stored PIN. Enter the new PIN in the "PIN Input"...

Page 546: Setting-Up Events
Easy Message (828D only) 16.4 Setting-up events In the area "send SMS for the following events" area, activate the appropriate checkbox and when required, enter the desired value (e.g. the unit quantity, which when it is reached, a notification should be sent).

Page 547 Easy Message (828D only) 16.4 Setting-up events ● Measuring cycle messages for tools An SMS is sent if measuring cycle messages are output that involve tools. ● Measuring cycle messages for workpieces An SMS is sent if measuring cycle messages are output that involve workpieces. ●...

Page 548: Logging An Active User On And Off
Easy Message (828D only) 16.5 Logging an active user on and off Press the "Save" softkey to save the settings for the result. Press the "Standard" softkey to return to the standard settings for the events. 16.5 Logging an active user on and off Only active users receive an SMS message for the specified events.

Page 549: Displaying Sms Logs
Easy Message (828D only) 16.6 Displaying SMS logs 16.6 Displaying SMS logs The SMS data traffic is recorded in the "SMS Log" window. In this way, it is possible to see the chronological sequence of activates when a fault occurs. Symbols Description Incoming SMS message for the Messenger.

Page 550: Making Settings For Easy Message
Easy Message (828D only) 16.7 Making settings for Easy Message 16.7 Making settings for Easy Message You can change the following Messenger configuration in the "Settings" window: ● Name of the controller that is part of an SMS message ● Number of sent messages –...

Page 551: Easy Extend (828D Only)
Easy Extend (828D only) 17.1 Overview Easy Extend enables machines to be retrofitted with additional units, which are controlled by the PLC or that require additional NC axes (such as bar loaders, swiveling tables or milling heads), at a later point in time. These additional devices are easily commissioned, activated, deactivated or tested with Easy Extend.

Page 552: Enabling A Device
Easy Extend (828D only) 17.2 Enabling a device 17.2 Enabling a device The available device options are protected by a password. Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure Select the "Parameter" operating area. Press the menu forward key and then the "Easy Extend" softkey. A list of the connected devices is displayed.

Page 553: Activating And Deactivating A Device
Easy Extend (828D only) 17.3 Activating and deactivating a device 17.3 Activating and deactivating a device Status Meaning Device activated System waiting for PLC checkback signal Device faulty Interface error in the communication module Procedure Easy Extend is opened. You can select the desired device in the list with the and ...

Page 554: Commissioning Easy Extend
Easy Extend (828D only) 17.4 Commissioning Easy Extend 17.4 Commissioning Easy Extend As a rule, the "Easy Extend" function has already been commissioned by the machine manufacturer. If a first commissioning has not been performed or if, for example, function tests are to be performed again (e.g.

Page 555: Service Planner (828D Only)
Service Planner (828D only) 18.1 Performing and monitoring maintenance tasks With the "Service Planner", maintenance tasks have been set up that have to be performed at certain intervals (e.g. top up oil, change coolant). A list is displayed of all the maintenance tasks that have been set up together with the time remaining until the end of the specified maintenance interval.

Page 556 Service Planner (828D only) 18.1 Performing and monitoring maintenance tasks Procedure Select the "Diagnostics" operating area. Press the menu forward key and then the "Service planner" softkey. The window with the list of all the maintenance tasks that have been set up appears.

Page 557: Set Maintenance Tasks
Service Planner (828D only) 18.2 Set maintenance tasks 18.2 Set maintenance tasks You can make the following changes in the list of maintenance tasks in the configuration mode: ● Set up a maximum of 32 maintenance tasks with interval, initial warning and number of warnings to be acknowledged ●...

Page 558 Service Planner (828D only) 18.2 Set maintenance tasks Procedure Select the "Diagnostics" operating area. Press the menu forward key and then the "Service planner" softkey. The window opens and displays a list of all the tasks that have been set up. The values cannot be edited.

Page 559: Ladder Viewer And Ladder Add-On (828D Only)
Ladder Viewer and Ladder add-on (828D only) 19.1 PLC diagnostics A PLC user program consists to a large degree of logical operations to implement safety functions and to support process sequences. These logical operations include the linking of various contacts and relays. These logic operations are displayed in a ladder diagram. Ladder add-on tool As a rule, the failure of a single contact or relay results in a failure of the whole system.

Page 560: Structure Of The User Interface
Ladder Viewer and Ladder add-on (828D only) 19.2 Structure of the user interface 19.2 Structure of the user interface Figure 19-1 Screen structure Table 19- 1 Key to screen layout Screen element Display Meaning Application area Supported PLC program language Name of the active program block Representation: Symbolic name (absolute name) Program status...

Page 561: Control Options
Ladder Viewer and Ladder add-on (828D only) 19.3 Control options Screen element Display Meaning Focus Performs the tasks of the cursor Information line Displays information, e.g. for searching 19.3 Control options In addition to the softkeys and the navigation keys, there are further shortcuts in this area. Shortcuts The cursor keys move the focus over the PLC user program.

Page 562 Ladder Viewer and Ladder add-on (828D only) 19.3 Control options Shortcuts Action To the last field of the last network -or- Open the next program block in the same window Open the previous program block in the same window The function of the Select key depends on the position of the input focus.

Page 563: Displaying Plc Properties
Ladder Viewer and Ladder add-on (828D only) 19.4 Displaying PLC properties 19.4 Displaying PLC properties The following PLC properties can be displayed in the "SIMATIC LAD" window: ● Operating mode ● Name of the PLC project ● PLC system version ●...

Page 564: Displaying And Editing Plc Signals
Ladder Viewer and Ladder add-on (828D only) 19.6 Displaying and editing PLC signals Procedure Ladder add-on tool is opened. Press the "NC/PLC variables" softkey. The "NC/PLC Variables" window appears. 19.6 Displaying and editing PLC signals PLC signals are displayed and can be changed here in the "PLC status list" window. The following lists are shown Inputs (IB) Bit memories (MB)

Page 565: Displaying Information On The Program Blocks
Ladder Viewer and Ladder add-on (828D only) 19.7 Displaying information on the program blocks 19.7 Displaying information on the program blocks You can display all the logic and graphic information of a program block. Display program block In the "Program block" list, select the program block that you want to display. Logic information The following logic information is displayed in a ladder diagram (LAD): ●...

Page 566: Downloading A Plc User Program
Ladder Viewer and Ladder add-on (828D only) 19.8 Downloading a PLC user program Procedure Ladder add-on tool is opened. Press the "Window 1" or "Window 2" softkey. Press the "Program block" softkey. The "Program block" list is displayed. Press the "Properties" softkey if you wish to display additional information.

Page 567: Editing The Local Variable Table
Ladder Viewer and Ladder add-on (828D only) 19.9 Editing the local variable table Procedure Ladder add-on tool is opened. You have changed project data. Press the "PLC Stop" softkey if the PLC is in the run mode. Press the "Load to CPU" softkey to start the loading operation. All data classes are loaded.

Page 568 Ladder Viewer and Ladder add-on (828D only) 19.9 Editing the local variable table Procedure The ladder diagram display (LAD) is opened. Press the "Program block" softkey. Press the "Local variables" softkey. The "Local Variables" window appears and lists the created variables. Press the "Edit"...

Page 569: Creating A New Block
Ladder Viewer and Ladder add-on (828D only) 19.10 Creating a new block 19.10 Creating a new block Create INT blocks i you wish to make changes with the PLC user program. Name INT _100, INT_101 The number from the selection field "Number, interrupt program" is taken for the name of the INT block.

Page 570: Editing Block Properties
Ladder Viewer and Ladder add-on (828D only) 19.11 Editing block properties 19.11 Editing block properties You can edit the title, author and comments of an INT block. Note You cannot edit the block name, interrupt number and data class assignment. Procedure The ladder diagram display is opened.

Page 571 Ladder Viewer and Ladder add-on (828D only) 19.12 Inserting and editing networks Note Logical AND (serial contact) and logical OR (parallel contact) are not possible. The bit combinations comprise one or several logical operations and the assignment to an output / bit memory. If the cursor is moved further to the left with the arrow key, the type of assignment or a logic operation can be selected.

Page 572: Editing Network Properties
Ladder Viewer and Ladder add-on (828D only) 19.13 Editing network properties Position the cursor on the operation that you want to delete and press the "Delete operation" softkey. - OR - Position the cursor on the title of the network that you want to delete and press the "Delete network"...

Page 573: Displaying And Editing Symbol Tables
Ladder Viewer and Ladder add-on (828D only) 19.14 Displaying and editing symbol tables 19.14 Displaying and editing symbol tables You can display the symbol tables that are used to obtain an overview of the global operands available in the project - which you can then edit. The name, address and possibly also a comment is displayed for each entry.

Page 574: Inserting/Deleting A Symbol Table
Ladder Viewer and Ladder add-on (828D only) 19.15 Inserting/deleting a symbol table 19.15 Inserting/deleting a symbol table New user symbol tables can be generated and changed. Tables that are no longer used can be deleted. Note Delete symbol table The "Delete" softkey is only available if a user symbol table has been selected. Procedure The symbol table is opened.

Page 575: Searching For Operands
Ladder Viewer and Ladder add-on (828D only) 19.16 Searching for operands 19.16 Searching for operands You can use the search function to quickly reach points in very large programs where you would like, for example, to make changes. Restricting the search ●...

Page 576: Displaying The Network Symbol Information Table
Ladder Viewer and Ladder add-on (828D only) 19.17 Displaying the network symbol information table Further search options Press the "Go to start" softkey to jump to the start of the ladder diagram in window 1 or window 2, or the list (cross references, symbol table).

Page 577: Displaying/Canceling The Access Protection
Ladder Viewer and Ladder add-on (828D only) 19.18 Displaying/canceling the access protection 19.18 Displaying/canceling the access protection You can password protect your program organizational units (POUs) in the PLC 828 programming tool. This prevents other users from accessing this part of the program. This means that it is invisible to other users and is encrypted when it is downloaded.

Page 578 Ladder Viewer and Ladder add-on (828D only) 19.19 Displaying cross references Searching Using a specific search, you can go directly to the location that you wish to view in more detail: ● Search for operand ● Jump to sought line Procedure Ladder add-on tool is opened.

Page 579: Alarms, Error Messages, And System Alarms
Alarms, error messages, and system alarms 20.1 Displaying alarms If faulty conditions are recognized in the operation of the machine, then an alarm will be generated and, if necessary, the machining will be interrupted. The error text that is displayed together with the alarm number gives you more detailed information on the error cause.

Page 580 Alarms, error messages, and system alarms 20.1 Displaying alarms Position the cursor on an alarm. Press the key that is specified as acknowledgement symbol to delete the alarm. - OR - Press the "Delete HMI alarm" softkey to cancel an HMI alarm. - OR - Press the "Acknowledge alarm"...

Page 581: Displaying An Alarm Log
Alarms, error messages, and system alarms 20.2 Displaying an alarm log 20.2 Displaying an alarm log A list of all the alarms and messages that have occurred so far are listed in the "Alarm Log" window. Up to 500 administered, incoming and outgoing events are displayed in chronological order. Machine manufacturer Please refer to the machine manufacturer's specifications.

Page 582: Plc And Nc Variables
Alarms, error messages, and system alarms 20.4 PLC and NC variables Proceed as follows Select the "Diagnosis" operating area. Press the "Messages" softkey. The "Messages" window appears. 20.4 PLC and NC variables 20.4.1 Displaying and editing PLC and NC variables The "NC/PLC variables"...

Page 583 Alarms, error messages, and system alarms 20.4 PLC and NC variables PLC variables Inputs Input bit (Ex), input byte (EBx), input word (EWx), input double word (EDx) Outputs Output bit (Ax), output byte (ABx), output word (AWx), output double word (ADx) Bit memory Memory bit (Mx), memory byte (MBx), memory word (MWx), memory...

Page 584 Alarms, error messages, and system alarms 20.4 PLC and NC variables Note NC system variables and PLC variables  System variables can be dependent on the channel. When the channel is switched over, the values from the corresponding channel are displayed. ...

Page 585 Alarms, error messages, and system alarms 20.4 PLC and NC variables Press the "Display comments" softkey. The "Comments" column is displayed. You have the option of creating comments or editing existing comments. Press the "Display comments" softkey once again to hide the column again.

Page 586: Saving And Loading Screen Forms
Alarms, error messages, and system alarms 20.4 PLC and NC variables 20.4.2 Saving and loading screen forms You have the option of saving the configurations of the variables made in the "NC/PLC variables" window in a screen form that you reload again when required. Editing screen forms If you change a screen form that has been loaded, then this is marked using with * after the screen form name.

Page 587: Loading Plc Symbols
Alarms, error messages, and system alarms 20.4 PLC and NC variables 20.4.3 Loading PLC symbols PLC data can also be edited via symbols. To do this, the symbol tables and texts for the symbols in the PLC project must have been suitably prepared (STEP7) and made available in SINUMERIK Operate.

Page 588: Version
Alarms, error messages, and system alarms 20.5 Version 20.5 Version 20.5.1 Displaying version data The following components with the associated version data are specified in the "Version data" window: ● System software ● Basic PLC program ● PLC user program ●...

Page 589: Save Information
Alarms, error messages, and system alarms 20.5 Version 20.5.2 Save information All the machine-specific information of the controller is combined in a configuration via the user interface. You can save machine-specific information on the drives that have been set- Procedure Select the "Diagnostics"...

Page 590: Logbook
Alarms, error messages, and system alarms 20.6 Logbook 20.6 Logbook The logbook provides you with the machine history in an electronic form. If service is carried out on the machine, this can be electronically saved. This means that it is possible to obtain a picture about the "History"...

Page 591: Making/Searching For A Logbook Entry
Alarms, error messages, and system alarms 20.6 Logbook 20.6.2 Making/searching for a logbook entry Using the "New logbook entry" window to make a new entry into the logbook. Enter your name, company and department and a brief description of the measure taken or a description of the fault.

Page 592: Creating Screenshots
Alarms, error messages, and system alarms 20.7 Creating screenshots Additional search option Press the "Go to Beginning" softkey to start the search at the latest entry. Press the "Go to End" softkey to start the search at the oldest entry. 20.7 Creating screenshots You can create screenshots of the current user interface.

Page 593: Remote Diagnostics
Alarms, error messages, and system alarms 20.8 Remote diagnostics 20.8 Remote diagnostics 20.8.1 Setting remote access You can influence the remote access to your control in the "Remote diagnostics (RCS)" window. Here, rights for all types of remote control are set. The selected rights are defined from the PLC and using the setting at the HMI.

Page 594 Press the "OK" softkey. The settings are accepted and saved. References For a description of configuration options, refer to the Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 595: Permit Modem
Alarms, error messages, and system alarms 20.8 Remote diagnostics 20.8.2 Permit modem You can permit remote access to your control via a teleservice adapter IE connected at X127. Machine manufacturer Please refer to the machine manufacturer's specifications. Software option You need the "MC Information System RCS Host" option to display the "Permit modem"...

Page 596: Exit Remote Diagnostics
Press the "Change" softkey if you would like to edit the values. Press the "OK" softkey. The request is sent to the remote PC. References Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl 20.8.4 Exit remote diagnostics Procedure The "Remote diagnostics (RCS)" is opened and it is possible that remote monitoring or remote access is active.

Page 597: Appendix
This document will be continuously improved with regard to its quality and ease of use. Please help us with this task by sending your comments and suggestions for improvement via e-mail or fax to: E-mail: mailto:[email protected] Fax: +49 9131 - 98 2176 Please use the fax form on the back of this page.

Page 598 Appendix A.1 Feedback on the documentation Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 599: Overview
Appendix A.2 Overview Overview Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 600 Appendix A.2 Overview Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

Page 601: Index
Index Search pointer, 111, 143, 146, 147 Search target parameters, 148 Search target specification, 145 Boring - CYCLE86 Actual-value display, 33 Function, 273 Alarm log Parameter, 275 display, 581 Alarms, 579 Align milling tool - CYCLE800 Function, 415 Parameter, 416 Centering - CYCLE81 Any file Function, 266...

Page 602 Index Parameters, predrilling, 346 Parameters, centering, 345 Contour turning - CYCLE952 Parameters, predrilling, 346 Function, grooving, 396 CYCLE70 - engraving Function, grooving residual material, 398 Function, 323 Function, plunge turning, 400 Parameters, 327 Function, plunge turning residual material, 403 CYCLE70 - thread milling Function, stock removal, 390 Function, 319 Function, stock removal residual, 394...

Page 603 Index Parameter, 275 Directory, 515 CYCLE899 - open slot Program, 515 Function, 311 Device Parameters, 317 Activate/deactivate, (See Easy Extend) CYCLE92 - cut-off Enabling, (See Easy Extend) Function, 376 Directory Parameter, 377 Copying, 513 CYCLE930 - groove Creating, 503 Function, 358 Deleting, 515 Parameter, 360 Highlight, 511...

Page 604 Index Program, 501 HOLES2 - circle position pattern EXTCALL, 517 Function, 286 Parameter, 287 HT 8, 535 Enabling button, 536 Touch Panel, 542 Face milling Traversing keys, 538 in JOG, 130 User menu, 539 Face milling - CYCLE61 Virtual keyboard, 540 Function, 289 Parameter, 291 Feed data...

Page 605 Index Stopping, 135 Parameter, 331 Machining schedule Number of teeth, 472 ShopMill, 218 Machining step program, 217 Magazine Open, 486 Obstacle, 434 Positioning, 488 Offset, 421 Selecting, 480 Online help Magazine management, 462 Context-sensitive, 47 Maintenance tasks Open Monitoring/performing, 555 Program, 500 Setting up, 557 Second program, 160...

Page 606 Index Function, 295 ShopMill, 218 Parameter, 298 Programs Polar coordinates, 431 Correcting, 35, 138, 141 Positions Editing, 156 Parameter, obstacle, 434 Managing, 495 Parameter, repeat, 288 Renumbering blocks, 160 Preview Replacing text, 158 Program, 511 Running-in, 137 Probe, 68 Searching for a program position, 157 Electronic, 74 Selecting, 136 Program...

Page 607 Index Rotation, 422 Views, 183 Simultaneous recording, 174 Before machining, 181 Single block Coarse (SB1), 137 Save Fine (SB3), 137 Setup data, 523 Skip blocks, 153 SB (single blocks), 151 SKP (skip blocks), 151 SB1, 137 SLOT1- longitudinal groove SB2, 137 Function, 305 SB3, 137 Parameter, 308...

Page 608 Index Circle intermediate position CIP, 454 Tool probe, 68 Deleting blocks, 458 Tool types, 463 General sequence, 449 Tool wear, 482 Inserting a position, 450 Tool wear list Inserting blocks, 452 open, 482 Motion type, 451 Touch Panel Parameter, 451 Calibrating, 542 Rapid traverse G0, 454 Selecting a block, 457...

Page 609 Index Workpiece Create, 504 Workpiece counter, 169 Workpiece zero Aligning the edge, 78 Aligning the plane, 95 Automatic measurement, 69 Changing the user interface, 97 Corrections after measurement, 98 Manual measurement, 69 Measuring, 69 Measuring a hole, 83 Measuring a rectangular pocket, 83 Measuring a rectangular spigot, 90 Measuring a right-angled corner, 80 Measuring any corner, 80...

Page 610 Index Milling Operating Manual, 03/2010, 6FC5398-7CP20-1BA0...

This manual is also suitable for:
Sinumerik828d

Siemens SINUMERIK 840D Operating Manual

1 Introduction

2 Setting up the Machine

3 Execution in Manual Mode

4 Machining the Workpiece

5 Simulating Machining

6 Creating G Code Program

7 Creating a Shopmill Program

8 Programming Technological Functions (Cycles)

9 Multi-Channel View

10 User Variables

11 Teaching in a Program

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Summary of Contents for Siemens SINUMERIK 840D