Page 1 Alarm, error and system messages Valid for: ___________________ Working with Manual Controller Machine SINUMERIK 840D sl / 840DE sl / 828D Working with a B axis (only ___________________ Software version 840D sl) CNC Software for 840D sl / 840DE sl 4.5 SP2 SINUMERIK Operate for PCU/PC 4.5 SP2...
Page 2 Siemens AG Order number: 6FC5398-8CP40-3BA1 Copyright © Siemens AG 2008 - 2013. Industry Sector Ⓟ 04/2013 Technical data subject to change All rights reserved Postfach 48 48 90026 NÜRNBERG GERMANY...
Page 3 Continuation Teaching in a program HT 8 Ctrl-Energy SINUMERIK 840D sl / 828D Turning Easy Message (828D only) Easy Extend (828D only) Operating Manual Service Planner (828D only) Ladder Viewer and Ladder add-on (828D only) Appendix...
Page 4 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 5: Preface
Training For information about the range of training courses, refer under: ● www.siemens.com/sitrain SITRAIN - Siemens training for products, systems and solutions in automation technology ● www.siemens.com/sinutrain SinuTrain - training software for SINUMERIK FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support.
Page 6 Preface SINUMERIK You can find information on SINUMERIK under the following link: www.siemens.com/sinumerik Target group This documentation is intended for users of turning machines running the SINUMERIK Operate software. Benefits The operating manual helps users familiarize themselves with the control elements and commands.
Page 7 Preface Technical Support You will find telephone numbers for other countries for technical support in the Internet under http://www.siemens.com/automation/service&support Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 8 Preface Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 9: Table Of Contents
Table of contents Preface ..............................5 Introduction.............................. 23 Product overview .........................23 Operator panel fronts ........................24 1.2.1 Overview ............................24 1.2.2 Keys of the operator panel......................26 Machine control panels ........................35 1.3.1 Overview ............................35 1.3.2 Controls on the machine control panel ..................35 User interface..........................38 1.4.1 Screen layout ..........................38 1.4.2...
Page 10 Table of contents 2.5.4 Measuring a tool with a magnifying glass ................... 78 Measuring the workpiece zero ....................80 Zero offsets ..........................82 2.7.1 Display active zero offset ......................83 2.7.2 Displaying the zero offset "overview"..................84 2.7.3 Displaying and editing base zero offset ..................86 2.7.4 Displaying and editing settable zero offset .................
Page 11 Table of contents 4.4.2 Displaying a basic block......................121 4.4.3 Display program level ........................122 Correcting a program .........................123 Repositioning axes........................124 Starting machining at a specific point ..................125 4.7.1 Use block search ........................125 4.7.2 Continuing program from search target ..................127 4.7.3 Simple search target definition....................128 4.7.4 Defining an interruption point as search target ................129 4.7.5...
Page 12 Table of contents Simulating machining..........................175 Overview ........................... 175 Simulation before machining of the workpiece ................. 181 Simultaneous recording before machining of the workpiece ............ 182 Simultaneous recording during machining of the workpiece ............ 183 Different views of the workpiece ....................184 5.5.1 Side view ...........................
Page 13 Table of contents 6.9.4 Programming variables ......................214 6.9.5 Changing a cycle call .........................215 6.9.6 Compatibility for cycle support ....................215 6.9.7 Additional functions in the input screens ...................216 6.10 Measuring cycle support ......................217 Creating a ShopTurn program ....................... 219 Graphic program control, ShopTurn programs ................219 Program views ...........................220 Program structure ........................224 Fundamentals ..........................225...
Page 14 Table of contents 8.1.1 General............................277 8.1.2 Centering (CYCLE81) ....................... 278 8.1.3 Drilling (CYCLE82)........................281 8.1.4 Reaming (CYCLE85) ........................ 283 8.1.5 Boring (CYCLE86) ........................285 8.1.6 Deep-hole drilling (CYCLE83)....................289 8.1.7 Tapping (CYCLE84, 840)......................293 8.1.8 Drill and thread milling (CYCLE78) ................... 299 8.1.9 Positions and position patterns ....................
Page 15 Table of contents 8.4.10 Long hole (LONGHOLE) - only for G code program..............424 8.4.11 Thread milling (CYCLE70) ......................426 8.4.12 Engraving (CYCLE60) .......................430 Contour milling ...........................437 8.5.1 General information ........................437 8.5.2 Representation of the contour....................437 8.5.3 Creating a new contour......................439 8.5.4 Creating contour elements......................441 8.5.5 Changing the contour.........................447...
Page 16 Table of contents Multi-channel machining (only 840D sl) ....................527 Multi-channel view (only 840D sl) ..................... 527 9.1.1 Multi-channel view in the "Machine" operating area ..............527 9.1.2 Multi-channel view for large operator panels ................530 9.1.3 Setting the multi-channel view ....................531 Multi-channel support (only 840D sl) ..................
Page 17 Table of contents 11.7 Tool data OEM ...........................608 11.8 Magazine............................610 11.8.1 Positioning a magazine......................612 11.8.2 Relocating a tool ........................613 11.8.3 Unload all tools...........................614 11.9 Sorting tool management lists....................615 11.10 Filtering the tool management lists ....................616 11.11 Specific search in the tool management lists................618 11.12 Displaying tool details ........................620 11.13...
Page 18 Table of contents 12.9 Copying and pasting a directory/program ................. 657 12.10 Deleting a directory/program..................... 659 12.11 Changing file and directory properties ..................660 12.12 Set up drives ..........................661 12.12.1 Overview ........................... 661 12.12.2 Setting up drives ........................662 12.13 Viewing PDF documents......................
Page 19 Table of contents 14.2 Measuring the tool ........................709 14.3 Setting the zero offset ........................709 14.4 Set limit stop..........................710 14.5 Simple workpiece machining .....................711 14.5.1 Traversing axes .........................711 14.5.2 Taper turning..........................712 14.5.3 Straight and circular machining....................713 14.5.3.1 Straight turning...........................713 14.5.3.2 Circular turning...........................714 14.6 More complex machining ......................716 14.6.1...
Page 20 Table of contents 17.7 Deleting a block......................... 749 17.8 Settings for teach-in ........................750 HT 8............................... 751 18.1 HT 8 overview ........................... 751 18.2 Traversing keys......................... 754 18.3 Machine control panel menu ..................... 755 18.4 Virtual keyboard ........................756 18.5 Calibrating the touch panel .......................
Page 21 Table of contents 23.4 Control options ...........................787 23.5 Displaying PLC properties ......................789 23.6 Displaying information on the program blocks................789 23.7 Displaying and editing NC/PLC variables ..................792 23.8 Loading modified PLC user program ..................793 23.9 Editing the local variable table ....................794 23.10 Creating a new block .........................795 23.11...
Page 22 Table of contents Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 23: 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 24: 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 25 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 Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 26: Keys Of The Operator Panel
Introduction 1.2 Operator panel fronts 1.2.2 Keys of the operator panel The following keys and key combinations are available for operation of the controller and the machine tool. Keys and key combinations Function Cancels alarms and messages that are marked with this symbol. ...
Page 27 Introduction 1.2 Operator panel fronts + + • Moves the cursor to the beginning of a program. • Moves the cursor in the first row of the current column. • Selects a contiguous selection from the current cursor position up to the target position.
Page 28 Introduction 1.2 Operator panel fronts • Editing box Closes a directory or program (e.g. cycle) in the program editor. If you have made changes, then these are accepted. • Navigation Moves the cursor further to the left by one character. ...
Page 29 Introduction 1.2 Operator panel fronts + In the program manager and in the program editor, selects a contiguous selection of directories and program blocks. key and the result is transferred into the field. Accepting parameters When you have correctly entered all necessary parameters, you can close the window and save your settings.
Page 51 Introduction 1.4 User interface Procedure Position the cursor on the desired entry field. Press the <=> key. The calculator is displayed. Input the arithmetic statement. You can use arithmetic symbols, numbers, and commas. Press the equals symbol on the calculator. - OR - Press the "Calculate"...
Page 52: Context Menu
Introduction 1.4 User interface 1.4.9 Context menu When you right-click, the context menu opens and provides the following functions: ● Cut Cut Ctrl+X ● Copy Copy Ctrl+C ● Paste Paste Ctrl+V Program editor Additional functions are available in the editor ●...
Page 53: Changing The User Interface Language
Introduction 1.4 User interface 1.4.11 Changing the user interface language Procedure Select the "Start-up" operating area. Press the "Change language" softkey. The "Language selection" window opens. The language set last is selected. Position the cursor on the desired language. Press the "OK" softkey. - OR - Press the ...
Page 54: Entering Asian Characters
Introduction 1.4 User interface 1.4.12 Entering Asian characters You have the possibility of entering Asian characters. Note Call the input editor with The input editor can only be called there where it is permissible to enter Asian characters. You can select a character by using the Pinyin phonetic notation, which enables Chinese characters to be expressed by combining Latin letters.
Page 55 Introduction 1.4 User interface 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 key to access the dictionary. By keeping the ...
Page 56: Protection Levels
You have the option of providing softkeys with protection levels or completely hiding them. 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...
Page 57 Introduction 1.4 User interface Diagnostics operating area Protection level Keyswitch 3 (protection level 4) User (protection level 3) User (protection level 3) Manufacturer (protection level 1) User (protection level 3) Service (protection level 2) Start-up operating area Protection levels End user (protection level 3) Keyswitch 3 (protection level 4)
Page 58: 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 59 Introduction 1.4 User interface Press the or key or double-click to open the manual and the section. Navigate to the desired topic with the "Cursor down" key. Press the softkey or the key to display the help page for the selected topic.
Page 60 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 "Start-up"...
Page 61: 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 62: 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 controller has been switched on –...
Page 63: 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 64 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 65: Modes And Mode Groups
Setting up the machine 2.3 Modes and mode groups Modes and mode groups 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 66 Setting up the machine 2.3 Modes and mode groups Selecting "Repos" Press the key. "MDI" mode (Manual Data Input) In "MDI" mode, you can enter and execute G code commands non-modally to set up the machine or to perform a single action. Selecting "MDI"...
Page 67: Modes Groups And Channels
Setting up the machine 2.3 Modes and mode groups 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. ●...
Page 68: Channel Switchover
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 operator panel, you can switch to the next channel or display the channel menu via touch operation in the status display.
Page 69: Settings For The Machine
Setting up the machine 2.4 Settings for the machine Settings for the machine 2.4.1 Switching over the coordinate system (MCS/WCS) The coordinates in the actual value display are relative to either the machine coordinate system or the workpiece coordinate system. By default, the workpiece coordinate system is set as a reference for the actual value display.
Page 70: 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 71: Setting The Zero Offset
Setting up the machine 2.4 Settings for the machine 2.4.3 Setting the zero offset You can enter a new position value in the actual value display for individual axes when a settable zero 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 zero offset (e.g.
Page 72 Setting up the machine 2.4 Settings for the machine Procedure Select the "JOG" mode in the "Machine" operating area. Press the "Set WO" softkey. - OR - Press the ">>", "REL act. vals" and "Set REL" softkeys to set position values in the relative coordinate system.
Page 73: 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 74 Setting up the machine 2.5 Measuring the tool You specify the position of the workpiece edge during the measurement. Note Lathes with B axis For lathes with a B axis, execute the tool change and alignment in the T, S, M window before performing the measurement.
Page 75: Measuring A Tool With A Tool Probe
References For further information about lathes with B axis, please refer to the following reference: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl The tool offset data is then calculated from the known position of the tool carrier reference point and the probe.
Page 76 Setting up the machine 2.5 Measuring the tool Adapting the user interface to calibrating and measuring functions The following selection options can be switched-in or switched-out: ● Calibration plane, measurement plane ● Probe ● Calibration feedrate (measuring feedrate) Preconditions ● If you wish to measure your tools with a tool probe, the machine manufacturer must parameterize special measuring functions for that purpose.
Page 77: Calibrating The Tool Probe
Setting up the machine 2.5 Measuring the tool Manually position the tool in the vicinity of the tool probe in such a way that any collisions can be avoided when the tool probe is being traversed in the corresponding direction. Press the ...
Page 78: Measuring A Tool With A Magnifying Glass
Setting up the machine 2.5 Measuring the tool Press the "X" or "Z" softkey, depending on which point of the tool probe you wish to determine first. Select the direction (+ or -), in which you would like to approach the tool probe.
Page 79 Setting up the machine 2.5 Measuring the tool Press the "Select tool” softkey. The "Tool selection" window is opened. Select the tool that you wish to measure. The cutting edge position and the radius or diameter of the tool must already be entered in the tool list.
Page 80: Measuring The Workpiece Zero
Setting up the machine 2.6 Measuring the workpiece zero Measuring the workpiece zero The reference point for programming a workpiece is always the workpiece zero. To determine this zero point, measure the length of the workpiece and save the position of the cylinder's face surface in the direction Z in a zero offset.
Page 81 Setting up the machine 2.6 Measuring the workpiece zero Procedure Select "JOG" mode in the "Machine" operating area. Press the "Workpiece zero" softkey. The "Set Edge" window opens. Select "Measuring only" if you only want to display the measured values. - OR - Select the desired zero offset in which you want to store the zero point (e.g.
Page 82: Zero Offsets
Setting up the machine 2.7 Zero offsets Zero offsets Following reference point approach, the actual value display for the axis coordinates is based on the machine zero (M) of the machine coordinate system (Machine). The program for machining the workpiece, however, is based on the workpiece zero (W) of the workpiece coordinate system (Work).
Page 83: Display Active Zero Offset
Setting up the machine 2.7 Zero offsets You can save the workpiece zero, for example, in the coarse offset, and then store the offset that occurs when a new workpiece is clamped between the old and the new workpiece zero in the fine offset.
Page 84: Displaying The Zero Offset "Overview
Setting up the machine 2.7 Zero offsets Procedure Select the "Parameter" operating area. Press the "Zero offset" softkey. The "Zero Offset - Active" window is opened. Note Further details on zero offsets If you would like to see further details about the specified offsets or if you would like to change values for the rotation, scaling or mirroring, press the "Details"...
Page 85 Setting up the machine 2.7 Zero offsets Zero offsets G500 Displays the zero offsets activated with G54 - G599. Under certain circumstances, you can change the data using "Set ZO", i.e. you can correct a zero point that has been set. Tool reference Displays the additional zero offsets programmed with $P_TOOLFRAME.
Page 86: Displaying And Editing Base Zero Offset
Setting up the machine 2.7 Zero offsets 2.7.3 Displaying and editing base zero offset The defined channel-specific and global base offsets, divided into coarse and fine offsets, are displayed for all set-up axes in the "Zero offset - Base" window. Machine manufacturer Please refer to the machine manufacturer's specifications.
Page 87: Displaying And Editing Settable Zero Offset
Setting up the machine 2.7 Zero offsets 2.7.4 Displaying and editing settable zero offset All settable offsets, divided into coarse and fine offsets, are displayed in the "Zero Offset - G54..G599" window. Rotation, scaling and mirroring are displayed. Procedure Select the "Parameter" operating area. Press the "Zero offset"...
Page 88: Displaying And Editing Details Of The Zero Offsets
Setting up the machine 2.7 Zero offsets 2.7.5 Displaying and editing details of the zero offsets For each zero offset, you can display and edit all data for all axes. You can also delete zero offsets. For every axis, values for the following data will be displayed: ●...
Page 89: Deleting A Zero Offset
Setting up the machine 2.7 Zero offsets - OR - Press the "Clear offset" softkey to reset all entered values. Press the "ZO +" or "ZO -" softkey to select the next or previous offset, respectively, within the selected area ("Active", "Base", "G54 to G599") without first having to switch to the overview window.
Page 90: Measuring The Workpiece Zero
Setting up the machine 2.7 Zero offsets Press the "Details" softkey. Position the cursor on the zero offset you would like to delete. Press the "Clear offset" softkey. 2.7.7 Measuring the workpiece zero Procedure Select the "Parameters" operating area and press the "Zero offset" softkey.
Page 91: Monitoring Axis And Spindle Data
Setting up the machine 2.8 Monitoring axis and spindle data Monitoring axis and spindle data 2.8.1 Specify working area limitations The "Working area limitation" function can be used to limit the range within which a tool can traverse in all channel axes. These commands allow you to set up protection zones in the working area which are out of bounds for tool movements.
Page 92: Editing Spindle Data
Setting up the machine 2.8 Monitoring axis and spindle data 2.8.2 Editing spindle data The speed limits set for the spindles that must not be under- or overshot are displayed in the "Spindles" window. You can limit the spindle speeds in fields "Minimum" and "Maximum" within the limit values defined in the relevant machine data.
Page 93: Spindle Chuck Data
Setting up the machine 2.8 Monitoring axis and spindle data 2.8.3 Spindle chuck data You store the chuck dimensions of the spindles at your machine in the "Spindle chuck data" window. Manually measuring a tool If you want to use the chuck of the main or counter spindle as a reference point during manual measuring, specify the chuck dimension ZC.
Page 94 Setting up the machine 2.8 Monitoring axis and spindle data Tailstock Dimensioning the tailstock The length of the tailstock (ZR) and the diameter of the tailstock (XR) of the spindle screen are needed for the display of the tailstock in the simulation. Procedure Select the "Parameter"...
Page 95: Displaying Setting Data Lists
Setting up the machine 2.9 Displaying setting data lists Parameter Description Unit Main spindle chuck dimensions (inc) Jaw type Dimensions of the forward edge or stop edge Jaw type 1 • Jaw type 2 • Chuck dimension, counter-spindle (inc) - only for a counter-spindle that has been set-up Stop dimension, counter-spindle (inc) - only for a counter-spindle that has been set-up...
Page 96: Handwheel Assignment
Setting up the machine 2.10 Handwheel assignment 2.10 Handwheel assignment You can traverse the axes in the machine coordinate system (Machine) or in the workpiece coordinate system (Work) via the handwheel. Software option You require the "Extended operator functions" option for the handwheel offset (only for 828D).
Page 97 Setting up the machine 2.10 Handwheel assignment Press the corresponding softkey to select the desired axis (e.g. "X"). - OR Open the "Axis" selection box using the key, navigate to the desired axis, and press the key. Selecting an axis also activates the handwheel (e.g., "X" is assigned to handwheel no.
Page 98: 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 99: Saving An Mda Program
Setting up the machine 2.11 MDA 2.11.2 Saving an MDA program Procedure Select the "Machine" operating area. Press the key. The MDI editor opens. Create the MDI program by entering the G-code commands using the operator's keyboard. Press the "Store MDI" softkey. The "Save from MDI: Select storage location"...
Page 100: 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 101: Working In Manual Mode
Working 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 102 Working 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 103: Selecting A Tool
Working 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 entry field. - OR - Press the "Select tool"...
Page 104: Starting And Stopping The Spindle Manually
Working in manual mode 3.2 Selecting a tool and spindle 3.2.3 Starting and stopping the spindle manually Procedure Select the "T,S,M" softkey in the "JOG" mode. Select the desired spindle (e.g. S1) and enter the desired spindle speed or cutting speed in the right-hand entry field. If the machine has a gearbox for the spindle, set the gearing step.
Page 105: Positioning The Spindle
Working in manual mode 3.2 Selecting a tool and spindle 3.2.4 Positioning the spindle Procedure Select the "T,S,M" softkey in the "JOG" mode. Select the "Stop Pos." setting in the "Spindle M function" field. The "Stop Pos." entry field appears. Enter the desired spindle stop position.
Page 106: Traversing Axes
Working 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 107: Traversing Axes By A Variable Increment
Working in manual mode 3.3 Traversing axes Note When the controller is switched on, the axes can be traversed right up to the limits of the machine as the reference points have not yet been approached and the axes referenced. Emergency limit switches might be triggered as a result.
Page 108: Positioning Axes
Working in manual mode 3.4 Positioning axes Positioning axes In order to implement simple machining sequences, you can traverse the axes to certain positions in manual mode. The feedrate / rapid traverse override is active during traversing. Procedure If required, select a tool. Select the "JOG"...
Page 109: Manual Retraction
Working in manual mode 3.5 Manual retraction Manual retraction After an interruption of a tapping operation (G33/G331/G332) or a general drilling operation (tools 200 to 299) due to power loss or a RESET at the machine control panel, you have the possibility to retract the tool in the JOG mode in the tool direction without damaging the tool or the workpiece.
Page 110 Working in manual mode 3.5 Manual retraction Select the required axis in the "Retraction axis" selection box. Use the traversing keys (e.g. Z +) to traverse the tool from the workpiece according to the retraction axis selected in the "Retract Tool" window.
Page 111: Simple Stock Removal Of Workpiece
Working in manual mode 3.6 Simple stock removal of workpiece Simple stock removal of workpiece Some blanks have a smooth or even surface. For example, you can use the stock removal cycle to turn the face surface of the workpiece before machining actually takes place. If you want to bore out a collet using the stock removal cycle, you can program an undercut (XF2) in the corner.
Page 112 Working in manual mode 3.6 Simple stock removal of workpiece Procedure Press the "Machine" operating area key Press the key. Press the "Stock removal" softkey. Enter desired values for the parameters. Press the "OK" softkey. The parameter screen is closed. Press the ...
Page 113 Working in manual mode 3.6 Simple stock removal of workpiece Parameter Description Unit Position Machining position Machining Face • direction Longitudinal • Reference point ∅ (abs) Reference point (abs) End point X ∅ (abs) or end point X in relation to X0 (inc) End point Z (abs) or end point Z in relation to X0 (inc) FS1...FS3 or R1...R3 Chamfer width (FS1...FS3) or rounding radius (R1...R3)
Page 114: Thread Synchronizing
Working in manual mode 3.7 Thread synchronizing Thread synchronizing If you wish to re-machine a thread, it may be necessary to synchronize the spindle to the existing thread turn. This is necessary as by reclamping the blank, an angular offset can occur in the thread.
Page 115 Working in manual mode 3.7 Thread synchronizing Note: The thread synchronization is activated by teaching in a spindle. In this case, the synchronizing positions of axes X and Z and the synchronizing angle of spindle (Sn) are saved in the Machine and displayed in the screen form.
Page 116: Default Settings For Manual Mode
Working in manual mode 3.8 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 117: 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 118: 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 119: Executing A Trail Program Run
Machining the workpiece 4.3 Executing a trail program run Place the cursor on the desired program. Press the "Select" softkey. The program is selected. When the program has been successfully selected, an automatic changeover to the "Machine" operating area occurs. Executing a trail program run 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.
Page 120: Displaying The Current Program Block
Machining the workpiece 4.4 Displaying the current program block Press the key. Depending on the execution variant, the first block will be executed. Then the machining stops. In the channel status line, the text “Stop: Block in single block ended" appears.
Page 121: 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 122: 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 123: 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 124: Repositioning Axes
Machining the workpiece 4.6 Repositioning axes Note Exit the editor using the "Close" softkey to return to the "Program manager" operating area. 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.
Page 125: Starting Machining At A Specific Point
Machining the workpiece 4.7 Starting machining at a specific point Procedure Press the key. Select the axes to be traversed one after the other. Press the <+> or <-> key for the relevant direction. The axes are moved to the interrupt position. Starting machining at a specific point 4.7.1 Use block search...
Page 126 Machining the workpiece 4.7 Starting machining at a specific point Determining a search target ● User-friendly search target definition (search positions) – Direct specification of the search target by positioning the cursor in the selected program (main program) – Search target via text search –...
Page 127: Continuing Program From Search Target
Machining the workpiece 4.7 Starting machining at a specific point Preconditions 1. You have selected the desired program. 2. The controller is in the reset state. 3. The desired search mode is selected. NOTICE Risk of collision Pay attention to a collision-free start position and appropriate active tools and other technological values.
Page 128: Simple Search Target Definition
Machining the workpiece 4.7 Starting machining at a specific point 4.7.3 Simple search target definition Requirement The program is selected and the controller is in Reset mode. Procedure Press the "Block search" softkey. Place the cursor on a particular program block. - OR - Press the "Find text"...
Page 129: 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 Requirement 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 130: 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 131: Parameters For Block Search In The Search Pointer
Machining the workpiece 4.7 Starting machining at a specific point The Search window closes. The current block will be displayed in the "Program" window as soon as the target is found. Press the key twice. Processing is continued from the defined location. Note Interruption point You can load the interruption point in search pointer mode.
Page 132: 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 133 Machine manufacturer Please refer to the machine manufacturer's specifications. 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 134: Controlling The Program Run
Machining the workpiece 4.8 Controlling the program run Controlling the program run 4.8.1 Program control You can change the program sequence in the "AUTO" and "MDI" modes. Abbreviation/program Mode of operation control The program is started and executed with auxiliary function outputs and dwell times. In this mode, the axes are not traversed.
Page 135: Skip Blocks
Machining the workpiece 4.8 Controlling the program run Activating program control You can control the program sequence however you wish by selecting and clearing the relevant checkboxes. 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 136 Machining the workpiece 4.8 Controlling the program run Skip levels, activate Select the corresponding checkbox to activate the desired skip level. Note The "Program Control - Skip Blocks" window is only available when more than one skip level is set up. Procedure Select the "Machine"...
Page 137: 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 138: Editing A Program
Machining the workpiece 4.10 Editing a program Note Block-by-block execution The key is also active in the overstore mode. If several blocks are entered in the overstore buffer, then these are executed block-by-block after each NC start Deleting blocks Press the "Delete blocks"...
Page 139: Searching In Programs
Machining the workpiece 4.10 Editing a program See also Editor settings (Page 147) Correcting a program (Page 123) Opening and closing the program (Page 641) Generating a G code program (Page 204) 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.
Page 140 Machining the workpiece 4.10 Editing a program Procedure Press the "Search" softkey. A new vertical softkey bar appears. The "Search" window opens at the same time. Enter the desired search term in the "Text" field. Select "Whole words" if you want to search for whole words only. - OR - Activate the "Exact expression"...
Page 141: 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. Procedure Press the "Search" softkey. A new vertical softkey bar appears. Press the "Find and replace"...
Page 142: Copying/Pasting/Deleting A Program Block
Machining the workpiece 4.10 Editing a program Note Replacing texts • Read-only lines (;*RO*) If hits are found, the texts are not replaced. • Contour lines (;*GP*) If hits are found, the texts are replaced as long as the lines are not read-only. •...
Page 143: Renumbering A Program
Machining the workpiece 4.10 Editing a program Press the "Cut" softkey to delete the selected program blocks. Note: When editing a program, you cannot copy or cut more than 1024 lines. While a program that is not on the NC is opened (progress display less than 100%), you cannot copy or cut more than 10 lines or insert more than 1024 characters.
Page 144: Creating A Program Block
Machining the workpiece 4.10 Editing a program Enter the values for the first block number and the increment to be used for numbering. Press the "OK" softkey. The program is renumbered. Note If you only want to renumber a section, select the program blocks whose block numbering you want to edit.
Page 145 Machining the workpiece 4.10 Editing a program Structuring programs ● Before generating the actual program, generate a program frame using empty blocks. ● By forming blocks, structure existing G code or ShopTurn programs. Procedure Select the "Program manager" operating area. Select the storage location and create a program or open a program.
Page 146: Opening Additional Programs
Machining the workpiece 4.10 Editing a program 4.10.6 Opening additional programs You have the option of viewing and editing two programs simultaneously in the editor. For instance, you can copy program blocks or machining steps of a program and paste them into another program.
Page 147: Editor Settings
Machining the workpiece 4.10 Editing a program 4.10.7 Editor settings Enter the default settings in the "Settings" window that are to take effect automatically when the editor is opened. Defaults Setting Meaning Number Yes: A new block number will automatically be assigned after every line •...
Page 148 Machining the workpiece 4.10 Editing a program Note All entries that you make here are effective immediately. Procedure Select the "Program" operating area. You have activated the editor. Press the ">>" and "Settings" softkeys. The "Settings" window opens. Make the desired changes here and press the "OK" softkey to confirm your settings.
Page 149: Display And Edit User Variables
Machining the workpiece 4.11 Display and edit user variables 4.11 Display and edit user variables 4.11.1 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 ●...
Page 150: R Parameters
Machining the workpiece 4.11 Display and edit user variables 4.11.2 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 controller is switched off. Number of channel-specific R parameters The number of channel-specific R parameters is defined in a machine data element.
Page 151: Displaying Global User Data (Gud)
Machining the workpiece 4.11 Display and edit user variables 4.11.3 Displaying global user data (GUD) Global user variables 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 152: Displaying Channel Guds
Machining the workpiece 4.11 Display and edit user variables 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"...
Page 153: Displaying Local User Data (Lud)
Machining the workpiece 4.11 Display and edit user variables 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 154: Displaying Program User Data (Pud)
Machining the workpiece 4.11 Display and edit user variables Procedure Select the "Parameter" operating area. Press the "User variable" softkey. Press the "Local LUD" softkey. 4.11.6 Displaying program user data (PUD) Program-global user variables PUDs are global part program variables (Program User Data). PUDs are valid in all main programs and subprograms, where they can also be written and read.
Page 155: Searching For User Variables
Machining the workpiece 4.11 Display and edit user variables 4.11.7 Searching for user variables You can search for R parameters and user variables. 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 variables.
Page 156 Machining the workpiece 4.11 Display and edit user variables Press the key. - OR - Press the key. The selected file is opened in the editor and can be edited there. Define the desired user variable. Press the "Exit" softkey to close the editor. Activating user variables Press the "Activate"...
Page 157: Displaying G Functions And Auxiliary Functions
Machining the workpiece 4.12 Displaying G functions and auxiliary functions 4.12 Displaying G functions and auxiliary functions 4.12.1 Selected G functions 16 selected G groups are displayed in the "G Function" window. Within a G group, the G function currently active in the controller is displayed. Some G codes (e.g.
Page 158 Machining the workpiece 4.12 Displaying G functions and auxiliary functions G groups displayed by default (ISO code) Group Meaning G group 1 Modally active motion commands (e.g. G0, G1, G2, G3) G group 2 Non-modally active motion commands, dwell time (e.g. G4, G74, G75) G group 3 Programmable offsets, working area limitations and pole programming (e.g.
Page 159: All G Functions
References For more information about configuring the displayed G groups, refer to the following document: SINUMERIK Operate (IM9) / SINUMERIK 840D sl Commissioning Manual 4.12.2 All G functions All G groups and their group numbers are listed in the "G Functions" window.
Page 160: G Functions For Mold Making
Machining the workpiece 4.12 Displaying G functions and auxiliary functions Procedure Select the "Machine" operating area. Press the , or key. Press the ">>" and "All G functions" softkeys. The "G Functions" window is opened. 4.12.3 G functions for mold making In the window "G functions", important information for machining free-form surfaces can be displayed using the "High Speed Settings"...
Page 161 Function Manual, Basic Functions; Chapter, "Contour/orientation tolerance" ● For information about configuring the displayed G groups, refer to the following document: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Procedure Select the "Machine" operating area Press the , or key.
Page 162: Auxiliary Functions
Machining the workpiece 4.12 Displaying G functions and auxiliary functions 4.12.4 Auxiliary functions Auxiliary functions include M and H functions preprogrammed by the machine manufacturer, which transfer parameters to the PLC to trigger reactions defined by the manufacturer. Displayed auxiliary functions Up to five current M functions and three H functions are displayed in the "Auxiliary Functions"...
Page 163 Machining the workpiece 4.12 Displaying G functions and auxiliary functions Status of synchronized actions You can see the status of the synchronized actions in the "Status" column. ● Waiting ● Active ● Blocked Non-modal synchronized actions can only be identified by their status display. They are only displayed during execution.
Page 164 Machining the workpiece 4.12 Displaying G functions and auxiliary functions Press the menu forward key and the "Synchron." softkey. The "Synchronized Actions" window appears. You obtain a display of all activated synchronized actions. Press the "ID" softkey if you wish to hide the modal synchronized actions in the automatic mode.
Page 165: Mold Making View
Machining the workpiece 4.13 Mold making view 4.13 Mold making view 4.13.1 Mold making view For large mold making programs, as provided by CAD systems, you have the option, using a fast view, to display the machining paths. This allows you to obtain a fast overview of the program and possibly correct it.
Page 166 Machining the workpiece 4.13 Mold making view NC blocks that can be interpreted Following NC blocks are supported for the mold building view. ● Types – Lines G0, G1 with X Y Z – Circles G2, G3 with center point I, J, K or radius CR, depending on the working plane G17, G18, G19, CIP with circular point I1, J1, K1 or radius CR –...
Page 167: Starting The Mold Making View
Machining the workpiece 4.13 Mold making view Changing and adapting the mold making view Just the same as for simulation and simultaneous recording, you have the option of changing and adapting the simulation graphical representation in order to achieve the optimum view. ●...
Page 168: Specifically Jump To The Program Block
Machining the workpiece 4.13 Mold making view 4.13.3 Specifically jump to the program block If you notice anything peculiar in the graphic or identify an error, then from this location, you can directly jump to the program block involved to possibly edit the program. Preconditions ●...
Page 169: Changing The View
Machining the workpiece 4.13 Mold making view Procedure Press the "Search" softkey. A new vertical softkey bar appears. See also Searching in programs (Page 139) Replacing program text (Page 141) 4.13.5 Changing the view 4.13.5.1 Enlarging or reducing the graphical representation Precondition ●...
Page 170: Modifying The Viewport
Machining the workpiece 4.13 Mold making view 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 171: Displaying The Program Runtime And Counting Workpieces
Machining the workpiece 4.14 Displaying the program runtime and counting workpieces Press one of the cursor keys to move the frame up, down, left or right. Press the "Accept" softkey to accept the section. 4.14 Displaying the program runtime and counting workpieces To gain an overview of the program runtime and the number of machined workpieces, open the "Times, Counter"...
Page 172 Machining the workpiece 4.14 Displaying the program runtime and counting workpieces Counting workpieces You can also display program repetitions and the number of completed workpieces. For the worpiece count, enter the actual and planned workpiece numbers. Workpiece count Completed workpieces can be counted via the end of program command (M30) or an M command.
Page 173: Setting For Automatic Mode
Machining the workpiece 4.15 Setting for automatic mode 4.15 Setting for automatic mode Before machining a workpiece, you can test the program in order to identify programming errors early on. Use the dry run feedrate for this purpose. In addition, you have the option of additionally limiting the traversing speed for rapid traverse so that when running-in a new program with rapid traverse, no undesirable high traversing speeds occur.
Page 174 Machining the workpiece 4.15 Setting for automatic mode Enter the desired percentage in the "Reduced rapid traverse RG0" field. RG0 has not effect if you do not change the specified amount of 100%. Enter "Automatic" in the "Display measurement result" box if the measurement result window should be automatically opened, or "Manual", if the measurement result window should be opened by pressing the "Measurement result"...
Page 175: Simulating Machining
Simulating machining Overview During simulation, the current program is calculated in its entirety and the result displayed in graphic form. The result of programming is verified without traversing the machine axes. Incorrectly programmed machining steps are detected at an early stage and incorrect machining on the workpiece prevented.
Page 176 The traversing paths of the tool are shown in color. Rapid traverse is red and the feedrate is green. Note Displaying the tailstock The tailstock is only visible with the option "ShopMill/ShopTurn". Machine manufacturer Please also refer to the machine manufacturer's specifications. References Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 177 Simulating machining 5.1 Overview Simulation display You can choose one of the following types of display: ● Material removal simulation During simulation or simultaneous recording you can follow stock removal from the defined blank. ● Path display You have the option of including the display of the path. The programmed tool path is displayed.
Page 178 Simulating machining 5.1 Overview Views The following views are available for all three variants: ● Side view ● Half section ● Front view ● 3D view ● 2-window Status display The current axis coordinates, the override, the current tool with cutting edge, the current program block, the feedrate and the machining time are displayed.
Page 179 Simulating machining 5.1 Overview Start position for simulation and simultaneous recording During simulation, the start position is converted via the zero offset to the workpiece coordinate system. The simultaneous recording starts at the position at which the machine is currently located. Constraint ●...
Page 180 Simulating machining 5.1 Overview Example An example for supported kinematics is a lathe with B axis: Lathe with B axis See also Spindle chuck data (Page 93) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 181: Simulation Before Machining Of The Workpiece
Simulating machining 5.2 Simulation before machining of the workpiece Simulation before machining of the workpiece Before machining the workpiece on the machine, you have the option of performing a quick run-through in order to graphically display how the program will be executed. This provides a simple way of checking the result of the programming.
Page 182: Simultaneous Recording Before Machining Of The Workpiece
Simulating machining 5.3 Simultaneous recording before machining of the workpiece Press the "Reset" softkey to cancel the simulation. Press the "Start" softkey to restart or continue the simulation. Note Operating area switchover The simulation is exited if you switch into another operating area. If you restart the simulation, then this starts again at the beginning of the program.
Page 183: Simultaneous Recording During Machining Of The Workpiece
Simulating machining 5.4 Simultaneous recording during machining of the workpiece Press the key. The program execution is displayed graphically on the screen. Press the "Sim. rec." softkey again to stop the recording. 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.
Page 184: Different Views Of The Workpiece
Simulating machining 5.5 Different views of the workpiece Different views of the 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 185: Face View
Simulating machining 5.5 Different views of the workpiece 5.5.3 Face view Start the simulation. Press the "Other views" and "Face view" softkeys. The side view shows the workpiece in the X-Y plane. Changing the display You can increase or decrease the size of the simulation graphic and move it, as well as change the segment.
Page 186: 2-Window
Simulating machining 5.6 Graphical display 5.5.5 2-window Start the simulation. Press the "Additional views" and "2-window view" softkeys. The 2-window view contains a side view (left-hand window) and a front view (right-hand window) of the workpiece. The viewing direction is always from the front to the cutting surface even if machining is to be performed from behind or from the back side.
Page 187: Editing The Simulation Display
Simulating machining 5.7 Editing the simulation display Editing the simulation display 5.7.1 Blank display 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 188 Simulating machining 5.7 Editing the simulation display Parameter Description Unit Mirroring Z • Mirroring is used when machining on the Z axis • Mirroring is not used when machining on the Z axis Blank Selecting the blank Centered cuboid • Tube •...
Page 189: Showing And Hiding The Tool Path
Simulating machining 5.7 Editing the simulation display 5.7.2 Showing and hiding the tool path The path display follows the programmed tool path of the selected program. The path is continuously updated as a function of the tool movement. The tool paths can be shown or hidden as required.
Page 190: Program Control During The Simulation
Simulating machining 5.8 Program control during the simulation Program control during the simulation 5.8.1 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 191: Simulating The Program Block By Block
Simulating machining 5.8 Program control during the simulation 5.8.2 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 192: Editing And Adapting A Simulation Graphic
Simulating machining 5.9 Editing and adapting a simulation graphic Editing and adapting a simulation graphic 5.9.1 Enlarging or reducing the graphical representation Precondition The simulation or the simultaneous recording is started. Procedure Press the <+> and <-> keys if you wish to enlarge or reduce the graphic display.
Page 193: Panning A Graphical Representation
Simulating machining 5.9 Editing and adapting a simulation graphic 5.9.2 Panning a graphical representation Precondition The simulation or the simultaneous recording is started. Procedure Press a cursor key if you wish to move the graphic up, down, left, or right. 5.9.3 Rotating the graphical representation In the 3D view you can rotate the position of the workpiece to view it from all sides.
Page 194: Modifying The Viewport
Simulating machining 5.9 Editing and adapting a simulation graphic Press the "Arrow right", "Arrow left", "Arrow up", "Arrow down", "Arrow clockwise" and "Arrow counterclockwise" softkeys to change the position of the workpiece. - OR - Keep the key pressed and then turn the workpiece in the desired direction using the appropriate cursor keys.
Page 195: Defining Cutting Planes
Simulating machining 5.9 Editing and adapting a simulation graphic Press one of the cursor keys to move the frame up, down, left or right. Press the "Accept" softkey to accept the section. 5.9.5 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.
Page 196: Displaying Simulation Alarms
Simulating machining 5.10 Displaying simulation alarms 5.10 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: ●...
Page 197: Creating A G Code Program
Creating a 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 198: Program Views
Creating a 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 display or graphic view Program view The program view in the editor provides an overview of the individual machining steps of a program.
Page 199 Creating a G code program 6.2 Program views Parameter screen with help display Press the key to open a selected program block or cycle in the program view. The associated parameter screen with help display is then displayed. Note Switching between the help display and the graphic view The key combination ...
Page 200 Creating a G code program 6.2 Program views Parameter screen with graphic view Using the "Graphic view" softkey, you can toggle between the help display and the graphic view in the screen. Figure 6-3 Parameter screen with a graphical view of a G code program block Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 201: Program Structure
Creating a 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 202: Current Planes In Cycles And Input Screens
Creating a G code program 6.4 Fundamentals Working planes Working planes are defined as follows: Plane Tool axis 6.4.2 Current planes in cycles and input screens Each input screen has a selection box for the planes, if the planes have not been specified by NC machine data.
Page 203: Programming A Tool (T)
Creating a G code program 6.4 Fundamentals 6.4.3 Programming a tool (T) Calling a tool You are in a part program Press the "Select tool” softkey. The "Tool selection" window is opened. Position the cursor on the desired tool and press the "To program" softkey.
Page 204: Generating A G Code Program
Creating a 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 205: Blank Input
Creating a G code program 6.6 Blank input See also Changing a cycle call (Page 215) Selection of the cycles via softkey (Page 209) Creating a new workpiece (Page 645) 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.
Page 206 Creating a G code program 6.6 Blank input Procedure Select the "Program" operating area. Press the "Misc." and "Blank" softkeys. The "Blank Input" window opens. Parameter Description Unit Data for Selection of the spindle for the blank Main spindle • Counterspindle •...
Page 207 Creating a G code program 6.6 Blank input Parameter Description Unit Spindle chuck Only chuck • data You enter spindle chuck data in the program. Complete • You enter tailstock data in the program. Note: Please observe the machine manufacturer’s instructions. Jaw type Selecting the jaw type of the counterspindle.
Page 208: Machining Plane, Milling Direction, Retraction Plane, Safe Clearance And Feedrate (Pl, Rp, Sc, F)
Creating a 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 always repeat. You will find the following parameters in every input screen for a cycle in a G code program.
Page 209: Selection Of The Cycles Via Softkey
Creating a G code program 6.8 Selection of the cycles via softkey Selection of the cycles via softkey Overview of the machining steps The following machining steps are available. 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 210 Creating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 211 Creating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 212 Creating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 213: Calling Technology Cycles
These are then generated with the appropriate default values when the cycles are called. For additional information, please refer to the following references: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Cycle support Example Use the softkeys to select whether you want support for programming contours, turning, drilling or milling cycles.
Page 214: Setting Data For Cycles
Setting data for cycles Cycle functions can be influenced and configured using machine and setting data. For additional information, please refer to the following references: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl 6.9.3 Checking cycle parameters The entered parameters are already checked during the program creation in order to avoid faulty entries.
Page 215: Changing A Cycle Call
Creating a G code program 6.9 Calling technology cycles 6.9.5 Changing a cycle call You have called the desired cycle via softkey in the program editor, entered the parameters and confirmed with "Accept". Procedure Select the desired cycle call and press the key. The associated input screen of the selected cycle call is opened.
Page 216: Additional Functions In The Input Screens
Creating a G code program 6.9 Calling technology cycles 6.9.7 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 217: Measuring Cycle Support
Software option You require the "Measuring cycles" option to use "Measuring cycles". References You will find a more detailed description on how to use measuring cycles in: Programming Manual Measuring cycles / SINUMERIK 840D sl/828D Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 218 Creating a G code program 6.10 Measuring cycle support Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 219: Creating A Shopturn Program
Creating a ShopTurn program Graphic program control, ShopTurn programs 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 ShopTurn machining step programs. Functions The following functionality is available: ●...
Page 220: Program Views
Creating a ShopTurn program 7.2 Program views Program views You can display a ShopTurn program in various views: ● Work plan ● Graphic view ● Parameter screen, either with help display or graphic view Work plan The work plan in the editor provides an overview of the individual machining steps of a program.
Page 221 Creating a ShopTurn program 7.2 Program views Note Switching between the help display and the graphic view The key combination + is also available for the switchover between the help display and the graphic view. Graphic view The graphic view shows the contour of the workpiece as a dynamic graphic with broken lines.
Page 222 Creating a ShopTurn program 7.2 Program views Note Switching between the help display and the graphic view The key combination + is also available for the switchover between the help display and the graphic view. Figure 7-3 Parameter screen with dynamic help display The animated help displays are always displayed with the correct orientation to the selected coordinate system.
Page 223 Creating a ShopTurn program 7.2 Program views Figure 7-4 Parameter screen with graphic view Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 224: Program Structure
Creating a ShopTurn program 7.3 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 process plan. Program header The program header contains parameters that affect the entire program, such as blank dimensions or retraction planes.
Page 225: Fundamentals
Creating a ShopTurn program 7.4 Fundamentals Fundamentals 7.4.1 Machining planes A workpiece can be machined on different planes. Two coordinate axes define a machining plane. On lathes with X, Z, and C axes, three planes are available: ● Turning ● Face ●...
Page 226 Creating a ShopTurn program 7.4 Fundamentals Turning The turning machining plane corresponds to the X/Z plane (G18). Face/Face C The Face/Face C machining plane corresponds to the X/Y plane (G17). For machines without a Y axis, however, the tools can only move in the X/Z plane. The X/Y coordinates that have been entered are automatically transformed into a movement in the X and C axis.
Page 227: Machining Cycle, Approach/Retraction
Creating a ShopTurn program 7.4 Fundamentals 7.4.2 Machining cycle, approach/retraction Approaching and retracting during the machining cycle always follows the same pattern if you have not defined a special approach/retraction cycle. If your machine has a tailstock, you can also take this into consideration when traversing. The retraction for a cycle ends at the safety clearance.
Page 228 Creating a ShopTurn program 7.4 Fundamentals Taking into account the tailstock Figure 7-6 Approach/retraction taking into account the tailstock ● The tool traverses in rapid traverse from the tool change point along the shortest path to the retraction plane XRR from the tailstock. ●...
Page 229: Absolute And Incremental Dimensions
Creating a ShopTurn program 7.4 Fundamentals 7.4.3 Absolute and incremental dimensions When generating a machining step program, you can input positions in absolute or incremental dimensions, depending on how the workpiece drawing is dimensioned. You can also use a combination of absolute and incremental dimensions, i.e. one coordinate as an absolute dimension and the other as an incremental dimension.
Page 230: Polar Coordinates
Creating a ShopTurn program 7.4 Fundamentals Incremental dimensions (INC) With incremental dimensions (also referred to as sequential dimensions) a position specification refers to the previously programmed point, i.e. the input value corresponds to the path to be traversed. As a rule, the plus/minus sign does not matter when entering the incremental value, only the absolute value of the increment is evaluated.
Page 231: Clamping The Spindle
Creating a ShopTurn program 7.4 Fundamentals Figure 7-9 Polar coordinates The position specifications for the pole and points P1 to P3 in polar coordinates are: Pole: X30 Z30 (relative to the zero point) P1: L30 α30° (relative to the pole) P2: L30 α60°...
Page 232: Creating A Shopturn Program
Creating a ShopTurn program 7.5 Creating a ShopTurn program Creating a ShopTurn 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 233 Creating a ShopTurn program 7.5 Creating a ShopTurn program Press the "Teach TC position" softkey if you want to set the actual position of the tool as a tool change point. The tool’s coordinates are transferred into parameters XT and ZT. Teaching in the tool change point is only possible if you have selected the machine coordinate system (Machine).
Page 234: Program Header
Creating a ShopTurn program 7.6 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 setting of the measurement unit in the program header only refers to the position data in the actual program.
Page 235 Creating a ShopTurn program 7.6 Program header Parameter Description Unit Retraction plane Z front (abs) or retraction plane Z referred to ZA (inc) • Retraction plane X external ∅ (abs) or retraction plane X referred to XA (inc) Retraction plane X internal ∅ (abs) or retraction plane X referred to XI (inc) Retraction plane Z front (abs) or retraction plane Z referred to ZA (inc)
Page 236 Creating a ShopTurn program 7.6 Program header Parameter Description Unit Stop dimension of the main spindle - (only for spindle chuck data "yes") Jaw dimension of the main spindle for jaw type 2 - (only for spindle chuck data "yes") Chuck dimension of the counterspindle - (only for spindle chuck data "yes"...
Page 237: Generating Program Blocks
Creating a ShopTurn program 7.7 Generating program blocks Generating program blocks After a new program is created and the program header is filled out, define the individual machining steps in program blocks that are necessary to machine the workpiece. You can only create the program blocks between the program header and the program end. Procedure Selecting a technological function Position the cursor in the work plan on the line behind which a new...
Page 238: Tool, Offset Value, Feedrate And Spindle Speed (T, D, F, S, V)
Creating a ShopTurn program 7.8 Tool, offset value, feedrate and spindle speed (T, D, F, S, V) Tool, offset value, feedrate and spindle speed (T, D, F, S, V) The following parameters should be entered for every program block. Tool (T) Each time a workpiece is machined, you must program a tool.
Page 239 Creating a ShopTurn program 7.8 Tool, offset value, feedrate and spindle speed (T, D, F, S, V) Feedrate (F) The feedrate F (also referred to as the machining feedrate) specifies the speed at which the axes move when machining the workpiece. The machining feedrate is entered in mm/min, mm/rev or in mm/tooth.
Page 240 Creating a ShopTurn program 7.8 Tool, offset value, feedrate and spindle speed (T, D, F, S, V) Converting the spindle speed (S) / cutting rate (V) when milling As an alternative to the cutting rate, you can also program the spindle speed. For the milling cycles, the cutting rate (m/min) that is entered is automatically converted into the spindle speed (rpm) using the tool diameter - and vice versa.
Page 241: Call Work Offsets
Creating a ShopTurn 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 242: Repeating Program Blocks
Creating a ShopTurn program 7.10 Repeating program blocks 7.10 Repeating program blocks If certain steps when machining a workpiece have to be executed more than once, it is only necessary to program these steps once. You have the option of repeating program blocks. Note Machining several workpieces The program repeat function is not suitable to program repeat machining of parts.
Page 243: Entering The Number Of Workpieces
Creating a ShopTurn program 7.11 Entering the number of workpieces Continue programming up to the point where you want to repeat the program blocks. Press the "Various" and "Repeat progr." softkeys. Enter the names of the start and end markers and the number of times the blocks are to be repeated.
Page 244: Changing Program Blocks
Creating a ShopTurn program 7.12 Changing program blocks Procedure Open the "Program end" program block, if you want to machine more than one workpiece. In the "Repeat" field, enter "Yes". Press the "Accept" softkey. If you start the program later, program execution is repeated. Depending on the settings in the "Times, counters"...
Page 245: Changing Program Settings
Creating a ShopTurn program 7.13 Changing program settings Press the key. The changes are accepted in the program. 7.13 Changing program settings Function All parameters specified in the program header with the exception of the blank shape and the unit of measurement can be changed at any point in the program.
Page 246 Creating a ShopTurn program 7.13 Changing program settings Parameters Parameter Description Unit Retraction Lift mode simple • Extended • • Retraction plane X external ∅ (abs) or retraction plane X referred to XA (inc) Retraction plane X internal ∅ (abs) or retraction plane X referred to XI (inc) - (only for retraction "extended"...
Page 247: Selection Of The Cycles Via Softkey
Creating a ShopTurn program 7.14 Selection of the cycles via softkey 7.14 Selection of the cycles via softkey Overview of the machining steps The following machining steps are available. 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 248 Creating a ShopTurn program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 249 Creating a ShopTurn program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 250 Creating a ShopTurn program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 251 A menu tree with all of the available measuring versions of the measuring cycle function "Measure workpiece" can be found in the following reference: Programming Manual Measuring cycles / SINUMERIK 840D sl/828D ⇒ A menu tree with all of the available measuring versions of the measuring cycle function "Measure tool"...
Page 252: Calling Technology Functions
Creating a ShopTurn 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 253: Programming Variables
7.15.4 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 Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 254: Changing A Cycle Call
Creating a ShopTurn program 7.15 Calling technology functions 7.15.5 Changing a cycle call You have called the desired cycle via softkey in the program editor, entered the parameters and confirmed with "Accept". Procedure Select the desired cycle call and press the key. The associated input screen of the selected cycle call is opened.
Page 255: Programming The Approach/Retraction Cycle
Creating a ShopTurn program 7.16 Programming the approach/retraction cycle 7.16 Programming the approach/retraction cycle If you wish to shorten the approach/retraction for a machining cycle or solve a complex geometrical situation when approaching/retracting, you can generate a special cycle. In this case, the approach/retraction strategy normally used is not taken into account.
Page 256 Creating a ShopTurn program 7.16 Programming the approach/retraction cycle Table 7- 1 Parameters Description Unit Feedrate to approach the first position mm/min Alternatively, rapid traverse 1. position ∅ (abs) or 1st position (inc) mm (in) 1. position (abs or inc) Feedrate for approach to the second position mm/min Alternatively, rapid traverse...
Page 257: Measuring Cycle Support
Software option You require the "Measuring cycles" option to use "Measuring cycles". References You will find a more detailed description on how to use measuring cycles in: Programming Manual Measuring cycles / SINUMERIK 840D sl/828D Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 258: Example: Standard Machining
Creating a ShopTurn program 7.18 Example: Standard machining 7.18 Example: Standard machining General information The following example is described in detail as ShopTurn 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 259: Workpiece Drawing
Creating a ShopTurn program 7.18 Example: Standard machining 7.18.1 Workpiece drawing 7.18.2 Programming 1. Program header Specify the blank. Measurement unit mm Blank Cylinder 90abs +1.0abs -120abs -100abs Retraction simple Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 260 Creating a ShopTurn program 7.18 Example: Standard machining 2inc 5inc Tool change point Machine 160abs 409abs 4000rev/min Machining direction Climbing 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.
Page 261 Creating a ShopTurn program 7.18 Example: Standard machining 3. Input of blank contour with contour computer Press the "Cont. turn." and "New contour" softkeys. The "New Contour" input window opens. Enter the contour name (in this case: Cont_1). The contour calculated as NC code is written as internal subprogram between a start and an end marker containing the entered name.
Page 262 Creating a ShopTurn program 7.18 Example: Standard machining Press the "Accept" softkey. It is only necessary to enter the blank contour when using a pre- machined blank. Blank contour 4. Input of finished part with contour computer Press the "Cont. turn." and "New contour" softkeys. The "New Contour"...
Page 263 Creating a ShopTurn program 7.18 Example: Standard machining 48abs α2 90° Direction of rotation 23abs 60abs -35abs Afterwards, entry fields are inactive. Using the "Dialog selection" softkey, select a required contour element and confirm using the "Dialog accept" softkey. The entry fields are active again.
Page 264 Creating a ShopTurn program 7.18 Example: Standard machining 5. Stock removal (roughing) Press the "Cont. turn." and "Stock removal" softkeys. The "Stock Removal" input window opens. Enter the following technology parameters: T Roughing tool 80 D1 F 0.350 mm/rev V 400 m/min Enter the following parameters: Machining Roughing (∇)
Page 265 Creating a ShopTurn program 7.18 Example: Standard machining If a blank programmed under "CONT_1" is used, under parameter "BL", the "Contour" blank description should be selected instead of "Cylinder". When selecting "Cylinder", the workpiece is cut from the solid material. Stock removal contour 6.
Page 266 Creating a ShopTurn program 7.18 Example: Standard machining Set machining area limits No Press the "Accept" softkey. 7. Stock removal (finishing) Press the "Cont. turn." and "Stock removal" softkeys. The "Stock Removal" input window opens. Enter the following technology parameters: T Finishing tool_D1 F 0.1 mm/rev V 450 m/min...
Page 267 Creating a ShopTurn program 7.18 Example: Standard machining Reference point 60abs 8inc 4inc α1 15Degrees α2 15Degrees 2inc 0.4inc 0.2inc Press the "Accept" softkey. Contour, groove Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 268 Creating a ShopTurn program 7.18 Example: Standard machining 9. Groove (finishing) Press the "Turning", "Groove" and "Groove with inclines" softkeys. The "Groove 2" entry field opens. Enter the following technology parameters: T Grooving tool F 0.1 mm/rev V 220 m/min Enter the following parameters: Machining Finishing (∇∇∇)
Page 269 Creating a ShopTurn program 7.18 Example: Standard machining 2mm/rev 995rev/min Machining type Roughing (∇) Infeed: Constant cutting Diminishing cross-section Thread External thread 48abs 0abs -25abs 4inc 4inc 1.227inc αP 30Degrees Infeed 0.150inc 1inc Multiple threads α0 0Degrees Press the "Accept" softkey. 11.
Page 270 Creating a ShopTurn program 7.18 Example: Standard machining 0abs -25abs 4inc 4inc 1.227inc αP 30Degrees Infeed 1inc Multiple threads α0 0Degrees Press the "Accept" softkey. 12. Drilling Press the "Drilling", "Drilling reaming" and "Drilling" softkeys. The "Drilling" input window opens. Enter the following technology parameters: T Drill_D5 F 0.1 mm/rev...
Page 271 Creating a ShopTurn program 7.18 Example: Standard machining 13. Positioning Press the "Drilling", "Positions" and "Freely Programmable Positions" softkeys. The "Positions" input window opens. Enter the following parameters: Machined surface Face C Coordinate system Polar 0abs 0abs 16abs 90abs 16abs 180abs 16abs 270abs...
Page 272: Results/Simulation Test
Creating a ShopTurn program 7.18 Example: Standard machining α0 4Degrees 5inc 0.1mm Insertion Vertical 0.015mm/tooth Press the "Accept" softkey. 7.18.3 Results/simulation test Figure 7-10 Programming graphics Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 273 Creating a ShopTurn program 7.18 Example: Standard machining Figure 7-11 Process plan Program test by means of simulation During simulation, the current program is calculated in its entirety and the result displayed in graphic form. Figure 7-12 3D view Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 274: G Code Machining Program
Creating a ShopTurn program 7.18 Example: Standard machining 7.18.4 G code machining program N1 G54 N2 WORKPIECE(,,"","CYLINDER",192,2,-120,-100,90) N3 G0 X200 Z200 Y0 ;***************************************** N4 T="ROUGHING TOOL_80" D1 N5 M06 N6 G96 S350 M04 N7 CYCLE951(90,2,-1.6,0,-1.6,0,1,2,0,0.1,12,0,0,0,1,0.3,0,2,1110000) N8 G96 S400 N9 CYCLE62(,2,"E_LAB_A_CONT_2","E_LAB_E_CONT_2") N10 CYCLE952("STOCK REMOVAL_1",,"BLANK_1",2301311,0.35,0.15,0,4,0.1,0.1,0.4,0.2,0.1,0,1,0,0,,,,,2,2,,,0,1,,0,12,1110110) N11 G0 X200 Z200...
Page 275 Creating a ShopTurn program 7.18 Example: Standard machining ;***************************************** N34 T="DRILL_D5" D1 N35 M06 N36 SPOS=0 N37 SETMS(2) N38 M24 ; couple-in driven tool, machine-specific N39 G97 S3183 M3 N40 G94 F318 N41 TRANSMIT N42 MCALL CYCLE82(1,0,1,,10,0,0,1,11) N43 HOLES2(0,0,16,0,30,4,1010,0,,,1) N44 MCALL N45 M25 ;...
Page 276 Creating a ShopTurn program 7.18 Example: Standard machining X30 ;*GP* ;CON,2,0.0000,1,1,MST:0,0,AX:Z,X,K,I;*GP*;*RO*;*HD* ;S,EX:0,EY:30;*GP*;*RO*;*HD* ;LL,EX:-40;*GP*;*RO*;*HD* ;LA,EX:-45,EY:40;*GP*;*RO*;*HD* ;LL,EX:-65;*GP*;*RO*;*HD* ;LA,EX:-70,EY:45;*GP*;*RO*;*HD* ;LL,EX:-95;*GP*;*RO*;*HD* ;LD,EY:0;*GP*;*RO*;*HD* ;LR,EX:0;*GP*;*RO*;*HD* ;LA,EX:0,EY:30;*GP*;*RO*;*HD* ;#End contour definition end - Don't change!;*GP*;*RO*;*HD* E_LAB_E_CONT_1: N65 E_LAB_A_CONT_2: ;#SM Z:4 ;#7__DlgK contour definition begin - Don't change!;*GP*;*RO*;*HD* G18 G90 DIAMOF;*GP* G0 Z0 X0 ;*GP* G1 X24 CHR=3 ;*GP* Z-18.477 ;*GP*...
Page 277: Programming Technology Functions (Cycles)
Programming technology 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 278: Centering (Cycle81)
Programming technology 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 279 Programming technology functions (cycles) 8.1 Drilling Approach/retraction 1. The tool moves with G0 to safety clearance of the reference point. 2. Inserted into the workpiece with G1 and the programmed feedrate F until the depth or the centering diameter is reached. 3.
Page 280 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Position At the front (face) • (only for At the rear (face) • ShopTurn) Outside (peripheral surface) • Inside (peripheral surface) • Clamp/release spindle The function must be set up by the machine manufacturer. (only for ShopTurn) Centering...
Page 281: Drilling (Cycle82)
Programming technology 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. Clamping the spindle For ShopTurn, the "Clamp spindle"...
Page 282 Programming technology functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopTurn 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 Machining Single position •...
Page 283: Reaming (Cycle85)
Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Drilling depth (abs) or drilling depth in relation to Z0 (inc) It is inserted into the workpiece until it reaches Z1. Dwell time (at final drilling depth) in seconds • Dwell time (at final drilling depth) in revolutions •...
Page 284 Programming technology functions (cycles) 8.1 Drilling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Drilling Reaming" softkey. Press the "Reaming" softkey. The "Reaming" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane...
Page 285: Boring (Cycle86)
Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Clamp/release spindle The function must be set up by the machine manufacturer. (only for ShopTurn) Drilling depth (abs) or drilling depth in relation to Z0 (inc) It is inserted into the workpiece until it reaches Z1. Dwell time (at final drilling depth) in seconds •...
Page 286 Programming technology functions (cycles) 8.1 Drilling Lift For "lift off contour", the retraction distance D and the tool orientation angle α can either be defined via machine data or in the parameter screen. If both parameters are pre-assigned via machine data, they do not appear in the parameter screen. Machine manufacturer Please refer to the machine manufacturer's specifications.
Page 287 Programming technology functions (cycles) 8.1 Drilling Press the softkeys "Drilling Reaming" and "Boring" for ShopTurn The "Boring" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev S / V Spindle speed or constant...
Page 288 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Clamp/release spindle The function must be set up by the machine manufacturer. (only for ShopTurn) Drilling depth (abs) or drilling depth in relation to Z0 (inc) Dwell time at final drilling depth in seconds •...
Page 289: Deep-Hole Drilling (Cycle83)
Programming technology functions (cycles) 8.1 Drilling 8.1.6 Deep-hole drilling (CYCLE83) Function With the "Deep-hole drilling" cycle, the tool is inserted in the workpiece with the programmed spindle speed and feedrate in several infeed steps until the depth Z1 is reached. The following can be specified: ●...
Page 290 Programming technology functions (cycles) 8.1 Drilling Approach/retraction during stock removal 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 291 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Machining Single position • position (only Drill hole at programmed position for G code) Position pattern • Position with MCALL Z0 (only for G Reference point Z code) Machining Face C •...
Page 292 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Infeed: Amount for each additional infeed • Percentage for each additional infeed • DF = 100%: Infeed increment remains constant DF < 100%: Infeed increment is reduced in direction of final drilling depth. Example: last infeed was 4 mm;...
Page 293: Tapping (Cycle84, 840)
Programming technology functions (cycles) 8.1 Drilling 8.1.7 Tapping (CYCLE84, 840) Function You can machine an internal thread with the "tapping" cycle. The tool moves to the safety clearance with the active speed and rapid traverse. The spindle stops, spindle and feedrate are synchronized. The tool is then inserted in the workpiece with the programmed speed (dependent on %S).
Page 294 Programming technology 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 295 Programming technology functions (cycles) 8.1 Drilling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Thread" and "Tapping" softkeys. The "Tapping" input window opens. Parameters, G code program Parameters, ShopTurn program Machining...
Page 296 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Machining - (with You can select the following technologies for tapping: compensating with encoder • chuck) Tapping with spindle encoder (only for G code) without encoder • Tapping without spindle encoder; –...
Page 297 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Selection Selection of table value: e.g. M3; M10; etc. (ISO metric) • W3/4"; etc. (Whitworth BSW) • G3/4"; etc. (Whitworth BSP) • 1" - 8 UNC; etc. (UNC) • Pitch ... - (selection MODULUS in MODULUS: MODULUS = Pitch/π...
Page 298 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Direction of rotation after end of cycle: (only for G code) • • • Technology • – Exact stop – Precontrol – Acceleration – Spindle • Exact stop (only Behavior the same as it was before the cycle was called •...
Page 299: Drill And Thread Milling (Cycle78)
Programming technology 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 300 Programming technology functions (cycles) 8.1 Drilling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Thread" and "Cut thread" softkeys. The "Drilling and thread milling" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane...
Page 301 Programming technology functions (cycles) 8.1 Drilling Parameters Description Unit Clamp/release spindle (only for end face Y/peripheral surface Y) The function must be set up by the machine manufacturer. (only for ShopTurn) Thread length (inc) or end point of the thread (abs) Maximum depth infeed Percentage for each additional infeed •...
Page 302 Programming technology functions (cycles) 8.1 Drilling Parameters Description Unit Feedrate for thread milling mm/min mm/tooth Table Thread table selection: without • ISO metric • Whitworth BSW • Whitworth BSP • • Selection - (not Selection, table value: e.g. for table M3;...
Page 303: Positions And Position Patterns
Programming technology functions (cycles) 8.1 Drilling 8.1.9 Positions and position patterns Function After you have programmed the technology (cycle call), you must program the positions. Several position patterns are available: ● Arbitrary positions ● Position on a line, on a grid or frame ●...
Page 304: Arbitrary Positions (Cycle802)
Programming technology functions (cycles) 8.1 Drilling Tool traverse path ● ShopTurn 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 305 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Repeat jump label for position (only for G code) Machining plane (only for G code) Machining Face C • surface Face Y • Peripheral surface C • (only for Peripheral surface Y ShopTurn) •...
Page 306 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Face C and face Y - polar: Z coordinate of the reference point (abs) Positioning angle for machining area (only for face Y) Degrees C coordinate of 1st position (abs) Degrees 1.
Page 307: Position Pattern Line (Holes1), Grid Or Frame (Cycle801)
Programming technology functions (cycles) 8.1 Drilling 8.1.11 Position pattern line (HOLES1), grid or frame (CYCLE801) Function You can program the following pattern using the "Position pattern" cycle: ● Line (HOLES1) In the "Line" selection option you can program any number of positions at equal distances along a line.
Page 308 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Position At the front (face) • (only for At the rear (face) • ShopTurn) Outside (peripheral surface) • Inside (peripheral surface) • Position pattern Selection option for the following patterns: Line •...
Page 309: Circle Position Pattern (Holes2)
Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Peripheral surface Y: X coordinate of the reference point (abs) Degrees Positioning angle for machining surface Y coordinate of the reference point – first position (abs) Z coordinate of the reference point – first position (abs) α0 Angle of rotation of line with reference to Y axis Degrees...
Page 310 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Repeat jump label for position (only for G code) Machining plane (only for G code) Circular pattern Selection option for the following patterns: Pitch circle • Full circle • X coordinate of the reference point (abs) Y coordinate of the reference point (abs) α0 Starting angle for first position referred to the X axis.
Page 311 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Face C: center/ Position circle center on the face surface off-center Position circle off-center on the face surface Z coordinate of the reference point (abs) X coordinate of the reference point (abs) – (only for off-center) Y coordinate of the reference point (abs) –...
Page 312 Programming technology functions (cycles) 8.1 Drilling Parameter Description Unit Peripheral surface C: Cylinder diameter ∅ (abs) Z coordinate of the reference point (abs) α0 Starting angle for first position referred to the Y axis. Degrees Positive angle: Circle is rotated counterclockwise. Negative angle: Circle is rotated clockwise.
Page 313: Displaying And Hiding Positions
Programming technology functions (cycles) 8.1 Drilling 8.1.13 Displaying and hiding positions Function You can hide any positions in the following position patterns: ● Position pattern line ● Position pattern grid ● Position pattern frame ● Full circle position pattern ● Pitch circle position pattern The hidden positions are skipped when machining.
Page 314 Programming technology functions (cycles) 8.1 Drilling Press the "Hide position" softkey. The "Hide position" window opens on top of the input form of the position pattern. The positions are displayed in a table. The numbers of the positions, their coordinates (X, Y) as well as a checkbox with the state (activated = on / deactivated = off) are displayed.
Page 315: Repeating Positions
Programming technology functions (cycles) 8.1 Drilling 8.1.14 Repeating positions 8.1.14.1 Function 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. The cycle automatically assigns this number (for ShopTurn).
Page 316: Rotate
Programming technology functions (cycles) 8.2 Rotate Rotate 8.2.1 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. 8.2.2 Stock removal (CYCLE951) Function...
Page 317 Programming technology functions (cycles) 8.2 Rotate 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. The cycle always observes the lower value;...
Page 318 Programming technology functions (cycles) 8.2 Rotate Straight stock removal cycle with radii or chamfers. The "Stock removal 2" input window opens. - OR Stock removal cycle with oblique lines, radii, or chamfers. The "Stock Removal 3" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane Tool name...
Page 319: Groove (Cycle930)
Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit Finishing allowance in X – (not for finishing) Finishing allowance in Z – (not for finishing) FS1...FS3 or R1...R3 Chamfer width (FS1...FS3) or rounding radius (R1...R3) - (not for stock removal 1) Parameter selection of intermediate point The intermediate point can be determined through position specification or angle.
Page 320 Programming technology functions (cycles) 8.2 Rotate Approach/retraction during roughing Infeed depth D > 0 1. The tool first moves to the starting point calculated internally in the cycle at rapid traverse. 2. The tool cuts a groove in the center of infeed depth D. 3.
Page 321 Programming technology functions (cycles) 8.2 Rotate - OR Groove cycle on an incline with inclines, radii or chamfers. The "Groove 3" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Safety clearance Cutting edge number Feedrate Feedrate mm/rev...
Page 322: Undercut Form E And F (Cycle940)
Programming technology functions (cycles) 8.2 Rotate Parameter 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 < 90°. FS1...FS4 or R1...R4 Chamfer width (FS1...FS4) or rounding radius (R1...R4) - (only for grooves 2 and α0...
Page 323 Programming technology functions (cycles) 8.2 Rotate Parameters, G code program (undercut, form E) Parameters, ShopTurn program (undercut, form E) Machining plane Tool name Safety clearance Cutting edge number Feedrate Feedrate mm/rev S / V Spindle speed or constant cutting rate m/min Parameters Description...
Page 324: Thread Undercuts (Cycle940)
Programming technology functions (cycles) 8.2 Rotate 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 ∅ (abs) or allowance in X (inc) Allowance in Z (abs) or allowance in Z (inc) –...
Page 325 Programming technology functions (cycles) 8.2 Rotate Procedure The part program or ShopTurn program to be processed 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)" input window opens. - OR - Press the "Thread undercut"...
Page 326 Programming technology functions (cycles) 8.2 Rotate Parameters Description Unit Thread pitch (select from the preset DIN table or enter) mm/rev Reference point X ∅ Reference point Z α Insertion angle Degrees Cross feed ∅ (abs) or cross feed (inc) - (only for ∇∇∇ and ∇ + ∇∇∇) Maximum depth infeed –...
Page 327: Thread Turning (Cycle99)
Programming technology functions (cycles) 8.2 Rotate Parameters Description Unit α Insertion angle Degrees 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 328 Programming technology functions (cycles) 8.2 Rotate Approach/retraction 1. The tool moves to the starting point calculated internally in the cycle at rapid traverse. 2. Thread with advance: The tool moves at rapid traverse to the first starting position displaced by the thread advance LW.
Page 329 Programming technology functions (cycles) 8.2 Rotate Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Cutting edge number S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Table Thread table selection: without • ISO metric •...
Page 330 Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit Infeed (only for ∇ and ∇ Linear: • + ∇∇∇) Infeed with constant cutting depth Degressive: • Infeed with constant cutting cross-section Thread Internal thread • External thread • Reference point X from thread table ∅ (abs) Reference point Z (abs) End point of the thread (abs) or thread length (inc) Incremental dimensions: The sign is also evaluated.
Page 331 Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit Infeed along the flank Infeed with alternating flanks (alternative) Instead of infeed along one flank, you can infeed along alternating flanks to avoid always loading the same tool cutting edge. As a consequence you can increase the tool life.
Page 332 Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit mm/rev Thread pitch in mm/revolution • 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) mm/rev G = 0: The thread pitch P does not change.
Page 333 Programming technology functions (cycles) 8.2 Rotate Parameter 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 334 Programming technology functions (cycles) 8.2 Rotate Parameter 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. until the final depth is reached. DA = 0: Thread changeover depth is not taken into account, i.e.
Page 335 Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇ + ∇∇∇ (roughing and finishing) • Infeed (only for ∇ and ∇ Linear: • + ∇∇∇) Infeed with constant cutting depth Degressive: • Infeed with constant cutting cross-section Thread Internal thread...
Page 336: Thread Chain (Cycle98)
Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit D1 or ND First infeed depth or number of roughing cuts (only for ∇ and The respective value is displayed when you switch between the number of ∇ + ∇∇∇) roughing cuts and the first infeed. Finishing allowance in X and Z –...
Page 337 Programming technology functions (cycles) 8.2 Rotate ● With a constant infeed depth, the cutting cross-section increases from cut to cut. The finishing allowance is machined in one cut after roughing. A constant infeed depth can produce better cutting conditions at small thread depths. ●...
Page 338: Parameters
Programming technology functions (cycles) 8.2 Rotate 8.2.7.1 Parameters Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Safety clearance Cutting edge number S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Machining ∇ (roughing) •...
Page 339 Programming technology functions (cycles) 8.2 Rotate Parameter Description Unit Thread pitch 3 (unit as parameterized for P0) mm/rev in/rev turns/" MODULUS End point X ∅ (abs) or • End point 3 in relation to X2 (inc) or • Degrees Thread taper 3 •...
Page 340: Cut-Off (Cycle92)
Programming technology functions (cycles) 8.2 Rotate 8.2.8 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 341 Programming technology functions (cycles) 8.2 Rotate Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Safety clearance Cutting edge number Feedrate Feedrate mm/rev S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Direction of spindle rotation (only for G code) Spindle speed rev/min...
Page 342: Contour Turning
Programming technology functions (cycles) 8.3 Contour turning Contour turning 8.3.1 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 343: Representation Of The Contour
Programming technology functions (cycles) 8.3 Contour turning 4. Stock removal along the contour (roughing) The contour is machined longitudinally, transversely or parallel to the contour. 5. Remove residual material (roughing) When removing stock along the contour, ShopTurn automatically detects residual material that has been left.
Page 344 Programming technology functions (cycles) 8.3 Contour turning Contour element Symbol Meaning 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 Meaning Black Blue Cursor on active element Black Orange Cursor on current element...
Page 345: Creating A New Contour
Programming technology functions (cycles) 8.3 Contour turning 8.3.3 Creating a new contour Function For each contour that you want to cut, you must create a new contour. The first step in creating a contour is to specify a starting point. Enter the contour element. The contour processor then automatically defines the end of the contour.
Page 346 Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Direction in front Direction of the contour element towards the starting point: of the contour In the negative direction of the horizontal axis • In the positive direction of the horizontal axis •...
Page 347: Creating Contour Elements
Programming technology functions (cycles) 8.3 Contour turning 8.3.4 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 348 Programming technology functions (cycles) 8.3 Contour turning 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. ● Selecting a dialog box If two different possible contours result from the parameters entered thus far, one of the options must be selected.
Page 349 Programming technology functions (cycles) 8.3 Contour turning In the opened input window, enter a name for the contour, e.g. contour_1. Press the "Accept" softkey. 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 "+"...
Page 350 Programming technology functions (cycles) 8.3 Contour turning 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 element Radius •...
Page 351 Programming technology functions (cycles) 8.3 Contour turning Parameters Description Unit DIN thread Thread pitch mm/rev α Insertion angle Degrees 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 352: Entering The Master Dimension
Programming technology functions (cycles) 8.3 Contour turning Parameters Description Unit End point X ∅ (abs) or end point X (inc) Circle center point K (abs or inc) Circle center point I ∅ (abs or circle center point I (inc) α1 Starting angle to Z axis Degrees β1...
Page 353 Programming technology functions (cycles) 8.3 Contour turning Fit calculator A fit calculator supports you when making entries. Procedure Position the cursor on the desired entry field. Press the <=> key. The calculator is displayed. Press the "Fit shaft" or "Fit hole" softkey. "F"...
Page 354: Changing The Contour
Programming technology functions (cycles) 8.3 Contour turning 8.3.6 Changing the contour Function You can change a previously created contour later. Individual contour elements can be ● added, ● changed, ● inserted or ● deleted. Procedure for changing a contour element Open the part program or ShopTurn program to be executed.
Page 355: Contour Call (Cycle62) - Only For G Code Program
Programming technology functions (cycles) 8.3 Contour turning 8.3.7 Contour call (CYCLE62) - only for G code program Function The input creates a reference to the selected contour. There are four ways to call the contour: 1. Contour name The contour is in the calling main program. 2.
Page 356: Stock Removal (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Subprogram PRG: Subprogram Labels in the PRG: Subprogram • subprogram LAB1: Label 1 • LAB2: Label 2 • 8.3.8 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 blank contour.
Page 357 Programming technology functions (cycles) 8.3 Contour turning Alternating cutting depth Instead of working with constant cutting depth D, you can use an alternating cutting depth to vary the load on the tool edge, As a consequence you can increase the tool life. The percentage for the alternating cutting depth is saved in a machine data element.
Page 358 Programming technology functions (cycles) 8.3 Contour turning For single-channel systems, cycles do not extend the name for the programs to be generated. Note G code programs For G code programs, the programs to be generated, which do not include any path data, are saved in the directory in which the main program is located.
Page 359 Programming technology functions (cycles) 8.3 Contour turning Parameters, G code program Parameters, ShopTurn program Name of the program to be Tool name generated Machining plane Cutting edge number Retraction plane – Feed (∇ or ∇∇∇) mm/rev (only for machining direction, longitudinal, inner) Safety clearance Finishing feedrate (only...
Page 360 Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Position front • back • internal • external • Maximum depth infeed - (only for ∇) Maximum depth infeed – (only for parallel to the contour, as an alternative to D) Always round on the contour.
Page 361 Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit - (only for ∇ machining) - (only for blank description, cylinder and allowance) For blank description, cylinder • – Version, absolute: Cylinder dimension (abs) – Version incremental: Allowance (inc) to maximum values of the CYCLE62 finished part contour For blank description, allowance •...
Page 362: Stock Removal Rest (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning 8.3.9 Stock removal rest (CYCLE952) Function Using the "Stock removal residual" function, you 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 363 Programming technology functions (cycles) 8.3 Contour turning Parameters, G code program Parameters, ShopTurn program Name of the program to be generated Tool name Machining plane Cutting edge number Retraction plane Feedrate mm/rev Safety clearance S / V Spindle speed or constant cutting rate m/min Feedrate...
Page 364 Programming technology functions (cycles) 8.3 Contour turning Parameters Description Unit Uniform cut segmentation Round cut segmentation at the edge only for align cut segmentation at the edge: Constant cutting depth alternating cutting depth Allowance Allowance for pre-finishing - (only for ∇∇∇) •...
Page 365: Plunge-Cutting (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning 8.3.10 Plunge-cutting (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 366 Programming technology functions (cycles) 8.3 Contour turning Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Contour turning" softkey. Press the "Grooving" softkey. The "Grooving" input window opens. Parameters, G code program Parameters, ShopTurn program Name of the program to be...
Page 367 Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇ + ∇∇∇ (roughing and finishing) • Machining Face • direction Longitudinal • Position front • back • internal • external • Maximum depth infeed - (only for ∇) 1.
Page 368: Plunge-Cutting Rest (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning Parameter 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 369 Programming technology functions (cycles) 8.3 Contour turning Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Contour turning" softkey. Press the "Grooving residual material" softkey. The "Grooving residual material" input window is opened. Parameters, G code program Parameters, ShopTurn program Name of the program to be generated...
Page 370: Plunge-Turning (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning parameters Description Unit 2. Grooving limit tool (abs) – (only for face machining direction) UX or U Finishing allowance in X or finishing allowance in X and Z – (only for ∇) Finishing allowance in Z – (only for UX) For zero: Continuous cut - (only for ∇) Allowance Allowance for pre-finishing - (only for ∇∇∇)
Page 371 Programming technology functions (cycles) 8.3 Contour turning Precondition For a G-code program, at least one CYCLE62 is required before CYCLE952. If CYCLE62 is only present once, then this involves the finished part contour. If CYCLE62 is present twice, then the first call is the unmachined part contour and the second call is the finished-part contour (also see Chapter "Programming").
Page 372 Programming technology functions (cycles) 8.3 Contour turning Parameters, G code program Parameters, ShopTurn program Name of the program to be Tool name generated Machining plane Cutting edge number Retraction S / V Spindle speed plane – (only or constant m/min for longitudinal cutting rate machining...
Page 373 Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Finishing allowance in Z – (only for ∇) For zero: Continuous cut - (only for ∇) Blank description (only for ∇) Cylinder (described using XD, ZD) • Allowance (XD and ZD on the finished part contour) •...
Page 374: Plunge-Turning Rest (Cycle952)
Programming technology functions (cycles) 8.3 Contour turning Parameter Description Unit Number of grooves Distance between grooves * Unit of feedrate as programmed before the cycle call 8.3.13 Plunge-turning rest (CYCLE952) Function The "Plunge turning residual material" function is used when you want to machine the material that remained after plunge turning.
Page 375 Programming technology functions (cycles) 8.3 Contour turning Parameters, G code program Parameters, ShopTurn program Name of the program to be generated Tool name Machining plane Cutting edge number Retraction plane – (only for Feedrate mm/rev longitudinal machining direction) Safety clearance S / V Spindle speed or constant cutting rate...
Page 376 Programming technology functions (cycles) 8.3 Contour turning parameters Description Unit For zero: Continuous cut - (only for ∇) Compensation allowance in X and Z direction (inc) – (only for allowance) Positive value: Compensation allowance is kept • Negative value: Compensation allowance is removed in addition to finishing •...
Page 377: Milling
Programming technology functions (cycles) 8.4 Milling Milling 8.4.1 Face milling (CYCLE61) Function You can face mill any workpiece with the "Face milling" cycle. A rectangular surface is always machined. The rectangle is obtained from corner points 1 and 2 - which for a ShopTurn program - are pre-assigned with the values of the blank part dimensions from the program header.
Page 378 Programming technology functions (cycles) 8.4 Milling Machining type The cycle makes a distinction between roughing and finishing: ● Roughing: Milling the surface Tool turns above the workpiece edge ● Finishing: Milling the surface once Tool turns at safety distance in the X/Y plane Retraction of milling cutter Depth infeed always takes place outside the workpiece.
Page 379 Programming technology functions (cycles) 8.4 Milling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Face milling" softkey. The "Face Milling" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane...
Page 380 Programming technology functions (cycles) 8.4 Milling parameters Description Unit (only for G code) The positions refer to the reference point: Corner point 1 in X Corner point 1 in Y Height of blank Corner point 2X (abs) or corner point 2X in relation to X0 (inc) Corner point 2Y (abs) or corner point 2Y in relation to Y0 (inc) Height of blank (abs) or height of blank in relation to Z0 (inc) (only ShopTurn)
Page 381: Rectangular Pocket (Pocket3)
Programming technology functions (cycles) 8.4 Milling 8.4.2 Rectangular pocket (POCKET3) Function You can use the "Mill rectangular pocket" cycle to mill any rectangular pockets on the face or peripheral surface. . The following machining variants are available: ● Mill rectangular pocket from solid material. ●...
Page 382 Programming technology functions (cycles) 8.4 Milling Machining type ● Roughing Roughing involves machining the individual planes of the pocket one after the other from the center out, until depth Z1 or X1 is reached. ● Finishing During finishing, the edge is always machined first. The pocket edge is approached on the quadrant that joins the corner radius.
Page 383 Programming technology functions (cycles) 8.4 Milling Procedure The part program or ShopTurn 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, ShopTurn program Machining plane...
Page 384 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Position At the front (face) • At the rear (face) • Outside (peripheral surface) • (only for ShopTurn) Inside (peripheral surface) • Clamp/release spindle (only for end face Y/peripheral surface Y) The function must be set up by the machine manufacturer.
Page 385 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Peripheral surface Y: The positions refer to the reference point: Positioning angle for machining surface – (only for single position) Degrees Reference point Y – (only for single position) Reference point Z – (only for single position) Reference point X –...
Page 386 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Clamp/release spindle (only for end face C/peripheral surface C, if inserted vertically) The function must be set up by the machine manufacturer. (only for ShopTurn) Depth infeed rate – (for vertical insertion only) (only for G code) Depth infeed rate –...
Page 387: Circular Pocket (Pocket4)
Programming technology functions (cycles) 8.4 Milling 8.4.3 Circular pocket (POCKET4) Function You can use the "Circular pocket" cycle to mill circular pockets on the face or peripheral surface. The following machining variants are available: ● Mill circular pocket from solid material. ●...
Page 388 Programming technology functions (cycles) 8.4 Milling Machining type: Plane by plane When milling circular pockets, you can select these methods for the following machining types: ● Roughing Roughing involves machining the individual planes of the circular pocket one after the other from the center out, until depth Z1 or X1 is reached.
Page 389 Programming technology functions (cycles) 8.4 Milling Chamfering machining Chamfering involves edge breaking at the upper edge of the circular pocket. Figure 8-2 Geometries when chamfering inside contours Note The following error messages can occur when chamfering inside contours: • Safety clearance in the program header too large This error message appears when chamfering would, in principle, be possible with the parameters entered for FS and ZFS, but the safety clearance then could not be maintained.
Page 390 Programming technology functions (cycles) 8.4 Milling Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Milling direction Cutting edge number Retraction plane Feedrate mm/min mm/tooth Safety clearance S / V Spindle speed or constant cutting rate m/min Feedrate Parameter Description Unit...
Page 391 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit The positions refer to the reference point: Reference point X – (only for single position) Reference point Y – (only for single position) Reference point Z (only for G code) Face C: The positions refer to the reference point: X0 or L0 Reference point X or reference point length polar –...
Page 392 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Insertion Various insertion modes can be selected – (only for plane-by-plane machining method and for ∇, ∇∇∇ and ∇∇∇ edge): Predrilled (only for G code) • Vertical: Insert vertically at center of pocket •...
Page 393: Rectangular Spigot (Cycle76)
Programming technology functions (cycles) 8.4 Milling 8.4.4 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: In addition to the required rectangular spigot, you must also define a blank spigot, i.e. the outer limits of the material.
Page 394 Programming technology functions (cycles) 8.4 Milling Machining type ● Roughing Roughing involves moving around the rectangular spigot until the programmed finishing allowance has been reached. ● Finishing If you have programmed a finishing allowance, the rectangular spigot is moved around until depth Z1 is reached.
Page 395 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Depth infeed rate (only for ∇ and ∇∇∇) (only for G code) Reference point The following different reference point positions can be selected: (center) • (bottom left) • (only for ShopTurn) (bottom right) •...
Page 396 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Face Y: The positions refer to the reference point: Positioning angle for machining area – (only single position) Degrees X0 or L0 Reference point X or reference point length polar – (only for single position) Y0 or C0 Reference point Y or reference point angle polar –...
Page 397: Circular Spigot (Cycle77)
Programming technology functions (cycles) 8.4 Milling 8.4.5 Circular spigot (CYCLE77) Function You can mill various circular spigots with the "Circular spigot" function. In addition to the required circular spigot, you must also define a blank spigot, i.e. the outer limits of the material. The tool moves at rapid traverse outside this area. The blank spigot must not overlap adjacent blank spigots and is automatically placed on the finished spigot in a centered position.
Page 398 Programming technology functions (cycles) 8.4 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 399 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Depth infeed rate (only for G code) Machining Face C • surface Face Y • Peripheral surface C • (only for Peripheral surface Y • ShopTurn) Position At the front (face) •...
Page 400 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Face Y: The positions refer to the reference point: Positioning angle for machining area – (only single position) Degrees X0 or L0 Reference point X or reference point length polar – (only for single position) Y0 or C0 Reference point Y or reference point angle polar –...
Page 401: Multi-Edge (Cycle79)
Programming technology functions (cycles) 8.4 Milling 8.4.6 Multi-edge (CYCLE79) Function You can mill a multi-edge with any number of edges with the "Multi-edge" cycle. You can select from the following shapes with or without a corner radius or chamfer: Clamping the spindle For ShopTurn, the "Clamp spindle"...
Page 402 Programming technology functions (cycles) 8.4 Milling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Multi-edge spigot" and "Multi-edge" softkeys. The "Multi-edge" input window opens. Parameters, G code program Parameters, ShopTurn program Machining plane...
Page 403 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇∇∇ edge (edge finishing) • Chamfering • Machining Single position • position A multiple edge is milled at the programmed position (X0, Y0, Z0). Position pattern •...
Page 404: Longitudinal Groove (Slot1)
Programming technology functions (cycles) 8.4 Milling 8.4.7 Longitudinal groove (SLOT1) Function You can use the "Longitudinal groove" function to mill any longitudinal groove. The following machining methods are available: ● Mill longitudinal slot from solid material. Depending on the dimensions of the longitudinal slot in the workpiece drawing, you can select a corresponding reference point for the longitudinal slot.
Page 405 Programming technology functions (cycles) 8.4 Milling Approach/retraction 1. The tool approaches the center point of the slot at rapid traverse at the height of the retraction plane and adjusts to the safety distance. 2. The tool is inserted into the material according to the method selected. 3.
Page 406 Programming technology functions (cycles) 8.4 Milling Note The following error messages can occur when chamfering inside contours: • Safety clearance in the program header too large This error message appears when chamfering would, in principle, be possible with the parameters entered for FS and ZFS, but the safety clearance then could not be maintained.
Page 407 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Reference point Position of the reference point: (lefthand edge) • (inside left) • (only for G code) (center) • (inside right) • (righthand edge) • Machining Face C • surface Face Y •...
Page 408 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Face Y: The positions refer to the reference point: Positioning angle for machining area – (only single position) Degrees X0 or L0 Reference point X or reference point length polar – (only for single position) Y0 or C0 Reference point Y or reference point angle polar - (only for single position) mm or...
Page 409 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Insertion The following insertion modes can be selected – (only for ∇, ∇∇∇ or ∇∇∇ edge): Predrilled (only for G code) • Approach reference point shifted by the amount of the safety clearance with G0. Vertical •...
Page 410: Circumferential Groove (Slot2)
Programming technology functions (cycles) 8.4 Milling 8.4.8 Circumferential groove (SLOT2) Function You can mill one or several circumferential slots of equal size on a full or pitch circle with the "circumferential slot" cycle. Tool size Please note that there is a minimum size for the milling cutter used to machine the circumferential slot: ●...
Page 411 Programming technology functions (cycles) 8.4 Milling Machining type You can select the machining mode for milling the circumferential groove as follows: ● Roughing During roughing, the individual planes of the groove are machined one after the other from the center point of the semicircle at the end of the groove until depth Z1 is reached. ●...
Page 412 Programming technology functions (cycles) 8.4 Milling Procedure The part program or ShopTurn 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, ShopTurn program Machining plane...
Page 413 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇∇∇ edge (edge finishing) • Chamfering • FZ (only for G Depth infeed rate code) Circular pattern Full circle • The circumferential slots are positioned around a full circle. The distance from one circumferential slot to the next circumferential slot is always the same and is calculated by the control.
Page 414 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Peripheral surface Y: The positions refer to the reference point: Positioning angle for machining surface – (only for single position) Degrees Reference point Y – (only for single position) Reference point Z – (only for single position) Reference point X –...
Page 415: Open Groove (Cycle899)
Programming technology functions (cycles) 8.4 Milling 8.4.9 Open groove (CYCLE899) Function Use the "Open slot" function if you want to machine open slots. For roughing, you can choose between the following machining strategies, depending on your workpiece and machine properties. ●...
Page 416 Programming technology functions (cycles) 8.4 Milling Approach/retraction for vortex milling 1. The tool approaches the starting point in front of the slot in rapid traverse and maintains the safety clearance. 2. The tool goes to the cutting depth. 3. The open slot is always machined along its entire length using the selected machining method.
Page 417 Programming technology functions (cycles) 8.4 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 418 Programming technology functions (cycles) 8.4 Milling Supplementary conditions for plunge cutting ● Roughing 1/2 slot width W - finishing allowance UXY ≤ milling cutter diameter ● Maximum radial infeed The maximum infeed depends on the cutting edge width of the milling cutter. ●...
Page 419 Programming technology functions (cycles) 8.4 Milling 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. During this process, the milling cutter travels through the safety clearance beyond the beginning and end of the slot, so that an even slot wall surface can be guaranteed across the entire length of the slot.
Page 420 Programming technology functions (cycles) 8.4 Milling Note The following error messages can occur when chamfering inside contours: • Safety clearance in the program header too large This error message appears when chamfering would, in principle, be possible with the parameters entered for FS and ZFS, but the safety clearance then could not be maintained.
Page 421 Programming technology functions (cycles) 8.4 Milling Parameters, G code program Parameters, ShopTurn program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/tooth Feedrate S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Machining Face C...
Page 422 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Technology Vortex milling • The milling cutter performs circular motions along the length of the slot and back again. Plunge cutting • Sequential drilling motion along the tool axis. Milling direction: - (except plunge cutting). Climbing •...
Page 423 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Peripheral surface Y: The positions refer to the reference point: Positioning angle for machining surface – (only for single position) Degrees Reference point Y – (only for single position) Reference point Z – (only for single position) Reference point X –...
Page 424: Long Hole (Longhole) - Only For G Code Program
Programming technology functions (cycles) 8.4 Milling 8.4.10 Long hole (LONGHOLE) - only for G code program Function In contrast to the groove, the width of the elongated hole is determined by the tool diameter. Internally in the cycle, an optimum traversing path of the tool is determined, ruling out unnecessary idle passes.
Page 425 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Machining plane Retraction plane (abs) Safety clearance (inc) Feedrate Machining type Plane-by-plane • The tool is inserted to infeed depth in the pocket center. Note: This setting can be used only if the cutter can cut across center. Oscillating •...
Page 426: Thread Milling (Cycle70)
Programming technology functions (cycles) 8.4 Milling 8.4.11 Thread milling (CYCLE70) Function Using a thread cutter, internal or external threads can be machined with the same pitch. Threads can be machined as right-hand or left-hand threads and from top to bottom or vice versa.
Page 427 Programming technology functions (cycles) 8.4 Milling Please note that when milling an internal thread the tool must not exceed the following value: Milling cutter diameter < (nominal diameter - 2 · thread depth H1) Approach/retraction when milling external threads 1. Positioning on retraction plane with rapid traverse. 2.
Page 428 Programming technology functions (cycles) 8.4 Milling Table 8- 1 Parameters, G code program Parameters, ShopTurn 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...
Page 429 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Position of the thread: Internal thread • An internal thread is cut. External thread • An external thread is cut. Number of teeth per cutting edge Single or multiple toothed milling inserts can be used. The motions required are executed by the cycle internally, so that the tip of the bottom tooth on the milling tool cutting edge corresponds to the programmed end position when the thread end position is reached.
Page 430: Engraving (Cycle60)
Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Pitch ... - (selection MODULUS In MODULUS: For example, generally used for worm gears that mesh with a gear • option only for Turns/" wheel. table selection Per inch: Used with pipe threads, for example. •...
Page 431 Programming technology functions (cycles) 8.4 Milling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Engraving" softkey. The "Engraving" input window opens. Entering the engraving text Press the "Special characters"...
Page 432 Programming technology functions (cycles) 8.4 Milling • Press the "Variable" and "Workpiece count 000123" softkeys to engrave a workpiece count with a fixed number of digits and leading zeroes. The format text <######,_$AC_ACTUAL_PARTS> is inserted and you return to the engraving field with the softkey bar. •...
Page 433 Programming technology functions (cycles) 8.4 Milling <#.#,_VAR_NUM> 12.4 Places before decimal point unformatted, 1 place after the decimal point (rounded) <#.##,_VAR_NUM> 12.35 Places before decimal point unformatted, 2 places after the decimal point (rounded) <#.####,_VAR_NUM> 12.3500 Places before decimal point unformatted, 4 places after the decimal point (rounded)
Page 434 Programming technology functions (cycles) 8.4 Milling If you do not want to output a count of 1 for the first workpiece, you can specify an additive value (e.g., <#,$AC_ACTUAL_PARTS + 100>). The workpiece count output is then incremented by this value (e. g. 101, 102, 103,...). ●...
Page 435 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Position At the front (face) • At the rear (face) • Outside (peripheral surface) • (only for ShopTurn) Inside (peripheral surface) • Clamp/release spindle (only for end face Y/peripheral surface Y) The function must be set up by the machine manufacturer.
Page 436 Programming technology functions (cycles) 8.4 Milling Parameter Description Unit Face Y: The positions refer to the reference point: Positioning angle for machining area Degrees X0 or L0 Reference point X or reference point length polar Y0 or C0 Reference point Y or reference point angle polar mm or degrees Reference point Z...
Page 437: Contour Milling
Programming technology functions (cycles) 8.5 Contour milling Contour milling 8.5.1 General information 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 438 Programming technology functions (cycles) 8.5 Contour milling Contour element Symbol Meaning Straight line right Straight line in 90° grid 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...
Page 439: Creating A New Contour
Programming technology functions (cycles) 8.5 Contour milling 8.5.3 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 440 Programming technology functions (cycles) 8.5 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 441: Creating Contour Elements
Programming technology functions (cycles) 8.5 Contour milling parameters Description Unit Starting point Distance to pole, end point (abs) ϕ1 Polar angle to the pole, end point (abs) Degrees Additional commands You can program feedrates and M commands, for example, using additional G code commands.
Page 442 Programming technology functions (cycles) 8.5 Contour milling Cylinder surface transformation For contours (e.g. slots) on cylinders, lengths are frequently specified in the form of angles. If the "Cylinder surface transformation" function is activated, you can also define on a cylinder the length of contours (in the circumferential direction of the cylinder surface) using angles.
Page 443 Programming technology functions (cycles) 8.5 Contour milling Procedure for entering or changing contour elements The part program or ShopTurn program to be executed is created. Select the file type (MPF or SPF), enter the desired name of the program and press the "OK" softkey or the "Input" key. This editor is opened.
Page 444 Programming technology functions (cycles) 8.5 Contour milling Contour element "Straight line, e.g. X" Parameters Description Unit Machining Face C • surface Face Y • Face B • (only for ShopTurn) Peripheral surface C • Peripheral surface Y • End point X (abs or inc) α1 Starting angle e.g.
Page 445 Programming technology functions (cycles) 8.5 Contour milling Contour element "Straight line e.g. XY" Parameters Description Unit Machining Face C • surface Face Y • Face B • (only for ShopTurn) Peripheral surface C • Peripheral surface Y • End point X (abs or inc) End point Y (abs or inc) Length α1...
Page 446 Programming technology functions (cycles) 8.5 Contour milling 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 Additional commands Additional G code commands...
Page 447: Changing The Contour
Programming technology functions (cycles) 8.5 Contour milling 8.5.5 Changing the contour Function You can change a previously created contour later. If you want to create a contour that is similar to an existing contour, you can copy the existing one, rename it and just alter selected contour elements. Individual contour elements can be ●...
Page 448: Contour Call (Cycle62) - Only For G Code Program
Programming technology functions (cycles) 8.5 Contour milling 8.5.6 Contour call (CYCLE62) - only for G code program Function The input creates a reference to the selected contour. There are four ways to call the contour: 1. Contour name The contour is in the calling main program. 2.
Page 449: Path Milling (Cycle72)
Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Subprogram PRG: Subprogram Labels in the PRG: Subprogram • subprogram LAB1: Label 1 • LAB2: Label 2 • 8.5.7 Path milling (CYCLE72) Function You can machine open or closed contours with the "Path milling" cycle. Before you can mill the contour, you must enter the contour.
Page 450 Programming technology functions (cycles) 8.5 Contour milling 4. Path milling (finishing) If you programmed a finishing allowance for roughing, the contour is machined again. 5. Path milling (chamfering) If you have planned edge breaking, chamfer the workpiece with a special tool. Path milling on right or left of the contour A programmed contour can be machined with the cutter radius compensation to the right or left.
Page 451 Programming technology functions (cycles) 8.5 Contour milling Machining type You can select the machining mode (roughing, finishing, or chamfer) for path milling. If you want to "rough" and then "finish", you have to call the machining cycle twice (Block 1 = roughing, Block 2 = finishing).
Page 452 Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Machining Face C • surface Face Y • (only for Peripheral surface C • ShopTurn) Peripheral surface Y • Position At the front (face) • At the rear (face) • Outside (peripheral surface) •...
Page 453 Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Positioning angle for machining surface Degrees - (only for ShopTurn, machining surface, peripheral surface Y) Reference point Z Final drilling depth (abs) or final drilling depth referred to Z0 or X0 (inc) Maximum depth infeed - (only for machining ∇...
Page 454: Contour Pocket/Contour Spigot (Cycle63/64)
Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Retraction axis-by-axis • strategy spatial • 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 to the start).
Page 455 Programming technology functions (cycles) 8.5 Contour milling Contours for spigots Contours for spigots must be closed, i.e. the starting point and end point of the contour are identical. You can define multiple spigots that can also overlap. The first contour specified is interpreted as a blank contour and all others as spigots.
Page 456: Predrilling Contour Pocket (Cycle64)
Programming technology functions (cycles) 8.5 Contour milling Name convention For multi-channel systems, cycles attach a "_C" and a two-digit number of the specific channel to the names of the programs to be generated, e.g. for channel 1 "_C01". This is the reason that the name of the main program must not end with "_C"...
Page 457 Programming technology functions (cycles) 8.5 Contour milling 7. Contour pocket 2 8. Predrilling 9. Contour pocket 1 10. Stock removal 11. Contour pocket 2 12. Stock removal If you are doing all the machining for the pocket at once, i.e. centering, rough-drilling and removing stock directly in sequence, and do not set the additional parameters for centering/rough-drilling, the cycle will take these parameter values from the stock removal (roughing) machining step.
Page 458 Programming technology functions (cycles) 8.5 Contour milling Parameters, G code program Parameters, ShopTurn program Name of the program to be generated Tool name Machining plane Cutting edge number Milling direction Feedrate mm/min Climbing • mm/tooth Conventional • Retraction plane S / V Spindle speed or constant cutting rate m/min...
Page 459 Programming technology functions (cycles) 8.5 Contour milling parameters Description Unit Finishing allowance, plane Lift mode Lift mode before new infeed If the machining operation requires several points of insertion, the retraction height can be programmed: To retraction plane • Z0 + safety clearance •...
Page 460 Programming technology functions (cycles) 8.5 Contour milling parameters Description Unit Reference tool Tool, which is used in the "stock removal" machining step. This is used to determine the plunge position. Machining Face C • surface Face Y • (only for Face B •...
Page 461: Milling Contour Pocket (Cycle63)
Programming technology functions (cycles) 8.5 Contour milling 8.5.10 Milling contour pocket (CYCLE63) Function You can use the "Mill pocket" function to mill a pocket on the face or peripheral surface. Before you remove stock from the pocket, you must first enter the contour of the pocket and, if applicable, the contour of an island.
Page 462 Programming technology functions (cycles) 8.5 Contour milling Parameters, G code program Parameters, ShopTurn program Name of the program to be Tool generated name Machining plane Cutting edge numbe Milling direction Feedra mm/min Climbi • mm/tooth Conv • ention millin Retraction plane S / V Spindl m/min...
Page 463 Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Positioning angle for machining area Degrees - (only for ShopTurn, machining surface, face Y) Positioning angle for machining surface Degrees - (only for ShopTurn, machining surface, peripheral surface Y) Maximum plane infeed •...
Page 464: Contour Pocket Residual Material (Cycle63, Option)
Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Note: Degrees During insertion with oscillation, the message “Ramp path too short” will appear if the tool is less than the milling cutter diameter away from the insertion point along the ramp.
Page 465 Programming technology functions (cycles) 8.5 Contour milling Software option For removing residual stock, you require the option "residual stock detection and machining". Clamping the spindle For ShopTurn, the "Clamp spindle" function can be set up by the machine manufacturer. Machine manufacturer Please refer to the machine manufacturer's specifications.
Page 466 Programming technology functions (cycles) 8.5 Contour milling Parameters, G code program Parameters, ShopTurn program Name of the program to be generated Tool name Machining plane Cutting edge number Milling direction Feedrate mm/min Climbing • mm/tooth Conventional • Retraction plane S / V Spindle speed or constant cutting rate m/min...
Page 467: Milling Contour Spigot (Cycle63)
Programming technology functions (cycles) 8.5 Contour milling parameters Description Unit Maximum depth infeed Lift mode Lift mode before new infeed If the machining operation requires several points of insertion, the retraction height can be programmed: To retraction plane • Z0 + safety clearance •...
Page 468 Programming technology functions (cycles) 8.5 Contour milling 6. Steps 4 and 5 are repeated until the programmed spigot depth is reached. 7. The tool retracts to the safety clearance at rapid traverse. Procedure The part program or ShopTurn program to be processed has been created and you are in the editor.
Page 469 Programming technology functions (cycles) 8.5 Contour milling Parameter Description Unit Machining Face C • surface Face Y • (only for Face B • ShopTurn) Peripheral surface C • Peripheral surface Y • Clamp/release spindle (only for end face Y/B and peripheral surface Y) The function must be set up by the machine manufacturer.
Page 470: Contour Spigot Residual Material (Cycle63, Option)
Programming technology functions (cycles) 8.5 Contour milling 8.5.13 Contour spigot residual material (CYCLE63, option) 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 471 Programming technology functions (cycles) 8.5 Contour milling Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Press the "Milling", "Contour milling" and "Spigot resid. mat." softkeys. The "Spigot Res. Mat." input window opens. For the ShopTurn program, press the "All parameters"...
Page 472 Programming technology functions (cycles) 8.5 Contour milling parameters Description Unit Reference tool Tool, which is used in the "stock removal" machining step. This is used to determine the residual corners. Cutting edge number Reference point in tool axes Z Pocket depth (abs) or depth referred to Z0 Positioning angle for machining area Degrees - (only for ShopTurn, machining surface, face Y)
Page 473: Further Cycles And Functions
Programming technology functions (cycles) 8.6 Further cycles and functions Further cycles and functions 8.6.1 Swiveling plane / aligning 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 474 Programming technology functions (cycles) 8.6 Further cycles and functions Example: N1 T1D1 N2 M6 N3 G17 G54 N4 CYCLE800(1,"",0,57,0,0,0,0,0,0,0,0,0,1,0,1)) ;swivel ZERO to ;initial position of the ;machine kinematics N5 WORKPIECE(,,,,"BOX",0,0,50,0,0,0,100,100) ;blank declaration for ;simulation and ;simultaneous recording For machines where swivel is set-up, each main program with a swivel should start in the initial position of the machine.
Page 475 Programming technology functions (cycles) 8.6 Further cycles and functions Machine manufacturer Please refer to the machine manufacturer's specifications. Block search when swiveling the plane / swiveling the tool For block search with calculation, after NC start, initially, the automatic rotary axes of the active swivel data set are pre-positioned and then the remaining machine axes are positioned.
Page 476 Programming technology functions (cycles) 8.6 Further cycles and functions Approaching a machining operation When approaching the programmed machining operation in the swiveled plane, under worst case conditions, the software limit switches could be violated. In this case, the system travels along the software limit switches above the retraction plane.
Page 477 Programming technology functions (cycles) 8.6 Further cycles and functions Swivel mode Swiveling can either be realized axis-by-axis, using the angle in space, using the projection angle or directly. The machine manufacturer determines when setting up the "Swivel plane/swivel tool" function which swivel methods are available. Machine manufacturer Please refer to the machine manufacturer's specifications.
Page 478 Programming technology functions (cycles) 8.6 Further cycles and functions Axis sequence Sequence of the axes which are rotated around: XYZ or XZY or YXZ or YZX or ZXY or ZYX Direction (minus/plus) Direction reference of traversing direction of rotary axis 1 or 2 of the active swivel data set (machine kinematics).
Page 479 Programming technology functions (cycles) 8.6 Further cycles and functions The machine in the basic setting (pole setting) of the kinematics (B = 0 C = 0) is shown in the following diagram. ● Direction "-" (minus) – Rotary axis B moves to -10 degrees in the negative direction (red arrow). –...
Page 480 Programming technology functions (cycles) 8.6 Further cycles and functions Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Select the "Miscellaneous" softkey. Press the "Swivel plane" softkey. The "Swivel plane" input window opens. Press the "Basic setting"...
Page 481 Programming technology functions (cycles) 8.6 Further cycles and functions Parameters Description Unit Reference point for rotation X Reference point for rotation Y Reference point for rotation Z Swivel mode axis-by-axis: Swivel coordinate system axis-by-axis • Solid angle: Swivel via solid angle •...
Page 482: Swiveling Tool (Cycle800)
Programming technology functions (cycles) 8.6 Further cycles and functions 8.6.2 Swiveling tool (CYCLE800) 8.6.2.1 Aligning turning tools - only for G code program (CYCLE800) Function The purpose of the "Align milling tool" or "Align turning tool" function is to support combined milling machines - lathes with a B axis that can be swiveled.
Page 483: Aligning Milling Tools - Only For G Code Program (Cycle800)
Programming technology functions (cycles) 8.6 Further cycles and functions Parameters Description Unit Name of swivel data set Retract No: No retraction before swiveling • Z: Retraction in the direction of machine axis Z • Tool direction, max.: Maximum retraction in tool direction •...
Page 484: Preloading Milling Tools - Only For G Code Program (Cycle800)
Programming technology functions (cycles) 8.6 Further cycles and functions Parameter Description Unit β Rotation around the 3rd geometry axis (for G18 Y) Degrees Tool Tool tip when swiveling Correct • The position of the tool tip is maintained during swiveling. No correction •...
Page 485 Programming technology 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 "Setting milling tool" softkeys. The "Setting tool" input window opens. Parameter Description Unit...
Page 486: High-Speed Settings (Cycle832)
Programming technology functions (cycles) 8.6 Further cycles and functions 8.6.3 High-speed settings (CYCLE832) Function With the "High Speed Settings" function (CYCLE832), data for the machining of free-form surfaces is pre-assigned values so that optimum machining is possible. The call of CYCLE832 contains three parameters: ●...
Page 487 In the "Machine" operating area, you have the option of displaying important HSC information. 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. See also...
Page 488 Programming technology functions (cycles) 8.6 Further cycles and functions Procedure The part program or ShopTurn program to be processed has been created and you are in the editor. Select the "Miscellaneous" softkey. Press the ">>" softkey. Press the "High Speed Settings" softkey. The "High Speed Settings"...
Page 489: Subroutines
Programming technology functions (cycles) 8.6 Further cycles and functions 8.6.4 Subroutines If you require the same machining steps in the programming of different workpieces, you can define these machining steps in a separate subprogram. You can then call this subprogram in any program.
Page 490 Programming technology functions (cycles) 8.6 Further cycles and functions Press the "Various" and "Subprogram" softkeys. Enter the path of the subprogram if the desired subprogram is not stored in the same directory as the main program. Enter the name of the subprogram that you want to insert. You only need to enter the file extension (*.mpf or *.spf) if the subprogram does not have the file extension specified for the directory in which the subprogram is stored.
Page 491: Additional Cycles And Functions In Shopturn
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Additional cycles and functions in ShopTurn 8.7.1 Drilling centric Function Using the "Drill centric" cycle, you can perform drilling operations at the center of a face surface. You can choose between chip breaking during drilling or retraction from the workpiece for stock removal.
Page 492 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Procedure The ShopTurn program to be edited has been created and you are in the editor. Press the "Drilling" and "Drill centric" softkeys. The "Drilling centered" input window opens. Parameters Description Unit...
Page 493: Thread Centered
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Clearance - (only for "stock removal" operation) distance Manual • Automatic • Clearance distance – (for "manual" clearance distance only) Dwell time in seconds • Dwell time in revolutions •...
Page 494 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 4. Steps 2 and 3 are repeated until the programmed final drilling depth Z1 is reached. 5. The direction of rotation of the spindle reverses and the tool retracts to the safety clearance at spindle speed SR or cutting rate VR.
Page 495 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Tool name Cutting edge number Feedrate mm/min mm/rev Table Thread table selection: without • ISO metric • Whitworth BSW • Whitworth BSP • • Selection Selection, table value: M1 - M68 (ISO metric) •...
Page 496: Transformations
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Retraction - (only for "chipbreaking" operation) Retraction distance Manual • Automatic • Retraction distance (only for "manual" retraction) Distance through which the tap is retracted for chipbreaking. V2 = automatic: The tool is retracted by one revolution.
Page 497 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Procedure for work offset, offset, rotation, scaling, mirroring or rotation C axis. The ShopTurn program has been created and you are in the editor. Press the "Various" and "Transformation" softkeys. Press the "Work offsets”...
Page 498: Translation
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.4 Translation For each axis, you can program an offset of the zero point. New offset Additive offset Parameters Description Unit Offset • New offset Additive • Additive offset Offset Z Offset X Offset Y...
Page 499: Rotation
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.5 Rotation You can rotate every axis through a specific angle. A positive angle corresponds to counterclockwise rotation. New rotation Additive rotation Parameters Description Unit Rotation • New rotation •...
Page 500: Scaling
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.6 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 Parameters...
Page 501: Mirroring
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.7 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/climb) is also mirrored.
Page 502: Rotation C
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.8 Rotation C You can rotate the C axis through a specific angle to enable subsequent machining operations to be performed at a particular position on the face or peripheral surface. The direction of rotation is set in a machine data element.
Page 503: Straight And Circular Machining
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.9 Straight and circular machining If you want to perform simple, i.e. straight or circular path movements or machining without defining a complete contour, you can use the functions "Straight" or "Circle" respectively. General sequence To program simple machining operations, proceed as follows: ●...
Page 504: Selecting A Tool And Machining Plane
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.10 Selecting a tool and machining plane Before you can program a line or circle, you have to select the tool, spindle, spindle speed and machining plane. If you program a sequence of different straight or circular path motions, the settings for the tool, spindle, spindle speed and machining plane remain active until you change them again.
Page 505: Programming A Straight Line
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Choose whether the spindle should be clamped or released or whether there should be no change (input field left blank). Press the "Accept" softkey. The values are saved and the window is closed. The process plan is displayed and the newly generated program block is marked.
Page 506 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Straight line when selecting radius Straight line when deselecting radius compensation compensation If you want to prevent deviation from the programmed path, you can program the first straight line with radius compensation or with deactivated radius compensation outside the workpiece.
Page 507: Programming A Circle With Known Center Point
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Target position of special axis (abs or inc) Note: Incremental dimension: The sign is also evaluated. Target angle (abs) or target angle referred to the actual position (inc) Degrees Target angle (abs) or target angle referred to the actual position (inc) Degrees...
Page 508 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Direction of rotation Direction of rotation in which the tool travels from the circle starting point to the circle end point: Direction of rotation clockwise (right) Direction of rotation counterclockwise (left) Machining plane, peripheral surface C Target position Y (abs) or target position X referred to the last programmed...
Page 509: Programming A Circle With Known Radius
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Machining plane rotation Target position X ∅ (abs) or target position Y referred to the last programmed position (inc) Target position Z (abs) or target position X referred to the last programmed position (inc) Circle center point I (ink).
Page 510 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Procedure The ShopTurn program to be processed has been created and you are in the editor. Press the menu forward key and the "Straight Circle" softkey. Press the "Circle radius" softkey. Parameters Description Unit...
Page 511: Polar Coordinates
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Machining plane rotation Target position X ∅ (abs) or target position Y referred to the last programmed position (inc) Target position Z (abs) or target position X referred to the last programmed position (inc) Note: Incremental dimension: The sign is also evaluated.
Page 512 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Machining plane peripheral surface/peripheral surface C Pole Y (abs) Pole Z (abs) or pole Z referred to the last programmed position (inc) Note: Incremental dimension: The sign is also evaluated. Machining plane, peripheral surface Y Pole Y (abs) Pole Z (abs) or pole Z referred to the last programmed position (inc)
Page 513: Straight Line Polar
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.15 Straight line polar When you want to program a straight line in polar coordinates, you can use the "Straight Polar" function. A straight line in the polar coordinate system is defined by the length L and the angle α. Depending on the selected machining plane, the angle refers to another axis.
Page 514 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Straight line with selected radius Straight line with deselected radius compensation compensation If you want to prevent deviation from the programmed path, you can program the first straight line with radius compensation or with deactivated radius compensation outside the workpiece.
Page 515: Circle Polar
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameters Description Unit Distance to the pole, end point α Polar angle to the pole, end point (abs) or Degrees Polar angle change to the pole, end point (inc) The sign specifies the direction.
Page 516 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Procedure The ShopTurn program to be processed has been created and you are in the editor. Press the menu forward key and the "Straight Circle" softkey. Press the "Polar" and "Circle Polar" softkeys. Parameters Description Unit...
Page 517: Machining With Movable Counterspindle
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.17 Machining with movable counterspindle If your lathe has a counterspindle, you can machine workpieces using turning, drilling and milling functions on the front and rear faces without reclamping the workpiece manually. Before machining commences on the rear face, the counterspindle must grip the workpiece, remove it from the main spindle and move it to the new machining position.
Page 518: Programming Example: Machining Main Spindle - Transfer Workpiece - Machining
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Press the “Teach park pos.” softkey. The actual tool park position is saved. Press the “Teach angl. offset" softkey. The actual angular difference between the main and counter spindles will be saved.
Page 519: Programming Example: Machining Bar Material
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Note Special feature regarding "rear face": The work offset that you choose in the parameter screen is only activated and not calculated. This means that the workpiece zero for counterspindle machining should be stored in the work offset.
Page 520 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameter Description Unit Function You can select between 5 different functions: Complete transfer • Gripping • Withdrawing • Rear face • Front face • Complete transfer Gripping function Coordinate Machine coordinate system (MCS) •...
Page 521 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameter Description Unit Function, complete Withdrawing Withdraw blank Withdraw complete blank: • • Feedrate mm/min Cutting-off Cutting-off cycle in the following block cycle • • Function, complete Rear face Work offset Work offset in which the coordinate system, which was shifted according to ZW and by ZV as well as mirrored in Z, must be saved:...
Page 522 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameter Description Unit α1 Angular offset Degrees Transfer position (abs.) Position, feedrate reduction (abs or inc) Position from which a reduced feedrate is used. Reduced feedrate mm/rev Fixed Travel to fixed stop stop •...
Page 523 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameter Description Unit Write to the work offset • The Z value of the work offset can be directly written to the input screen form. • The actual Z value of the work offset is used. Machining position for special axis (abs.);...
Page 524: Machining With Fixed Counterspindle
Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn 8.7.18 Machining with fixed counterspindle If your lathe is equipped with a second spindle, which is setup as a counterspindle and cannot be traversed, then the workpieces must be manually reclamped Machine manufacturer Please refer to the machine manufacturer's specifications.
Page 525 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Parameter Description Unit Function, rear face Work offset Work offset in which the coordinate system, which was shifted according to ZW and by ZV as well as mirrored in Z, must be saved: Basic reference •...
Page 526 Programming technology functions (cycles) 8.7 Additional cycles and functions in ShopTurn Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 527: Multi-Channel Machining (Only 840D Sl)
Multi-channel machining (only 840D sl) Multi-channel view (only 840D sl) The multi-channel view allows you to simultaneously view several channels in the following operating areas: ● "Machine" operating area ● "Program" operating area 9.1.1 Multi-channel view in the "Machine" operating area With a multi-channel machine, you have the option of simultaneously monitoring and influencing the execution of several programs.
Page 528 Multi-channel machining (only 840D sl) 9.1 Multi-channel view (only 840D sl) 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 529 Multi-channel machining (only 840D sl) 9.1 Multi-channel view (only 840D sl) Displaying/hiding a multi-channel view Select the "Machine" operating area Select the "JOG", "MDA" or "AUTO" mode. Press the menu forward key and the "Settings" softkey. Press the "Multi-channel view" softkey. In the window "Settings for Multi-Channel View"...
Page 530: Multi-Channel View For Large Operator Panels
Multi-channel machining (only 840D sl) 9.1 Multi-channel view (only 840D sl) 9.1.2 Multi-channel view for large operator panels On the OP015 and OP019 operator panels as well as on the PC, you have the option of displaying up to four channels next to each one. This simplifies the creation and run-in for multi-channel programs.
Page 531: Setting The Multi-Channel View
Multi-channel machining (only 840D sl) 9.1 Multi-channel view (only 840D sl) Note 2-channel display Unlike the smaller operator panels, the T,F,S window is visible for a 2-channel view in the "Machine" operating area. Program operating area You can display as many as ten programs next to each other in the editor. Displaying a program You can define the width of the program in the Editor window using the settings in the editor.
Page 532 Multi-channel machining (only 840D sl) 9.1 Multi-channel view (only 840D sl) Example Your machine has 6 channels. You configure channels 1 - 4 for the multi-channel view and define the display sequence (e.g. 1,3,4,2). In the multi-channel view, for a channel switchover, you can only switch between the channels configured for the multi-channel view;...
Page 533: Multi-Channel Support (Only 840D Sl)
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Multi-channel support (only 840D sl) 9.2.1 Working with several channels Multi-channel support SINUMERIK Operate supports you when generating the program, the simulation and when running-in a program on multi-channel machines. Software options For the multi-channel functionality and support, i.e.
Page 534: Creating A Multi-Channel Program
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) In the multi-channel editor, you have the option of simultaneously opening several programs and editing them. In this case, the multi-channel editor supports you regarding program synchronization from a time perspective. Software options You require the "programSYNC"...
Page 535: Entering Multi-Channel Data
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Enter the required name and press the "OK" softkey. The "Job list *.JOB" window opens. For each channel that has been set-up, the window has one line to input or select the assigned program. Position the cursor on the required channel line, enter the required program name and select the program type (G code or ShopTurn).
Page 536 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Measurement unit Selecting the measurement unit inch Main spindle Work offset Selecting the work offset Write to the • work offset Parameter ZV is displayed • Parameter ZV is not displayed Z value of the work offset For G54, the Z value is entered into the work offset.
Page 537 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Spindle chuck Only chuck • data You enter spindle chuck data in the program. Complete • You enter tailstock data in the program. Note: Please observe the machine manufacturer’s instructions. The main spindle chuck dimensions - (only for spindle chuck data "yes") •...
Page 538 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Write to the • work offset Parameter ZV is displayed • Parameter ZV is not displayed Z value of the work offset For G54, the Z value is entered into the work offset. Blank Tube •...
Page 539: Multi-Channel Functionality For Large Operator Panels
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.4 Multi-channel functionality for large operator panels For the large OP15, OP019 operator panels as well as at the PC, there is more space in the "Machine", "Program" and "Parameter" operating areas – as well as in all lists – to display NC blocks, tools etc.
Page 540 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Displaying functions Channel view Display in the "Machine" operating area Selection using vertical softkeys: 3-channel view The T,F,S window is overlaid by pressing one of the vertical softkeys. • 4-channel view The window showing the G codes is overlaid if you press one of the •...
Page 541 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Program operating area In the editor, just as many programs are displayed next to one another as in the "Machine" operating area. Displaying a program You can define the width of the program in the editor window using the settings in the editor. This means that you can distribute programs evenly - or you can display the column with the active program wider.
Page 542: Editing The Multi-Channel Program
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.5 Editing the multi-channel program 9.2.5.1 Changing the job list You now have the option to change the composition of the programs and/or the assignment of the channel and program in a job list. Precondition ●...
Page 543: Editing A G Code Multi-Channel Program
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.5.2 Editing a G code multi-channel program Editing a G code multi-channel program Precondition ● The "programSYNC" option is set. ● In order to display the machining at the counterspindle at the correct position in the simulation, the linear axis of the counterspindle must be positioned before CYCLE208 (multi-channel data).
Page 544 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Adding multi-channel data in a G code program You have the possibility of adding the multi-channel cycle (CYCLE208) subsequently. Procedure The double editor is opened and the cursor is positioned in the G code program.
Page 545 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Machining dimension (abs) or machining dimension in relation to ZA (inc) Outside diameter – (only for tube and cylinder) Inside diameter (abs) or wall thickness (inc) – for tube only Procedure The double editor is opened and the cursor is positioned in the G code program.
Page 546: Editing A Shopturn Multi-Channel Program
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.5.3 Editing a ShopTurn multi-channel program Precondition The "programSYNC" option is set. Procedure Position the cursor in the "Workpieces" folder on a job list and press the "Open" softkey. Note: If the cursor is located on a workpiece, then a search is made for a job list with the same name.
Page 547 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Retraction The retraction area indicates the area outside of which collision-free traversing of the axes must be possible. simple • Extended • • Retraction plane X external ∅ (abs) or retraction plane X referred to XA (inc) - not for "basic"...
Page 548 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit - only for a pipe blank retraction plane X internal ∅ (abs) or retraction plane X referred to XI (inc) Retraction plane Z front (abs) or rev/min retraction plane Z referred to ZA (inc) Retraction plane Z rear –...
Page 549 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Program header without multi-channel data If a program is to be executed through one channel, then deselect multi-channel data. You then have the option of entering cross-program values into the program header as usual. Parameter Description Unit...
Page 550 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Outer diameter ∅ Inner diameter ∅ (abs) or wall thickness (inc) Initial dimension Final dimension (abs) or final dimension in relation to ZA (inc) Machining dimension (abs) or machining dimension in relation to ZA (inc) Retraction The retraction area indicates the area outside of which collision-free traversing of the axes must be possible.
Page 551 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Tool change point X ∅ Tool change point Z Spindle speed rev/min Spindle chuck data • You enter spindle chuck data in the program. • Spindle chuck data are transferred from the setting data. Note: Please observe the machine manufacturer’s instructions.
Page 552 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Tool change point Tool change point, which must be approached by the revolver with its zero point. WCS (Workpiece Coordinate System) • MCS (Machine Coordinate System) •...
Page 553 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameter Description Unit Retraction plane X internal ∅ (abs) or retraction plane X referred to XI (inc) - (only for retraction "extended" and "all") Retraction plane Z front (abs) or retraction plane Z referred to ZA (inc) Retraction plane Z rear –...
Page 554: Creating A Program Block
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.5.4 Creating a program block In order to structure programs in order to achieve a higher degree of transparency when preparing for the synchronized view, you have the possibility of combining several blocks (G code and/or ShopTurn machining steps) to form program blocks.
Page 555 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Settings for a program block Display Meaning Text Block designation Spindle • • Spindle assignment. Defines at which spindle a program block is to be executed. Addit. run-in code •...
Page 556: Setting The Multi-Channel Function
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Opening and closing blocks Position the cursor on the desired program block. Press the <+> key or the key. The block is opened. Press the <-> key or the key. The block is closed again.
Page 557 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Precondition Software options You require the "programSYNC" option to generate and edit synchronized programs in the multi-channel editor as well as for the multi-channel functions in the "Machine" operating area. Example Your machine has 6 channels.
Page 558: Synchronizing Programs
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.7 Synchronizing programs Using the synchronized view, you have the possibility of obtaining an overview of the time sequence of a program. In this case, program instructions are evaluated to coordinate channels and are arranged in parallel in the editor view.
Page 559 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Wait marks can also be used within blocks. ● Closed block – If there is a WAIT mark within a closed block, the clock of this WAIT mark is displayed in front of the block name.
Page 560 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Procedure Select the required job list. Press the "Open" softkey. The job list is opened in the editor. Press the ">>" and "View" softkeys. Press the "Synchron. view" softkey. Press the "Synchronizing"...
Page 561: Insert Wait Marks
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.8 Insert WAIT marks To synchronize programs via several channels, you have the option of inserting WAIT marks. In the wait mark you define the type, and depending on the synchronizing command, the number or the variable and the channels to be synchronized.
Page 562: Optimizing The Machining Time
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) In the associated selection field of a channel, select "Yes" if the WAIT mark for this channel is to be valid. Press the "Accept" softkey. The WAIT mark is displayed in the program as machining step. Using "Cursor right", as usual, open the machining step in the editor.
Page 563 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Time-related view The wait time at the wait marks is displayed in seconds. The total runtime is displayed at the end of the program. If you change the program, time data is still displayed at the corresponding wait marks or the corresponding blocks dimmed.
Page 564: Simulating Machining
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) 9.2.10 Simulating machining 9.2.10.1 Simulation For classic lathes with main and counterspindle, up to two channels can be simultaneously simulated. You have the option of executing the programs together before the actual machining. In this case, start, stop and reset - as well as the functions to control the program, act simultaneously on all of the simulated channels.
Page 565: Different Workpiece Views For Multi-Channel Support
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Press the "Counterspindle" softkey if you wish to view the counterspindle. If you have pressed the "Main spindle" and "Counterspindle" softkeys, the simulation view is split into two and you can see the main spindle and counterspindle simultaneously.
Page 566: Display/Edit The Multi-Channel Functionality In The "Machine" Operating Area
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Press the "3D view" softkey if you wish to view the workpiece as a three-dimensional model. - OR - Press the 2-window softkey if you wish to simultaneously view the side view (left-hand window) and front view (right-hand window) of the workpiece.
Page 567: Block Search And Program Control
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Precondition ● Multi-channel machine ● You have selected the multi-channel view via "Settings for channel functionalities". Procedure Select the "AUTO" operating area. Press the "Prog. ctrl." softkey. The "Program control - General" window appears on the screen. Press the "Run-in"...
Page 568 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Procedure Press the "Block search" softkey. Press the "Search mode" softkey. The "Search Mode" window is displayed. Select the required mode for the channel group. Press the "OK" softkey to confirm the setting. Press the "Search text"...
Page 569: Synchronizing A Counterspindle
Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Note Search target via "Search text" If, for a block search, you approach the program position using "Search text", please note that a search is only made in the selected channel column. 9.2.12 Synchronizing a counterspindle For multi-channel machines, the counterspindle steps must be synchronized across all...
Page 570 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameters Description Unit Function You can select one of the following functions: Synchronizing • Complete • Gripping • Withdrawing • Rear face • Front face • Synchronization function Synchronizes with the counterspindle in the other channel. Coordinate •...
Page 571 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameters Description Unit Reduced feedrate mm/rev Fixed Travel to fixed stop stop • The counterspindle stops at a defined distance away from transfer position Z1 and then traverses with a defined feedrate up to the fixed stop. •...
Page 572 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameters Description Unit Flush chuck Flush counterspindle chuck • • Direction of rotation Spindle rotates clockwise • Spindle rotates counter-clockwise • Spindle does not rotate • Spindle speed – (only when the spindle rotates) rev/min α1 Angular offset...
Page 573 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Parameters Description Unit Function, rear face Zero offset Zero offset in which the coordinate system, which was shifted according to ZW and by ZV as well as mirrored in Z, must be saved: Basic reference •...
Page 574 Multi-channel machining (only 840D sl) 9.2 Multi-channel support (only 840D sl) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 575: Collision Avoidance (Only 840D Sl)
Collision avoidance (only 840D sl) 10.1 Collision monitoring in the machine operator area: With the aid of collision avoidance, you can avoid collisions and therefore major damage during the machining of a workpiece or when creating programs. Software option You require the software option in order to use this function: "Collision avoidance (machine, operating range)"...
Page 576: Switching The Collision Avoidance On And Off
Collision avoidance (only 840D sl) 10.2 Switching the collision avoidance on and off Press the "Sim. rec." softkey. Press the "Other views" and "Machine space" softkeys. During simultaneous recording, an active machine model is displayed. 10.2 Switching the collision avoidance on and off Using "Settings", you have the option of separately activating or deactivating the collision monitoring for the Machine operating area (operating modes, AUTO, JOG and MDI) separately for the machine and tools.
Page 577 Collision avoidance (only 840D sl) 10.2 Switching the collision avoidance on and off Procedure Select the "Machine" operating area. Select the "JOG", "MDI" or "AUTO" mode. Press the menu forward key and the "Settings" softkey. Press the "Collision avoidance" softkey. The "Collision Avoidance"...
Page 578 Collision avoidance (only 840D sl) 10.2 Switching the collision avoidance on and off Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 579: Tool Management
Tool management 11.1 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 580: Magazine Management
Tool management 11.2 Magazine management ● Only tools that have reached the pre-alarm limit ● Only locked tools ● Only tools with active code Search functions You have the option of searching through the lists according to the following objects: ●...
Page 581: Tool Types
Tool management 11.3 Tool types 11.3 Tool types A number of tool types are available when you create a new tool. The tool type determines which geometry data is required and how it will be computed. Tool types Figure 11-1 Example of Favorites list Figure 11-2 Available tools in the "New Tool - Milling Cutter"...
Page 582 Tool management 11.3 Tool types Figure 11-3 Available tools in the "New Tool - Drill" window Figure 11-4 Tools listed in the "New Tool - Grinding Tools" window Figure 11-5 Available tools in the "New Tool - Turning Tools" window Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 583 Tool management 11.3 Tool types Figure 11-6 Available tools in the "New Tool - Special Tools" window See also Changing the cutting edge position or tool type (Page 622) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 584: Tool Dimensioning
Tool management 11.4 Tool dimensioning 11.4 Tool dimensioning This section provides an overview of the dimensioning of tools. Tool types Figure 11-7 Finishing tool (Type 510) Figure 11-8 Plunge cutter (Type 520) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 585 Tool management 11.4 Tool dimensioning Figure 11-9 Milling cutter (Type 120) Figure 11-10 Drill (Type 200) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 586 Tool management 11.4 Tool dimensioning Figure 11-11 Threading tool (Type 540) Figure 11-12 Button tool (Type 550) Figure 11-13 Stop (Type 730) Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 587 Tool management 11.4 Tool dimensioning Figure 11-14 Rotary drill(Type 560) Figure 11-15 Tap (Type 240) Figure 11-16 3D probe Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 588 Tool management 11.4 Tool dimensioning Machine manufacturer The tool length is measured to the center of the ball or to the ball circumference. Please refer to the machine manufacturer's specifications. Note A 3D probe must be calibrated before use. Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 589: Tool List
Tool management 11.5 Tool list 11.5 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. For the tool display, i.e.
Page 590 Tool management 11.5 Tool list Column heading Meaning Width/ Cutting edge for Type 150 - side milling cutter and Type 151 - saw Tip width/ Tip width for Type 520 - plunge cutter and Type 530 - cut-off tool Tip angle / Tip angle for Type 200 –...
Page 591 Please refer to the machine manufacturer's specifications. References Information on the configuration and setting up of the tool list can be found in the following references: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 592 Tool management 11.5 Tool list Icons in the tool list Icon/ Meaning Marking 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.
Page 593: Additional Data
Tool management 11.5 Tool list 11.5.1 Additional data The following tool types require geometry data that is not included in the tool list display. Tool types with additional geometry data Tool type Additional parameters 111 Conical ballhead cutter Corner radius 121 End mill with corner Corner radius rounding...
Page 594: Creating A New Tool
Tool management 11.5 Tool list 11.5.2 Creating a new tool When creating a new tool, the "New tool - favorites" window offers you a number of selected tool types, known as "favorites". If you do not find the desired tool type in the favorites list, then select the milling, drilling, turning or special tool via the corresponding softkeys.
Page 595 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 (IM9) / SINUMERIK 840D sl Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 596: Measuring The Tool
Tool management 11.5 Tool list 11.5.3 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 597: Managing Several Cutting Edges
Tool management 11.5 Tool list 11.5.4 Managing several cutting edges In the case of tools with more than one cutting edge, a separate set of offset data is assigned to each cutting edge. The number of possible cutting edges depends on the control configuration.
Page 598: Loading And Unloading Tools
Tool management 11.5 Tool list Press the "OK" softkey if you really want to delete the tool. Use this softkey to delete the tool. If the tool is in a magazine location, it is unloaded and then deleted. Multiple load points - tool in magazine location If you have configured several loading points for a magazine, then the "Loading Point Selection"...
Page 599 Tool management 11.5 Tool list Enter the location number you require and press the "OK" softkey. - OR - Press the "Spindle" softkey. The tool is loaded into the specified magazine location or spindle. Several magazines If you have configured several magazines, the "Load to ..." window appears after pressing the "Load"...
Page 600: Selecting A Magazine
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 (IM9) / SINUMERIK 840D sl Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 601: Code Carrier Connection (Only 840D Sl)
SINUMERIK Operate can be found in the following reference: ● Function Manual MCIS TDI Ident Connection ● Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl For the code carrier connection, in addition there is a tool available in the list of favorites.
Page 602 Tool management 11.5 Tool list Create new tool from code carrier The tool list is opened. Place the cursor in the tool list at the position where the new tool should be stored. For this, you can select an empty magazine location or the NC tool memory outside of the magazine.
Page 603 The deletion of the tool can be set differently, i.e. the softkey "On code carrier" is not available. References A description of the configuration options can be found in the following reference: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 604: Tool Wear
Tool management 11.6 Tool wear 11.6 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 605 Tool management 11.6 Tool wear Column heading Meaning You have the option of changing the tool position or the tool type using the key and select • 0° or • 90° or • Value entry box to freely enter the angle. Aligning the turning tool with γ...
Page 736 Working with a B axis (only 840D sl) 15.8 Measuring a tool with the B axis Procedure Select "JOG" mode in the "Machine" operating area. Execute the tool change and alignment in the T, S, M window before performing the measurement. Press the "Meas.
Page 737: Working With Two Tool Carriers
Working with two tool carriers With SINUMERIK Operate, you can work at a lathe with two tool holders, both of which are mounted on an X axis. The tool carriers may be revolvers, multifix, or a combination of both. The main machining is performed in the negative X axis direction. As both tool holders are mounted on the same axis it is only possible to machine with one tool.
Page 738: Measure Tool
Working with two tool carriers 16.2 Measure tool In the simulation, the tool is always displayed on the correct side, just the same as it is used at the machine. The programmed C offset around 180° only affects C axes, not spindles. It is not possible to machine a thread with tools that are distributed between both tool holders.
Page 739: Teaching In A Program
Teaching in a program 17.1 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 740: Inserting A Block
Teaching in a program 17.3 Inserting a block Note All defined axes are "taught in" in the first teach-in block. In all additional teach-in blocks, only axes modified by axis traversing or manual input are "taught in". If you exit teach-in mode, this sequence begins again. 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.
Page 741: Input Parameters For Teach-In Blocks
Teaching in a program 17.3 Inserting a block Traverse the axes to the relevant position. Press the "Teach position" softkey. A new program block with the current actual position values will be created. 17.3.1 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...
Page 742 Teaching in a program 17.3 Inserting a block Motion types for teach-in of position and teach-in of G0 and G1 The following motion parameters are offered: Parameter Description Path-synchronous Point-to-point PTPG0 Only G0 point-to-point Transition behavior at the beginning and end of the spline curve The following motion parameters are offered: Parameter Description...
Page 743: Teach-In Via Windows
Teaching in a program 17.4 Teach-in via Windows 17.4 Teach-in via Windows 17.4.1 General The cursor must be positioned on an empty line. The windows for pasting program blocks contain input and output fields for the actual values in the WCS. Depending on the default setting, selection fields with parameters for motion behavior and motion transition are available.
Page 744: Teach In Rapid Traverse G0
Teaching in a program 17.4 Teach-in via Windows Press the "Accept" softkey. A new program block will be inserted at the cursor position. - OR - Press the "Cancel" softkey to cancel your input. 17.4.2 Teach in rapid traverse G0 You traverse the axes and teach-in a rapid traverse block with the approached positions.
Page 745: Teaching In Circle Intermediate And Circle End Point Cip
Teaching in a program 17.4 Teach-in via Windows 17.4.4 Teaching in circle intermediate and circle end point CIP Enter the intermediate and end positions for the circle interpolation CIP. You teach-in each of these separately in a separate block. The order in which you program these two points is not specified.
Page 746 Teaching in a program 17.4 Teach-in via Windows Procedure Select the "Machine" operating area. Press the or key. Press the key. Press the "Teach prog." softkey. Press the ">>" and "ASPLINE" softkeys. The "Akima-spline" window opens with the input fields. Traverse the axes to the required position and if necessary, set the transition type for the starting point and end point.
Page 747: Editing A Block
Teaching in a program 17.5 Editing a block 17.5 Editing a block You can only overwrite a program block with a teach-in block of the same type. The axis values displayed in the relevant window are actual values, not the values to be overwritten in the block.
Page 748: Selecting A Block
Teaching in a program 17.6 Selecting a block 17.6 Selecting a block You have the option of setting the interrupt pointer to the current cursor position. The next time the program is started, processing will resume from this point. With teach-in, you can also change program areas that have already been executed. This automatically disables program processing.
Page 749: Deleting A Block
Teaching in a program 17.7 Deleting a block 17.7 Deleting a block You have the option of deleting a program block entirely. Requirement "AUTO" mode: The program to be processed is selected. Procedure Select the "Machine" operating area. Press the or key. Press the ...
Page 750: Settings For Teach-In
Teaching in a program 17.8 Settings for teach-in 17.8 Settings for teach-in In the "Settings" window, you define which axes are to be included in the teach-in block and whether motion-type and continuous-path mode parameters are to be provided. Proceed as follows Select the "Machine"...
Page 751: Ht 8
HT 8 18.1 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 752 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 753 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 Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 754: Traversing Keys
HT 8 18.2 Traversing keys 18.2 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 755: Machine Control Panel Menu
HT 8 18.3 Machine control panel menu 18.3 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 756: Virtual Keyboard
HT 8 18.4 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 757 HT 8 18.4 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 758: Calibrating The Touch Panel
HT 8 18.5 Calibrating the touch panel 18.5 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 759: Ctrl-Energy
Ctrl-Energy 19.1 Overview The "Ctrl-Energy" function provides you with the following options to improve the energy utilization of your machine. Ctrl-E Analysis: Measuring and evaluating the energy consumption Acquiring the actual energy consumption is the first step to achieving better energy efficiency.
Page 760: Displaying Energy Consumption
The display in the table depends on the configuration. References Information on the configuration is provided in the following reference: System Manual "Ctrl-Energy", SINUMERIK 840D sl / 828D Procedure 1. Select the "Parameter" operating area and press the "Ctrl-Energy" softkey.
Page 761: Measuring And Saving The Energy Consumption
Ctrl-Energy 19.3 Measuring and saving the energy consumption 19.3 Measuring and saving the energy consumption For the currently selected axes, you have the option of measuring and recording the energy consumption. Measurement of the energy consumption by part programs The energy consumption of part programs can be measured. The measurement should take single drives into account.
Page 762: Long-Term Measurement Of The Energy Consumption
The selection of the axis to be measured depends on the configuration. References Information on the configuration is provided in the following reference: System Manual "Ctrl-Energy", SINUMERIK 840D sl / 828D 19.4 Long-term measurement of the energy consumption The long-term measurement of energy consumption is performed in the PLC and saved. The values from times in which the HMI is not active are also recorded.
Page 763: Displaying Measured Curves
Ctrl-Energy 19.5 Displaying measured curves 19.5 Displaying measured curves Display Meaning Start of the measurement Shows the time at which the measurement was started by the pressing the "Start measurement" softkey. Duration of the Shows the measuring duration in seconds until the "Stop measurement" measurement [s] softkey is pressed.
Page 764: Using The Energy-Saving Profile
Ctrl-Energy 19.6 Using the energy-saving profile 19.6 Using the energy-saving profile In the "SINUMERIK Ctrl-Energy Energy-Saving Profile" window, you can display all of the defined energy-saving profiles. Here, directly activate the required energy-saving profile - or inhibit or release profiles. SINUMERIK Ctrl-Energy energy-saving profiles Display Meaning...
Page 765 19.6 Using the energy-saving profile References Information on the configuration of the energy-saving profiles is provided in the following reference: System Manual "Ctrl-Energy", SINUMERIK 840D sl / 828D Procedure Select the "Parameter" operating area. Press the menu forward key and then the "Ctrl-Energy" softkey.
Page 766 Ctrl-Energy 19.6 Using the energy-saving profile Turning Operating Manual, 03/2013, 6FC5398-8CP40-3BA1...
Page 767: Easy Message (828D Only)
Easy Message (828D only) 20.1 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 768 Easy Message (828D only) 20.1 Overview Action log You can obtain precise information about incoming and outgoing messages via SMS logs. References Information on the GSM modem can be found in the PPU SINUMERIK 828D Manual Calling the SMS Messenger Select the "Diagnostics"...
Page 769: Activating Easy Message
Easy Message (828D only) 20.2 Activating Easy Message 20.2 Activating Easy Message To commission the connection to the modem for the SMS Messenger, activate the SIM card at the initial start-up. Requirement The modem is connected and activated. Machine manufacturer The modem is activated via the machine data 51233 $MSN_ENABLE_GSM_MODEM.
Page 770: Creating/Editing A User Profile
Easy Message (828D only) 20.3 Creating/editing a user profile 20.3 Creating/editing a user profile User identification Display Meaning User name Name of the user to be created or logged on. Telephone number Telephone number of the user to which the messages are to be sent. The telephone number must include the country code in order that control commands can identify the sender (e.g.
Page 771 Easy Message (828D only) 20.3 Creating/editing a user profile 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 772: Setting-Up Events
Easy Message (828D only) 20.4 Setting-up events 20.4 Setting-up events In the "Send SMS for the following events" area, select the events using the check box, which when they occur, an SMS is sent to the user. ● Programmed messages from the part program (MSG) In the part program, program an MSG command via which you receive an SMS.
Page 773 Easy Message (828D only) 20.4 Setting-up events ● Maintenance intervals An SMS is sent if the service planner registers pending maintenance work. ● Additional alarm numbers: Here, specify additional alarms where you should be notified if they occur. You can enter individual alarms, several alarms or alarm number ranges. Examples: 1234,400 1000-2000...
Page 774: Logging An Active User On And Off
Easy Message (828D only) 20.5 Logging an active user on and off 20.5 Logging an active user on and off Only active users receive an SMS message for the specified events. You can activate users, already created for Easy Message, with certain control commands via the user interface or via SMS.
Page 775: Displaying Sms Logs
Easy Message (828D only) 20.6 Displaying SMS logs 20.6 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 776: Making Settings For Easy Message
Easy Message (828D only) 20.7 Making settings for Easy Message 20.7 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 777: Easy Extend (828D Only)
Easy Extend (828D only) 21.1 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 778: Enabling A Device
Easy Extend (828D only) 21.2 Enabling a device 21.2 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 779: Activating And Deactivating A Device
Easy Extend (828D only) 21.3 Activating and deactivating a device 21.3 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 780: Commissioning Easy Extend
Easy Extend (828D only) 21.4 Commissioning Easy Extend 21.4 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 781: Service Planner (828D Only)
Service Planner (828D only) 22.1 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 782 Service Planner (828D only) 22.1 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 783: Set Maintenance Tasks
Service Planner (828D only) 22.2 Set maintenance tasks 22.2 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 784 Service Planner (828D only) 22.2 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 The values cannot be edited.
Page 785: Ladder Viewer And Ladder Add-On (828D Only)
Ladder Viewer and Ladder add-on (828D only) 23.1 Introduction 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. 23.2 Ladder add-on tool The failure of a single input, output or relay normally results in the failure of the complete...
Page 786: Structure Of The User Interface
Ladder Viewer and Ladder add-on (828D only) 23.3 Structure of the user interface See also Inserting and editing networks (Page 797) 23.3 Structure of the user interface Figure 23-1 Screen structure Table 23- 1 Key to screen layout Screen element Display Meaning Application area...
Page 787: Control Options
Ladder Viewer and Ladder add-on (828D only) 23.4 Control options Screen element Display Meaning Absolute representation Display of the active keys (,

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