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Advertisement



SINUMERIK
SINUMERIK 840D sl/828D
Milling
Operating Manual
Valid for:
SINUMERIK 840D sl / 840DE sl / 828D controls
Software
CNC for 840D sl / 840DE sl
SINUMERIK Operate for PCU/PC
02/2012
6FC5398-7CP40-3BA0
___________________
___________________
Introduction
___________________
Setting up the machine
___________________
Execution in manual mode
___________________
Machining the workpiece
___________________
Simulating machining
Generating a G code
___________________
program
___________________
Programming technological
___________________
functions (cycles)
___________________
___________________
___________________
___________________
Working with Manual
Machine
___________________
___________________
Managing programs
Software version
___________________
4.5
4.5
___________________
HT 8
Continued on next page
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   Summary of Contents for Siemens SINUMERIK 840D SL

  • Page 1 Working with Manual Machine ___________________ Tool management Valid for: ___________________ Managing programs SINUMERIK 840D sl / 840DE sl / 828D controls Software Software version ___________________ CNC for 840D sl / 840DE sl Setting up drives SINUMERIK Operate for PCU/PC ___________________...
  • Page 2 Legal information Siemens AG Order number: 6FC5398-7CP40-3BA0 Copyright © Siemens AG 2012. Industry Sector Ⓟ 01/2012 Technical data subject to change All rights reserved Postfach 48 48 90026 NÜRNBERG GERMANY...
  • Page 3 Continuation Ctrl-Energy Easy Message (828D only) Easy Extend (828D only) SINUMERIK 840D sl/828D Milling Service Planner (828D only) Ladder Viewer and Ladder add-on (828D only) Operating Manual Alarm, error, and system messages 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 milling 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 Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 8 Preface Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 9: Table Of Contents

    Table of contents Preface ..............................5 Introduction.............................. 21 Product overview .........................21 Operator panel fronts ........................22 1.2.1 Overview ............................22 1.2.2 Keys of the operator panel......................23 Machine control panels ........................33 1.3.1 Overview ............................33 1.3.2 Controls on the machine control panel ..................33 User interface..........................36 1.4.1 Screen layout ..........................36 1.4.2...
  • Page 10: Table Of Contents

    Table of contents 2.5.4 Fixed point calibration ......................... 74 2.5.5 Measuring a tool with an electrical tool probe................75 2.5.6 Calibrating the electrical tool probe..................... 77 Measuring the workpiece zero ....................78 2.6.1 Overview ............................. 78 2.6.2 Sequence of operations ......................82 2.6.3 Examples with manual swivel .....................
  • Page 11: Table Of Contents

    Table of contents Manual retraction ........................139 Simple face milling of the workpiece..................141 Default settings for manual mode ....................144 Machining the workpiece ........................145 Starting and stopping machining....................145 Selecting a program........................146 Testing a program........................147 Displaying the current program block ..................149 4.4.1 Current block display .........................149 4.4.2 Displaying a basic block......................149...
  • Page 12: Table Of Contents

    Table of contents 4.13 Displaying the program runtime and counting workpieces ............189 4.14 Setting for automatic mode ....................... 191 Simulating machining..........................193 Overview ........................... 193 Simulation before machining of the workpiece ................. 200 Simultaneous recording before machining of the workpiece ............ 201 Simultaneous recording during machining of the workpiece ............
  • Page 13: Table Of Contents

    Table of contents 6.9.5 Changing a cycle call .........................231 6.9.6 Compatibility for cycle support ....................231 6.9.7 Additional functions in the input screens ...................232 6.10 Measuring cycle support ......................233 Creating a ShopMill program ......................... 235 Program views ...........................236 Program structure ........................240 Fundamentals ..........................241 7.3.1 Machining planes ........................241...
  • Page 14: Table Of Contents

    Table of contents 8.1.4 Reaming (CYCLE85) ........................ 290 8.1.4.1 Function............................. 290 8.1.5 Deep-hole drilling (CYCLE83)....................292 8.1.5.1 Function............................. 292 8.1.6 Boring (CYCLE86) ........................295 8.1.6.1 Function............................. 295 8.1.7 Tapping (CYCLE84, 840)......................297 8.1.7.1 Function............................. 297 8.1.8 Drill and thread milling (CYCLE78) ................... 303 8.1.8.1 Function.............................
  • Page 15: Table Of Contents

    Table of contents 8.4.5 Thread undercut (CYCLE940) ....................400 8.4.6 Thread turning (CYCLE99) ......................403 8.4.7 Thread chain (CYCLE98)......................412 8.4.8 Cut-off (CYCLE92)........................416 Contour turning - only for G code programs ................418 8.5.1 General information ........................418 8.5.2 Representation of the contour....................419 8.5.3 Creating a new contour......................420 8.5.4 Creating contour elements......................422 8.5.5...
  • Page 16: Table Of Contents

    Table of contents 10.1 Overview ........................... 493 10.2 R parameters ..........................494 10.3 Displaying global user data (GUD) ................... 495 10.4 Displaying channel GUDs ......................496 10.5 Displaying local user data (LUD) ....................497 10.6 Displaying program user data (PUD) ..................498 10.7 Searching for user variables .....................
  • Page 17: Table Of Contents

    Table of contents 13.2 Magazine management ......................529 13.3 Tool types...........................530 13.4 Tool dimensioning........................532 13.5 Tool list............................538 13.5.1 Additional data ...........................541 13.5.2 Creating a new tool ........................543 13.5.3 Measuring the tool ........................544 13.5.4 Managing several cutting edges ....................545 13.5.5 Delete tool ..........................545 13.5.6 Loading and unloading tools ......................546 13.5.7...
  • Page 18: Table Of Contents

    Table of contents 14.7 Displaying the program in the Preview..................588 14.8 Selecting several directories/programs..................589 14.9 Copying and pasting a directory/program ................. 591 14.10 Deleting a program/directory..................... 593 14.10.1 Deleting a program/directory..................... 593 14.11 Changing file and directory properties ..................594 14.12 Viewing PDF documents......................
  • Page 19: Table Of Contents

    Table of contents 18.1 Overview ............................637 18.2 Activating Easy Message......................638 18.3 Creating/editing a user profile ....................639 18.4 Setting-up events ........................641 18.5 Logging an active user on and off....................643 18.6 Displaying SMS logs ........................644 18.7 Making settings for Easy Message ....................645 Easy Extend (828D only) ........................
  • Page 20: Table Of Contents

    Table of contents Alarm, error, and system messages ...................... 677 22.1 Displaying alarms........................677 22.2 Displaying an alarm log......................679 22.3 Displaying messages ........................ 679 22.4 Sorting, alarms, faults and messages..................680 22.5 PLC and NC variables....................... 681 22.5.1 Displaying and editing PLC and NC variables ................681 22.5.2 Saving and loading screen forms....................
  • Page 21: Product Overview

    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 22: 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 23: Keys Of The Operator Panel

    A more precise description as well as a view of the other operator panel fronts that can be used may be found in the following reference: Operator Components and Networking Manual; SINUMERIK 840D sl/840Di sl 1.2.2 Keys of the operator panel The following keys and key combinations are available for operation of the controller and the machine tool.
  • Page 24 Introduction 1.2 Operator panel fronts Function <HELP> Calls the context-sensitive online help for the selected window. <NEXT WINDOW> • Toggles between the windows. • For a multi-channel view or for a multi-channel functionality, switches within a channel gap between the upper and lower window.
  • Page 25 Introduction 1.2 Operator panel fronts Function <PAGE UP> + <SHIFT> In the program manager and in the program editor from the cursor position, selects directories or program blocks up to the beginning of the window. <PAGE UP> + <CTRL> Positions the cursor to the topmost line of a window. <PAGE DOWN>...
  • Page 26 Introduction 1.2 Operator panel fronts Function <Cursor left> + <CTRL> • Editing box Moves the cursor further to the left by one word. • Navigation Moves the cursor in a table to the next cell to the left. <Cursor up> •...
  • Page 27 Introduction 1.2 Operator panel fronts Function <SELECT> Switches between several specified options in selection drop- down list boxes and in selection boxes. Activates checkboxes. In the program editor and in the program manager, selects a program block or a program. <SELECT>...
  • Page 28: Ctrl-energy

    Introduction 1.2 Operator panel fronts Function <BACKSPACE> + <CTRL> • Editing window Deletes a word selected to the left of the cursor. • Navigation Deletes all of the selected characters to the left of the cursor. <TAB> • In the program editor, indents the cursor by one character. •...
  • Page 29 Introduction 1.2 Operator panel fronts Function <CTRL> + <SHIFT> + <L> Scrolls the actual operator interface through all installed languages in the inverse sequence. <CTRL> + <P> Generates a screenshot from the actual operator interface and saves it as file. <CTRL>...
  • Page 30 Introduction 1.2 Operator panel fronts Function <SHIFT> + <ALT> + <D> Backs up the log files on the USB-FlashDrive. If a USB- FlashDrive is not inserted, then the files are backed-up in the manufacturer's area of the CF card. <SHIFT> + <ALT> + <T> Starts "HMI Trace".
  • Page 31 Introduction 1.2 Operator panel fronts Function <Equals> Opens the calculator in the entry fields. <Asterisk> Opens a directory with all of the subdirectories. <Tilde> Changes the sign of a number between plus and minus. <INSERT> • Opens an editing window in the insert mode. Pressing the key again, exits the window and the entries are undone.
  • Page 32 Introduction 1.2 Operator panel fronts Function Menu forward key Advances in the extended horizontal softkey bar. Menu back key Returns to the higher-level menu. <MACHINE> Calls the "Machine" operating area. <MENU SELECT> Calls the main menu to select the operating area. Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 33: Machine Control Panels

    1.3.1 Overview The machine tool can be equipped with a machine control panel by Siemens or with a specific machine control panel from the machine manufacturer. You use the machine control panel to initiate actions on the machine tool such as traversing an axis or starting the machining of a workpiece.
  • Page 34 Introduction 1.3 Machine control panels Machine manufacturer For additional responses to pressing the Emergency Stop button, please refer to the machine manufacturer's instructions. Installation locations for control devices (d = 16 mm) RESET Stop processing the current programs. • The NCK control remains synchronized with the machine. It is in its initial state and ready for a new program run.
  • Page 35 Introduction 1.3 Machine control panels Machine manufacturer A machine data code defines how the increment value is interpreted. Customer keys T1 to T15 Traversal axes with rapid traverse superposition and coordinate exchange Axis keys Selects an axis. Direction keys Select the traversing direction. <RAPID>...
  • Page 36: User Interface

    Introduction 1.4 User interface User interface 1.4.1 Screen layout Overview Active operating area and mode Alarm/message line Program name Channel state and program control Channel operational messages Axis position display in actual value window Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 37: Status Display

    Introduction 1.4 User interface Display for active tool T • current feedrate F • active spindle with current status (S) • Spindle utilization rate in percent • Operating window with program block display Display of active G functions, all G functions, auxiliary functions and input window for different functions (for example, skip blocks, program control).
  • Page 38 Introduction 1.4 User interface Display Description "Program manager" operating area "Diagnosis" operating area "Start-up" operating area Active mode or submode "Jog" mode "MDA" mode "Auto" mode "Teach In" submode "Repos" submode "Ref Point" submode Alarms and messages Alarm display The alarm numbers are displayed in white lettering on a red background.
  • Page 39 Introduction 1.4 User interface Second line Display Description Program path and program name The displays in the second line can be configured. Machine manufacturer Please also refer to the machine manufacturer's instructions. Third line Display Description Display of channel status. If several channels are present on the machine, the channel name is also displayed.
  • Page 40: Actual Value Window

    Introduction 1.4 User interface Machine manufacturer Please also refer to the machine manufacturer's instructions. 1.4.3 Actual value window The actual values of the axes and their positions are displayed. Work/Machine The displayed coordinates are based on either the machine coordinate system or the workpiece coordinate system.
  • Page 41: T,f,s Window

    Introduction 1.4 User interface Overview of display Display Meaning Header columns Work/Machine Display of axes in selected coordinate system. Item Position of displayed axes. Display of distance-to-go The distance-to-go for the current NC block is displayed while the program is running. Feed/override The feed acting on the axes, as well as the override, are displayed in the full-screen version.
  • Page 42 Introduction 1.4 User interface Display Meaning Z value of the actual tool X value of the actual tool Feed data Display Meaning Feed disable Actual feed value If several axes traverse, is displayed for: "JOG" mode: Axis feed for the traversing axis •...
  • Page 43: Current Block Display

    Introduction 1.4 User interface 1.4.5 Current block display The window of the current block display shows you the program blocks currently being executed. Display of current program The following information is displayed in the running program: ● The workpiece name or program name is entered in the title row. ●...
  • Page 44 Introduction 1.4 User interface You can call the "Machine" operating area directly using the key on the operator panel. Press the <MACHINE> key to select the "machine" operating area. Changing the operating mode You can select a mode or submode directly using the keys on the machine control panel or using the vertical softkeys in the main menu.
  • Page 45: Entering Or Selecting Parameters

    Introduction 1.4 User interface 1.4.7 Entering or selecting parameters When setting up the machine and during programming, you must enter various parameter values in the entry fields. The background color of the fields provides information on the status of the entry field. Orange background The input field is selected Light orange background...
  • Page 46 Introduction 1.4 User interface Changing or calculating parameters If you only want to change individual characters in an input field rather than overwriting the entire entry, switch to insertion mode. In this mode, you can also enter simple calculation expressions, without having to explicitly call the calculator.
  • Page 47: Pocket Calculator

    Introduction 1.4 User interface + <number> Enter "s" or "S" as well as the number x for which you would like to generate the square. Close the value entry using the <INPUT> 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 48 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 49: 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 50: 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 <INPUT>...
  • Page 51: 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 <Alt + S> 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 52 Introduction 1.4 User interface Procedure Editing characters Open the screen form and position the cursor on the entry field and press the <Alt +S> keys. The editor is displayed. Enter the desired phonetic notation. Click the <Cursor down> key to access the dictionary. By keeping the <Cursor down>...
  • Page 53: 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 54 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 55: 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 56 Introduction 1.4 User interface Select the desired manual with the <Cursor down> and <Cursor up> keys. Press the <Cursor right> or <INPUT> key or double-click to open the manual and the section. Navigate to the desired topic with the "Cursor down" key. Press the <Follow reference>...
  • Page 57 Introduction 1.4 User interface If you are in the "Start-up" operating area in the windows for the display of the machine, setting and drive data, position the cursor on the desired machine data or drive parameter and press the <HELP> or the <F12>...
  • Page 58 Introduction 1.4 User interface Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 59: Switching On And Switching Off

    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 60: 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 61: User Agreement

    Setting up the machine 2.2 Approaching a reference point Procedure Press the <JOG> key. Press the <REF. POINT> key. 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 62 Setting up the machine 2.2 Approaching a reference point Procedure Select the "Machine" operating area. Press the <REF POINT> key. 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.
  • Page 63: Operating Modes

    Setting up the machine 2.3 Operating modes Operating modes 2.3.1 General You can work in three different operating modes. "JOG" mode "JOG" mode is used for the following preparatory actions: ● Approach reference point, i.e. the machine axis is referenced ●...
  • Page 64 Setting up the machine 2.3 Operating modes Selecting "Repos" Press the <REPOS> key. "MDA" mode (Manual Data Automatic) In "MDA" mode, you can enter and execute G code commands non-modally to set up the machine or to perform a single action. Selecting "MDA"...
  • Page 65: Modes Groups And Channels

    Setting up the machine 2.3 Operating modes 2.3.2 Modes groups and channels Every channel behaves like an independent NC. A maximum of one part program can be processed per channel. ● Control with 1channel One mode group exists. ● Control with several channels Channels can be grouped to form several "mode groups."...
  • Page 66 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 67: 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 68: Setting The Zero Offset

    Setting up the machine 2.4 Settings for the machine Machine manufacturer Please also refer to the machine manufacturer's instructions. Proceed as follows Select <JOG> or <AUTO> mode in the "Machine" operating area. Press the menu forward key and the "Settings" softkey. A new vertical softkey bar appears.
  • Page 69 Setting up the machine 2.4 Settings for the machine Relative actual value Further, you also have the possibility of entering position values in the relative coordinate system. Note The new actual value is only displayed. The relative actual value has no effect on the axis positions and the active zero offset.
  • Page 70 Setting up the machine 2.4 Settings for the machine Procedure Select the "JOG" mode in the "Machine" operating area. Press the "Set ZO" softkey. - OR - Press the ">>", "REL act. vals" and "Set REL" softkeys to set position values in the relative coordinate system.
  • Page 71: 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 72: Measuring The Tool Length With The Workpiece As Reference Point

    Setting up the machine 2.5 Measuring the tool 2.5.2 Measuring the tool length with the workpiece as reference point Procedure Insert the tool you want to measure in the spindle. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" and "Length manual" softkeys. The "Length Manual"...
  • Page 73: Measuring Radius Or Diameter

    Setting up the machine 2.5 Measuring the tool 2.5.3 Measuring radius or diameter Procedure Insert the tool you want to measure in the spindle. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" softkey. Press the "Radius manual" or "Diam. manual" softkey. Select the cutting edge number D and the the number of the replacement tool ST.
  • Page 74: Fixed Point Calibration

    Setting up the machine 2.5 Measuring the tool 2.5.4 Fixed point calibration If you want to use a fixed point as the reference point in manual measurement of the tool length, you must first determine the position of the fixed point relative to the machine zero. Test socket You can use a mechanical test socket as the fixed point, for example.
  • Page 75: Measuring A Tool With An Electrical Tool Probe

    Setting up the machine 2.5 Measuring the tool 2.5.5 Measuring a tool with an electrical tool probe For automatic measurement, you determine the length and radius or diameter of the tool with the aid of a tool probe (table contact system). The control uses the known positions of the toolholder reference point and tool probe to calculate the tool offset data.
  • Page 76 Setting up the machine 2.5 Measuring the tool Procedure Insert the tool that you want to measure. Select "JOG" mode in the "Machine" operating area. Press the "Meas. tool" softkey. Press the "Length auto" softkey if you want to measure the length of the tool.
  • Page 77: Calibrating The Electrical Tool Probe

    Setting up the machine 2.5 Measuring the tool 2.5.6 Calibrating the electrical tool probe If you want to measure your tools automatically, you must first determine the position of the tool probe on the machine table with reference to the machine zero. Tool probes are typically shaped like a cube or a cylindrical disk.
  • Page 78: Measuring The Workpiece Zero

    Setting up the machine 2.6 Measuring the workpiece zero Click in the selection field "Spindle rotation" entry "Yes" if you want to perform the "Calibration with rotation". Press the <CYCLE START> key. Calibration is automatically executed at the measuring feedrate. The distance measurements between the machine zero and tool probe are calculated and stored in an internal data area.
  • Page 79 Setting up the machine 2.6 Measuring the workpiece zero Measuring with rotation Under the function "Measuring with rotation" you have the option to measure without prior calibration and without entry of a calibration dataset to be used. To do this, you will need a positionable spindle as well as an electronic 3D workpiece probe. The radius of the probe ball of the electrical probe must be determined once by calibration and entered in the tool data.
  • Page 80 Information on user-specific settings is provided in the Chapter "Measuring in the JOG mode". Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl Selecting the measuring plane The measuring plane (G17,18,19) can be selected to flexibly adapt to measuring tasks. If the measuring plane selection is not activated, then the measurement is performed based on the currently active measuring plane.
  • Page 81 Setting up the machine 2.6 Measuring the workpiece zero Entering the calibration feedrate The actual calibration feedrate can be entered into this entry field. The calibration feedrate is stored in the calibration data and is used for the measurements. If the entry field does not exist, then the calibration feedrate from a central parameter is used.
  • Page 82: Sequence Of Operations

    Setting up the machine 2.6 Measuring the workpiece zero Rotary axes If your machine has rotary axes, you can include these rotary axes in the measurement and setup procedure. If you store the workpiece zero in a work offset, rotary axis positioning may be necessary in the following cases.
  • Page 83: Examples With Manual Swivel

    Setting up the machine 2.6 Measuring the workpiece zero Pre-positioning If you want to preposition a rotary axis before measuring with "Align edge", move the rotary axis so that your workpiece is approximately parallel to the coordinate system. Set the relevant rotary axis angle to zero with "Set WO". Measurement with "Align edge" will then correct the value for rotary axis offset or include it in the coordinate rotation and align the workpiece edge precisely.
  • Page 84: Calibrating The Electronic Workpiece Probe

    Setting up the machine 2.6 Measuring the workpiece zero 8. Measure workpiece Apply "Set edge Z" to define the offset in Z. 9. Start part program to remachine under AUTO. Start the program with swivel zero. Second example Measuring workpieces in swiveled states. The workpiece is to be probed in the X direction even though the probe cannot approach the workpiece in the X direction because of an obstructing edge (e.g.
  • Page 85 Setting up the machine 2.6 Measuring the workpiece zero Select the "JOG" mode in the "Machine" operating area. Press the "Workpiece zero" and "Probe calibration" softkeys. The window "Calibration: Probe" is opened. Press the "Radius" softkey. In ∅, enter the calibration bore corresponding to the diameter. Press the <CYCLE START>...
  • Page 86: Setting The Edge

    Setting up the machine 2.6 Measuring the workpiece zero Note User-specific defaults • "Setting ring diameter" For the entry field "Diameter setting ring" (diameter, reference piece), fixed values can be separately entered at parameters for each probe number (calibration data set number). If these parameters are assigned, the values saved there are displayed in the entry field "Diameter setting ring";...
  • Page 87 Setting up the machine 2.6 Measuring the workpiece zero Procedure Select the "Machine" operating area and press the <JOG> key. Press the "Workpiece zero" and "Set edge" softkeys. The "Set Edge" window opens. Select "Measuring only" if you only want to display the measured values.
  • Page 88: Edge Measurement

    Setting up the machine 2.6 Measuring the workpiece zero Note Settable zero offsets The labeling of the softkeys for the settable zero offsets varies, i.e. the settable zero offsets configured on the machine are displayed (examples: G54…G57, G54…G505, G54…G599). Please refer to the machine manufacturer's specifications. 2.6.6 Edge measurement The following options are available to you when measuring an edge:...
  • Page 89 Setting up the machine 2.6 Measuring the workpiece zero Press the "Align edge" softkey. - OR - Press the "Distance between 2 edges" softkey. - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired measurement version.
  • Page 90 Setting up the machine 2.6 Measuring the workpiece zero Note Settable zero offsets The labeling of the softkeys for the settable zero offsets varies, i.e. the settable zero offsets configured on the machine are displayed (examples: G54…G57, G54…G505, G54…G599). Please refer to the machine manufacturer's specifications. Automatic measurement Prepare the measurement (see steps 1 to 5 above).
  • Page 91: Measuring A Corner

    Setting up the machine 2.6 Measuring the workpiece zero 2.6.7 Measuring a corner You have the option to measure workpiece corners, which are defined by a right angle (90°) or any inner angle. Measuring a right-angled corner The workpiece corner to be measured has a 90° inner angle and is clamped to the worktable in any position.
  • Page 92 Setting up the machine 2.6 Measuring the workpiece zero Press the "Right-angled corner" softkey if the workpiece has a right- angled corner. - OR - Press the "Any corner" softkey, if you want to measure a corner not equal to 90°. - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired...
  • Page 93 Setting up the machine 2.6 Measuring the workpiece zero - OR - Press the "Set ZO" softkey. The corner point now corresponds to the setpoint position. The calculated offset is stored in the zero offset. Note Settable zero offsets The labeling of the softkeys for the settable zero offsets varies, i.e. the settable zero offsets configured on the machine are displayed (examples: G54…G57, G54…G505, G54…G599).
  • Page 94: Measuring A Pocket And Hole

    Setting up the machine 2.6 Measuring the workpiece zero 2.6.8 Measuring a pocket and hole You can measure rectangular pockets and one or more holes and then align the workpiece. Measuring a rectangular pocket The rectangular pocket must be aligned at right-angles to the coordinate system. By automatically measuring four points inside the pocket, its length, width and center point can be determined.
  • Page 95 Setting up the machine 2.6 Measuring the workpiece zero Note You can only measure 2, 3, and 4 holes automatically. Requirement You can insert any tool in the spindle for scratching when measuring the workpiece zero manually. - OR - An electronic workpiece probe is inserted in the spindle and activated when measuring the workpiece zero automatically.
  • Page 96 Setting up the machine 2.6 Measuring the workpiece zero Press the "Select ZO" softkey to select an settable zero offset. In the window "Zero Offset – G54 ... G599", select a zero offset, in which the zero point should be saved and press the "In manual" softkey. You return to the measurement window.
  • Page 97 Setting up the machine 2.6 Measuring the workpiece zero Automatic measurement Select the "Measure workpiece zero" function (see steps 1 and 2 above). Press the "Rectangular pocket" softkey. - OR - Press the "1 hole" softkey. - OR - Press the "2 holes" softkey. - OR - Press the "3 holes"...
  • Page 98 Setting up the machine 2.6 Measuring the workpiece zero - OR - 2 holes • If you do not make any entry in the entry field "Øhole", then the axis moves with the measuring feed from the starting point. If the measuring stroke does not reach the edge of the hole, then the approximate diameter must be entered.
  • Page 99 Setting up the machine 2.6 Measuring the workpiece zero 4 holes • If you do not make any entry in the entry field "Øhole", then the axis moves with the measuring feed from the starting point. If the measuring stroke does not reach the edge of the hole, then the approximate diameter must be entered.
  • Page 100: Measuring A Spigot

    Setting up the machine 2.6 Measuring the workpiece zero 2 holes The tool automatically probes four points of the inside wall of the first hole successively and after pressing <CYCLE START> again probes the four points of the inside wall of the second hole. The angle between the line connecting the center points and the reference axis is calculated and displayed.
  • Page 101 Setting up the machine 2.6 Measuring the workpiece zero Measuring two circular spigots The workpiece is located anywhere on the work table and has 2 spigots. Four points are automatically measured at the two spigots and the spigot centers are calculated from them. The angle α...
  • Page 102 Setting up the machine 2.6 Measuring the workpiece zero Procedure Select the "Machine" operating area and press the <JOG> key. Press the "Workpiece zero" softkey. Press the "Rectangular spigot" softkey. - OR - Press the "1 circular spigot" softkey. - OR - If these softkeys are not listed, press any vertical softkey (with the exception of "Set edge") and in the drop-down list, select the desired measurement version.
  • Page 103 Setting up the machine 2.6 Measuring the workpiece zero Press the "Calculate" softkey. The diameter and center point of the spigot are calculated and displayed. - OR - Press the "Set ZO" softkey. The setpoint position of the center point is stored as a new zero point with "Set ZO".
  • Page 104 Setting up the machine 2.6 Measuring the workpiece zero Traverse the workpiece probe to approximately the center above the rectangular or circular spigot, or for several, above the first spigot to be measured. Specify whether you want "Measurement only" or in which zero offset you want to store the zero point.
  • Page 105 Setting up the machine 2.6 Measuring the workpiece zero 4 circular • Enter the approximate diameter of the spigot into "Øspigot". spigots • Enter the infeed value in "DZ" to determine the measuring depth. • In "Angle offs.", select entry "Yes" if you want to align using coordinate rotation or select in "Angle offs."...
  • Page 106: Aligning The Plane

    Setting up the machine 2.6 Measuring the workpiece zero 3 spigots The center point and the diameter of the circle on which the three spigot center points lie are calculated and displayed. If you selected entry "Yes" in "Coor. rotation", then angle α is additionally calculated and displayed.
  • Page 107 Setting up the machine 2.6 Measuring the workpiece zero Press the "Workpiece zero" and "Align plane" softkeys. The "Align plane" window opens. Select "Measuring only" if you only want to display the measured values. - OR - Select the desired zero offset in which you want to store the zero point (e.g.
  • Page 108: Defining The Measurement Function Selection

    Setting up the machine 2.6 Measuring the workpiece zero 2.6.11 Defining the measurement function selection The measurement versions "Set edge", "Align edge", "Right-angled corner", "1 hole" and "1 circular spigot" are listed in the "Measure workpiece zero" in the associated vertical softkey bar.
  • Page 109: Corrections After Measurement Of The Zero Point

    Setting up the machine 2.6 Measuring the workpiece zero Press the "Back" softkey. The selected softkey is assigned the new measurement version, in this case, "Align plane". 2.6.12 Corrections after measurement of the zero point If you store the workpiece zero in a work offset, changes to the coordinate system or axis positions might be necessary in the following cases.
  • Page 110 Setting up the machine 2.6 Measuring the workpiece zero Positioning a rotary axis and entering a feedrate Once you have measured the workpiece zero you must reposition the rotary axis. Note: Retract the probe to a safe position before the rotary axis should move. The activation window asking whether you want to "Position rotary axis X to align?"...
  • Page 111: 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 112: 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 113: Displaying The Zero Offset "overview

    Setting up the machine 2.7 Zero offsets 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 114: Displaying And Editing Base Zero Offset

    Setting up the machine 2.7 Zero offsets Procedure Select the "Parameter" operating area. Press the "Zero offset" and "Overview" softkeys. The "Zero Offsets - Overview" window opens. 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"...
  • Page 115: 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 116 Setting up the machine 2.7 Zero offsets Machine manufacturer Please refer to the machine manufacturer's specifications. Note Settings for rotation, scaling and mirroring are specified here and can only be changed here. Procedure Select the "Parameter" operating area. Press the "Zero offset" softkey. Press the "Active", "Base"...
  • Page 117: Deleting A Zero Offset

    Setting up the machine 2.7 Zero offsets Machine manufacturer Please refer to the machine manufacturer's specifications. Press the "Back" softkey to close the window. 2.7.6 Deleting a zero offset You have the option of deleting zero offsets. This resets the entered values. Procedure Select the "Parameter"...
  • Page 118 Setting up the machine 2.7 Zero offsets 2.7.7 Measuring the workpiece zero Procedure Select the "Parameters" operating area and press the "Zero offset" softkey. Press the "G54...G599" softkey and select the zero offset in which the zero point is to be saved. Press the "Workpiece zero"...
  • Page 119: 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 120: 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 121: Displaying Setting Data Lists

    Setting up the machine 2.9 Displaying setting data lists Displaying setting data lists You can display lists with configured setting data. Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure Select the "Parameter" operating area. Press the "Setting data" and "Data lists" softkeys. The "Setting Data Lists"...
  • Page 122: 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 123 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 <INSERT> key, navigate to the desired axis, and press the <INPUT> key. Selecting an axis also activates the handwheel (e.g., "X" is assigned to handwheel no.
  • Page 124: Loading An Mda Program From The Program Manager

    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 125: 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 <MDI> 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 126: 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 <MDA> key. The MDA editor opens. Input the desired G-code commands using the operator’s keyboard. Press the <CYCLE START> key. The control executes the input blocks.
  • Page 127: General

    Execution in manual mode General Always use "JOG" mode when you want to set up the machine for the execution of a program or to carry out simple traversing movements on the machine: ● Synchronize the measuring system of the controller with the machine (reference point approach) ●...
  • Page 128 Execution in manual mode 3.2 Selecting a tool and spindle Display Meaning Input of the tool (name or location number) You can select a tool from the tool list using the "Select tool" softkey. Cutting edge number of the tool (1 - 9) Spindle Spindle selection, identification with spindle number Spindle M function...
  • Page 129: Selecting A Tool

    Execution in manual mode 3.2 Selecting a tool and spindle 3.2.2 Selecting a tool Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Enter the name or the number of the tool T in the input field. - OR - Press the "Select tool"...
  • Page 130: Starting And Stopping A Spindle Manually

    Execution in manual mode 3.2 Selecting a tool and spindle 3.2.3 Starting and stopping a spindle manually Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Select the desired spindle (e.g. S1) and enter the desired spindle speed (rpm) in the adjacent input field.
  • Page 131: Position Spindle

    Execution in manual mode 3.2 Selecting a tool and spindle 3.2.4 Position spindle Procedure Select the "JOG" operating mode. Press the "T, S, M" softkey. Select the "Stop Pos." setting in the "Spindle M function" field. The "Stop Pos." entry field appears. Enter the desired spindle stop position.
  • Page 132: Traversing Axes

    Execution in manual mode 3.3 Traversing axes Traversing axes You can traverse the axes in manual mode via the Increment or Axis keys or handwheels. During a traverse initiated from the keyboard, the selected axis moves at the programmed setup feedrate. During an incremental traverse, the selected axis traverses a specified increment.
  • Page 133: Traversing Axes By A Variable Increment

    Execution 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 134: Positioning Axes

    Execution in manual mode 3.4 Positioning axes Positioning axes In manual mode, you can traverse individual or several axes to certain positions in order to implement simple machining sequences. The feedrate / rapid traverse override is active during traversing. Procedure If required, select a tool.
  • Page 135: Swiveling

    Execution in manual mode 3.5 Swiveling Swiveling Manual swivel in the JOG mode provides functions that make it far easier to setup, measure, and machine workpieces with swiveled surfaces. If you want to create or correct an inclined position, the required rotations of the workpiece coordinate system around the geometry axes (X, Y, Z) are automatically converted into suitable positions of the machine kinematics.
  • Page 136 Execution in manual mode 3.5 Swiveling ● Swivel plane You can start the swivel plane as "new" or "additive" to a swivel plane that is already active. ● Swivel mode Swiveling can be axis by axis or direct. – Axis-by-axis swiveling is based on the coordinate system of the workpiece (X, Y, Z). The coordinate axis sequence can be selected freely.
  • Page 137 Execution in manual mode 3.5 Swiveling ● Zero plane The zero plane corresponds to the tool plane (G17, G18, G19) including the active zero offset (G500, G54, ...). Rotations of the active zero offset and the rotary axes are taken into account for manual swiveling.
  • Page 138 Execution in manual mode 3.5 Swiveling Press the "Basic setting" softkey and the <CYCLE START> key to move the machine into the initial position. If the actual zero offset does not include a rotation, then the rotary axes of the swivel data record are moved to zero. The tool is located vertically to the machining plane.
  • Page 139: Manual Retraction

    Execution in manual mode 3.6 Manual retraction Parameter Description Unit Direction Preferred direction of rotation for two alternatives (swiveling axis-by-axis) +: Larger angle of the axis on the scale of the swivel head / swivel table -: Smaller angle of the axis on the scale of the swivel head / swivel table Tool Correction: The position of the tool tip is maintained during swiveling No correction: The position of the tool tip changes during swiveling...
  • Page 140 Execution in manual mode 3.6 Manual retraction Press the "Retract" softkey. The "Retract Tool" window opens. The softkey is available only when an active tool and retraction data are present. Select the "WCS" coordinate system on the machine control panel. Select the required axis in the "Retraction axis"...
  • Page 141: Simple Face Milling Of The Workpiece

    Execution in manual mode 3.7 Simple face milling of the workpiece Simple face milling of the workpiece You can use this cycle to face mill any workpiece. A rectangular surface is always machined. Selecting the machining direction In the "Direction" field, using the SELECT key, select the desired machining direction: ●...
  • Page 142 Execution in manual mode 3.7 Simple face milling of the workpiece Requirement To carry out simple stock removal of a workpiece in manual mode, a measured tool must be in the machining position. Procedure Select the "Machine" operating area. Press the <JOG> key. Press the <Face milling>...
  • Page 143 Execution in manual mode 3.7 Simple face milling of the workpiece Parameters Description Unit Feedrate mm/min mm/rev S / V Spindle speed or constant cutting rate m/min Spindle M function Direction of spindle rotation (only when ShopMill is not active) •...
  • Page 144: Default Settings For Manual Mode

    Execution 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 145: Starting And Stopping Machining

    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 146: Selecting A Program

    Machining the workpiece 4.2 Selecting a program Stopping machining Press the <CYCLE STOP> 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 <RESET>...
  • Page 147: Testing A Program

    Machining the workpiece 4.3 Testing a program 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. Testing a program When testing a program, the system can interrupt the machining of the workpiece after each program block, which triggers a movement or auxiliary function on the machine.
  • Page 148 Machining the workpiece 4.3 Testing a program Procedure Press the "Prog. ctrl." softkey and select the desired variant in the "SBL" field. Press the <SINGLE BLOCK> key. Press the <CYCLE START> key. Depending on the execution variant, the first block will be executed. Then the machining stops.
  • Page 149: Displaying The Current Program Block

    Machining the workpiece 4.4 Displaying the current program block Displaying the current program block 4.4.1 Current block display The window of the current block display shows you the program blocks currently being executed. Display of current program The following information is displayed in the running program: ●...
  • Page 150: Display Program Level

    Machining the workpiece 4.4 Displaying the current program block ● Other programmed addresses ● M functions Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure A program is selected for execution and has been opened in the "Machine" operating area. Press the "Basic blocks"...
  • Page 151: Correcting A Program

    Machining the workpiece 4.5 Correcting a program Display of program level The following information will be displayed: ● Level number ● Program name ● Block number, or line number ● Remain program run throughs (only for several program run throughs) Precondition A program must be selected for execution in "AUTO"...
  • Page 152 Machining the workpiece 4.5 Correcting a program Procedure The program to be corrected is in the Stop or Reset mode. Press the "Prog. corr.” softkey The program is opened in the editor. The program preprocessing and the current block are displayed. The current block is also updated in the running program, but not the displayed program section, i.e.
  • Page 153: Repositioning Axes

    Machining the workpiece 4.6 Repositioning axes Repositioning axes After a program interruption in automatic mode (e.g. after a tool breaks) you can move the tool away from the contour in manual mode. The coordinates of the interrupt position will be saved. The distances traversed in manual mode are displayed in the actual value window.
  • Page 154 Machining the workpiece 4.6 Repositioning axes Proceed as follows Press the <REPOS> 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. Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 155: Starting Machining At A Specific Point

    Machining the workpiece 4.7 Starting machining at a specific point Starting machining at a specific point 4.7.1 Use block search If you would only like to perform a certain section of a program on the machine, then you need not start the program from the beginning. You can also start the program from a specified program block.
  • Page 156 Machining the workpiece 4.7 Starting machining at a specific point Cascaded search You can start another search from the "Search target found" state. The cascading can be continued any number of times after every search target found. Note Another cascaded block search can be started from the stopped program execution only if the search target has been found.
  • Page 157: Continuing Program From Search Target

    Machining the workpiece 4.7 Starting machining at a specific point 4.7.2 Continuing program from search target To continue the program at the desired position, press the <CYCLE START> key twice. ● The first CYCLE START outputs the auxiliary functions collected during the search. The program is then in the Stop state.
  • Page 158: Defining An Interruption Point As Search Target

    Machining the workpiece 4.7 Starting machining at a specific point 4.7.4 Defining an interruption point as search target Precondition A program was selected in "AUTO" mode and interrupted during execution through CYCLE STOP or RESET. Software option You require the "Extended operator functions" option (only for 828D). Procedure Press the "Block search"...
  • Page 159: 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 160: 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 <CYCLE START> key twice. Processing is continued from the defined location. Note Interruption point You can load the interruption point in search pointer mode.
  • Page 161: 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 162 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 <AUTO> key. Press the "Block search" and "Block search mode" softkeys.
  • Page 163: 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 "MDA" 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 164: 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 165 Machining the workpiece 4.8 Controlling the program run Software option In order to have more than two skip levels, for 828D you require the "Extended operator functions" option. Skip levels, activate Select the corresponding checkbox to activate the desired skip level. Note The "Program Control - Skip Blocks"...
  • Page 166: 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 167: Editing A Program

    Machining the workpiece 4.10 Editing a program Note Block-by-block execution The <SINGLE BLOCK> 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 168: Searching In Programs

    Machining the workpiece 4.10 Editing a program See also Editor settings (Page 175) Opening and closing the program (Page 575) Correcting a program (Page 151) Generating a G code program (Page 220) 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 169 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 170: 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 171: 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 172: Renumber Program

    Machining the workpiece 4.10 Editing a program Deleting program blocks Use the "Cut" softkey to delete 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 173: Creating A Program Block

    Machining the workpiece 4.10 Editing a program Note If you only want to renumber a section, select the program blocks whose block numbering you want to edit. 4.10.5 Creating a program block In order to structure programs to achieve a higher degree of transparency, you have the option of combining several blocks (G-code and/or ShopMill machining steps) to form program blocks.
  • Page 174: Opening Additional Programs

    Machining the workpiece 4.10 Editing a program Press the "Open all blocks" softkey if you wish to display the program with all blocks. Press the "Close all blocks" softkey, if you wish to display the program again in a structured form. 4.10.6 Opening additional programs You have the option of viewing and editing two programs simultaneously in the editor.
  • Page 175: Editor Settings

    Machining the workpiece 4.10 Editing a program Select the program or programs that you wish to display in addition to the already opened program. Press the "OK" softkey. The editor opens and displays both programs next to each another. See also Copying/pasting/deleting a program block (Page 171) 4.10.7 Editor settings...
  • Page 176 Machining the workpiece 4.10 Editing a program Setting Meaning Visible programs 1 - 10 • Select how many programs can be displayed next to one another in the editor. Auto • Specifies that the number of programs entered in a job list or up to ten selected programs will be displayed next to each other.
  • Page 177: Mold Making View

    Machining the workpiece 4.11 Mold making view 4.11 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 178 Machining the workpiece 4.11 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 179: Starting The Mold Making View

    Machining the workpiece 4.11 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 180: Specifically Jump To The Program Block

    Machining the workpiece 4.11 Mold making view 4.11.2 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 181: Changing The View

    Machining the workpiece 4.11 Mold making view See also Searching in programs (Page 168) Replacing program text (Page 170) 4.11.4 Changing the view 4.11.4.1 Enlarging or reducing the graphical representation Precondition ● The mold making view has been started. ● The "Graphic" softkey is active. Procedure Press the <+>...
  • Page 182: Modifying The Viewport

    Machining the workpiece 4.11 Mold making view Note Selected section The selected sections and size changes are kept as long as the program is selected. 4.11.4.2 Modifying the viewport Use the magnifying glass if you would like to move, increase or reduce the size of the section of the mold making view, e.g.
  • Page 183: 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 184 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 185: All G Functions

    References For more information about configuring the displayed G groups, refer to the following document: Commissioning Manual SINUMERIK Operate (IM9) / SINUMERIK 840D sl 4.12.2 All G functions All G groups and their group numbers are listed in the "G Functions" window.
  • Page 186: Auxiliary Functions

    Machining the workpiece 4.12 Displaying G Functions and Auxiliary Functions Procedure Select the "Machine" operating area. Press the <JOG>, <MDA> or <AUTO> key. Press the ">>" and "All G functions" softkeys. The "G Functions" window is opened. 4.12.3 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.
  • Page 187 Machining the workpiece 4.12 Displaying G Functions and Auxiliary Functions Press the "H functions" softkey. The "Auxiliary Functions" window opens. Press the "H functions" softkey again to hide the window again. You can display status information for diagnosing synchronized actions in the "Synchronized Actions"...
  • Page 188 Machining the workpiece 4.12 Displaying G Functions and Auxiliary Functions Display of synchronized actions Using softkeys, you have the option of restricting the display to activated synchronized actions. Procedure Select the "Machine" operating area. Press the <AUTO>, <MDA> or <JOG> key. Press the menu forward key and the "Synchron."...
  • Page 189: Displaying The Program Runtime And Counting Workpieces

    Machining the workpiece 4.13 Displaying the program runtime and counting workpieces 4.13 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" window. Machine manufacturer Please refer to the machine manufacturer's specifications.
  • Page 190 Machining the workpiece 4.13 Displaying the program runtime and counting workpieces Procedure Select the "Machine" operating area. Press the <AUTO> key. Press the "Times, Counter" softkey. The "Times, Counter" window opens. Select "Yes" under "Count workpieces" if you want to count completed workpieces.
  • Page 191: Setting For Automatic Mode

    Machining the workpiece 4.14 Setting for automatic mode 4.14 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 192 Machining the workpiece 4.14 Setting for automatic mode References Programming Manual Measuring Cycles / 840D sl/828D Note The feedrate can be changed while the operation is running. See also Program control (Page 163) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 193: Overview

    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 194 Simulating machining 5.1 Overview Machine references The simulation is implemented as workpiece simulation. This means that it is not assumed that the zero offset has already been precisely scratched or is known. In spite of this, unavoidable machine references are in the programming, such as for example, the tool change point in the machine, the retraction position when swiveling and the table components of a swivel kinematic.
  • Page 195 Simulating machining 5.1 Overview Display variants You can choose between three variants of graphical display: ● Simulation before machining of the workpiece Before machining the workpiece on the machine, you can perform a quick run-through in order to graphically display how the program will be executed. ●...
  • Page 196 Simulating machining 5.1 Overview Properties of simultaneous recording and simulation Traversing paths For the simulation, the displayed traversing paths are saved in a ring buffer. If this buffer is full, then the oldest traversing path is deleted with each new traversing path. Optimum display If simultaneous machining is stopped or has been completed, then the display is again converted into a high-resolution screen.
  • Page 197 Simulating machining 5.1 Overview Examples Several examples for machine types that are supported: Swivel head 90°/90° Swivel head 90°/45° Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 198 Simulating machining 5.1 Overview Swivel table 90°/90° Swivel table 90°/45° Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 199 Simulating machining 5.1 Overview Swivel combination 90°/90° Swivel combination 45°/90° Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 200: 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 201: Simultaneous Recording Before Machining Of The Workpiece

    Simulating machining 5.3 Simultaneous recording before machining of the workpiece 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. Simultaneous recording before machining of the workpiece Before machining the workpiece on the machine, you can graphically display the execution of the program on the screen to monitor the result of the programming.
  • Page 202: Simultaneous Recording During Machining Of The Workpiece

    Simulating machining 5.4 Simultaneous recording during machining of the workpiece Simultaneous recording during machining of the workpiece If the view of the work space is blocked by coolant, for example, while the workpiece is being machined, you can also track the program execution on the screen. Software option You require the option "Simultaneous recording (real-time simulation)"...
  • Page 203: 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 204: Side View

    Simulating machining 5.5 Different views of the workpiece Changing the display You can increase or decrease the size of the simulation graphic, move it, turn it, or change the segment. Displaying and moving cutting planes You can display and move cutting planes X, Y, and Z. See also Defining cutting planes (Page 211) 5.5.3...
  • Page 205: Editing The Simulation Display

    Simulating machining 5.6 Editing the simulation display Editing the simulation display 5.6.1 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 206: Program Control During The Simulation

    Simulating machining 5.7 Program control during the simulation Program control during the simulation 5.7.1 Changing the feedrate You can change the feedrate at any time during the simulation. You can track the changes in the status line. Note If you are working with the "Simultaneous recording" function, the rotary switch (override) on the control panel is used.
  • Page 207: Simulating The Program Block By Block

    Simulating machining 5.7 Program control during the simulation 5.7.2 Simulating the program block by block You can control the program execution during simulation, i.e. execute a program block by block, as when executing a program. Procedure Simulation is started. Press the "Program control" and "Single block" softkeys. Press the "Back"...
  • Page 208: Changing And Adapting A Simulation Graphic

    Simulating machining 5.8 Changing and adapting a simulation graphic Changing and adapting a simulation graphic 5.8.1 Enlarging or reducing the graphical representation Precondition The simulation or the simultaneous recording is started. Procedure Press the <+> and <-> keys if you wish to enlarge or reduce the graphic display.
  • Page 209: Panning A Graphical Representation

    Simulating machining 5.8 Changing and adapting a simulation graphic 5.8.2 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. 5.8.3 Rotating the graphical representation In the 3D view you can rotate the position of the workpiece to view it from all sides.
  • Page 210 Simulating machining 5.8 Changing and adapting a simulation graphic Keep the <Shift> key pressed and then turn the workpiece in the desired direction using the appropriate cursor keys. 5.8.4 Modifying the viewport If you would like to move, enlarge or decrease the size of the segment of the graphical display, e.g.
  • Page 211: Defining Cutting Planes

    Simulating machining 5.8 Changing and adapting a simulation graphic 5.8.5 Defining cutting planes In the 3D view, you have the option of "cutting" the workpiece and therefore displaying certain views in order to show hidden contours. Precondition The simulation or the simultaneous recording is started. Procedure Press the "Details"...
  • Page 212: Displaying Simulation Alarms

    Simulating machining 5.9 Displaying simulation alarms Displaying simulation alarms Alarms might occur during simulation. If an alarm occurs during a simulation run, a window opens in the operating window to display it. The alarm overview contains the following information: ● Date and time ●...
  • Page 213: Graphical Programming

    Generating 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 214: Program Views

    Generating 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 screen or graphic view Program view The program view in the editor provides an overview of the individual machining steps of a program.
  • Page 215 Generating a G code program 6.2 Program views Parameter screen with help display Press the <Cursor right> key to open a selected program block or cycle in the program view. The associated parameter screen with help screen is then displayed. Figure 6-2 Parameter screen with help display The animated help displays are always displayed with the correct orientation to the selected...
  • Page 216 Generating a G code program 6.2 Program views Parameter screen with graphic view Using the "Graphic view" softkey, you can toggle between the help screen and the graphic view in the screen. Figure 6-3 Parameter screen with a graphical view of a G code program block Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 217: Program Structure

    Generating 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 218: Fundamentals

    Generating a G code program 6.4 Fundamentals Fundamentals 6.4.1 Machining planes A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2½-D machining).
  • Page 219: Programming A Tool (t)

    Generating a G code program 6.4 Fundamentals For G17, reference points in the plane are called X0 Y0, for G18 they are called Z0 X0 - and for G19, they are called Y0 Z0. The depth specification in the tool axis for G17 is called Z1, for G18, Y1 and for G19, X1.
  • Page 220: Generating A G Code Program

    Generating 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 221: Blank Input

    Generating a G code program 6.6 Blank input See also Changing a cycle call (Page 231) Creating a new workpiece (Page 580) Selection of the cycles via softkey (Page 224) 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 222 Generating 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. Parameters Description Unit Data for Selection of the spindle for blank Main spindle • Counterspindle •...
  • Page 223: Machining Plane, Milling Direction, Retraction Plane, Safe Clearance And Feedrate (pl, Rp Sc, F)

    Generating 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 are always repeated.
  • Page 224: Selection Of The Cycles Via Softkey

    Generating a G code program 6.8 Selection of the cycles via softkey Selection of the cycles via softkey Overview of machining steps The following softkey bars are available to insert machining steps. All of the cycles/functions available in the control are shown in this display. However, at a specific system, only the steps possible corresponding to the selected technology can be selected.
  • Page 225 Generating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 226 Generating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 227 Generating a G code program 6.8 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 228 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 229: Calling Technology Functions

    These are then generated with the appropriate default values when the cycles are called. For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Cycle support Example Use the softkeys to select whether you want support for programming contours, drilling or milling cycles.
  • Page 230: Checking Cycle Parameters

    Generating a G code program 6.9 Calling technology functions 6.9.3 Checking cycle parameters The entered parameters are already checked during the program creation in order to avoid faulty entries. If a parameter is assigned an illegal value, this is indicated in the input screen and is designated as follows: ●...
  • Page 231: Changing A Cycle Call

    Generating a G code program 6.9 Calling technology functions 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 <Cursor right> key. The associated input screen of the selected cycle call is opened.
  • Page 232: Additional Functions In The Input Screens

    Generating a G code program 6.9 Calling technology functions 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 233: 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 Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 234 Generating a G code program 6.10 Measuring cycle support Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 235: Creating A Shopmill Program

    Creating a ShopMill program The program editor offers graphic programming to generate machining step programs that you can directly generate at the machine. Software option You require the "ShopMill/ShopTurn" option to generate ShopMill machining step programs. Program loops When you open a ShopMill program a program test is always executed. For larger program loops or nested program loops, this can result in performance problems in the editor.
  • Page 236 Creating a ShopMill program 7.1 Program views Program views You can display a ShopMill program in various views: ● Machining schedule ● Programming graphics ● Parameter screen, either with help display or programming graphics Machining schedule The machining schedule in the editor provides an overview of the individual machining steps of a program.
  • Page 237 Creating a ShopMill program 7.1 Program views Programming graphics The programming graphics show the contour of the workpiece as a dynamic graphic with dotted lines. The program block selected in the machining schedule is highlighted in color in the programming graphics. Figure 7-2 Programming graphics of a ShopMill program Milling...
  • Page 238 Creating a ShopMill program 7.1 Program views Parameter screen with help display Press the <Cursor right> key to open a selected program block or cycle in the machining schedule. The associated parameter screen with help screen is then displayed. Figure 7-3 Parameter screen with help display The animated help displays are always displayed with the correct orientation to the selected coordinate system.
  • Page 239 Creating a ShopMill program 7.1 Program views Parameter screen with programming graphics In the screen, you can toggle between the help display and the program graphics using the "Graphic view". Figure 7-4 Parameter screen with programming graphics Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 240 Creating a ShopMill program 7.2 Program structure Program structure A machining step program is divided into three sub-areas: ● Program header ● Program blocks ● End of program These sub-areas form a work plan. Program header The program header contains parameters that affect the entire program, such as blank dimensions or retraction planes.
  • Page 241 Creating a ShopMill program 7.3 Fundamentals Fundamentals 7.3.1 Machining planes A plane is defined by means of two coordinate axes. The third coordinate axis (tool axis) is perpendicular to this plane and determines the infeed direction of the tool (e.g. for 2½-D machining).
  • Page 242: Absolute And Incremental Dimensions

    Creating a ShopMill program 7.3 Fundamentals Example Points P1 and P2 can then be described – with reference to the pole – as follows: P1: Radius =100 / angle =30° P2: Radius =60 / angle =75° 7.3.3 Absolute and incremental dimensions Absolute dimensions With absolute dimensions, all the position specifications refer to the currently valid zero point.
  • Page 243 Creating a ShopMill program 7.3 Fundamentals Incremental dimensions In the case of production drawings in which dimensions refer to some other point on the workpiece rather than the zero point, it is possible to enter an incremental dimension. When incremental dimensions are entered, each item of position data refers to a point programmed beforehand.
  • Page 244 Creating a ShopMill program 7.4 Creating a ShopMill program Creating a ShopMill program Create a separate program for each new workpiece that you would like to produce. The program contains the individual machining steps that must be performed to produce the workpiece.
  • Page 245: Program Header

    Creating a ShopMill program 7.5 Program header Program header In the program header, set the following parameters, which are effective for the complete program. Parameter Description Unit Measurement unit The dimension unit (mm or inch) set in the program header only refers to the position data in the actual program.
  • Page 246 Creating a ShopMill program 7.5 Program header Parameter Description Unit Retraction plane RP Planes above the workpiece. Safety clearance SC: During machining the tool travels in rapid traverse from the tool change point to the return plane (RP) and then to the safety clearance (SC). The machining feedrate is activated at this level.
  • Page 247: Generating Program Blocks

    Creating a ShopMill program 7.6 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 248: Tool, Offset Value, Feed And Spindle Speed (t, D, F, S, V)

    Creating a ShopMill program 7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) Tool, offset value, feed and spindle speed (T, D, F, S, V) Generally, the following parameters are entered for a program block. Tool (T) Each time a workpiece is machined, you must program a tool.
  • Page 249 Creating a ShopMill program 7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) Radius compensation to right of contour Radius compensation to left of contour Radius compensation off Radius compensation remains as previously set Feedrate (F) The feedrate F (also referred to as the machining feedrate) specifies the speed at which the tool moves when machining the workpiece.
  • Page 250: Defining Machine Functions

    You have the option of defining machine functions as well as your own texts in the "Machine functions" window. References A description of the configuration options is provided in Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Procedure The ShopMill program to be edited has been created and you are in the editor.
  • Page 251 Creating a ShopMill program 7.8 Defining machine functions Parameter Description Unit Spindle M function, defines the spindle direction of rotation or spindle position Spindle off • Spindle rotates clockwise • Spindle rotates counterclockwise • Spindle positions • Stop position Spindle stop position - (only for spindle M function SPOS) Degrees Other M function Machine functions, e.g.
  • Page 252: Call Work Offsets

    Creating a ShopMill program 7.9 Call work offsets Call work offsets You can call work offsets (G54, etc.) from any program. You define work offsets in work offset lists. You can also view the coordinates of the selected offset here. Procedure Press the "Various", "Transformations"...
  • Page 253: Repeating Program Blocks

    Creating a ShopMill 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. NOTICE Machining several workpieces The program repeat function is not suitable to program repeat machining of parts.
  • Page 254 Creating a ShopMill program 7.10 Repeating program blocks Press the "Set marker" and "Accept" softkeys again. An end marker is inserted after the actual block. 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 255: Specifying The Number Of Workpieces

    Creating a ShopMill program 7.11 Specifying the number of workpieces 7.11 Specifying the number of workpieces If you wish to produce a certain quantity of the same workpiece, then at the end of the program, specify that you wish to repeat the program. Control the numbers of times that the program is repeated using the "Times, counters"...
  • Page 256: Changing Program Blocks

    Creating a ShopMill program 7.12 Changing program blocks 7.12 Changing program blocks You can subsequently optimize the parameters in the programmed blocks or adapt them to new situations, e.g. if you want to increase the feedrate or shift a position. In this case, you can directly change all the parameters in every program block in the associated parameter screen form.
  • Page 257: Changing Program Settings

    Creating a ShopMill program 7.13 Changing program settings 7.13 Changing program settings Function All parameters defined in the program header, with the exception of the dimension unit, can be changed at any location in the program. The settings in the program header are modal, i.e. they remain active until they are changed. For the simulation and the simultaneous recording use a blank.
  • Page 258 Creating a ShopMill program 7.13 Changing program settings Table 7- 1 Parameter Description Unit Blank Selecting the blank without • Cylinder • Tube • Centered cuboid • Cuboid • Polygon • Machining plane G17 (XY) G18 (ZX) G19 (YZ) Retraction plane (abs) Safety clearance (inc) Acts in relation to the reference point.
  • Page 259 Creating a ShopMill program 7.14 Selection of the cycles via softkey 7.14 Selection of the cycles via softkey Overview of machining steps The following machining steps are available for insertion. All of the cycles/functions available in the control are shown in this display. However, at a specific system, only the steps possible corresponding to the selected technology can be selected.
  • Page 260 Creating a ShopMill program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 261 Creating a ShopMill program 7.14 Selection of the cycles via softkey ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ ⇒ Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 262 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 263 Creating a ShopMill program 7.15 Calling technology functions 7.15 Calling technology functions 7.15.1 Additional functions in the input screens Selection of units If, for example, the unit can be switched in a field, this is highlighted as soon as the cursor is positioned on the element.
  • Page 264: Checking Input Parameters

    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 Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 265 Creating a ShopMill 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 <Cursor right> key. The associated input screen of the selected cycle call is opened.
  • Page 266 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 Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 267: Example, Standard Machining

    Creating a ShopMill program 7.17 Example, standard machining 7.17 Example, standard machining General The following example is described in detail as ShopMill program. A G code program is generated in the same way; however, some differences must be observed. If you copy the G code program listed below, read it into the control and open it in the editor, then you can track the individual program steps.
  • Page 268: Workpiece Drawing

    Creating a ShopMill program 7.17 Example, standard machining 7.17.1 Workpiece drawing Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 269: Programming

    Creating a ShopMill program 7.17 Example, standard machining 7.17.2 Programming 1. Program header Specify the blank. Measurement unit mm Work offset Blank Cuboid -2.5abs -2.5abs 182.5abs 182.5abs 1abs -20abs Machining direction Climbing Retraction position pattern Optimized Press the "Accept" softkey. The work plan is displayed.
  • Page 270 Creating a ShopMill program 7.17 Example, standard machining 0abs Press the "Accept" softkey. 3. Outside contour of the workpiece Press the "Milling", "Multi-edge spigot" and "Rectangular spigot" softkeys. Enter the following technology parameters: T MILLER20 F 0.14 mm/tooth V 240 m/min Enter the following parameters: Position of reference point Bottom left Machining...
  • Page 271 Creating a ShopMill program 7.17 Example, standard machining 4. Outside contour islands To simply machine the entire surface outside the island, define a contour pocket around the blank and then program the island. In this way, the entire surface area is machined and no residual material is left behind.
  • Page 272 Creating a ShopMill program 7.17 Example, standard machining Outside contour of the island Press the "Contour milling", "Contour" and "New contour" softkeys. The "New Contour" input window opens. Enter the contour name (in this case: Part_4_island). The contour calculated as NC code is written as internal subprogram between a start and an end marker containing the entered name.
  • Page 273 Creating a ShopMill program 7.17 Example, standard machining 165abs 95abs α1290 degreesR 155abs α1 Degre 140abs α1225 degreesR Press the ">>" and "Close contour" softkeys, to close the contour. Press the "Accept" softkey. Contour milling/solid machining Press the "Contour milling" and "Pocket" softkeys. Enter the following technology parameters: T MILLER20 F 0.1 mm/tooth...
  • Page 274 Creating a ShopMill program 7.17 Example, standard machining Note • When selecting the milling tool, please make sure that the tool diameter is large enough to cut the intended pocket. A message will be displayed if you make a mistake. •...
  • Page 275 Creating a ShopMill program 7.17 Example, standard machining 6. Milling a rectangular pocket (small) Press the "Milling", "Pocket" and "Rectangular pocket" softkeys. The "Rectangular Pocket" input window opens. Enter the following technology parameters: T MILLER10 F 0.04 mm/tooth V 260 m/min Enter the following parameters: Reference point Center...
  • Page 276 Creating a ShopMill program 7.17 Example, standard machining 7. Milling a circumferential slot Press the "Milling", "Groove" and "Circ. groove" softkeys. The "Circumferential Groove" input window opens. Enter the following technology parameters: T MILLER8 F 0.018 mm/tooth FZ 0.01 mm/tooth V 230 m/min Enter the following parameters: Machining...
  • Page 277 Creating a ShopMill program 7.17 Example, standard machining 8. Drilling/centering Press the "Drilling" and "Centering" softkeys. The "Centering" input window opens. Enter the following technology parameters: T CENTERING F 1000 mm/min S 12000 rev/min TOOL10 Enter the following parameters: Diameter/tip Diameter ∅...
  • Page 278 Creating a ShopMill program 7.17 Example, standard machining 10. Positions Press the "Drilling", "Positions" and "Drilling Positions" softkeys. The "Any positions" input window opens. Enter the following parameters: Rectangular -10abs 15abs 15abs 165abs 15abs Press the "Accept" softkey. 11. Obstacle Press the "Drilling", "Positions", and “Obstacle”...
  • Page 279 Creating a ShopMill program 7.17 Example, standard machining 12. Positions Press the "Drilling", "Positions" and "Drilling Positions" softkeys. The "Any positions" input window opens. Enter the following parameters: Rectangular -10abs 165abs 165abs 15abs 165abs Press the "Accept" softkey. 13. Milling the circular pocket Press the "Milling", "Pocket"...
  • Page 280: Results/simulation Test

    Creating a ShopMill program 7.17 Example, standard machining Insertion Helical Solid machining Complete machining Press the "Accept" softkey. You also program the 4 countersinks ∅16 and 4 deep using a circular pocket and repeating positions 1, 2 and 4. 7.17.3 Results/simulation test Figure 7-5 Programming graphics...
  • Page 281 Creating a ShopMill program 7.17 Example, standard machining Figure 7-6 Machining schedule Program test by means of simulation During simulation, the current program is calculated in its entirety and the result displayed in graphic form. Figure 7-7 3D view Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 282: G Code Machining Program

    Creating a ShopMill program 7.17 Example, standard machining 7.17.4 G code machining program G17 G54 G71 WORKPIECE(,,"","BOX",112,1,-20,-100,-2.5,-2.5,182.5,182.5) ;****************Tool change**************** T="FACING TOOL" D1 M6 G95 FZ=0.1 S3000 M3 M8 CYCLE61(50,1,1,0,-2.5,-2.5,185,185,2,80,0,0.1,31,0,1,10) G0 Z200 M9 ;****************Tool change**************** T="MILLER20" D1 M6 G95 FZ=0.14 S3900 M3 M8 CYCLE76(50,0,1,,20,180,180,10,0,0,0,5,0,0,0.14,0.14,0,1,185,185,1,2,2100,1,101) ;CYCLE62(,2,"MA1","MA0") CYCLE62(,2,"E_LAB_A_PART_4_POCKET","E_LAB_E_PART_4_POCKET")
  • Page 283 Creating a ShopMill program 7.17 Example, standard machining T="MILLER8" D1 M06 G95 FZ=0.018 S12000 M3 M8 POCKET4(50,-10,1,12,30,85,135,5,0,0,0.018,0.01,0,21,40,9,15,2,1,0,1,2,10100,111,111) MCALL POCKET4(50,-10,1,4,16,0,0,5,0,0,0.018,0.018,0,11,40,9,15,0,2,0,1,2,10100,111,111) REPEATB POS_1 ;#SM MCALL G0 Z200 M9 ;****************Tool change**************** ;Contour chamfering T="CENTERING TOOL10" D1 M6 G94 F500 S8000 M3 M8 CYCLE62(,2,"E_LAB_A_PART_4_ISLAND","E_LAB_E_PART_4_ISLAND") CYCLE72("",100,0,1,20,2,0.5,0.5,500,100,305,41,1,0,0.1,1,0,0,0.3,2,101,1011,101) POCKET3(50,0,1,4,70,40,10,90,60,15,4,0,0,500,0.2,0,25,40,8,3,15,2,1,0,0.3,2,11100,11,111) POCKET3(50,-4,1,2,35,20,6,90,60,15,2,0,0,500,0.2,0,35,40,8,3,15,10,2,0,0.3,2,11100,11,111)
  • Page 284 Creating a ShopMill program 7.17 Example, standard machining Y115 RND=20 ;*GP* X15 Y135 ;*GP* Y155 RND=10 ;*GP* X60 RND=15 ;*GP* Y135 ;*GP* G3 X110 I=AC(85) J=AC(135) ;*GP* G1 Y155 RND=15 ;*GP* X143.162 ;*GP* X165 Y95 ;*GP* X155 Y77.679 RND=28 ;*GP* Y40 ;*GP* X140 Y25 ;*GP* X90 ;*GP*...
  • Page 285: Drilling

    Programming technological functions (cycles) Drilling 8.1.1 General General geometry parameters ● Retraction plane RP and reference point Z0 Normally, reference point Z0 and retraction plane RP have different values. The cycle assumes that the retraction plane is in front of the reference point. Note If the values for reference point and retraction planes are identical, a relative depth specification is not permitted.
  • Page 286: Centering (cycle81)

    Programming technological functions (cycles) 8.1 Drilling Drilling positions The cycle assumes the tested hole coordinates of the plane. The hole centers should therefore be programmed before or after the cycle call as follows (see also Section, Cycles on single position or position pattern (MCALL)): ●...
  • Page 287 Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Machining Single position •...
  • Page 288: Drilling (cycle82)

    Programming technological functions (cycles) 8.1 Drilling 8.1.3 Drilling (CYCLE82) 8.1.3.1 Function Function With the "Drilling" function, the tool drills with the programmed spindle speed and feedrate down to the specified final drilling depth (shank or tip). The tool is retracted after a programmed dwell time has elapsed. Approach/retraction 1.
  • Page 289 Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Machining Single position •...
  • Page 290: Reaming (cycle85)

    Programming technological functions (cycles) 8.1 Drilling 8.1.4 Reaming (CYCLE85) 8.1.4.1 Function Function With the "Reaming" cycle, the tool is inserted in the workpiece with the programmed spindle speed and the feedrate programmed at F. If Z1 has been reached and the dwell time expired, the reamer is retracted at the programmed retraction feedrate to the retraction plane.
  • Page 291 Programming technological functions (cycles) 8.1 Drilling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Retraction plane Cutting edge number Safety clearance Feedrate mm/min mm/rev Feedrate S / V Spindle speed or constant cutting rate m/min Parameter Description Unit Machining Single position...
  • Page 292: Deep-hole Drilling (cycle83)

    Programming technological functions (cycles) 8.1 Drilling 8.1.5 Deep-hole drilling (CYCLE83) 8.1.5.1 Function 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 293 Programming technological functions (cycles) 8.1 Drilling 8. Steps 4 to 7 are repeated until the programmed final drilling depth Z1 is reached. 9. The tool retracts to the retraction plane at rapid traverse. Procedure The part program or ShopMill program to be processed has been created and you are in the editor.
  • Page 294 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit D - (only for G 1. Drilling depth (abs) or 1st drilling depth in relation to Z0 (inc) code) D - (only for Maximum depth infeed ShopMill) Percentage for the feedrate for the first infeed Infeed: Amount for each additional infeed •...
  • Page 295: Boring (cycle86)

    Programming technological functions (cycles) 8.1 Drilling 8.1.6 Boring (CYCLE86) 8.1.6.1 Function Function With the "Boring" cycle, the tool approaches the programmed position in rapid traverse, allowing for the retraction plane and safety clearance. It is then inserted into the workpiece at the feedrate programmed under F until it reaches the programmed depth (Z1).
  • Page 296 Programming technological functions (cycles) 8.1 Drilling 6. Retraction with G0 to the safety clearance of the reference point. 7. Retraction to retraction plane with G0 to drilling position in the two axes of the plane (coordinates of the hole center point). Procedure The part program or ShopMill program to be processed has been created and you are in the editor.
  • Page 297: Tapping (cycle84, 840)

    Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Lift mode Do not lift off contour • The cutting edge is not fully retracted, but traverses back to the retraction plane. Lift • The cutting edge retracts from the edge of the hole and then retracts to the safety clearance from the reference point and then positions at the retraction plane and hole center point.
  • Page 298 Programming technological functions (cycles) 8.1 Drilling Approach/retraction - CYCLE840 - with compensating chuck 1. The tool moves with G0 to safety clearance of the reference point. 2. The tool drills with G1 and the programmed spindle speed and direction of rotation to depth Z1.
  • Page 299 Programming technological functions (cycles) 8.1 Drilling Approach/retraction during chipbreaking 1. The tool drills at the programmed spindle speed S (dependent on %S) as far as the first infeed depth (maximum infeed depth D). 2. Spindle stop and dwell time DT. 3.
  • Page 300 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Compensating With compensating chuck • chuck mode Without compensating chuck • 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)
  • Page 301 Programming technological 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 302 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit (only for Direction of rotation after end of cycle: G code) • • • Technology • – Exact stop – Precontrol – Acceleration – Spindle • Exact stop (only Behavior the same as it was before the cycle was called •...
  • Page 303: Drill And Thread Milling (cycle78)

    Programming technological functions (cycles) 8.1 Drilling 8.1.8 Drill and thread milling (CYCLE78) 8.1.8.1 Function 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 304 Programming technological functions (cycles) 8.1 Drilling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Thread" and "Drill and thread mill" softkeys. The "Drilling and thread milling" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...
  • Page 305 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Percentage for each additional infeed • DF=100: Infeed increment remains constant DF<100: Amount of infeed is reduced in direction of final drilling depth Z1 Example: last infeed 4 mm; DF 80% next infeed = 4 x 80% = 3.2 mm next but one infeed = 3.2 x 80% = 2.56 mm etc.
  • Page 306 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit Table Thread table selection: without • ISO metric • Whitworth BSW • Whitworth BSP • • Selection - (not Selection of table value: e.g. for table M3; M10; etc. (ISO metric) •...
  • Page 307: Positioning And Position Patterns

    Programming technological functions (cycles) 8.1 Drilling 8.1.9 Positioning 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 308 Programming technological functions (cycles) 8.1 Drilling Cylinder surface transformation When working with the cylinder surface transformation, please note that the A axis or B axis is not supported in all cases. Programming of any position in the XYA plane is not possible while cylinder surface transformation is active.
  • Page 309: Arbitrary Positions (cycle802)

    Programming technological functions (cycles) 8.1 Drilling 8.1.10 Arbitrary positions (CYCLE802) Function The "Arbitrary positions" cycle allows you to program positions freely, i.e. rectangular or polar. Individual positions are approached in the order in which you program them. Press softkey "Delete all" to delete all positions programmed in X/Y. Rotary axis XA plane You program in XA to prevent the Y axis moving during machining.
  • Page 310 Programming technological functions (cycles) 8.1 Drilling XYA plane You program in XYA if the Y axis should also move during machining. A value can be specified for each position. In addition to the possibilities of XA, the following is also possible, for example.
  • Page 311 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit LAB - (only for G Repeat jump label for position code) - (only for G Machining plane code) Axes Selection of the participating axes XY (1st and 2nd axis of the plane) •...
  • Page 312: Position Pattern Line (holes1), Grid Or Frame (cycle801)

    Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit (only for ShopMill) Axes: YB Y coordinate of the 1st position (abs) B coordinate (angle) of the 1st position (abs) Degrees ... Y8 Y coordinates of additional positions (abs or inc) ...
  • Page 313 Programming technological functions (cycles) 8.1 Drilling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Drilling" softkey. Press the "Positions" and "Line" softkeys. The "Position pattern" input window opens. Parameter Description Unit...
  • Page 314: Circle Position Pattern (holes2)

    Programming technological functions (cycles) 8.1 Drilling 8.1.12 Circle position pattern (HOLES2) Function You can program holes on a full circle or pitch circle with defined radius with the "Circle position pattern" cycle. The basic angle of rotation (α0) for the 1st position is relative to the X axis.
  • Page 315 Programming technological functions (cycles) 8.1 Drilling Parameter Description Unit For G code and ShopMill – axes XY (right angled) X coordinate of the reference point X (abs) Y coordinate of the reference point Y (abs) α0 Starting angle for first position. Degrees Positive angle: Full circle is rotated counter-clockwise.
  • Page 316: Displaying And Hiding Positions

    Programming technological 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 (only for axis selection XY) ●...
  • Page 317: Repeating Positions

    Programming technological 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 318 Programming technological functions (cycles) 8.1 Drilling After you have entered the label or the position pattern number, e.g. 1, press the "Accept" softkey. The position pattern you have selected is then approached again. Parameter Description Unit LAB (only for G Repeat jump label for position code) Position (only for...
  • Page 319: Milling

    Programming technological functions (cycles) 8.2 Milling Milling 8.2.1 Face milling (CYCLE61) 8.2.1.1 Function Function You can face mill any workpiece with the "Face milling" cycle. A rectangular surface is always machined. Workpieces with and without limits can be face-milled. Approach/retraction 1.
  • Page 320 Programming technological functions (cycles) 8.2 Milling Selecting the machining direction Toggle the machining direction in the "Direction" field until the symbol for the required machining direction appears. ● Same direction of machining ● Alternating direction of machining Selecting limits Press the respective softkey for the required limit. Left Bottom Right...
  • Page 321 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Machining The following machining operations can be selected: ∇ (roughing) • ∇∇∇ (finishing) • Direction Same direction of machining • • Alternating direction of machining • • The positions refer to the reference point: Corner point 1 in X Corner point 1 in Y Height of blank...
  • Page 322: Rectangular Pocket (pocket3)

    Programming technological functions (cycles) 8.2 Milling 8.2.2 Rectangular pocket (POCKET3) Function You can mill any rectangular pocket with the "rectangular pocket milling" function. The following machining variants are available: ● Mill rectangular pocket from solid material. ● Pre-drill rectangular pocket in the center first if, for example, the milling cutter does not cut in the center (program the drilling, rectangular pocket and position program blocks in succession).
  • Page 323 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Pocket" and "Rectangular pocket" softkeys. The "Rectangular pocket" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...
  • Page 324 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Machining Single position • position Mill rectangular pocket to the programmed position (X0, Y0, Z0). Position pattern • Position with MCALL The positions refer to the reference point: Reference point X – (single position only) Reference point Y –...
  • Page 325: Circular Pocket (pocket4)

    Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Depth infeed rate – (for perpendicular insertion only) mm/min (only for ShopMill) mm/tooth Maximum pitch of helix – (for helical insertion only) mm/rev Radius of helix – (for helical insertion only) The radius cannot be any larger than the cutter radius;...
  • Page 326 Programming technological functions (cycles) 8.2 Milling Approach/retraction for plane-by-plane solid machining In plane-by-plane machining of the circular pocket, the material is removed horizontally, one layer at a time. 1. The tool approaches the center point of the pocket at rapid traverse at the height of the retraction plane and adjusts to the safety clearance.
  • Page 327 Programming technological functions (cycles) 8.2 Milling Machining type: Helical When milling circular pockets, you can select the following machining types: ● Roughing During roughing, the circular pocket is machined downward with helical movements. A full circle is effected down to pocket depth to remove the residual material. The tool is retracted from the edge and base of the pocket in a quadrant and retracted with rapid traverse to a safety clearance.
  • Page 328 Programming technological functions (cycles) 8.2 Milling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Milling direction Cutting edge number Retraction plane Feedrate mm/min mm/tooth Safety clearance S / V Spindle speed or constant cutting rate m/min Feedrate Parameter Description Unit...
  • Page 329 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Depth finishing allowance – (only for ∇ and ∇∇∇) Insertion Various insertion modes can be selected – (only for plane-by-plane machining method and for ∇, ∇∇∇ or ∇∇∇ edge) Predrilled (only for G code) •...
  • Page 330: Rectangular Spigot (cycle76)

    Programming technological functions (cycles) 8.2 Milling 8.2.4 Rectangular spigot (CYCLE76) Function You can mill various rectangular spigots with the "Rectangular spigot" cycle. You can select from the following shapes with or without a corner radius: Depending on the dimensions of the rectangular spigot in the workpiece drawing, you can select a corresponding reference point for the rectangular spigot.
  • Page 331 Programming technological functions (cycles) 8.2 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 332 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Depth infeed rate (only for G code) Reference point The following different reference point positions can be selected: (center) • (bottom left) • (bottom right) • (top left) • (top right) •...
  • Page 333: Circular Spigot (cycle77)

    Programming technological functions (cycles) 8.2 Milling 8.2.5 Circular spigot (CYCLE77) 8.2.5.1 Function 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.
  • Page 334 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Multi-edge spigot" and "Circular spigot" softkeys. The "Circular Spigot" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...
  • Page 335: Multi-edge (cycle79)

    Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Maximum depth infeed - (only for ∇ and ∇∇∇) Plane finishing allowance for the length (L) and width (W) of the circular spigot. Smaller circular spigot dimensions are obtained by calling the cycle again and programming it with a lower finishing allowance.
  • Page 336 Programming technological functions (cycles) 8.2 Milling 4. The multi-edge is traversed again in a quadrant. This process is repeated until the depth of the multi-edge has been reached. 5. The tool retracts to the safety clearance at rapid traverse. Note A multi-edge with more than two edges is traversed helically;...
  • Page 337 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Machining Single position • position A polygon is milled at the programmed position (X0, Y0, Z0). Position pattern • Several polygons are milled at the programmed position pattern (e.g. pitch circle, grid, line).
  • Page 338: Longitudinal Groove (slot1)

    Programming technological functions (cycles) 8.2 Milling 8.2.7 Longitudinal groove (SLOT1) Function You can mill any longitudinal groove with the "longitudinal groove" milling function. The following machining methods are available: ● Mill longitudinal groove from solid material. ● Pre-drill longitudinal groove in the center first if, for example, the milling cutter does not cut in the center (e.g.
  • Page 339 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Groove" and "Longitudinal groove" softkeys. The "Longitudinal Groove (SLOT1)" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...
  • Page 340 Programming technological functions (cycles) 8.2 Milling Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇∇∇ edge (edge finishing) • • Chamfering Machining Single position • position A slot is milled at the programmed position (X0, Y0, Z0). Position pattern • Several slots are milled at the programmed position pattern (e.g. pitch circle, grid, line).
  • Page 341: Circumferential Groove (slot2)

    Programming technological functions (cycles) 8.2 Milling Depth infeed rate – (for perpendicular insertion only) mm/min mm/tooth (only for ShopMill) Maximum pitch of helix – (for helical insertion only) mm/rev (only for G code) Radius of helix – (for helical insertion only) (only for G code) The radius cannot be any larger than the cutter radius;...
  • Page 342 Programming technological functions (cycles) 8.2 Milling Approach/retraction 1. The tool approaches the center point of the semicircle at the end of the slot at rapid traverse at the height of the retraction plane and adjusts to the safety clearance. 2. Then, the tool enters the workpiece at machining infeed (taking into consideration the maximum infeed in the Z direction and the finishing allowance).
  • Page 343 Programming technological functions (cycles) 8.2 Milling Parameters, G code program Parameters, ShopMill program Machining plane Tool name Milling direction Cutting edge number Retraction plane Feedrate mm/min mm/tooth Safety clearance S / V Spindle speed or constant cutting rate m/min Feedrate Parameter Description Unit...
  • Page 344: Open Groove (cycle899)

    Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Chamfer width for chamfering (inc) - (for chamfering only), Insertion depth of tool tip (abs or inc) - (for chamfering only), Plane finishing allowance - (only for ∇, ∇∇∇ and ∇∇∇ edge) Positioning Positioning motion between the grooves: Straight line:...
  • Page 345 Programming technological functions (cycles) 8.2 Milling Plunge cutting Plunge cutting is the preferred method of machining slots for "unstable" machines and workpiece geometries. This method generally only exerts forces along the tool axis, i.e. perpendicular to the surface of the pocket/slot to be machined (with the XY plane in Z direction).
  • Page 346 Programming technological functions (cycles) 8.2 Milling Vortex milling: Climbing or conventional Vortex milling: Climbing - conventional milling milling Supplementary conditions for vortex milling ● Roughing 1/2 slot width W – finishing allowance UXY ≤ milling cutter diameter ● Slot width minimum 1.15 x milling cutter diameter + finishing allowance maximum, 2 x milling cutter diameter + 2 x finishing allowance ●...
  • Page 347 Programming technological functions (cycles) 8.2 Milling Machining type, roughing plunge cutting Roughing of the slot takes place sequentially along the length of the groove, with the milling cutter performing vertical insertions at the machining feedrate. The milling cutter is then retracted and repositioned at the next insertion point.
  • Page 348 Programming technological functions (cycles) 8.2 Milling ● Retraction Retraction is performed perpendicular to the wrapped surface. ● Safety clearance Traverse through the safety clearance beyond the end of the workpiece to prevent rounding of the slot walls at the ends. Please note that the milling cutter’s cutting edge cannot be checked for the maximum radial infeed.
  • Page 349 Programming technological functions (cycles) 8.2 Milling Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Milling" softkey. Press the "Slot" and "Open slot" softkeys. The "Open slot" input window opens. Parameters, G code program Parameters, ShopMill program Machining plane...
  • Page 350 Programming technological functions (cycles) 8.2 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 351: Long Hole (longhole) - Only For G Code Programs

    Programming technological functions (cycles) 8.2 Milling 8.2.10 Long hole (LONGHOLE) - only for G code programs 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 352 Programming technological functions (cycles) 8.2 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 353: Thread Milling (cycle70)

    Programming technological functions (cycles) 8.2 Milling 8.2.11 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 354 Programming technological functions (cycles) 8.2 Milling Approach/retraction when milling external threads 1. Positioning on retraction plane with rapid traverse. 2. Approach of starting point of the approach circle in the current plane with rapid traverse. 3. Infeed to a starting point in the tool axis calculated internally in the controller with rapid traverse.
  • Page 355 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • Machining direction: Z0 → Z1 • Machining from top to bottom Z1 → Z0 • Machining from bottom to top Direction of rotation of the thread: Right-hand thread •...
  • Page 356 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Selection – (not Selection of table value: e.g. for table "without") M3; M10; etc. (ISO metric) • W3/4"; etc. (Whitworth BSW) • G3/4"; etc. (Whitworth BSP) • N1" - 8 UNC; etc. (UNC) •...
  • Page 357: Engraving (cycle60)

    Programming technological functions (cycles) 8.2 Milling 8.2.12 Engraving (CYCLE60) Function The "Engraving" function is used to engrave a text on a workpiece along a line or arc. You can enter the text directly in the text field as "fixed text" or assign it via a variable as "variable text".
  • Page 358 Programming technological functions (cycles) 8.2 Milling Press the "Lowercase" softkey to enter lowercase letters. Press it again to enter uppercase letters. Press the "Variable" and "Date" softkeys if you want to engrave the current date. The data is inserted in the European date format (<DD>.<MM>.<YYYY>).
  • Page 359 Programming technological functions (cycles) 8.2 Milling • Press the "Variable" and "Number 123.456" softkeys if you want to engrave a any number in a certain format. The format text <#.###,_VAR_NUM> is inserted and you return to the engraving field with the softkey bar. •...
  • Page 360 Programming technological functions (cycles) 8.2 Milling Press the "Variable" and "Variable text" softkeys if you want to take the text to be engraved (up to 200 characters) from a variable. The format text <Text, _VAR_TEXT> is inserted and you return to the engraving field with the softkey bar.
  • Page 361 Programming technological functions (cycles) 8.2 Milling Parameters, G code program Parameters, ShopMill 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 Depth infeed rate (only for G code)
  • Page 362 Programming technological functions (cycles) 8.2 Milling Parameter Description Unit Reference point Y (abs) (for linear alignment only) Reference point Z (abs) Engraving depth (abs) or depth referred to Z0 (inc) Character height DX1 or α2 Distance between characters or angle of opening – (for curved alignment only) mm or degrees DX1 or DX2...
  • Page 363: Contour Milling

    Programming technological functions (cycles) 8.3 Contour milling Contour milling 8.3.1 General Function You can mill simple or complex contours with the "Contour milling" cycle. You can define open contours or closed contours (pockets, islands, spigots). A contour comprises separate contour elements, whereby at least two and up to 250 elements result in a defined contour.
  • Page 364 Programming technological functions (cycles) 8.3 Contour milling Contour element Symbol Meaning Straight line in any direction Straight line with any gradient Arc right Circle Arc left Circle Pole Straight diagonal or circle in polar coordinates Finish contour End of contour definition The different colors of the symbols indicate their status: Foreground Background...
  • Page 365: Creating A New Contour

    Programming technological functions (cycles) 8.3 Contour milling 8.3.3 Creating a new contour Function For each contour that you want to mill, you must create a new contour. The contours are stored at the end of the program. Note When programming in the G code, it must be ensured that the contours are located after the end of program identifier! The first step in creating a contour is to specify a starting point.
  • Page 366 Programming technological functions (cycles) 8.3 Contour milling Cartesian starting point Enter the starting point for the contour. Enter any additional commands in G code format, as required. Press the "Accept" softkey. Enter the individual contour elements. Polar starting point Press the "Pole" softkey. Enter the pole position in Cartesian coordinates.
  • Page 367: Creating Contour Elements

    Programming technological functions (cycles) 8.3 Contour milling 8.3.4 Creating contour elements After you have created a new contour and specified the starting point, you can define the individual elements that make up the contour. The following contour elements are available for the definition of a contour: ●...
  • Page 368 Programming technological functions (cycles) 8.3 Contour milling The contour end is an exception. Although there is no intersection to another element, you can still define a radius or a chamfer as a transition element for the blank. Additional functions The following additional functions are available for programming a contour: ●...
  • Page 369 Programming technological functions (cycles) 8.3 Contour milling The "Straight (e.g. XY)" input window opens. - OR The "Circle" input window opens. - OR The "Pole Input" input window opens. Enter all the data available from the workpiece drawing in the input screen (e.g.
  • Page 370 Programming technological functions (cycles) 8.3 Contour milling Contour element "straight line, e.g. Y" Parameter Description Unit End point Y (abs or inc) α1 Starting angle to X axis Degrees Transition to next Type of transition element Radius • Chamfer • Radius Transition to following element - radius Chamfer...
  • Page 371 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit e.g. J Circle center point J (abs or inc) α1 Starting angle to X axis Degrees α2 Angle to the preceding element Degrees β1 End angle to Z axis Degrees β2 Angle of opening Degrees...
  • Page 372: Changing The Contour

    Programming technological functions (cycles) 8.3 Contour milling 8.3.5 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 373: Contour Call (cycle62) - Only For G Code Program

    Programming technological functions (cycles) 8.3 Contour milling 8.3.6 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 374: Path Milling (cycle72)

    Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Subprogram PRG: Subprogram Labels in the PRG: Subprogram • subprogram LAB1: Label 1 • LAB2: Label 2 • 8.3.7 Path milling (CYCLE72) Function You can mill along any programmed contour with the "Path milling" cycle. The function operates with cutter radius compensation.
  • Page 375 Programming technological functions (cycles) 8.3 Contour milling 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. You can also select various modes and strategies of approach and retraction from the contour.
  • Page 376 Programming technological functions (cycles) 8.3 Contour milling Parameters, G code program Parameters, ShopMill 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...
  • Page 377 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Approach Planar approach mode: Straight line: • Slope in space Quadrant: • Part of a spiral (only with path milling left and right of the contour) Semi-circle: • Part of a spiral (only with path milling left and right of the contour) Perpendicular: •...
  • Page 378: Contour Pocket/contour Spigot (cycle63/64)

    Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Depth infeed rate – (only for axis-by-axis approach strategy) mm/min (only for ShopMill) mm/tooth FZ - (only for G Depth infeed rate – (only for axis-by-axis approach strategy) code) Chamfer width for chamfering - (only for chamfering machining) Insertion depth of tool tip (abs or inc) - (for machining only) * Unit of feedrate as programmed before the cycle call Note...
  • Page 379 Programming technological functions (cycles) 8.3 Contour milling Machining You program the machining of contour pockets with islands/blank contour with spigots e.g. as follows: 1. Enter the pocket contour/blank contour 2. Enter the island/spigot contour 3. Call the contour for pocket contour/blank contour or island/spigot contour (only for G code program) 4.
  • Page 380: Predrilling Contour Pocket (cycle64)

    Programming technological functions (cycles) 8.3 Contour milling 8.3.9 Predrilling contour pocket (CYCLE64) Function In addition to predrilling, the cycle can be used for centering. The centering or predrilling program generated by the cycle is called for this purpose. The number and positions of the required predrilled holes depends on the specific conditions, e.g.
  • Page 381 Programming technological functions (cycles) 8.3 Contour milling Procedure when centering The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Cont. mill.", "Predrilling", and "Centering" softkeys. The "Centering" input window opens. Parameters, G code program Parameters, ShopMill program Name of the program to be generated...
  • Page 382 Programming technological functions (cycles) 8.3 Contour milling Predrilling procedure The part program or ShopMill program to be processed has been created and you are in the editor. Press the "Cont. mill.", "Predrilling", and "Predrilling" softkeys. The "Predrilling" input window opens. Parameters, G code program Parameters, ShopMill program Name of the program to be generated...
  • Page 383: Milling Contour Pocket (cycle63)

    Programming technological functions (cycles) 8.3 Contour milling 8.3.10 Milling contour pocket (CYCLE63) Function Before you can machine a pocket with islands, you must enter the contour of the pocket and islands. The first contour you specify is interpreted as the pocket contour and all the others as islands.
  • Page 384 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Machining The following machining operations can be selected: ∇ (roughing) • ∇∇∇ base (base finishing) • ∇∇∇ edge (edge finishing) • • Chamfering Reference point in the tool axis Z Pocket depth (abs) or depth relative to Z0 (inc) - (only for ∇, ∇∇∇...
  • Page 385: Residual Material Contour Pocket (cycle63)

    Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Radius of helix – (for helical insertion only) The radius cannot be any larger than the cutter radius; otherwise, material will remain. Maximum insertion angle – (for insertion with oscillation only) Degrees Lift mode Lift mode before new infeed - (only for ∇, ∇∇∇...
  • Page 386 Programming technological functions (cycles) 8.3 Contour milling 6. Remove residual material 7. Contour pocket 2 8. Remove residual material Software option For solid machining residual material, you require the option "residual material detection and machining". Procedure The part program or ShopMill program to be processed has been created and you are in the editor.
  • Page 387: Milling Contour Spigot (cycle63)

    Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Maximum plane infeed • Maximum plane infeed as a percentage of the milling cutter diameter • Maximum depth infeed Finishing allowance, plane Finishing allowance, depth Lift mode Lift mode before new infeed If the machining operation requires several points of insertion, the retraction height to which the tool is retracted, is selected as follows: To retraction plane...
  • Page 388 Programming technological functions (cycles) 8.3 Contour milling 5. The spigot is again approached in a quadrant and machine in parallel with the contours from outside in. 6. Steps 4 and 5 are repeated until the programmed spigot depth is reached. 7.
  • Page 389: Residual Material Contour Spigot (cycle63)

    Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Maximum depth infeed – (only for ∇ or ∇∇∇ edge) Plane finishing allowance – (only for ∇, ∇∇∇ base or ∇∇∇ edge) Depth finishing allowance – (only for ∇ or ∇∇∇ base) Lift mode Lift mode before new infeed If the machining operation requires several points of insertion, the retraction height to...
  • Page 390 Programming technological functions (cycles) 8.3 Contour milling 11. Contour spigot 2 12. Clear residual material spigot 2 Software option For solid machining residual material, you require the option "residual material detection and machining". Procedure The part program or ShopMill program to be processed has been created and you are in the editor.
  • Page 391 Programming technological functions (cycles) 8.3 Contour milling Parameter Description Unit Maximum depth infeed Lift mode Lift mode before new infeed If the machining operation requires several points of insertion, the retraction height to which the tool is retracted, is selected as follows: To retraction plane •...
  • Page 392: Turning - Only For G Code Programs

    Programming technological functions (cycles) 8.4 Turning - only for G code programs Turning - only for G code programs 8.4.1 General In all turning cycles apart from contour turning (CYCLE95), in the combined roughing and finishing mode, when finishing it is possible to reduce the feedrate as a percentage. Machine manufacturer Please also refer to the machine manufacturer's specifications.
  • Page 393 Programming technological functions (cycles) 8.4 Turning - only for G code programs Machine manufacturer Please also refer to the machine manufacturer's instructions. If the tool does not round the corner at the end of the cut, it is raised by the safety distance or a value specified in the machine data at rapid traverse.
  • Page 394 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • Position Stock removal position: Machining Stock removal direction (longitudinal or transverse) in the coordinate system direction Parallel to the Z axis (longitudinal) Parallel to the X axis (transverse) External Internal...
  • Page 395: Groove (cycle930)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit α1 Angle of the 1st edge Degrees α2 Angle of the 2nd edge Degrees * Unit of feedrate as programmed before the cycle call 8.4.3 Groove (CYCLE930) Function You can use the "Groove"...
  • Page 396 Programming technological functions (cycles) 8.4 Turning - only for G code programs Approach/retraction during finishing 1. The tool first moves to the starting point calculated internally in the cycle at rapid traverse. 2. The tool moves at the machining feedrate down one flank and then along the bottom to the center.
  • Page 397 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇ + ∇∇∇ (roughing and finishing) • Position Groove position/reference point: Reference point in X ∅ Reference point in Z Groove width Groove depth ∅...
  • Page 398: Undercut Form E And F (cycle940)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs 8.4.4 Undercut form E and F (CYCLE940) Function You can use the "Undercut form E" or "Undercut form F" cycle to turn form E or F undercuts in accordance with DIN 509. Approach/retraction 1.
  • Page 399 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters, G code program (undercut, form E) Machining plane Safety clearance Feedrate Parameter Description Unit Position Form E machining position: Undercut size according to DIN table: E.g.: E1.0 x 0.4 (undercut form E) Reference point X ∅...
  • Page 400: Thread Undercut (cycle940)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Position Form F machining position: Undercut size according to DIN table: e.g.: F0.6 x 0.3 (undercut form F) Reference point X ∅ Reference point Z Allowance in X ∅...
  • Page 401 Programming technological functions (cycles) 8.4 Turning - only for G code programs Procedure The part program to be executed has been created and you are in the editor. Press the "Turning" softkey. Press the "Undercut" softkey. Press the "Thread undercut DIN" softkey. The "Thread Undercut (DIN 76)"...
  • Page 402 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Reference point Z 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 403: Thread Turning (cycle99)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit U or UX Finishing allowance in X or finishing allowance in X and Z – (only for ∇ and ∇ + ∇∇∇) Finishing allowance in Z – (only for UZ, ∇ and ∇ + ∇∇∇) * Unit of feedrate as programmed before the cycle call 8.4.6 Thread turning (CYCLE99)
  • Page 404 Programming technological functions (cycles) 8.4 Turning - only for G code programs 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 405 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters, G code program (thread, longitudinal) Machining plane Parameter Description Unit Table Thread table selection: Without • ISO metric • Whitworth BSW • Whitworth BSP • • Selection - (not for Data, table value, e.g.
  • Page 406 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit 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 407 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Number of thread turns The thread turns are distributed evenly across the periphery of the turned part; the 1st thread turn is always located at 0°. Thread changeover depth (inc) First machine all thread turns sequentially to thread changeover depth DA, then machine all thread turns sequentially to depth 2 ·...
  • Page 408 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇ + ∇∇∇ (roughing and finishing) • Infeed (only for ∇ and ∇ Linear: • + ∇∇∇) Infeed with constant cutting depth Degressive: •...
  • Page 409 Programming technological functions (cycles) 8.4 Turning - only for G code programs 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 ∇...
  • Page 410 Programming technological functions (cycles) 8.4 Turning - only for G code programs 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 411 Programming technological functions (cycles) 8.4 Turning - only for G code programs 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 412: Thread Chain (cycle98)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs 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.
  • Page 413 Programming technological functions (cycles) 8.4 Turning - only for G code programs Interruption of thread cutting You have the option to interrupt thread cutting (for example if the cutting tool is broken). 1. Press the <CYCLE STOP> key. The tool is retracted from the thread and the spindle is stopped. 2.
  • Page 414 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters, G code program Machining plane Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • ∇ + ∇∇∇ (roughing and finishing) • Infeed (only for ∇ and ∇ Linear: •...
  • Page 415 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameter Description Unit End point X ∅ (abs) or • End point 3 in relation to X2 (inc) or • Degrees Thread taper 3 • End point Z ∅ (abs) or •...
  • Page 416: Cut-off (cycle92)

    Programming technological functions (cycles) 8.4 Turning - only for G code programs 8.4.8 Cut-off (CYCLE92) Function The "Cut-off" cycle is used when you want to cut off dynamically balanced parts (e.g. screws, bolts, or pipes). You can program a chamfer or rounding on the edge of the machined part. You can machine at a constant cutting rate V or speed S up to a depth X1, from which point the workpiece is machined at a constant speed.
  • Page 417 Programming technological functions (cycles) 8.4 Turning - only for G code programs Parameters, G code program Machining plane Safety clearance Feedrate Parameter Description Unit Direction of spindle rotation Spindle speed rev/min Constant cutting rate mm/min Maximum speed limit - (only for constant cutting rate V) rev/min Reference point in X ∅...
  • Page 418: Contour Turning - Only For G Code Programs

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Contour turning - only for G code programs 8.5.1 General information Function You can machine simple or complex contours with the "Contour turning" cycle. A contour comprises separate contour elements, whereby at least two and up to 250 elements result in a defined contour.
  • Page 419: Representation Of The Contour

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 4. Stock removal along the contour (roughing) The contour is machined longitudinally, transversely or parallel to the contour. 5. Remove residual material (roughing) For G code programming, when removing stock, it must first be decided whether to rough (machine) with residual material detection or not.
  • Page 420 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Foreground Background Meaning Black Blue Cursor on new element Black Orange Cursor on current element Black White Normal element White Element not currently evaluated (element will only be evaluated when it is selected with the cursor) Graphical display...
  • Page 421 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Press the "Contour" and "New contour" softkeys. The "New Contour" input window opens. Enter a name for the new contour. The contour name must be unique. Press the "Accept" softkey. The input window for the starting point of the contour appears.
  • Page 422 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Additional You can enter additional commands in the form of G code for each contour element. commands You can enter the additional commands (max. 40 characters) in the extended parameter screens ("All parameters"...
  • Page 423 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Contour transition elements As transition element between two contour elements, you can select a radius or a chamfer or, in the case of linear contour elements, an undercut. The transition element is always attached at the end of a contour element.
  • Page 424 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs ● Feedrate, transition element If you have chosen a chamfer or a radius as the transition element, enter a reduced feedrate in the "FRC" parameter. The slower machining rate means that the transition element is machined more accurately.
  • Page 425 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Press the "Accept" softkey. The contour element is added to the contour. When entering data for a contour element, you can program the transition to the preceding element as a tangent. Press the "Tangent to prec.
  • Page 426 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Contour element "Straight line e.g. X" Parameters Description Unit End point X ∅ (abs) or end point X (inc) α1 Starting angle to Z axis Degrees α2 Angle to the preceding element Degrees Transition to next...
  • Page 427 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters Description Unit Grinding allowance Grinding allowance to right of contour • Grinding allowance to left of contour • Additional commands Additional G code commands Contour element "Circle" Parameters Description Unit...
  • Page 428 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.5 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 to be executed.
  • Page 429: Contour Call (cycle62)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.6 Contour call (CYCLE62) 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 430: Stock Removal (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Subprogram PRG: Subprogram Labels in the PRG: Subprogram • subprogram LAB1: Label 1 • LAB2: Label 2 • 8.5.7 Stock removal (CYCLE952) Function For stock removal, the cycle takes into account a blank that can comprise a cylinder, an allowance on the finished-part contour or any blank contour.
  • Page 431 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 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 432 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 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 433 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters, G code program Name of the program to be generated Machining plane Retraction plane – (only for machining direction, longitudinal, inner) Safety clearance Feedrate Residual With subsequent residual material removal material •...
  • Page 434 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Do not round contour at end of cut. Always round contour at end of cut. Uniform cut segmentation Round cut segmentation at the edge Constant cutting depth Alternating cutting depth - (only with align cut segmentation to edge) Maximum depth infeed - (only for position parallel to the contour and UX)
  • Page 435 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 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 436: Stock Removal Residual (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.8 Stock removal residual (CYCLE952) Function Using the "Stock removal residual" function, you can remove material that has remained for stock removal along the contour. During stock removal along the contour, the cycle automatically detects any residual material and generates an updated blank contour.
  • Page 437 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Machining ∇ (roughing) • ∇∇∇ (finishing) • Machining Face From inside to outside • • direction Longitudinal From outside to inside • • Parallel to the contour From end face to rear side •...
  • Page 438: Grooving (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Relief cuts Machine relief cuts • • Insertion feedrate, relief cuts * Unit of feedrate as programmed before the cycle call 8.5.9 Grooving (CYCLE952) Function The "Grooving"...
  • Page 439 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Machining type You can freely select the machining type (roughing or finishing). For more detailed information, please refer to section "Stock removal". Procedure The part program to be executed has been created and you are in the editor.
  • Page 440 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Maximum depth infeed - (only for ∇) 1. Grooving limit tool (abs) – (only for face machining direction) 2. Grooving limit tool (abs) – (only for face machining direction) UX or U Finishing allowance in X or finishing allowance in X and Z –...
  • Page 441: Grooving Residual Material (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit with limited machining area only, yes: 1. Limit XA ∅ 2. Limit XB ∅ (abs) or 2nd limit referred to XA (inc) 1. Limit ZA 2.
  • Page 442 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameters, G code program Name of the program to be generated Machining plane Retraction plane – (only for longitudinal machining direction) Safety clearance Feedrate Name of the updated blank contour for residual material machining (without the attached character "_C"...
  • Page 443: Plunge Turning (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit 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 444 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Feedrate interruption To prevent the occurrence of excessively long chips during machining, you can program a feedrate interruption. Machining type You can freely select the machining type (roughing or finishing). For more detailed information, please refer to section "Stock removal".
  • Page 445 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Feedrate in X direction Feedrate in Z direction Machining ∇ (roughing) • ∇∇∇ (finishing) • Machining Face • direction Longitudinal • Position front • back •...
  • Page 446 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit - (only for ∇ machining) - (only for unmachined part description, cylinder and allowance) • For unmachined part description, cylinder – Version, absolute: Cylinder dimension (abs) –...
  • Page 447: Plunge Turning Residual Material (cycle952)

    Programming technological functions (cycles) 8.5 Contour turning - only for G code programs 8.5.12 Plunge turning residual material (CYCLE952) Function The "Plunge turning residual material" function is used when you want to machine the material that remained after plunge turning. For a G code program, select the function in the screen.
  • Page 448 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit Feedrate in X direction Feedrate in Z direction Machining ∇ (roughing) • ∇∇∇ (finishing) • Machining Face • direction Longitudinal • Position front • back •...
  • Page 449 Programming technological functions (cycles) 8.5 Contour turning - only for G code programs Parameter Description Unit with limited machining area only, yes: 1. Limit XA ∅ 2. Limit XB ∅ (abs) or 2nd limit referred to XA (inc) 1. Limit ZA 2.
  • Page 450: Further Cycles And Functions

    Programming technological functions (cycles) 8.6 Further cycles and functions Further cycles and functions 8.6.1 Swivel plane/tool (CYCLE800) The CYCLE800 swivel cycle is used to swivel to any surface in order to either machine or measure it. In this cycle, the active workpiece zeros and the work offsets are converted to the inclined surface taking into account the kinematic chain of the machine by calling the appropriate NC functions - and rotary axes (optionally) are positioned.
  • Page 451 Programming technological functions (cycles) 8.6 Further cycles and functions For machines where swivel is set-up, each main program with a swivel should start in the basic setting of the machine. The definition of the blank (WORKPIECE) always refers to the currently effective work offset. For programs that use "swivel", a swivel to zero must be made before the blank is defined.
  • Page 452 Programming technological functions (cycles) 8.6 Further cycles and functions Aligning tools In contrast to "Swivel plane", no rotation is operative in the active frame chain (WCS) in the case of "Swivel tool" or "Align milling tool". Only the offsets calculated by the NC and the corresponding tool orientation are effective.
  • Page 453 Programming technological functions (cycles) 8.6 Further cycles and functions Swivel plane (only for G code programming) ● New Previous swivel frames and programmed frames are deleted and a new swivel frame is formed according to the values specified in the input screen. Every main program must begin with a swivel cycle with the new swivel plane, in order to ensure that a swivel frame from another program is not active.
  • Page 454 Programming technological functions (cycles) 8.6 Further cycles and functions When projection angles around XZ and ZX are programmed, the new Z-axis of the swiveled coordinate system lies in the old Y-Z plane. When projection angles around YZ and ZY are programmed, the new Y-axis of the swiveled coordinate system lies in the old X-Y plane.
  • Page 455 Programming technological functions (cycles) 8.6 Further cycles and functions ● Swivel table with rotary axis 2 (C) rotates around machine axis Z. ● Angle traversing range of rotary axis 2 (C) from 0 to 360 degrees (modulo 360). ● Machine manufacturer has set the direction reference to rotary axis 1 (B) when he commissioned the swivel function.
  • Page 456 Programming technological functions (cycles) 8.6 Further cycles and functions Procedure The part program or ShopMill program to be processed has been created and you are in the editor. Select the "Miscellaneous" softkey. Press the "Swivel plane" softkey. The "Swivel plane" input window opens. Press the "Basic setting"...
  • Page 457 Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit Swivel mode Axis by axis: Rotate coordinate system axis-by-axis • Solid angle: Swivel via solid angle • Proj. angle: Swiveling via projection angle • Direct: Directly position rotary axes •...
  • Page 458 Programming technological functions (cycles) 8.6 Further cycles and functions Example (machine with swivel table) N1 G54 N2 T="MILL_10mm" N3 M6 N4 CYCLE800(1,"",0,57,0,40,0,-45,0,0,0,0,0,-1) ;Swivel cycle N5 CYCLE71(50,24,2,0,0,0,80,60,0,4,10,5,0,2000,31,5) ;Face milling N6 TCARR=0 ;Swivel data set ;deselection N7 PAROTOF ;Deactivate ;rotary table reference N8 TOROTOF ;Deactivate ;tool reference...
  • Page 459: Swiveling Tool (cycle800)

    Programming technological functions (cycles) 8.6 Further cycles and functions 8.6.2 Swiveling tool (CYCLE800) 8.6.2.1 Swiveling tool/preloading milling tools - only for G code program (CYCLE800) After "Swivel plane", the tool orientation is always perpendicular on the machining plane. When milling with radial cutters, it can make technological sense to set the tool at an angle to the normal surface vector.
  • Page 460: Swiveling Aligning Tool - Only For G Code Program (cycle800)

    Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit Name of the swivel data set Retraction No: No retraction before swiveling • Z: Retraction in the direction of machine axis Z • Z, X, Y: Move machining axis to retraction position before swiveling •...
  • Page 461 Programming technological functions (cycles) 8.6 Further cycles and functions Machine manufacturer Please refer to the machine manufacturer's specifications. Procedure The part program to be executed has been created and you are in the editor. Press the "Various" softkey. Press the "Swivel tool" and "Align milling tool" softkeys. The "Align milling tool"...
  • Page 462: High-speed Settings (cycle832)

    Programming technological 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 463 - that are declared in the machine data for the reset state. References For additional information, please refer to the following documentation: Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl Machine manufacturer Please refer to the machine manufacturer's specifications.
  • Page 464 Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Unit Machining ∇ (roughing) • Plain text: _ROUGH ∇∇ (semi-finishing) • Plain text: _SEMIFIN ∇∇∇ (finishing) • Plain text entry: _FINISH Deselection • Plain text entry: _OFF For "Multi-axis programming yes", the following plain texts are generated in accordance with the machining type: ∇...
  • Page 465: Subroutines

    Programming technological functions (cycles) 8.6 Further cycles and functions 8.6.4 Subroutines If you require the same machining steps when programming different workpieces, you can define these machining steps in a separate subprogram. You can then call this subprogram in any programs. Identical machining steps therefore only have to be programmed once.
  • Page 466 Programming technological functions (cycles) 8.6 Further cycles and functions Parameter Description Path/workpiece Path of the subprogram if the desired subprogram is not stored in the same directory as the main program. Program name Name of the subprogram that is to be inserted. Programming example N10 T1 D1 ;Load tool...
  • Page 467: Additional Cycles And Functions In Shopmill

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Additional cycles and functions in ShopMill 8.7.1 Transformations To make programming easier, you can transform the coordinate system. Use this possibility, for example, to rotate the coordinate system. Coordinate transformations only apply in the actual program. You can define shift, rotation, scaling or mirroring.
  • Page 468: Translation

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill - OR - Press the "Mirroring" softkey. The "Mirroring" input window opens. 8.7.2 Translation For each axis, you can program an offset of the zero point. New offset Additive offset Parameter Description Unit...
  • Page 469: Rotation

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.3 Rotation You can rotate every axis through a specific angle. A positive angle corresponds to counterclockwise rotation. New rotation Additive rotation Parameter Description Unit Rotation • New rotation Additive •...
  • Page 470: Scaling

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.4 Scaling You can specify a scale factor for the active machining plane as well as for the tool axis. The programmed coordinates are then multiplied by this factor. New scaling Additive scaling Parameter...
  • Page 471: Mirroring

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.5 Mirroring Furthermore, you can mirror all axes. Enter the axis to be mirrored in each case. Note Travel direction of the milling cutter Note that with mirroring, the travel direction of the cutting tool (conventional/climbing) is also mirrored.
  • Page 472: Cylinder Surface Transformation

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.6 Cylinder surface transformation You require the cylinder surface transformation to machine ● Longitudinal grooves on cylindrical bodies, ● Transverse grooves on cylindrical objects ● grooves with any path on cylindrical bodies. The path of the grooves is programmed with reference to the unwrapped, level surface of the cylinder.
  • Page 473 Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Slot side compensation Cylinder surface transformation is available in the following versions: ● Slot side compensation off ● Slot side compensation on (path milling only) Longitudinal slot with parallel limit, slot side compensation on Slot side compensation off When slot side compensation is deactivated, any type of slot with parallel sides can be...
  • Page 474: General Programming

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.6.1 General programming The basic programming procedure is as follows: 1. Select work offset for cylinder surface transformation (e.g. offset the zero point on the center point of the cylinder end face) 2.
  • Page 475: Straight Or Circular Machining

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameters Description Unit Slot side compensation • on - only for "Cylinder surface transformation yes" Activates slot side compensation. off - only for "Cylinder surface transformation yes" • Deactivates slot side compensation. The selection for "slot side compensation"...
  • Page 476 Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Before you can program a straight line or circle, you have to select the tool, spindle speed and machining plane. If you program a sequence of different straight or circular path movements, the settings for the tool and spindle speed remain active until you change these again.
  • Page 477: Programming A Straight Line

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameter Description Unit Tool name Cutting edge number S / V Spindle speed or rev/min Constant cutting rate m/min Allowance, tool radius 8.7.8 Programming a straight line The tool moves at the programmed feedrate or with rapid traverse from its actual position to the programmed end position.
  • Page 478: Programming A Circle With Known Center Point

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameter Description Unit Target position X (abs) or target position X referred to the last programmed position (inc) Target position Y (abs) or target position Y referred to the last programmed position (inc) Target position Z (abs) or target position Z referred to the last programmed position (inc)
  • Page 479: Programming A Circle With Known Radius

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameter Description Unit Direction of rotation The tool travels in the programmed direction from the circle starting point to its end point. You can program this direction as clockwise or counter-clockwise. Clockwise direction of rotation Counter-clockwise direction of rotation Target position X (abs) or target position X referred to the last programmed...
  • Page 480: Helix

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameter Description Unit Direction of rotation The tool travels in the programmed direction from the circle starting point to its end point. You can program this direction as clockwise or counter-clockwise. Clockwise direction of rotation Counter-clockwise direction of rotation Target position X (abs) or target position X referred to the last programmed...
  • Page 481: Polar Coordinates

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill Parameter Description Unit Center point of the helix in the Y direction (abs or inc) Helix pitch The pitch is programmed in mm per revolution. mm/rev Target position of the helical end point (abs or inc) Machining feedrate mm/rev mm/min...
  • Page 482: Straight Polar

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.13 Straight polar A straight line in the polar coordinate system is defined by a radius (L) and an angle (α). The angle refers to the X axis. The tool moves from its actual position along a straight line to the programmed end point at the machining feedrate or in rapid traverse.
  • Page 483: Circle Polar

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.14 Circle polar A circle in the polar coordinate system is defined by an angle (α). The angle refers to the X axis. The tool moves from its actual position on a circular path to the programmed end point (angle) at the machining feedrate.
  • Page 484: Obstacle

    Programming technological functions (cycles) 8.7 Additional cycles and functions in ShopMill 8.7.15 Obstacle Function If there is an obstacle between 2 position patterns, it can be crossed. The height of the obstacle can be programmed absolutely or incrementally. If all positions in the 1st pattern have been machined, the tool axis travels with rapid traverse to a height corresponding to the obstacle height + safety clearance.
  • Page 485: Multi-channel View

    Multi-channel view Multi-channel view The multi-channel view allows you to simultaneously view several channels in the following operating areas: ● "Machine" operating area ● "Program" operating area See also Editor settings (Page 175) 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 486 Multi-channel view 9.2 Multi-channel view in the "Machine" operating area Multi-channel view 2 - 4 channels are simultaneously displayed in channel columns on the user interface. ● Two windows are displayed one above the other for each channel. ● The actual value display is always in the upper window. ●...
  • Page 487 Multi-channel view 9.2 Multi-channel view in the "Machine" operating area Editing a program in the block display You can perform simple editing operations as usual with the <INSERT> key in the actual block display. If there is not sufficient space, you switch over into the single-channel view. Running-in a program You select individual channels to run-in the program at the machine.
  • Page 488 Multi-channel view 9.2 Multi-channel view in the "Machine" operating area In the window "Settings for Multi-Channel View" in the selection box "View", select the required entry (e.g. "2 channels") and define the channels as well as the sequence in which they are to be displayed.
  • Page 489: Multi-channel View For Large Operator Panels

    Multi-channel view 9.3 Multi-channel view for large operator panels 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 490: Setting The Multi-channel View

    Multi-channel view 9.4 Setting the multi-channel view 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 491 Multi-channel view 9.4 Setting the multi-channel view 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 492 Multi-channel view 9.4 Setting the multi-channel view Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 493: User Variables

    User variables 10.1 Overview The defined user data may be displayed in lists. The following variables can be defined: ● Data parameters (R parameters) ● Global user data (GUD) is valid in all programs ● Local user data (LUD) is valid in one program ●...
  • Page 494: R Parameters

    User variables 10.2 R parameters 10.2 R parameters R parameters (arithmetic parameters) are channel-specific variables that you can use within a G code program. G code programs can read and write R parameters. These values are retained after the 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 495: Displaying Global User Data (gud)

    User variables 10.3 Displaying global user data (GUD) 10.3 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 496: Displaying Channel Guds

    User variables 10.4 Displaying channel GUDs - OR - 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 497: Displaying Local User Data (lud)

    User variables 10.5 Displaying local user data (LUD) Procedure Select the "Parameter" operating area. Press the "User variable" softkey. Press the "Channel GUD" and "GUD selection" softkeys. A new vertical softkey bar appears. Press the "SGUD" ... "GUD6" softkeys if you want to display the SGUD, MGUD, UGUD as well as GUD4 to GUD 6 of the channel-specific user variables.
  • Page 498: Displaying Program User Data (pud)

    User variables 10.6 Displaying program user data (PUD) Procedure Select the "Parameter" operating area. Press the "User variable" softkey. Press the "Local LUD" softkey. 10.6 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 499: Searching For User Variables

    User variables 10.7 Searching for user variables 10.7 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 500 User variables 10.8 Defining and activating user variables Press the "Open" softkey. - OR - Press the <INPUT> key. - OR - Press the <Cursor right> key. The selected file is opened in the editor and can be edited there. Define the desired user variable.
  • Page 501: Teaching In A Program

    Teaching in a program 11.1 Overview The "Teach in" function can be used to edit programs in the "AUTO" and "MDA" modes. You can create and modify simple traversing blocks. You traverse the axes manually to specific positions in order to implement simple machining sequences and make them reproducible.
  • Page 502: Inserting A Block

    Teaching in a program 11.3 Inserting a block Operating mode or operating area switchover If you switch to another operating mode or operating area in teach-in mode, the position changes will be canceled and teach-in mode will be cleared. 11.3 Inserting a block You have the option of traversing the axes and writing the current actual values directly to a new position block.
  • Page 503: Input Parameters For Teach-in Blocks

    Teaching in a program 11.3 Inserting a block 11.3.1 Input parameters for teach-in blocks Parameters for teach-in of position and teach-in of G0, G1, and circle end position CIP Parameter Description Approach position in X direction Approach position in Y direction Approach position in Z direction Feedrate (mm/r;...
  • Page 504: Teach-in Via Window

    Teaching in a program 11.4 Teach-in via window Transition behavior at the beginning and end of the spline curve The following motion parameters are offered: Parameter Description Start BAUTO Automatic calculation BNAT Curvature is zero or natural BTAN Tangential EAUTO Automatic calculation ENAT Curvature is zero or natural...
  • Page 505: Teach In Rapid Traverse G0

    Teaching in a program 11.4 Teach-in via window Procedure Select the "Machine" operating area. Press the <AUTO> or <MDA> key. Press the <TEACH IN> key. Press the "Teach prog." softkey. Use the cursor and input keys to position the cursor at the desired point in the program.
  • Page 506: Teach In Straight G1

    Teaching in a program 11.4 Teach-in via window 11.4.3 Teach in straight G1 You traverse the axes and teach-in a machining block (G1) with the approached positions. Note Selection of axes and parameters for teach-in You can select the axes to be included in the teach-in block in the "Settings" window. You also specify here whether motion and transition parameters are offered for teach-in.
  • Page 507: Teach-in A Spline

    Teaching in a program 11.4 Teach-in via window 11.4.5 Teach-in A spline For Akima-spline interpolation, you enter interpolation points that are connected by a smooth curve. Enter a starting point and specify a transition at the beginning and end. You teach-in each interpolation point via "Teach in of position". Software option You require the "Spline-Interpolation"...
  • Page 508 Teaching in a program 11.4 Teach-in via window Press the "Accept" softkey. A new program block will be inserted at the cursor position. - OR - Press the "Cancel" softkey to cancel your input. Note Selection of axes and parameters for teach-in You can select the axes to be included in the teach-in block in the "Settings"...
  • Page 509: Editing A Block

    Teaching in a program 11.5 Editing a block 11.5 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 510: Selecting A Block

    Teaching in a program 11.6 Selecting a block 11.6 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 511: Deleting A Block

    Teaching in a program 11.7 Deleting a block 11.7 Deleting a block You have the option of deleting a program block entirely. Requirement "AUTO" mode: The program to be processed is selected. Procedure Select the "Machine" operating area. Press the <AUTO> or <MDA> key. Press the <TEACH IN>...
  • Page 512 Teaching in a program 11.7 Deleting a block Press the <TEACH IN> key. Press the "Teach prog." softkey. Press the ">>" and "Settings" softkeys. The "Settings" window appears. Under "Axes to be taught" and "Parameters to be taught", select the check boxes for the relevant settings and press the "Accept"...
  • Page 513: Working With Manual Machine

    Working with Manual Machine "Manual Machine" offers a modified comprehensive spectrum of functions for manual mode. You can carry out all the important machining processes without writing a program. Software options You require the "ShopMill/ShopTurn" option for working with "Manual Machine"...
  • Page 514 Working with Manual Machine 12.1 Measuring the tool Machining options You have the following options for machining the workpieces: ●Manual mode ●Single-cycle machining 12.1 Measuring the tool All the options of the manual and automatic measurement are available to determine the tool offset data (see also Section "Measuring the tool (Page 71)").
  • Page 515 Working with Manual Machine 12.3 Setting the zero offset 12.3 Setting the zero offset As an alternative to selecting the zero offset in the selection box of the basic screen, you can select the zero offset directly in the zero offset list. Machine manufacturer Please refer to the machine manufacturer's specifications.
  • Page 516: Simple Workpiece Machining

    Working with Manual Machine 12.5 Simple workpiece machining Procedure "Manual Machine" is active Press the "Limit stops" softkey. The "Limit Stops" window appears. Enter the desired position of the limit stop for each axis. - OR - Press the "Set limit stop" softkey to enter the current position of an axis. In the field next to the position specification select the entry "On"...
  • Page 517 Working with Manual Machine 12.5 Simple workpiece machining 12.5.1 Traversing axes For preparatory actions and simple traversing movements, input the parameters directly into the "Manual Machine" input fields of the basic screen. Tool selection "Manual Machine" is active. Tool selection Select the desired tool in "T".
  • Page 518: Angular Milling

    Working with Manual Machine 12.5 Simple workpiece machining 12.5.2 Angular milling The basic effective direction can be selected via the axis direction keys or via the cross- switching lever. In addition, an angle (α1) can also be entered. Procedure "Manual Machine" is active. Press the "Angular milling"...
  • Page 519: Straight And Circular Machining

    Working with Manual Machine 12.5 Simple workpiece machining 12.5.3 Straight and circular machining 12.5.3.1 Straight milling Use this function for simple, straight machining (e.g. face or longitudinal turning). Procedure "Manual Machine" is active. Press the "Straight Circle" softkey. Select the desired straight machining and press the "Straight all axes" softkey - OR - Press the "Straight X α"...
  • Page 520: Circular Milling

    Working with Manual Machine 12.5 Simple workpiece machining Parameter Description Unit Straight X α Target position in the X direction (abs or inc) α Angle of the straight line to the X axis Degrees Straight Z α Target position in the Z direction (abs or inc) α...
  • Page 521: More Complex Machining

    Working with Manual Machine 12.6 More complex machining Parameter Description Unit Target position in the Z direction (abs and inc) Target position in the X direction (abs and inc) Center of the circle K (inc) - only if circle input via end point and center point Note: Incremental dimensions: The sign is also evaluated.
  • Page 522: Drilling With Manual Machine

    Working with Manual Machine 12.6 More complex machining Drilling a position pattern You can drill a position pattern: ● First select the desired function (e.g. "Centering") via the softkey in "Drilling". ● Select the appropriate tool, enter the desired values in the parameter screen and press the "Accept"...
  • Page 523 Working with Manual Machine 12.6 More complex machining ⇒ ⇒ Parameter The parameters of the input screen forms correspond to the parameters under Automatic (see Section "Drilling (Page 285)"). Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 524: Milling With Manual Machine

    Working with Manual Machine 12.6 More complex machining 12.6.2 Milling with Manual Machine The same range of technological functions (cycles) is available as in automatic mode for the milling of simple geometric shapes: ⇒ ⇒ ⇒ ⇒ ⇒ Parameter The parameters of the input screen forms correspond to the parameters under Automatic (see Section "Milling (Page 319)").
  • Page 525: Simulation And Simultaneous Recording

    Working with Manual Machine 12.7 Simulation and simultaneous recording 12.7 Simulation and simultaneous recording For more complex machining processes, you can check the result of your inputs with the aid of the simulation, without having to traverse the axes (see Section "Simulating machining (Page 193)").
  • Page 526 Working with Manual Machine 12.7 Simulation and simultaneous recording Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 527: Tool Management

    Tool management 13.1 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 528 Tool management 13.1 Lists for the tool management Search functions You have the option of searching through the lists according to the following objects: ● Tool ● Magazine location ● Empty location Machine manufacturer Please refer to the machine manufacturer's specifications. Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 529: Magazine Management

    Tool management 13.2 Magazine management 13.2 Magazine management Depending on the configuration, the tool lists support a magazine management. Magazine management functions ● Press the "Magazine" horizontal softkey to obtain a list that displays tools with magazine- related data. ● The Magazine / Magazine location column is displayed in the lists. ●...
  • Page 530: Tool Types

    Tool management 13.3 Tool types 13.3 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 13-1 Example of Favorites list Figure 13-2 Available tools in the "New Tool - Milling Cutter"...
  • Page 531 Tool management 13.3 Tool types Figure 13-3 Available tools in the "New Tool - Drill" window Figure 13-4 Available tools in the "New Tool - Special Tools" window See also Changing a tool type (Page 566) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 532: Tool Dimensioning

    Tool management 13.4 Tool dimensioning 13.4 Tool dimensioning This section provides an overview of the dimensioning of tools. Tool types Figure 13-5 End mill (Type 120) Figure 13-6 Face mill (Type 140) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 533 Tool management 13.4 Tool dimensioning Figure 13-7 Angle head cutter (Type 130) Figure 13-8 Drill (Type 200) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 534 Tool management 13.4 Tool dimensioning Figure 13-9 Tap (Type 240) Figure 13-10 3D tool with an example of a cylindrical die-sinking cutter (Type 110) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 535 Tool management 13.4 Tool dimensioning Figure 13-11 3D tool type with an example of a ballhead cutter (Type 111) Figure 13-12 3D tool with an example of an end mill with corner rounding (Type 121) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 536 Tool management 13.4 Tool dimensioning Figure 13-13 3D tool type with an example of a bevel cutter (Type 155) Figure 13-14 3D tool with an example of a bevel cutter with corner rounding (Type 156) Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 537 Tool management 13.4 Tool dimensioning Figure 13-15 3D tool with an example of a tapered die-sinking cutter (Type 157) Figure 13-16 Electronic workpiece probe Milling Operating Manual, 02/2012, 6FC5398-7CP40-3BA0...
  • Page 538: Tool List

    Tool management 13.5 Tool list Machine manufacturer The tool length of the workpiece probe is measured to the center of the ball (length m) or to the ball circumference (length u). Please refer to the machine manufacturer's specifications. Note An electronic workpiece probe must be calibrated before use. 13.5 Tool list All parameters and functions that are required to create and set up the tools are displayed in...
  • Page 539 Tool management 13.5 Tool list Column heading Meaning Tool name The tool is identified by the name and the replacement tool number. You may enter the names as text or numbers. Note: The maximum length of tool names is 31 ASCII characters. The number of characters is reduced for Asian characters or Unicode characters.
  • Page 540 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 Icons in the tool list Icon/ Meaning...
  • Page 541: Additional Data

    Tool management 13.5 Tool list Procedure Select the "Parameter" operating area. Press the "Tool list" softkey. The "Tool List" window opens. See also Displaying tool details (Page 565) Changing a tool type (Page 566) 13.5.1 Additional data The following tool types require geometry data that is not included in the tool list display. Tools with additional geometry data Tool type Additional parameters...
  • Page 542 Tool management 13.5 Tool list Tool type Additional parameters 585 Calibration tool Geometry length (length X, length Y, length Z) Wear length (Δ length X, Δ length Y, Δ length Z) 710 3D-probe milling Geometry length (length X, length Y, length Z) Wear length (Δ...
  • Page 543: Creating A New Tool

    Tool management 13.5 Tool list 13.5.2 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 or special tool using the corresponding softkeys.
  • Page 544 ● Size of tool References: For a description of configuration options, refer to the Commissioning Manual SINUMERIK Operate / SINUMERIK 840D sl 13.5.3 Measuring the tool You can measure the to