Page 1 W1: Tool offset SINUMERIK W5: 3D tool radius compensation SINUMERIK 840D sl Tools W4: Grinding-specific tool offset and tool monitoring Appendix Function Manual Valid for: Control system SINUMERIK 840D sl / 840DE sl Software CNC software version 4.92 06/2019 A5E47435126B AA...
Page 2 Note the following: WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems.
Page 3: Preface
Siemens' content, and adapt it for your own machine documentation. Training At the following address (http://www.siemens.com/sitrain), you can find information about SITRAIN (Siemens training on products, systems and solutions for automation and drives). FAQs You can find Frequently Asked Questions in the Service&Support pages under Product Support (https://support.industry.siemens.com/cs/de/en/ps/faq).
Page 4 Note regarding the General Data Protection Regulation Siemens observes standard data protection principles, in particular the principle of privacy by design. That means that this product does not process / store any personal data, only technical functional data (e.g. time stamps).
Page 5 Preface Information on the structure and contents Structure This Function Manual is structured as follows: ● Inner title (page 3) with the title of the Function Manual, the SINUMERIK controls as well as the software and the version for which this version of the Function Manual is applicable and the overview of the individual functional descriptions.
Page 6 Preface Quantity structure Explanations concerning the NC/PLC interface are based on the absolute maximum number of the following components: ● Mode groups (DB11) ● Channels (DB21, etc.) ● Axes/spindles (DB31, etc.) Data types The control provides the following data types that can be used for programming in part programs: Type Meaning...
Page 7 Preface Program code Comment ELSE <> AXPOS ENDIF Tools Function Manual, 06/2019, A5E47435126B AA...
Page 8 Preface Tools Function Manual, 06/2019, A5E47435126B AA...
Page 9: Table Of Contents
Table of contents Preface .................................3 Fundamental safety instructions.........................15 General safety instructions.....................15 Warranty and liability for application examples ..............15 Industrial security ........................16 W1: Tool offset ............................19 Introduction ..........................19 2.1.1 Programmed contour and tool path..................19 2.1.2 Tool length compensation ......................19 2.1.3 Tool radius compensation ......................20 Tool change and activation of tool offset................21 2.2.1 Selection of tool and cutting edge and tool change ...............21...
Page 10 Table of contents 2.5.5 Deselecting the TRC (G40)....................70 2.5.6 Compensation at outside corners ..................70 2.5.7 Compensation and inner corners ...................74 2.5.8 Collision monitoring ("bottleneck detection") ................76 2.5.8.1 Function ..........................76 2.5.8.2 Parameterization ........................77 2.5.8.3 Programming..........................77 2.5.8.4 Supplementary conditions......................78 2.5.8.5 Example ..........................79 2.5.9 Slot shape recognition (option) ....................80 2.5.10...
Page 11 Table of contents 2.11 Assignment of tool length components to geometry axes............171 2.11.1 Assignment according to tool type and working plane............171 2.11.2 Assignment when changing plane ..................171 2.11.3 Assignment independent of tool type ...................172 2.12 Paraxial tool orientation......................173 2.12.1 Basic tool orientation......................173 2.12.2 Tool orientation for plane change..................173...
Page 12 Table of contents W5: 3D tool radius compensation......................237 Function ..........................237 3.1.1 Introduction ..........................237 3.1.2 Circumferential milling......................238 3.1.2.1 Corners in circumferential milling ..................240 3.1.2.2 Behavior at outer corners.....................241 3.1.2.3 Behavior at inside corners....................242 3.1.2.4 Monitoring of path curvature ....................244 3.1.3 Face milling ..........................244 3.1.3.1 Tool shapes and tool data for face milling................245 3.1.3.2...
Page 13 Table of contents 4.1.3.9 $TC_TPG_DRSPATH and $TC_TPG_DRSPROG ..............283 4.1.3.10 Definition of additional parameters $TC_TPC1 ... 10............283 4.1.3.11 Access to tool-specific parameters ..................284 4.1.4 Planes and axis assignments....................284 4.1.5 Examples ..........................285 Online tool offset ........................288 4.2.1 Function ..........................288 4.2.2 Commissioning........................289 4.2.3 Programming........................290 4.2.3.1 Defining a polynomial function (FCTDEF)................290...
Page 14 Table of contents Tools Function Manual, 06/2019, A5E47435126B AA...
Page 15: Fundamental Safety Instructions
Fundamental safety instructions General safety instructions WARNING Danger to life if the safety instructions and residual risks are not observed If the safety instructions and residual risks in the associated hardware documentation are not observed, accidents involving severe injuries or death can occur. ●...
Page 16: Industrial Security
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Products and solutions from Siemens constitute one element of such a concept.
Page 17 Fundamental safety instructions 1.3 Industrial security WARNING Unsafe operating states resulting from software manipulation Software manipulations, e.g. viruses, Trojans, or worms, can cause unsafe operating states in your system that may lead to death, serious injury, and property damage. ● Keep the software up to date. ●...
Page 18 Fundamental safety instructions 1.3 Industrial security Tools Function Manual, 06/2019, A5E47435126B AA...
Page 19: W1: Tool Offset
W1: Tool offset Introduction 2.1.1 Programmed contour and tool path Workpiece dimensions are programmed directly (e.g. according to the production drawing). Therefore, tool data, such as milling tool diameter, cutting edge position of the turning tool (counterclockwise/clockwise turning tool) and tool length, does not have to be taken into consideration when creating the program.
Page 20: Tool Radius Compensation
W1: Tool offset 2.1 Introduction Tool carrier reference point Tool tip This length is measured and entered in the tool compensation memory of the control together with definable wear values. From this data, the control calculates the traversing movements in the infeed direction.
Page 21: Tool Change And Activation Of Tool Offset
W1: Tool offset 2.2 Tool change and activation of tool offset Tool change and activation of tool offset 2.2.1 Selection of tool and cutting edge and tool change Tool selection A tool is selected in the NC program with the T function. The T function or the tool number can assume the following integer numbers: ●...
Page 22 W1: Tool offset 2.2 Tool change and activation of tool offset Default setting: M06 (acc. to DIN 66025) ① Spindle ② Gripper ③ Magazine (here: chain magazine) ④ Tool change position Preselected tool The tool for which the tool length offset values are to be taken into consideration during power up of the controller and for reset or part program end depending on MD20110 $MC_RESET_MODE_MASK and for part program start depending on MD20112 $MC_START_MODE_MASK is defined with the machine data:...
Page 23: Activation Of The Tool Offset
W1: Tool offset 2.2 Tool change and activation of tool offset Selection of cutting edge for tool change Following selection and loading of a new tool, the following options are provided for selection of the cutting edge: ● Programming of the cutting edge number D<x>. ●...
Page 24: Tool Offset Memory
W1: Tool offset 2.3 Tool offset memory Tool offset memory 2.3.1 Compensation memory structure Tool offset memory size Each channel can have a dedicated tool offset memory (TO unit). Which tool offset memory exists for the relevant channel is set with the machine data: MD28085 $MC_MM_LINK_TOA_UNIT (assignment of TO unit to a channel) The maximum number of tool cutting edges for all tools managed by the NC is set with the machine data:...
Page 25: Calculating The Tool Compensation
W1: Tool offset 2.3 Tool offset memory Tool cutting edges Each tool can have up to 12 cutting edges (D1 to D12). The first cutting edge (D1) is set up automatically when a new tool is loaded to the tool offset memory. Other cutting edges (max. 11) are set up consecutively and contiguously using the "New cutting edge"...
Page 26: Address Extension For Nc Addresses T And M
W1: Tool offset 2.3 Tool offset memory Programming The above compensation block is to be calculated in the NC. Part program call: 2.3.3 Address extension for NC addresses T and M MD20096 Whether the address extension of T and M is also to be interpreted as spindle number when the tool management is not activated, can be set via the machine data: MD20096 $MC_T_M_ADDRESS_EXT_IS_SPINO (spindle number as address extension) The same rules then apply to the relationship between the D number and T number as when...
Page 27: Free Assignment Of D Numbers
W1: Tool offset 2.3 Tool offset memory Two spindles are considered. Spindle 1 is the master spindle. M6 was defined as the tool change signal. T1 = 5 M1 = 6 T2 = 50 M2 = 6 ● If tool management is active, D4 refers to tool "5". T2=50 defines the tool for the secondary spindle, whose tool does not influence the path compensation.
Page 28 W1: Tool offset 2.3 Tool offset memory Functions Expansions to functions when assigning D numbers: ● The maximum permitted D numbers are defined via the machine data: MD18105 $MN_MM_MAX_CUTTING_EDGE_NO (max. value of the D numbers (DRAM)) The default value is 9, in order to maintain compatibility with existing applications. ●...
Page 29 W1: Tool offset 2.3 Tool offset memory A read operation returns CE=D. A write operation is ignored without an alarm message. Note The compensation values $TC_DP1 to $TC_DP25 of the active tool offset can be read with system variable $P_AD[n], where n=1 to 25. The CE cutting edge number of the active compensation is returned with n=26.
Page 30 W1: Tool offset 2.3 Tool offset memory Activation In order to work with unique D numbers and, therefore, with the defined language commands, it must be possible to name D numbers freely for the tools. To do this, the following precondition must be satisfied: ●...
Page 31 W1: Tool offset 2.3 Tool offset memory The D number of cutting edge CE = 3 is to be renamed from 2 to 17. The following specifications apply: ● $TC_DPx[ <tool Tn>, <cutting edge Dm> ] ● Internal T number Tn = 1 ●...
Page 32 W1: Tool offset 2.3 Tool offset memory The following tools must be defined (all with cutting edge number 1): D no. of cutting edge CE=1 T1, D1 D no. of cutting edge CE=1 T2, D10 D no. of cutting edge CE=1 T3, D100 The following command is then programmed: Program code...
Page 33: Compensation Block In Case Of Error During Tool Change
W1: Tool offset 2.3 Tool offset memory 2.3.5 Compensation block in case of error during tool change MD22550 If a tool preparation has been programmed in the part program and the NC detects an error (e.g. the data set for the programmed T number does not exist in the NC), the user can assess the error situation and perform appropriate tasks, in order to subsequently resume machining.
Page 34 W1: Tool offset 2.3 Tool offset memory Error in the part program The options for intervention in the event of an error depend on how the tool change was programmed, defined via the machine data: MD22550 $MC_TOOL_CHANGE_MODE (new tool offset for M function) Tool change with T programming (MD22550 = 0) In this case, the "Compensation block"...
Page 35: Definition Of The Effect Of The Tool Parameters
W1: Tool offset 2.3 Tool offset memory Renewed execution of the program points results in the following: ; Error! Data set with xx does not exist, ; Note state; note xx; ; continue in program ..Tyy M06 ; Detect bit memory "xx missing" → reject without further response, ;...
Page 36: Tool Parameters
W1: Tool offset 2.4 Tool parameters MD20360 $MC_TOOL_PARAMETER_DEF_MASK bit 9 = 1 (definition of tool parameters) Deselecting an axial DRF offset (DRFOF) also deletes an existing tool offset (handwheel override in tool direction). Note For further information about superimposed movements with the handwheel, please refer to: Further information Function Manual Axes and Spindles;...
Page 37: Tool Parameter 1: Tool Type
W1: Tool offset 2.4 Tool parameters Tool parameter Meaning Remark Radius 2 3D face milling: Corner radius (for tools with corner rounding) Grooving saw: Slot width Length 4 Grooving saw: Projection Length 5 3D face milling: Upper bevel cutter diameter (of spherical tools) Angle 1 Turning: Holder angle...
Page 38 W1: Tool offset 2.4 Tool parameters Each tool type is assigned a unique 3-digit number. The assignment of the tool to one of the following technologies or tool groups is realized using the first digit (the hundreds position): Tool type Tool group Milling tools Drilling tools...
Page 39 W1: Tool offset 2.4 Tool parameters CLDATA = "cutter location data" (tool position data according to DIN66215) GWPS = Grinding wheel peripheral speed ST = Special tools Note The tool type has no significance in the turning tool groups. Unlisted numbers are also permitted, in particular with grinding tools (400-499). Tools Function Manual, 06/2019, A5E47435126B AA...
Page 40 W1: Tool offset 2.4 Tool parameters Calculating tool offset data The CNC combines these individual components to produce a result variable (e.g. total length, total radius). The relevant overall dimension becomes effective when the offset memory is activated. The use of these values in the axes is determined by the tool type and current machining plane G17, G18 or G19.
Page 41: Tool Parameter 2: Cutting Edge Position
W1: Tool offset 2.4 Tool parameters Geometry Wear Tool base di‐ Unit mension Slot width b $TC_DP7 $TC_DP16 Projection k $TC_DP8 $TC_DP17 The width of the saw blade is taken into account for the tool radius compensation (G40/G41/ G42) as follows: Function Meaning No saw blade compensation...
Page 42 W1: Tool offset 2.4 Tool parameters Cutting edge position (1 ... 9) for machining in front of the turning center Cutting edge position (1 ... 9) for vertical boring and turning mills Special aspects ● If the cutting edge center point S is used instead of point P as a reference point to calculate the tool length compensation, the identifier 9 must be entered for the cutting edge position.
Page 43: Tool Parameters 3
W1: Tool offset 2.4 Tool parameters 2.4.4 Tool parameters 3 ... 5: Geometry - tool lengths The lengths of the tools are required for the geometry tool length compensation. They are input as tool lengths 1 to 3 in the tool parameters 3 to 5. The minimum required tool length depends on the respective tool type: Tool type Required tool lengths...
Page 44 W1: Tool offset 2.4 Tool parameters In most cases, only tool parameter 6 (tool radius 1) is used: Tool parameter Meaning Tool radius 1 The tool radius must be specified for the following tool types: Milling tools Turning tools Tool parameter 2: Cutting edge position (Page 41) must also be specified for turning tools.
Page 45 W1: Tool offset 2.4 Tool parameters 3D face milling The tool parameters relevant to the tool description in 3D face milling are dependent on the tool type used. Thus, for example, for a ball end mill, only tool parameter 6, for a bevel cutter with corner rounding additionally tool parameters 7, 9 and 11, are relevant.
Page 46: Tool Parameters 12
W1: Tool offset 2.4 Tool parameters 2.4.6 Tool parameters 12 ... 14: Wear - tool lengths While geometry tool length compensation (tool parameters 3 to 5) is used to define the size of the tool, wear tool length compensation can be used to correct the change in the active tool size. The active tool variable can change as a result of the following influences: ●...
Page 47 W1: Tool offset 2.4 Tool parameters Example 1: Tool and tool adapter are measured separately, however, are installed in the machine as one unit ① Tool ② Tool holder ③ Tool adapter Adapter reference point (for inserted tool = tool carrier reference point) Tool carrier reference point Geometry - length 1 Adapter dimension - length 1...
Page 48 W1: Tool offset 2.4 Tool parameters Example 2: The tool adapters of a tool turret are in different positions Tool carrier reference point Tool carrier reference point Geometry - length 1 Geometry - length 2 Base dimension - length 1 Base dimension - length 2 Tools Function Manual, 06/2019, A5E47435126B AA...
Page 49: Tool Parameter 24: Clearance Angle
W1: Tool offset 2.4 Tool parameters 2.4.9 Tool parameter 24: Clearance angle Certain turning cycles, in which traversing motions with relief cuts are generated, monitor the clearance angle of the active tool for possible contour violation. α Clearance angle ① The contour to be machined is not violated.
Page 50: Tool Radius Compensation
W1: Tool offset 2.5 2D tool radius compensation Longitudinal or face machining The clearance angle is entered differently according to the type of processing. If a tool is to be used for both longitudinal and face machining, two tool cutting edges must be entered for different clearance angles.
Page 51: Selecting The Trc (G41/G42)
W1: Tool offset 2.5 2D tool radius compensation Why TRC? The contour (geometry) of the workpiece programmed in the part program should be independent of the tools used in production. This makes it necessary to obtain the values for the tool length and tool radius from a current offset memory. With the current tool radius, tool radius compensation (TRC) can be used to calculate the equidistant path to the programmed contour in the plane.
Page 52: Approach And Retraction Behavior (Norm/Kont/Kontc/Kontt)
W1: Tool offset 2.5 2D tool radius compensation Intermediate blocks In general, only program blocks with positions on geometry axes in the current plane are programmed when TRC is active. However, dummy blocks can still also be programmed with active TRC. Dummy blocks are program blocks, which do not contain any positions on a geometry axis in the current plane: ●...
Page 53 W1: Tool offset 2.5 2D tool radius compensation Special features ● KONT only differs from NORM when the tool start position is behind the contour. Figure 2-3 Example for selecting TRC with KONT or NORM in front of and behind the contour ●...
Page 54 W1: Tool offset 2.5 2D tool radius compensation Axes The continuity condition is observed in all three axes. It is thus possible to program a simultaneous path component perpendicular to the compensation plane for approach/ retraction. Only linear blocks are permitted for the original approach and retraction blocks with KONTT/ KONTC.
Page 55 W1: Tool offset 2.5 2D tool radius compensation Figure 2-4 Approach and retraction with constant curvature during inside machining of a full circle: Projection in the X-Y plane. Figure 2-5 Approach and retraction with constant curvature during inside machining of a full circle: 3D representation.
Page 56 W1: Tool offset 2.5 2D tool radius compensation KONTT and KONTC compared The figure below shows the differences in approach/retraction behavior between KONTT and KONTC. A circle with a radius of 20 mm about the center point at X0 Y-40 is compensated with a tool with an external radius of 20 mm.
Page 57: Smooth Approach And Retraction
W1: Tool offset 2.5 2D tool radius compensation 2.5.4 Smooth approach and retraction 2.5.4.1 Function Description The SAR (Smooth Approach and Retraction) function is used to achieve a tangential approach to the start point of a contour, regardless of the position of the start point. The approach behavior can be varied and adapted to special needs using a range of additional parameters.
Page 58 W1: Tool offset 2.5 2D tool radius compensation ● G347: Approach with a semicircle ● G348: Retraction with a semicircle Figure 2-7 Approach behavior depending on G147 to G347 and DISR (with simultaneous activation of tool radius compensation) Modal G command for defining the approach and retraction contour This G command is only relevant if the approach contour is a quadrant or semicircle.
Page 59 W1: Tool offset 2.5 2D tool radius compensation Modal G command (G340, G341), which defines the subdivision of the movement into individual blocks from the start point to the end point The approach characteristic from P to P is shown in the figure. If G247 or G347 is active (quadrant or semicircle) and start point P is outside the machining plane defined by the end point P...
Page 60 W1: Tool offset 2.5 2D tool radius compensation Approach/retraction with circles DISR indicates always the radius of the tool center point path. If tool radius compensation is activated, a circle is generated internally, the radius of which is dimensioned such that the tool center path is derived, in this case also, from the programmed radius.
Page 61 W1: Tool offset 2.5 2D tool radius compensation The end point is deemed to have been programmed in the actual SAR block for approach if at least one geometry axis is programmed on the machining plane (X or Y with G17). If only the position of the axis perpendicular to the machining plane (Z with G17) is programmed in the SAR block, this component is taken from the SAR block, but the position in the plane is taken from the following block.
Page 62 W1: Tool offset 2.5 2D tool radius compensation The end position is always taken from the SAR block, no matter how many axes have been programmed. We distinguish between the following situations: 1. No geometry axis is programmed in the SAR block. In this case, the contour ends at point P (or at point P , if P...
Page 63 W1: Tool offset 2.5 2D tool radius compensation Programming the feedrate with FAD FAD programmed with ... Feedrate from P or P to P G340 Feedrate of the infeed movement perpendicular to the machining G341 plane from P to P If FAD is not programmed, this part of the contour is traversed at the velocity, which is active modally from the preceding block, in the event that no F command defining the velocity is programmed in the SAR block.
Page 64: Velocities
W1: Tool offset 2.5 2D tool radius compensation Program code Comment Programming feed F This feed value is effective from point P (or from point P , if FAD is not programmed). If no F command is programmed in the SAR block, the speed of the preceding block is valid. The velocity defined by FAD is not used for following blocks.
Page 65 W1: Tool offset 2.5 2D tool radius compensation Figure 2-10 Velocities in the SAR subblocks on approach with G341 Velocities at retraction During retraction, the rolls of the modally active feedrate from the previous block and the programmed feedrate value in the SAR block are interchanged, i.e., the actual retraction contour (straight line, circle, helix) is traversed with the old feedrate value and a new velocity programmed with the F word applies from point P up to P...
Page 66: System Variables
W1: Tool offset 2.5 2D tool radius compensation Figure 2-11 Velocities in the SAR subblocks on retraction 2.5.4.4 System variables Points P and P can be read in the WCS as system variables during approach. $P_APR: Read P (start point) in WCS $P_AEP: Read P (contour start point) in WCS...
Page 67: Examples
W1: Tool offset 2.5 2D tool radius compensation ● At least two blocks must always be taken into consideration: – The SAR block itself – The block, which defines the approach or retraction direction Further blocks can be programmed between these two blocks. The number of possible dummy blocks is limited with the machine data: MD20202 $MC_WAB_MAXNUM_DUMMY_BLOCKS (maximum number of blocks with no traversing motions with SAR).
Page 68 W1: Tool offset 2.5 2D tool radius compensation ● Because of G341, the approach movement takes place with a circle in the plane, resulting in a start point at (20, -20, 0) ● Because DISCL=5, point P2 is at position (20, -20, 5) and, because of Z30, point P1 is in N10 at (20, -20, 30) Figure 2-12 Contour example 1...
Page 69 W1: Tool offset 2.5 2D tool radius compensation ● The end point of the circle is obtained from N30, since only the Z position is programmed in N20 ● Infeed movement – From Z20 to Z7 (DISCL=AC(7)) with rapid traverse –...
Page 70: Deselecting The Trc (G40)
W1: Tool offset 2.5 2D tool radius compensation Program code Comment N80 M 30 Note The contour generated in this way is modified by tool radius compensation, which is activated in the SAR approach block and deactivated in the SAR retraction block. The tool radius compensation allows for an effective radius of 15, which is the sum of the tool radius (10) and the contour offset (5).
Page 71 W1: Tool offset 2.5 2D tool radius compensation Figure 2-14 Example of a 90 degree outside corner with G450 and G451 G450 (transition circle) With the active G command G450, on outside corners, the center point of the tool travels a circular path along the tool radius.
Page 72 W1: Tool offset 2.5 2D tool radius compensation Figure 2-15 Example: Overshoot with DISC= 25 Figure 2-16 Overshoot with DISC depending on contour angle G451 (intersection) If the G451 G command is active, the position (intersection) resulting from the path lines (straight line, circle or helix only) located at a distance of the tool radius to the programmed contour (center-point path of the tool) is approached.
Page 73 W1: Tool offset 2.5 2D tool radius compensation Very pointed outside corners Where outside corners are very pointed, G451 can result in excessive idle paths. Therefore, the system switches automatically from G451 (intersection) to G450 (transition circle, with DISC where appropriate) when outside corners are very pointed. The threshold angle (contour angle) for this automatic switchover (intersection point →...
Page 74: Compensation And Inner Corners
W1: Tool offset 2.5 2D tool radius compensation Figure 2-18 Example of automatic switchover to intersection 2.5.7 Compensation and inner corners Point of intersection If two consecutive blocks form an inside corner, an attempt is made to find a point at which the two equidistant paths intersect.
Page 75 W1: Tool offset 2.5 2D tool radius compensation No intersection For inside corners, it is possible that no intersection is found between two consecutive blocks. In this case, the control automatically checks the next block and attempts to find an intersection with the equidistant paths of this block: Point of intersection Figure 2-20...
Page 76: Collision Monitoring ("Bottleneck Detection")
W1: Tool offset 2.5 2D tool radius compensation Multiple intersections With inside corners it is also possible that predictive contour calculation finds multiple intersections of the equidistant paths in several consecutive blocks. In this case, the last intersection is always used as the valid intersection. The previous intersection points are not approached: Figure 2-21 In this example, the pocket is machined only as much as is possible without causing a...
Page 77: Parameterization
W1: Tool offset 2.5 2D tool radius compensation Figure 2-22 Bypassing a bottleneck during active collision monitoring (looking 8 blocks ahead) Activation / deactivation The function is activated / deactivated in the NC program with commands of G Group 23. See "Programming (Page 77)."...
Page 78: Supplementary Conditions
W1: Tool offset 2.5 2D tool radius compensation Meaning Activating collision detection ("bottleneck detection") CDON: CDON performs a check over an adjustable (MD20240 (Page 77)) number of blocks as to whether the tool paths of non-adjacent blocks intersect. This look-ahead function allows possible collisions to be detected in advance and permits the control to actively avoid them.
Page 79: Example
W1: Tool offset 2.5 2D tool radius compensation 2.5.8.5 Example Effect of collision detection using an example The NC program describes the center point path of a standard tool. The contour for a tool that is actually used results in undersize, which is shown unrealistically large to demonstrate the geometric relationships in the following figure.
Page 80: Slot Shape Recognition (Option)
To give the user this option, the tool radius correction has been expanded to include the function "slot shape recognition". Note The "slot shape recognition" function is an option for SINUMERIK 840D sl that requires a license. Article number: 6FC5800-0AS18-0YB0 Function If the "slot shape recognition"...
Page 81 W1: Tool offset 2.5 2D tool radius compensation The following conditions must be met: ● The radius of a new tool (R2) must not exceed the radius of the original tool (R1) by the factor R2 < 2 * R1 ●...
Page 82: Blocks With Variable Compensation Value
W1: Tool offset 2.5 2D tool radius compensation Program code Comment N13 G03 X0.100 Y-0.100 I0.100 N14 G01 X49.700 N15 G02 X0.200 Y-0.200 J-0.200 ; Rounding at the end of the deflec- tion line contour. N16 G01 Y-24.500 If slot shape recognition is inactive (SD42977 $SC_SLOT_FORM_RECOGN = 0), the tool radius correction will detect and omit the programmed deflection line as an impermissible contour for the tool used (laser beam) because the slot width is 0.3 mm but the tool has radius 0.2 mm.
Page 83 W1: Tool offset 2.5 2D tool radius compensation Figure 2-23 Tool radius compensation with variable compensation value Calculation of intersection When the intersections in blocks with variable compensation value are calculated, the intersection of the offset curves (tool paths) is always calculated based on the assumption that the compensation value is constant.
Page 84: Alarm Behavior
W1: Tool offset 2.5 2D tool radius compensation Maintain stability of closed contour If a radius of two circles is increased slightly, a third block may be necessary in order to maintain the stability of the closed contour. This is the case if two adjacent blocks, which represent two possible intersection points for a closed contour, are skipped due to the compensation.
Page 85: Intersection Procedure For Polynomials
W1: Tool offset 2.5 2D tool radius compensation 2.5.12 Intersection procedure for polynomials Function If two curves with active tool radius compensation form an outside corner, depending on the G command of the 18th group (corner behavior with tool compensation; G450/G451) and regardless of the type of curves involved (straight lines, circles, polynomials): ●...
Page 86 W1: Tool offset 2.5 2D tool radius compensation Figure 2-25 Retraction behavior with G460 The last block with active tool radius compensation (N20) is so short that an intersection no longer exists between the offset curve and the preceding block (or a previous block) for the current tool radius.
Page 87 W1: Tool offset 2.5 2D tool radius compensation The control attempts to cut this circle with one of the preceding blocks. If CDOF is active, the search is terminated when an intersection is found, i.e. the system does not check for more intersections with even earlier blocks.
Page 88 W1: Tool offset 2.5 2D tool radius compensation End point in front of contour If the end point is located in front of the contour, the retraction behavior is the same as for NORM. This feature does not change, even if the last contour block with G451 is extended with a straight line or a circle.
Page 89: Tools With A Relevant Tool Point Direction
W1: Tool offset 2.6 2 1/2 D tool radius compensation 2.5.14 Tools with a relevant tool point direction The following must be observed for tools with relevant cutting edge position: ● The straight line between the tool edge center points at the block start and block end is used to calculate intersection points with the approach and retraction block.
Page 90 W1: Tool offset 2.6 2 1/2 D tool radius compensation 2½ tool radius compensation referred to a differential tool 2½ D tool radius compensation, referred to a differential tool, is activated using theCUT2DD or CUT2DFD commands. It should be applied if the programmed contour refers to the center point path of a differential tool, and a tool other than a differential tool is used for machining.
Page 91 W1: Tool offset 2.6 2 1/2 D tool radius compensation For machining inclined surfaces, the tool offsets must be appropriately defined or calculated based on the functions for "Tool length compensation for tools that can be orientated". 2½ D tool radius compensation with rotation of the compensation plane (CUT2DF, CUT2DFD) If a frame is programmed that contains a rotation, then for CUT2DF or CUT2DFD, the plane in which the tool radius compensation takes place (correction plane) is also rotated.
Page 92: Keep Tool Radius Compensation Constant
W1: Tool offset 2.7 Keep tool radius compensation constant For further information see the "Tools" Function Manual. See also Tool length compensation (Page 19) Keep tool radius compensation constant Meaning The "Keep tool radius compensation constant" function is used to suppress tool radius compensation for a number of blocks, whereby a difference between the programmed and the actual traveled tool center path established by tool radius compensation in the previous blocks is retained as the offset.
Page 93 W1: Tool offset 2.7 Keep tool radius compensation constant a traversing motion in the compensation plane and is not such a circle. Vertical circle in this sense can only occur during circumferential milling. Example: ; Definition of tool d1 N20 $TC_DP1[1,1] = 110 ;...
Page 94 W1: Tool offset 2.7 Keep tool radius compensation constant Figure 2-28 Sample program for contour suppression Special cases ● If tool radius compensation is not active (G40), CUTCONON has no effect. No alarm is produced. The G command remains active, however. This is significant if tool radius compensation is to be activated in a later block with G41 or G42.
Page 95: Tool Carriers With Orientation Capability
W1: Tool offset 2.8 Tool carriers with orientation capability ● The response after reprogramming G41 or G42 when tool radius compensation is already active is similar to compensation suppression. The following deviations apply: – Only linear blocks are permissible – A single traversing block that contains G41 or G42 is modified so that it ends at the offset point of the start point in the following block.
Page 96 W1: Tool offset 2.8 Tool carriers with orientation capability Toolholder selection A toolholder defined in the control must be specified for the "Toolholder with orientation capability" function. The NC program command below is used for this purpose: TCARR = m m: Number of the toolholder The toolholder has an associated toolholder data block that describes its geometry.
Page 97 W1: Tool offset 2.8 Tool carriers with orientation capability Tool carriers with orientation capability Example: Cardan toolholder with two axes for the tool orientation Figure 2-29 Cardan toolholder with two axes Processing toolholder data blocks Two options are available: ● Explicit entry in the toolholder data block from the part program ●...
Page 98 W1: Tool offset 2.8 Tool carriers with orientation capability If no toolholder or a toolholder without change in orientation is active, then the Z direction is in the new frame: ● The same as the old Z direction with G17. ●...
Page 99 W1: Tool offset 2.8 Tool carriers with orientation capability The following kinematics cannot achieve any orientation: ● If the two rotary axes which are necessary to define the kinematics are not perpendicular to each other and if the tool axis which defines the tool direction is not perpendicular to the second rotary axis ●...
Page 100 W1: Tool offset 2.8 Tool carriers with orientation capability Any character other than the three mentioned here will result in an alarm if it is tried to activate the toolholder with orientation capability: Alarm "14153 Channel %1 block %2 unknown toolholder type: %3" Rotary axis parameters: $TC_CARR24 to $TC_CARR33 The system variables in $TC_CARR24 to $TC_CARR33 can be used to define offsets, angle...
Page 101 W1: Tool offset 2.8 Tool carriers with orientation capability Description NC variable Language Default setting format z component of rotary axis v $TC_CARR9 REAL x component of rotary axis v $TC_CARR10 REAL y component of rotary axis v $TC_CARR11 REAL z component of rotary axis v $TC_CARR12 REAL...
Page 102: Kinematic Interaction And Machine Design
W1: Tool offset 2.8 Tool carriers with orientation capability Description NC variable Language Default setting format Identifier $TC_CARR37 * Position component X $TC_CARR38 * REAL Position component Y $TC_CARR39 * REAL Position component Z $TC_CARR40 * REAL x comp. fine offset of offset vector l $TC_CARR41 REAL y comp.
Page 103 W1: Tool offset 2.8 Tool carriers with orientation capability Zero vectors Vectors v and v can be zero. The associated angle of rotation (explicitly programmed or calculated from the active frame) must then also be zero, since the direction of the rotating axis is not defined.
Page 104 W1: Tool offset 2.8 Tool carriers with orientation capability The kinematic chains used to describe the machine with rotary tool (general case) are shown in the figure below: Figure 2-30 Kinematic chain to describe a tool with orientation Vectors, which describe offsets in the rotary head, are positive in the direction from the tool tip to the reference point of the toolholder.
Page 105 W1: Tool offset 2.8 Tool carriers with orientation capability Figure 2-31 Kinematic chain to describe a rotary table Vectors, which describe offsets in the rotary table, are positive in the direction from the machine reference point to the table. The following kinematic type is defined for machines with a rotary workpiece: $TC_CARR23 using letter P Note On machines with rotary workpiece it is generally useful if the selected machine reference point...
Page 106 W1: Tool offset 2.8 Tool carriers with orientation capability Figure 2-32 Kinematic sequence with extended kinematics The following kinematic type is defined for machines with a rotary tool and rotary workpiece: $TC_CARR23 using letter M (extended kinematics) Note On machines with extended kinematics it is generally useful, as with machines where only the table can be rotated, for the machine reference point and the reference point of the table to be identical.
Page 107 W1: Tool offset 2.8 Tool carriers with orientation capability The parameter $TC_CARR5 is assigned to the fine offset $TC_CARR45. Note For the significance of the system variables $TC_CARR41 to $TC_CARR65 available for the fine offset see: Further information Programming Manual Advanced; Tool offsets Activation The following setting adds the fine offset values to the basic values: SD42974 $SC_TOCARR_FINE_CORRECTION = 1 (fine offset TCARR on/off)
Page 108 W1: Tool offset 2.8 Tool carriers with orientation capability The following settings are obtained at the mill head shown for a machine with toolholder with orientation capability of kinematic type T: Component of the offset vector l (-200, 0, 0) Component of the offset vector l (0, 0, 0) Component of the offset vector l...
Page 109 W1: Tool offset 2.8 Tool carriers with orientation capability Suitable assumptions were made for the following values in the data block: ● The two rotary axes intersect at one point. All components of l are therefore zero. ● The first rotary axis lies in the x/z plane, the second rotary axis is parallel to the x axis. These conditions define the directions of v and v (the lengths are irrelevant, provided that...
Page 110: Tool Carrier With Kinematic Chains
W1: Tool offset 2.8 Tool carriers with orientation capability Note The required data cannot be determined unequivocally from the geometry of the toolholder, i.e. the user is free to a certain extent to decide the data to be stored. Thus, for the example, it is possible to specify only one z component for the tool base dimension up to the second axis.
Page 111 W1: Tool offset 2.8 Tool carriers with orientation capability Example for a rotatable tool Orange: Kinematic chain of the tool carrier Blue: Kinematic chain of the machine Figure 2-34 Tool carrier with rotatable tool Example of a rotatable workpiece Orange: Kinematic chain of the tool carrier Blue: Kinematic chain of the machine...
Page 112 W1: Tool offset 2.8 Tool carriers with orientation capability Example of mixed kinematics and I Offset of the tool chain of the tool holder Rotary axis of the tool chain and I Offset of the workpiece chain of the tool holder Rotary axis of the tool chain Figure 2-36 Mixed kinematics...
Page 113 W1: Tool offset 2.8 Tool carriers with orientation capability Define a kinematic element of type "OFFSET" (=I ) in the X, Y, and Z direction. Corresponds to $TC_CARR4 - $TC_CARR6. Define a kinematic element of type "AXIS_ROT" (=v ) in the X, Y, and Z direction. Corresponds to $TC_CARR7 - $TC_CARR9.
Page 114 W1: Tool offset 2.8 Tool carriers with orientation capability Syntax Description Bit0=1 The tool carrier is parameterized from the kinematic chain elements. The following data of the tool carrier, including the fine offset, are replaced with geometry data from the kinematic chain ele‐ ments: Conventional tool carrier Kinematic chain...
Page 115 W1: Tool offset 2.8 Tool carriers with orientation capability $TC_CARR_KIN_TOOL_END and $TC_CARR_KIN_PART_END System variables $TC_CARR_KIN_TOOL_END and $TC_CARR_KIN_PART_END define the end points of the kinematic chains that are used to parameterize the tool or workpiece part of a tool carrier. At least one of these two names must be not equal to the null string. Syntax Description $TC_CARR_KIN_TOOL_END[n] =...
Page 116 W1: Tool offset 2.8 Tool carriers with orientation capability These chain elements can be uniquely identified with system variable $TC_CARR_CORR_ELEM[m, n]. where m is the index of the tool carrier data set and n is the index of the correction vector (n = 0...3]). Read out length and direction of the vectors of TCARR.
Page 117: Machine Measuring For Tool Carrier
W1: Tool offset 2.8 Tool carriers with orientation capability Figure 2-37 Tool carriers with orientation capability with 3 rotary axes. The rotary axes are not orientation axes, as used for the 5-axis-transformation. Defining rotation axes (more than two rotary axes) If a tool carrier comprises more than two rotation axes, this is defined via the relevant axes using the system variable $TC_CARR_KIN_ROTAX_NAME.
Page 118 W1: Tool offset 2.8 Tool carriers with orientation capability Note The correction values written with the CORRTC function are not immediately effective in the transformation. The correction values do not become effective until after a transformation deselection, NEWCONF and transformation selection. Syntax <_Corr_Status>...
Page 119 W1: Tool offset 2.8 Tool carriers with orientation capability Correction mode <_Corr_Mode>: Data type: The <Corr_Index> parameter is decimal coded (units to thousands position): Units Reserved position: Tens Specifies how the correction element to which the content of <_Corr_Index> position: refers, is to be modified.
Page 120 W1: Tool offset 2.8 Tool carriers with orientation capability The CORRTC function writes lever arm lengths and axis directions on machines with an orientation transformation in special correction elements. A kinematic chain is described, for example, with elements of the type OFFSET, which are defined via $ NK_TYPE. CORRTC works with sections The two subchains can each be divided into a maximum of four sections: ●...
Page 121: Inclined Surface Machining With 3 + 2 Axes
W1: Tool offset 2.8 Tool carriers with orientation capability 2.8.5 Inclined surface machining with 3 + 2 axes Description of function Inclined machining with 3 + 2 axes describes an extension of the concept of toolholders with orientation capability and applies this concept to machines with a rotary table, on which the orientation of tool and table can be changed simultaneously.
Page 122: Machine With Rotary Work Table
W1: Tool offset 2.8 Tool carriers with orientation capability 2.8.6 Machine with rotary work table System variables To date, the angles stored in $TC_CARR13 and $TC_CARR14 were used for the calculation of the active tool length with TCOABS. This still applies if $TC_CARR21 and $TC_CARR22 do not refer to rotary axes.
Page 123 W1: Tool offset 2.8 Tool carriers with orientation capability TCOFR/TCOABS frame rotation A frame rotation does not take place on activation and a rotation which is already active is not changed. As in case T (only the tool can be rotated), the position of the rotary axes used for the calculation is dependent on the G command TCOFR/TCOABS and determined from the rotation component of an active frame or from the entries $TC_CARRn.
Page 124 W1: Tool offset 2.8 Tool carriers with orientation capability Activation of kinematic types P and M With kinematics of type P and M the selection of a toolholder activates an additive frame (table offset of the toolholder with orientation capability), which takes into account the zero point offset as a result of the rotation of the table.
Page 125: Procedure When Using Toolholders With Orientation Capability
W1: Tool offset 2.8 Tool carriers with orientation capability Language command PAROT is not rejected if no orientable toolholder is active. This causes no changes in the programmed frame. Note For additional explanations regarding the functions TCARR and TOROT, as well as PAROT, with regard to channel-specific system frames, see Function Manual "Basic Functions", Section "Axes, coordinate systems, frames".
Page 126 W1: Tool offset 2.8 Tool carriers with orientation capability Accessing the data of a tool carrier: ● Part program – Write: $TC_CARR<n>[<m>] = <value> Value <value> is written to parameter <n> of tool carrier <m> . – Read: <value> = $TC_CARR<n>[<m>] Parameter <n>...
Page 127 W1: Tool offset 2.8 Tool carriers with orientation capability The effect of TCOFR is such that, when machining on an inclined surface, tool offsets are considered implicitly as if the tool were standing vertically on the surface. Note The tool orientation is not bound strictly to the frame orientation. When a frame is active and G command TCOABS is active, you can select a tool, whereby the orientation of the tool is independent of the orientation of the active frame.
Page 128 W1: Tool offset 2.8 Tool carriers with orientation capability Tool radius compensation with CUT2D or CUT3DFS: The current tool orientation is included in the tool radius compensation if either CUT2D or CUT3DFS is active in G group 22 (tool offset type). For nonrotating tool carriers, the behavior depends solely on the active plane of the G command of group 6 (G17 - G19) and is, therefore, identical to the previous behavior.
Page 129: Programming
W1: Tool offset 2.8 Tool carriers with orientation capability Limit values Limit angles (software limits) can be specified for each rotary axis in the system variable set ($TC_CARR30 to $TC_CARR33) used to describe the tool carrier with orientation capability. These limits are not evaluated if both the minimum and maximum value is zero. If at least one of the two limits is not equal to zero, the system checks whether the previously calculated solution is within the permissible limits.
Page 130: Supplementary Conditions And Control System Response For Orientation
W1: Tool offset 2.8 Tool carriers with orientation capability Canceling all toolholder data blocks All values of all toolholder data sets can be deleted from within the part program using one command. $TC_CARR1[0] = 0 Values not set by the user are preset to 0. Activation A toolholder becomes active when both a toolholder and a tool have been activated.
Page 131 W1: Tool offset 2.8 Tool carriers with orientation capability If vector v or v , which describes the direction of a rotary axis, is set to zero, the associated angle of rotation α1 or α2 must also be set to zero. Otherwise, an alarm is produced. The alarm is not output until the toolholder is activated, i.e.
Page 132 W1: Tool offset 2.8 Tool carriers with orientation capability Toolholder kinematics The following supplementary conditions must be met for toolholder kinematics: ● Tool orientation in initial state, both angles α and α zero, as per default setting, even if: – G17 parallel to Z –...
Page 133: Examples
W1: Tool offset 2.8 Tool carriers with orientation capability 2.8.10 Examples 2.8.10.1 Example: Toolholder with orientation capability Requirement The following example uses a toolholder, which is described fully by a rotation about the Y axis. It is therefore sufficient to enter only one value to define the rotary axis (block N20). Blocks N50 to N70 describe an end mill with radius 5 mm and length 20 mm.
Page 134 W1: Tool offset 2.8 Tool carriers with orientation capability N40 MOVT=AC(20) ; Retraction in tool direction at dis- tance of ; 20 mm from the zero point Machine with rotary table Complete definition for the use of a toolholder with orientation capability with rotary table: N10 $TC_DP1[1,1]= 120 N20 $TC_DP3[1,1]= 13 ;...
Page 135 W1: Tool offset 2.8 Tool carriers with orientation capability N280 PAROT N290 X0 Y0 Z0 N300 G18 MOVT=AC(20) N310 G17 X10 Y0 Z0 N320 MOVT=-10 N330 PAROTOF N340 TCOFR N350 X10 Y10 Z-13 A0 B0 N360 ROTS X-45 Y45 N370 X20 Y0 Z0 D0 N380 Y20 N390 X0 Y0 Z20 N400 M30...
Page 136: Calculation Of Compensation Values On A Location-Specific And Workpiece-Specific Basis
W1: Tool offset 2.8 Tool carriers with orientation capability In N360, solid angles are used to define a plane whose intersecting lines in the XZ and in the YZ plane each form an angle of +45 degrees or -45 degrees with the X or Y axis. The plane defined in such a way therefore has the following position: The surface normal points towards the solid diagonals.
Page 137 W1: Tool offset 2.8 Tool carriers with orientation capability Program code Comment N170 $TC_MPP2[1,1]=9 ; Location type N180 $TC_MPP4[1,1]=2 ; Location status N190 $TC_MPP7[1,1]=1 ; Bring adapter into position N200 $TC_MPP6[1,1]=1 ; T number "MillingTool" N210 $TC_MAP1[9999]= 7 ; Magazine type: Buffer N220 $TC_MAP2[9999]="Buffer"...
Page 138: Example: Tool Carrier With Orientation Capability Via Kinematic Chain
W1: Tool offset 2.8 Tool carriers with orientation capability SD42935 $SC_WEAR_TRANSFORM (transformations for tool components) This means that the tool wear and the insert offset are not subject to the adapter transformation because of TOWMCS in block N400. The sum of these two compensations is 1.01. The Z position is, therefore, increased by this amount and the Y position is reduced by this amount compared with block N390.
Page 139 W1: Tool offset 2.8 Tool carriers with orientation capability Program code Comment N1180 $TC_CARR_KIN_PART_START[_CARR_CNT]="X_AXIS" ; Start element of the part chain. N1190 $TC_CARR_KIN_PART_END[_CARR_CNT]="END_PART_CHAIN" ; End element of the part chain. N1200 $TC_CARR21[_CARR_CNT]=B N1210 $TC_CARR22[_CARR_CNT]=C N1220 $TC_CARR23[_CARR_CNT]="M" N1230 $NK_NAME[_KIE_CNT] = "ROOT" N1240 $NK_PARALLEL[_KIE_CNT]="X_AXIS"...
Page 140 W1: Tool offset 2.8 Tool carriers with orientation capability Program code Comment N1630 $NK_TYPE[_KIE_CNT] = "OFFSET" N1640 $NK_NEXT[_KIE_CNT] = "" N1650 _KIE_CNT=_KIE_CNT+1 ;***** End tool chain ***** ;***** Start part chain ***** N1660 $NK_NAME[_KIE_CNT] = "X_AXIS" N1670 $NK_TYPE[_KIE_CNT] = "AXIS_LIN" N1680 $NK_OFF_DIR[_KIE_CNT,0] = 1 N1690 $NK_AXIS[_KIE_CNT] = "X1"...
Page 141: Modification Of The Offset Data For Rotatable Tools
W1: Tool offset 2.9 Modification of the offset data for rotatable tools Modification of the offset data for rotatable tools 2.9.1 Introduction Function With function "Modification of the offset data for rotatable tools", the modified geometrical relationships that result when a tool is rotated (predominantly turning tools, but also drilling and milling tools) relative to the workpiece being machined can be taken into account.
Page 142: Rotating Turning Tools
W1: Tool offset 2.9 Modification of the offset data for rotatable tools Activation Modification of the offset data for rotatable tools is activated in the NC program with the language commands CUTMOD (in combination with tool carriers with orientation capability) or CUTMODK (for orientation transformations that were defined with kinematic chains).
Page 143 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Cutting edge position and cut direction Turning tools are limited by their main and secondary cutting edges. The cutting edge position is defined via the position of the primary and secondary cutting edges relative to the coordinate axes.
Page 144 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Holder angle and clearance angle The following figure shows the holder angle and clearance angle for a rotary tool with cutting edge position 3. The machining plane is G18 (Z/X). The cut direction is 3 (negative Z or abscissa direction).
Page 145: Modifications During The Rotation Of Turning Tools
W1: Tool offset 2.9 Modification of the offset data for rotatable tools 2.9.2.2 Modifications during the rotation of turning tools Description of tool orientation Unlike milling tools, turning tools are not rotation-symmetric. This means that normally 3 degrees of freedom or three rotary axes are required to describe the tool orientation. The concrete kinematics therefore, is independent of the machine only to the extent the desired orientation can be set.
Page 146 W1: Tool offset 2.9 Modification of the offset data for rotatable tools tool carrier is no longer treated separately because it must be assumed that this frame component is already included in the complete frame (system frame PAROT). When orientation transformation is active, bit 17 of machine data MD20360 $MC_TOOL_PARAMETER_DEF_MASK can be used, should the cutting edge no longer be in the active machining plane, either to project the cutting edge into the machine plane (bit 17 = 0) or alternatively to rotate the cutting edge into the machining plane (bit 17 = 1) in order to...
Page 147 W1: Tool offset 2.9 Modification of the offset data for rotatable tools pTCutMod or ptCut- ModS and in system variables $P_CUTMOD_ANG or $AC_CUTMOD_ANG. This angle is the original angle without any final rounding to multiples of 45° or 90°. Limit cases If, for a turning tool, the cutting edge position, cut direction, clearance and holder angles have valid values so that all cutting edge positions (1 to 8) are possible through suitable rotations in the plane, then the cutting edge positions 1 to 4 are preferred to cutting edge positions 5 to 8...
Page 148 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Cutting edge center point Cutting edge reference point Cutting edge position ① Tool with cutting edge position 3, clearance angle 22.5°, and holder angle 112.5° ② For rotations of the tool up to 22.5°, the cutting edge position is maintained, the position of the cutting edge reference point relative to the tool however, is compensated in such a way that the relative position of both points is maintained in the machining plane.
Page 149: Rotation Of Milling And Drilling Tools
W1: Tool offset 2.9 Modification of the offset data for rotatable tools 2.9.3 Rotation of milling and drilling tools 2.9.3.1 Cutting edge position for milling and tapping tools Milling and drilling tools Milling and drilling tools means the following tools whose tool type ($TC_DP1) has values in the range of 100 to 299.
Page 150: Modifications During Rotation Of Milling And Tapping Tools
W1: Tool offset 2.9 Modification of the offset data for rotatable tools Figure 2-44 Cutting edge position 5 - 8 of a milling tool 2.9.3.2 Modifications during rotation of milling and tapping tools The cutting edge position is recalculated appropriately during a rotation of a milling or tapping tool.
Page 151 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Two bits of the machine data are assigned to each fault condition: Fault status Meaning No valid cutting direction is defined for the active tool. Alarm output Program stop The cutting edge angle (clearance angle and holder angle) of the Alarm output active tool are both zero.
Page 152 W1: Tool offset 2.9 Modification of the offset data for rotatable tools MD20360 $MC_TOOL_PARAMETER_DEF_MASK The following bits are relevant for function "Modification of the offset data for rotatable tools". Meaning Bit 17 is used to set whether, on modification of the offset data for turning and grinding tools, the cutting edge plane for calculating the offset values will be projected into the machining plane or rotated.
Page 153: Programming
W1: Tool offset 2.9 Modification of the offset data for rotatable tools SD42998 = 5.0 ⇒ The tool insert must not be turned by more than 5° away from the machining plane. Note SD42998 = 0 If SD42998 $SC_CUTMOD_PLANE_TOL is set to "0", variations of up to 89° are permissible! Difference between tool tip plane and machining plane for ORISOLH The maximum permissible angle through which the tool insert can be turned away from the machining plane when function ORISOLH (Page 161) is called is set in the setting data:...
Page 154 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Syntax <RetVal> = ORISOLH(<Cntrl>,<W1>,<W2>) Meaning Function call ORISOLH: Function return value <RetVal>: Data type: Range of val‐ 0, -2, -3, ..., -17 ues: Values: 0 Function has ended without an error. -2 No valid transformation (6-axis orientation transformation) is active.
Page 155 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Controls the behavior of the function <Cntrl>: Data type: The <Cntrl> parameter is decimal coded (unit to thousands position): Unit position: The unit position controls the response to errors. xxx0 In the event of an error (return value <...
Page 156 W1: Tool offset 2.9 Modification of the offset data for rotatable tools If the angles <W1> and <W2> are selected arbitrarily, the cutting edge of the tool is generally not in the machining plane. The angle γ through which the cutting edge is rotated out of the machining plane, must not be greater than the limit value which is defined by the setting data SD42999 $SC_OR‐...
Page 157 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Further information The number of solutions found together with further status information when executing the ORISOLH function, can be read via the following system variables: System variable Meaning $P_ORI_POS Returns the angles of the orientation axes that result from the orientation program‐...
Page 158 W1: Tool offset 2.9 Modification of the offset data for rotatable tools System variable Meaning $P_ORI_SOL If for an orientation transformation with more than one orientation axis, the axis angles are calculated that should result in a specified orientation, there is generally more than one solution.
Page 159 W1: Tool offset 2.9 Modification of the offset data for rotatable tools System variable Meaning 1 There is a solution. There can be three different causes for this case: ● Based on the specified orientation and the machine kinematics, there is only one solution (from the mathematical point of view, two coinciding solutions) even without consideration of the axis limits.
Page 160 W1: Tool offset 2.9 Modification of the offset data for rotatable tools System variable Meaning $P_ORI_STAT Returns the status for each of the maximum three orientation axes after ORISOLH [<n>] has been called. <n>: Index of the orientation axis (correspnds to the index of the relevant orientation axis in $NT_ROT_AX_NAME) Range of values: 0 ...
Page 161: Activating The Modification Of The Offset Data For Rotatable Tools (Cutmod, Cutmodk)
W1: Tool offset 2.9 Modification of the offset data for rotatable tools System variable Meaning sition). This information is also contained in the $P_ORI_SOL system variable. Of the error numbers that indicate a violation of the axis limits, several can occur simultaneously.
Page 162 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Meaning Function call in combination with orientable tool carriers CUTMOD: Assigned value <Value>: Data type: Value: 0 The function is deactivated. The values supplied from system variables $P_AD... are the same as the corresponding tool parameters.
Page 163 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Assigned Command <Command>: Data type: STRING Value: The states of an active transformation defined with kinematic "NEW" chains relevant for the "Modification of the offset data", the name of the transformation and the current contour frame are saved.
Page 164 W1: Tool offset 2.9 Modification of the offset data for rotatable tools The data is always modified with respect to the corresponding tool parameters ($TC_DP2[..., ...] etc.) when the "Modification of the offset data for rotatable tools" function was activated with the CUTMOD or CUTMODK command and the tool was rotated by an orientable tool carrier or a suitable orientation transformation.
Page 165 W1: Tool offset 2.9 Modification of the offset data for rotatable tools System variable Meaning $P_CUTMOD_ERR Error state after the last call of the CUTMOD function The CUTMOD function can also be called implicitly for a tool change. At a reset, the variable is reset to zero.
Page 166: Example
W1: Tool offset 2.9 Modification of the offset data for rotatable tools Effectiveness of the modified cutting data The modified cutting edge position and the modified cutting edge reference point are immediately effective when programming, even for a tool that is already active. A tool does not have to be re-selected for this purpose.
Page 167 W1: Tool offset 2.9 Modification of the offset data for rotatable tools Program code Comment N80 $TC_DP24[1,1]=25 ; Clearance angle N90 $TC_CARR7[2]=0 $TC_CARR8[2]=1 $TC_CARR9[2]=0 ; B axis N100 $TC_CARR10[2]=0 $TC_CARR11[2]=0 ; C axis $TC_CARR12[2]=1 N110 $TC_CARR13[2]=0 N120 $TC_CARR14[2]=0 N130 $TC_CARR21[2]=X N140 $TC_CARR22[2]=X N150 $TC_CARR23[2]="M"...
Page 168: Incrementally Programmed Compensation Values
W1: Tool offset 2.10 Incrementally programmed compensation values In block N260, contrary to block N200, CUTMOD=2 is effective. As a result of the tool holder rotation that can be orientated, the modified cutting edge position becomes 8. Deviating axis positions also result from this. The tool radius compensation (TRC) is activated in blocks N220 and/or N270.
Page 169: Traversing In The Direction Of Tool Orientation (Movt)
W1: Tool offset 2.10 Incrementally programmed compensation values For further information, see Function Manual "Basic Functions", Chapter "Axes, coordinate systems, frames". Boundary condition If the behavior is set such that the offset remains active even after the end of the program and RESET MD20110 $MC_RESET_MODE_MASK, bit6=1 (specification of the controller initial setting after reset / TP end)
Page 170 W1: Tool offset 2.10 Incrementally programmed compensation values Figure 2-45 Definition of the position for absolute programming of a motion in tool direction The reference to this auxiliary plane serves only to calculate the end position. Active frames are not affected by this internal calculation. Instead of MOVT= ...
Page 171: Assignment Of Tool Length Components To Geometry Axes
W1: Tool offset 2.11 Assignment of tool length components to geometry axes 2.11 Assignment of tool length components to geometry axes 2.11.1 Assignment according to tool type and working plane. The values of the tool parameters length 1 ... 3 are stored in the system variables $TC_DP3 ...
Page 172: Assignment Independent Of Tool Type
W1: Tool offset 2.11 Assignment of tool length components to geometry axes Table 2-4 Milling / special tools ($TC_DP1 <> 400 … 599) SD42940 Assignment of tool length components to geometry axes Length L1 Length L2 Length L3 = x17 = x18 = x19 = -x17...
Page 173: Paraxial Tool Orientation
W1: Tool offset 2.12 Paraxial tool orientation <value> Assignment of the tool length components Activates setting data SD42942 $SC_TOOL_LENGTH_CONST_T. With this setting, it is possible to define the assignment of the tool length compo‐ nents that is effective on a machining plane change (Page 171) separately for milling/special tools and turning/grinding tools: SD42940 Assignment for milling/special tools...
Page 174 W1: Tool offset 2.12 Paraxial tool orientation Standard behavior With the default setting (SD42954 and SD42956 = 0), the tool orientation changes with a plane change as follows: Plane change Change in tool orientation G17 → G18 1. Rotation by -90° about the Z coordinate G18 →...
Page 175: Parameterizable Basic Tool Orientation
W1: Tool offset 2.13 Parameterizable basic tool orientation 2.13 Parameterizable basic tool orientation 2.13.1 Function Note Tool T and cutting edge D In the following, the syntax [...] represents [<t>, <d>] in relation to the system variables of the basic tool orientation. In this regard, <t> designates the number of the tool T=<t> and <d> the number of the tool cutting edge D=<d>.
Page 176: Parameterization
W1: Tool offset 2.13 Parameterizable basic tool orientation MD18114 $MN_MM_ENABLE_TOOL_ORIENTATION = <value> <value> Meaning The function "Parameterizable basic tool orientation" is not active. Activation of system variables: ● Function selection: $TC_DPV[...] With the system variable $TC_DPV[...] = 1, 2, ... 6, one of six predefined basic tool orienta‐ tions can be assigned for each tool cutting edge D=<d>...
Page 177: Programming
W1: Tool offset 2.13 Parameterizable basic tool orientation Note SD42954 / SD42956 The assignment of the system variables $TC_DPVx[...] can only be changed with SD42954 $SC_TOOL_ORI_CONST_M and SD42956 $SC_TOOL_ORI_CONST_T if the 1000s position is equal to "1" Irrespective of the value of setting data SD42950 $SC_TOOL_LENGTH_TYPE, SD42954 is only effective for a tool for which parameter $TC_DP1[...] defines a milling tool.
Page 178: Examples
W1: Tool offset 2.13 Parameterizable basic tool orientation Selection of a predefined orientation vector $TC_DPV[...] = <value> Table 2-7 Turning / grinding tools ($TC_DP1 = 400 … 599) <value> Meaning $TC_DPV3[...] $TC_DPV5[...] $TC_DPV4[...] Table 2-8 Milling / special tools ($TC_DP1 <> 400 … 599) <value>...
Page 179 W1: Tool offset 2.13 Parameterizable basic tool orientation Example 1 Program code Comment $SC_TOOL_LENGTH_TYPE=2 ; assignment to the coordinate axes as for turning/ grinding tools. $SC_TOOL_ORI_CONST_M=1019 ; Working plane G19 N10 $TC_DP1[1,1]=120 ; Tool type: Milling tool N20 $TC_DP3[1,1]=10 ; Length compensation vector: L1=10 N30 $TC_DPV[1,1]=0 ;...
Page 180: Special Handling Of Tool Offsets
W1: Tool offset 2.14 Special handling of tool offsets 2.14 Special handling of tool offsets 2.14.1 Relevant setting data SD42900- 42960 Setting data SD42900 - SD42940 can be used to make the following settings with reference to tool offset: ● Sign of the tool length ●...
Page 181: Mirroring Tool Lengths
W1: Tool offset 2.14 Special handling of tool offsets ● SD42950 $SC_TOOL_LENGTH_TYPE (allocation of the tool length components independent of tool type) (Page 172) ● SD42960 $SC_TOOL_TEMP_COMP (tool length offsets) (Page 184) 2.14.2 Mirroring tool lengths Activation Tool length mirroring is activated via the setting data: SD42900 $SC_MIRROR_TOOL_LENGTH <>...
Page 182: Mirroring Wear Lengths
W1: Tool offset 2.14 Special handling of tool offsets 2.14.3 Mirroring wear lengths Activation Wear length mirroring is activated by: SD42920 $SC_WEAR_SIGN_CUTPOS <> 0 (TRUE) (Sign of wear for tools with cutting edge systems) Function Length of cutting edge Length 1 Length 2 Inverted Inverted...
Page 183: Tool Lengths In The Wcs, Allowing For The Orientation
W1: Tool offset 2.14 Special handling of tool offsets Example: N10 $SC_WEAR_SIGN = 0 ; No sign inversion of the wear values N20 $TC_DP1[1,1] = 120 ; End mill N30 $TC_DP6[1,1] = 100 ; Tool radius 100 mm N40 $TC_DP15[1,1] = 1 ;...
Page 184: Tool Length Offsets In Tool Direction
W1: Tool offset 2.14 Special handling of tool offsets 2.14.5 Tool length offsets in tool direction Temperature compensation in real time On 5-axis machines with a moving tool, temperature fluctuations can occur in the machining heads. These can result directly in expansion fluctuations which are transmitted to the tool spindle in the form of linear expansion.
Page 185 W1: Tool offset 2.14 Special handling of tool offsets Temperature compensation in the tool direction also works in conjunction with orientation transformations (not generic 5-axis transformations) with: ● Transformation type 64 to 69 Rotating linear axis Note Temperature compensation can be activated with all other types of transformation. It is not affected by a change in tool orientation.
Page 186 W1: Tool offset 2.14 Special handling of tool offsets Temperature compensation values immediately follow any applied change in orientation. This applies in particular when an orientation transformation is activated or deactivated. The same is true when the assignment between geometry axes and channel axes is changed. The temperature compensation value for an axis is reduced to zero (interpolatory), for example, when it ceases to be a geometry axis after a transformation change.
Page 187 W1: Tool offset 2.14 Special handling of tool offsets Machine data Value Remark MD24120 $MC_TRAFO_GEOAX_AS‐ Geometry axis for channel axis 1 SIGN_TAB_1[0] MD24120 $MC_TRAFO_GEOAX_AS‐ Geometry axis for channel axis 2 SIGN_TAB_1[1] MD24120 $MC_TRAFO_GEOAX_AS‐ Geometry axis for channel axis 3 SIGN_TAB_1[2] MD24570 $MC_TRAFO5_AXIS1_1[0] = 0.0 MD24570 $MC_TRAFO5_AXIS1_1[1]...
Page 188: Special Characteristics Of Orientable Tool Carriers
W1: Tool offset 2.14 Special handling of tool offsets still at 90 degrees. However, because the transformation is already deactivated, the applied orientation is parallel to the Z axis again. Machine data Value Remark MD20390 $MC_TOOL_TEMP_COMP_ON = TRUE Temperature compensation active MD32750 $MA_TEMP_COMP_TYPE[ AX1 ] Compensation in tool direction MD32750 $MA_TEMP_COMP_TYPE[ AX2 ]...
Page 189: Sum And Setup Offsets
W1: Tool offset 2.15 Sum and setup offsets 2.15 Sum and setup offsets 2.15.1 General information Sum offsets Sum offsets can be treated as programmable process compensations during machining and are composed of all the error sizes (including the wear), which cause the workpiece to deviate from the specified dimensions.
Page 190: Description Of Function
W1: Tool offset 2.15 Sum and setup offsets 2.15.2 Description of function Sum offsets Several sum offsets (DL numbers) can be defined per D number. In this way, for example, workpiece location-dependent offset values can be determined and assigned to a cutting edge.
Page 191 W1: Tool offset 2.15 Sum and setup offsets Parameters for geometry and wear Tool geometry compensations are assigned to system variables $TC_DP3 to $TC_DP11. System variables $TC_DP12 to $TC_DP20 allow you to name a wear for each of these parameters: Geometry Wear Compensations...
Page 192 W1: Tool offset 2.15 Sum and setup offsets The effect of the parameters is similar to the wear (additive to the tool geometry). Up to six sum/ setup parameters can be defined per cutting edge parameter. Tool geometry parame‐ Sum / setup parameters Tool wear param‐...
Page 193: Activation
W1: Tool offset 2.15 Sum and setup offsets Supplementary conditions The maximum number of DL data sets of a cutting edge and the total number of sum offsets in the NC are defined via machine data. The default value is zero, i.e. no sum offsets can be programmed.
Page 194 W1: Tool offset 2.15 Sum and setup offsets DL = 0 Note DL0 is not permitted. If compensation is deselected (D0 and T0), the sum offset also becomes ineffective. Programming a sum offset that does not exist triggers an alarm, similar to programming a D compensation that does not exist.
Page 195 W1: Tool offset 2.15 Sum and setup offsets DL=2 Sum offset 2 is added to the D2 compensation instead of sum offset 1, i.e. $TC_SCP23 to $TC_SCP31. DL=0 Deselection of sum offset; only the data of D2 remains active. MD18112 $MN_MM_KIND_OF_SUMCORR, bit 4=1: Setup offsets are available The sum offset is now composed of the "sum offset fine"...
Page 196 W1: Tool offset 2.15 Sum and setup offsets The significance of the individual variables is similar to geometry variables $TC_DP3 to $TC_DP11. Only length 1, length 2 and length 3 are enabled for the basic functionality (variables $TC_SCP13 to $TC_SCP15 for the first sum offset of the cutting edge). R5 = $TC_SCP13[ t, d ] Sets the value of the R parameter to the value of the first component of sum offset 1 for cutting edge (d)
Page 197 W1: Tool offset 2.15 Sum and setup offsets Creating a new setup offset If the compensation data set (x) does not yet exist, it is created on the first write operation to one of its parameters (y). $TC_ECPxy[ t, d ] = r.r The value "r.r"...
Page 198: Examples
W1: Tool offset 2.15 Sum and setup offsets It is advisable to save the sum offsets, in order to allow the current status to be restored in the event of an acute problem. Machine data settings can be made to exclude sum offsets from a data backup (settings can be made separately for "setup offsets"...
Page 199: Extensions For Tool Length Determination
W1: Tool offset 2.15 Sum and setup offsets MD20270 $MC_CUTTING_EDGE_DEFAULT=2 (Basic setting of tool cutting edge without programming) MD20272 $MC_SUMCORR_DEFAULT=1 (default setting sum offset without program) T5 M06 ; Tool number 5 is loaded - D2 + DL=1 are active (= values of machine data) D1 DL=3 ;...
Page 200 W1: Tool offset 2.15 Sum and setup offsets Type of action of the individual vectors The type of action of the individual vectors or groups of vectors depends on the following further quantities: Influencing quantity Operating principle G commands Active machining plane Tool type Milling tool or turning/grinding tools Machine data...
Page 201 W1: Tool offset 2.15 Sum and setup offsets Minor operator compensations Minor compensations, however, must also be modified during the normal production mode. The reasons for this are, for example: ● Tool wear ● Clamping errors ● Temperature sensitivity of the machine: These compensations are defined as follows: Definition Wear components...
Page 202 W1: Tool offset 2.15 Sum and setup offsets The setting data is considered in the following functions: ● Wear values in the machine coordinate system Part program instruction: TOWMCS ● Wear values in the workpiece coordinate system Part program instruction: TOWWCS Figure 2-49 Transformation of wear data dependent on SD42935 Programming...
Page 203: Functionality Of The Individual Wear Values
W1: Tool offset 2.15 Sum and setup offsets Coordinate systems for offsets in tool length G commands TOWMCS, TOWWCS, TOWBCS, TOWTCS and TOWKCS can be used, e.g. to measure the wear tool length component in five different coordinate systems. 1. Machine coordinate system 1.
Page 204 W1: Tool offset 2.15 Sum and setup offsets In the case of an active rotation by means of a tool carrier with orientation capability: ● The tool carrier only rotates the vector of the resultant tool length. Wear is ignored. Then the tool length vector rotated in this way and the wear are added.
Page 205 W1: Tool offset 2.15 Sum and setup offsets TOWTCS Wear values in TCS (tool coordinate system): ● If a tool carrier with orientation capability is active, the tool vector is calculated as for TOWMCS, without taking the wear into account. ●...
Page 206: Working With Tool Environments
W1: Tool offset 2.16 Working with tool environments Special features If TOWMCS or TOWWCS is active, the following setting data does not affect the non- transformed wear components: SD42920 $SC_WEAR_SIGN_CUTPOS (Sign of wear for tools with cutting edge systems) The following setting data also does not affect the non-transformed wear components in case of TOWWCS: SD42910 $SC_MIRROR_TOOL_WEAR (Sign change tool wear when mirroring) In this case, a possibly active mirroring is already contained in the frame, which is referred to...
Page 207: Save Tool Environment (Toolenv)
W1: Tool offset 2.16 Working with tool environments 2.16.1 Save tool environment (TOOLENV) The TOOLENV function is used to save any current states needed for the evaluation of tool data stored in the memory. The individual data are as follows: ●...
Page 208 W1: Tool offset 2.16 Working with tool environments Meaning Predefined function to save a tool environment TOOLENV(...): Alone in the block: Function return value. Negative values indicate error states. <Status>: Data type: Value: Function OK No memory reserved for tool environments: MD18116 $MN_MM_NUM_TOOL_ENV = 0 This means that the "tool environments"...
Page 209: Delete Tool Environment (Deltoolenv)
W1: Tool offset 2.16 Working with tool environments By saving the complete data necessary to determine the overall tool length, it is possible to calculate the effective length of the tool at a later point in time, even if the tool is no longer active or if the conditions of the environment (e.g.
Page 210: Read T, D And Dl Number (Gettenv)
W1: Tool offset 2.16 Working with tool environments DELTOOLENV() deletes data sets describing tool environments without spec‐ DELTOOLENV(): ifying a name 2.16.3 Read T, D and DL number (GETTENV) The GETTENV function is used to read the T, D and DL numbers stored in a tool environment. Syntax <Status>...
Page 211: Read Information About The Saved Tool Environments ($P_Toolenvn, ($P_Toolenv)
W1: Tool offset 2.16 Working with tool environments 2.16.4 Read information about the saved tool environments ($P_TOOLENVN, ($P_TOOLENV) Information regarding the saved tool environments can be read using the following system variables: Supplies the number of data sets (which have still not been deleted) – defined $P_TOOLENVN: using TOOLENV –...
Page 212 W1: Tool offset 2.16 Working with tool environments Function return value. Negative values indicate error states. <Status>: Data type: Value: Function OK No memory reserved for tool environments: MD18116 $MN_MM_NUM_TOOL_ENV = 0 This means that the "tool environments" functionality is not available.
Page 213 W1: Tool offset 2.16 Working with tool environments Tool length components (optional) <Comp>: Data type: STRING The character string consists of two substrings, which are separated from one another by a colon. General form: "<SubStr_1> [: <SubStr_2]" The first substring designates the tool length components to be <SubStr_1>: taken into account when calculating the tool length.
Page 214 W1: Tool offset 2.16 Working with tool environments Internal T number of the tool (optional). <T>: Data type: If this parameter is not specified or if its value is "0", then the tool stored in <Stat> is used. If the value of this parameter is "-1", then the T number of the active tool is used. It is also possible to explicitly specify the number of the active tool.
Page 215 W1: Tool offset 2.16 Working with tool environments Additional information Adapter transformation/toolholder with orientation capability/kinematic transformation Any rotations and component exchanges initiated by the adapter transformation, toolholder with orientation capability and kinematic transformation, are part of the tool environment. They are thus always performed, even if the corresponding length component is not supposed to be included.
Page 216 W1: Tool offset 2.16 Working with tool environments Program code Comment N140 R4=_LEN[3] ; 7.5 (= 0.5 * 3.0 + 0.5 * 12.0) N150 R5=_LEN[4] ; 19.0 (= 5.0 + 14.0) N160 M30 Length components of the kinematic transformation and toolholder with orientation capability If a toolholder with orientation capability is taken account of during the tool length calculation, the following vectors are included in that calculation: Type...
Page 217: Change Tool Components (Settcor)
W1: Tool offset 2.16 Working with tool environments 2.16.6 Change tool components (SETTCOR) The SETTCOR function is used to change tool components taking into account all general conditions that can be involved when evaluating the individual components. Note Regarding the terminology: If in the following, in conjunction with the tool length, tool components are involved, then the components considered from a vectorial perspective are meant, which make up the complete tool length (e.g.
Page 218 W1: Tool offset 2.16 Working with tool environments Function return value. Negative values indicate error states. <Status>: Data type: Value: Function OK No memory reserved for tool environments: MD18116 $MN_MM_NUM_TOOL_ENV = 0 This means that the "tool environments" functionality is not available.
Page 219 W1: Tool offset 2.16 Working with tool environments Tool component(s) <Comp>: Data type: STRING The character string consists of two substrings, which are separated from one another by a colon. General form: "<SubStr_1> [: <SubStr_2]" The first substring must always be available, and can either <SubStr_1>: comprise one or two characters.
Page 220 W1: Tool offset 2.16 Working with tool environments Specifies the component(s) of the tool data sets that are to be described (optional). <CorComp>: Data type: Value: Offset value <CorVal>[0] refers to the geometry axis transferred in parameter <GeoAx> in the workpiece coordinate system – or in the tool coordinate system (also see a description of param‐...
Page 221 W1: Tool offset 2.16 Working with tool environments Specifies the type of write operation to be executed (optional). <CorMode>: Data type: Value: = <CorVal> 1new = Val + <CorVal> 1new 1old = <CorVal> 1new 2new = Val + Val + <CorVal> 1new 1old 2old...
Page 222 W1: Tool offset 2.16 Working with tool environments Name of the data set for describing a tool environment (optional) <Stat>: Data type: STRING If the value of this parameter is the null string (""), or is not specified, then the current status is used.
Page 223 W1: Tool offset 2.16 Working with tool environments Program code Comment N70 R1=SETTCOR(_CORVAL,"G",0,0,2) N80 T1 D1 X0 Y0 Z0 ; ==> MCS position X0.000 Y0.000 Z1.333 N90 M30 <CorComp> is "0", therefore, the coordinate value of the geometry component acting in the Z direction must be replaced by the offset value 0.333.
Page 224 W1: Tool offset 2.16 Working with tool environments Program code Comment N40 $TC_DP12[1,1]=1.0 ; wear L1 N50 _CORVAL[0]=0.333 N60 T1 D1 G17 G0 N70 R1=SETTCOR(_CORVAL,"GW",0,3,2) N80 T1 D1 X0 Y0 Z0 ; ==> MCS position X0.000 Y0.000 Z11.333 N90 M30 <CorComp>...
Page 225 W1: Tool offset 2.16 Working with tool environments G18 is active. Since <CorMode> = 3, the tool wear in the direction of the X axis of the WCS must become zero once N100 has been executed. The contents of the relevant tool parameters at the end of the program are thus: $TC_DP3[1,1]: 21.830 ;...
Page 226 W1: Tool offset 2.16 Working with tool environments The same result as that achieved by calling the SETTCOR function with the <CorComp> = 0 parameter twice can also be reached by calling <CorComp> = 1 (vectorial compensation) just once: Program code Comment N10 DEF REAL _CORVAL[3] N20 $TC_DP1[1,1]=500...
Page 227 W1: Tool offset 2.16 Working with tool environments Example 8 Program code Comment N10 DEF REAL _CORVAL[3] N20 $TC_DP1[1,1]=500 ; turning tool N30 $TC_DP3[1,1]=10.0 ; geometry L1 N40 $TC_DP4[1,1]=15.0 ; geometry L2 N50 $TC_DP5[1,1]=20.0 ; geometry L3 N60 $TC_DP12[1,1]=10.0 ; wear L1 N70 $TC_DP13[1,1]=0.0 ;...
Page 228 W1: Tool offset 2.16 Working with tool environments However, since the wear is evaluated negatively, due to setting data SD42930 $SC_WEAR_SIGN, the compensation determined in this way has to be entered in the compensation memory with a negative sign. The contents of the relevant tool parameters at the end of the program are thus: $TC_DP3[1,1]: 10.000 ;...
Page 229: Read The Assignment Of The Tool Lengths L1, L2, L3 To The Coordinate Axes (Lentoax)
W1: Tool offset 2.17 Read the assignment of the tool lengths L1, L2, L3 to the coordinate axes (LENTOAX) Program code Comment N40 $TC_DP2[1,1]=2 ; Cutting edge position N50 $TC_DP3[1,1]=3. ; Geometry - length 1 N60 $TC_DP4[1,1]=4. ; Geometry - length 2 N70 $TC_DP5[1,1]=5.
Page 230 W1: Tool offset 2.17 Read the assignment of the tool lengths L1, L2, L3 to the coordinate axes (LENTOAX) Function return value. Negative values indicate error states. <Status>: Data type: Value: Function OK Information provided in <AxInd> is sufficient for the descrip‐ tion (all tool length components are in parallel to the geom‐...
Page 231 W1: Tool offset 2.17 Read the assignment of the tool lengths L1, L2, L3 to the coordinate axes (LENTOAX) coordinate system applicable for the assignment (optional) <Coord>: Data type: STRING Charac‐ The tool length is represented in the machine coordinate ters: system.
Page 232: Boundary Conditions
W1: Tool offset 2.18 Boundary conditions ROT Z60 The direction of the applicate (Z direction) remains unchanged; the main component of L2 now lies in the direction of the new X axis; the main component of L1 now lies in the direction of the negative Y axis.
Page 233: Data Lists
W1: Tool offset 2.19 Data lists 2.19 Data lists 2.19.1 Machine data 2.19.1.1 NC-specific machine data Number Identifier: $MN_ Description 18082 MM_NUM_TOOL Number of tools that the NC can manage (SRAM) 18088 MM_NUM_TOOL_CARRIER Maximum number of the defined toolholders 18094 MM_NUM_CC_TDA_PARAM Number of tool data (SRAM) 18096...
Page 234: Axis/Spindlespecific Machine Data
W1: Tool offset 2.19 Data lists Number Identifier: $MC_ Description 20182 TOCARR_ROT_ANGLE_OFFSET[i] Rotary axis offset of tool carrier with orientation capa‐ bility 20184 TOCARR_BASE_FRAME_NUMBER Number of the basic frames to accept the table offset 20188 TOCARR_FINE_LIM_LIN Limit linear fine offset TCARR 20190 TOCARR_FINE_LIM_ROT Limit of the rotary fine offset TCARR...
Page 235: Setting Data
W1: Tool offset 2.19 Data lists 2.19.2 Setting data 2.19.2.1 Channelspecific setting data Number Identifier $SC_ Description 42442 TOOL_OFFSET_INCR_PROG Tool length compensation 42470 CRIT_SPLINE_ANGLE Core limit angle, for compressor 42480 STOP_CUTCOM_STOPRE Alarm response for tool radius compensation and pre‐ processing stop 42494 CUTCOM_ACT_DEACT_CTRL Approach and retraction behavior for tool radius com‐...
Page 236 W1: Tool offset 2.19 Data lists Number Identifier $SC_ Description 42930 WEAR_SIGN Sign of the wear 42935 WEAR_TRANSFORM Transformations for tool components 42940 TOOL_LENGTH_CONST Change of tool length components for change of plane 42950 TOOL_LENGTH_TYPE Assignment of the tool length offset independent of tool type 42960 TOOL_TEMP_COMP...
Page 237: W5: 3D Tool Radius Compensation
W5: 3D tool radius compensation Function 3.1.1 Introduction 3D circumferential milling and 3D face milling 3D tool radius compensation (3D-TRC) is used to process contours with tools that can be controlled in their orientation independently of the tool path and shape. SINUMERIK provides the 3D-TRC in different variants, which are used in combination with the following manufacturing processes: ●...
Page 238: Circumferential Milling
W5: 3D tool radius compensation 3.1 Function Parameterization The machine and setting data set for the 2D-TRC are also in effect for the 3D-TRC. Further information W1: Tool offset (Page 19) In addition to this, there is special system data that is only relevant to 3D-TRC. See Chapter "Parameter assignment (Page 252)"...
Page 239 W5: 3D tool radius compensation 3.1 Function Milling tool machining point Milling tool tip Milling tool reference point Insertion depth Tool vector Vector from the milling tool reference point to the milling tool machining point with length of shank radius R Figure 3-1 Circumferential milling Insertion depth...
Page 240: Corners In Circumferential Milling
W5: 3D tool radius compensation 3.1 Function 3.1.2.1 Corners in circumferential milling Inside and outside corners are handled separately. The terms inside corner and outside corner are dependent on the tool orientation. ① Inside corner ② Outside corner When the orientation changes at a corner, for example, the corner type may change while machining is in progress: Whenever this occurs, the machining operation is aborted with alarm 10770.
Page 241: Behavior At Outer Corners
W5: 3D tool radius compensation 3.1 Function 3.1.2.2 Behavior at outer corners At outside corners during circumferential milling with 3D-TRC analogous to the conditions in the 2½D-TRC, the G commands of Group 18 (corner behavior tool offset) are evaluated: ● G450: Transition circle (tool travels around workpiece corners on a circular path) Outside corners are treated like circles with a radius of 0, where the circular plane stretches from the end tangent of the first block and the start tangent of the second block.
Page 242: Behavior At Inside Corners
W5: 3D tool radius compensation 3.1 Function first traversing block is used for the offset calculation. The circle block with constant orientation is inserted immediately before the second traversing block. See also "Example 1: Orientation change at outside corner during 3D circumferential milling (Page 268)".
Page 243 W5: 3D tool radius compensation 3.1 Function Figure 3-3 Path end position and change in orientation at inside corners See also "Example 2: Orientation change at inside corner during 3D circumferential milling (Page 271)". Change in insertion depth Generally speaking, the contour elements that form an inside corner are not positioned on the plane perpendicular to the tool.
Page 244: Monitoring Of Path Curvature
W5: 3D tool radius compensation 3.1 Function Figure 3-4 Change in insertion depth 3.1.2.4 Monitoring of path curvature The path curvature is monitored for an unchangeable orientation in the following way: 1. The contour in each block is projected on the plane that is orthogonal to the tool orientation. 2.
Page 245: Tool Shapes And Tool Data For Face Milling
W5: 3D tool radius compensation 3.1 Function Milling tool machining point Milling tool tip Surface normal vector Tool vector Shaft radius Corner radius Difference between the shank radius R and corner radius r Figure 3-5 Face milling with a torus cutter 3.1.3.1 Tool shapes and tool data for face milling An overview of the tool shapes, which may be used for face milling operations and relevant tool...
Page 246: Face Milling With A Specified Surface Normal Vector
W5: 3D tool radius compensation 3.1 Function Cutter type Type No. Bevel cutter > 0 > 0 Bevel cutter with corner rounding > 0 > 0 > 0 Tapered die-sinking cutter > 0 > 0 - : is not evaluated. Tool data Tool parameters Tool dimensions...
Page 247 W5: 3D tool radius compensation 3.1 Function vector of zero length (all three components are zero) is ignored, i.e. the direction programmed beforehand remains valid, no alarm is generated. If only the start vector is programmed (A4, B4, C4) in a block, then the programmed surface normal vector remains constant over the entire block.
Page 248: Compensation On Path
W5: 3D tool radius compensation 3.1 Function from their programmed values at the path end point. This is because the orientation has changed relative to the surface normal vector or path tangent vector when the absolute orientation of the tool is the same as at the original path end point. 3.1.3.3 Compensation on path A special case must be examined with respect to face milling operations, i.e.
Page 249: Corners In Face Milling
W5: 3D tool radius compensation 3.1 Function migrate from the tool tip to the periphery (at outside corners or convex surfaces) or the paths must be shortened to prevent contour violations (at inside corners or concave surfaces). It is therefore necessary to activate both the smoothing of the contours ("Top Surface" function) and the smoothing of the surface normal to ensure that the transitions run smoothly.
Page 250: Behavior At Outer Corners
W5: 3D tool radius compensation 3.1 Function between the activation block and the first corrected block or between the last corrected block and the deactivation block. Other intermediate block are allowed, however. 3.1.3.5 Behavior at outer corners In face milling, outside corners are treated like circles with a radius of 0, where the circular plane stretches from the end tangent of the first block and the start tangent of the second block.
Page 251 W5: 3D tool radius compensation 3.1 Function Figure 3-8 Inside corner with face milling (view in direction of longitudinal axis of tool) Note The amount by which the contact points deviate from the programmed contour will generally be small since the explanatory example shown in the Figure, in which the machining point "changes"...
Page 252: Monitoring Of Path Curvature
W5: 3D tool radius compensation 3.2 Commissioning impermissible side angles (at points which are virtually singular) occurring in the shortened block. If this type of situation is detected during processing of an inside corner, the machining operation is aborted with an alarm. No block division takes place at the singular points since the compensatory motions this would involve frequently cause contour violations and the change in machining side on the tool is not generally intended or even foreseen by the user.
Page 253: Programming
W5: 3D tool radius compensation 3.3 Programming The lower the value of MD21080, the higher the computation effort generally is, which is needed to check adherence to the cited conditions. Exceptions apply to linear blocks with constant orientation. Minimal angle between surface normal vector and tool orientation In 3D face milling, the following machine data specifies the minimum angle which the surface normal vector and tool orientation must form in each point of the path if you are working with a side angle that is not equal to zero and the tool is not a cherry:...
Page 254 W5: 3D tool radius compensation 3.3 Programming Syntax G41/G42 ORIC/ORID ISD=... CUT3DC/CUT3DCD CDOF2 X... Y... Z... G40 X... Y... Z... Meaning 3D TRC for circumferential milling (only when 5-axis transforma‐ CUT3DC: tion is active) 3D TRC in relation to a differential tool for circumferential milling CUT3DCD: (only when 5-axis transformation is active) The radius difference is specified by the tool parameter...
Page 255 W5: 3D tool radius compensation 3.3 Programming Example Program code Comment ; Definition of tool D1: $TC_DP1[1,1]=120 ; Type (end mill) $TC_DP3[1,1]=20 ; Length compensation vector $TC_DP6[1,1]=8 ; Radius N10 X0 Y0 Z0 T1 D1 F12000 ; Selection of the tool. N20 TRAORI(1) ;...
Page 256 W5: 3D tool radius compensation 3.3 Programming Figure 3-10 Circumferential milling Approach behavior The approach behavior is always NORM for the 3D variant of the tool radius compensation. Behavior at outside corners The G commands of group 18 (corner behavior, tool offset) are evaluated at the outside corners for circumferential milling with 3D TRC in the same way as for the conditions for the 2½D TRC: ●...
Page 257 W5: 3D tool radius compensation 3.3 Programming ① Programmed path ② Milling tool machining point ③ Milling tool reference point ④ Milling tool tip Insertion depth (InSertion Depth) Figure 3-11 Insertion depth Tool radius compensation referred to a differential tool 3D TRC for circumferential milling referred to a differential tool is activated via the CUT3DCD command.
Page 258: Selecting 3D Tool Radius Compensation For The 3D Face Milling (Cut3Df, Cut3Dfs, Cut3Dff, Cut3Dfd)
Surface" or "Top Surface" option (requiring a license), the setting recommendations regarding "Advanced Surface" / "Top Surface" must be observed. Special test programs are provided in the SIOS portal for checking the set data: ● Test programs for Advanced Surface (https://support.industry.siemens.com/cs/ww/en/view/ 78956392) ● Test programs for Top Surface (https://support.industry.siemens.com/cs/ww/en/view/ 109738423) 3.3.2...
Page 259 W5: 3D tool radius compensation 3.3 Programming 3D TRC in relation to a differential tool for face milling with CUT3DFD: change in orientation (only with active 5-axis transformation) The radius difference is specified by the tool parameter $TC_DP15. Note: CUT3DFD is only possible in combination with "Smoothing of surface normals in 3D face milling".
Page 260 W5: 3D tool radius compensation 3.3 Programming Program code Comment N80 X0 Y0 Z0 A0 B0 C0 G17 T1 D1 F12000 ; Selection of the tool. N90 TRAORI(1) ; Select orientation transformation. N100 B4=-1 C4=1 ; Definition of the plane. N110 G41 ORID CUT3DF G64 X10 Y0 Z0 ;...
Page 261 W5: 3D tool radius compensation 3.3 Programming Program code Comment TRAORI(1) ; Select orientation transformation. G500 CYCLE832(0.01, _TOP_SURFACE_SMOOTH_ON + _ORI_FIN- ; Call CYCLE832 with: ISH, 1) ; Contour tolerance = 0.01 mm, ; Processing type: Top Surface with smoothing, ; Finishing with input of an orientation toler- ance, ;...
Page 262 W5: 3D tool radius compensation 3.3 Programming Program code Comment N23 X-248.07130 Y30.15119 Z8.71082 A5=-.060165696 B5=.971048883 C5=-.231179920 A3=-.214177198 B3=.926684940 C3=-.308841625 N24 X-248.07829 Y29.97126 Z8.05094 A5=-.059884286 B5=.968941717 C5=-.239928784 A3=-.213318480 B3=.923853466 C3=-.317789237 N25 X-248.08317 Y29.78487 Z7.38844 A5=-.059584206 B5=.966718449 C5=-.248807482 A3=-.212397895 B3=.920898045 C3=-.326854594 N26 X-248.08578 Y29.59254 Z6.72679 A5=-.059263963 B5=.964380907 C5=-.257793037 A3=-.211418355 B3=.917822366 C3=-.336012474...
Page 263: Circumferential Milling Taking Into Account A Limitation Surface (Cut3Dcc, Cut3Dccd)
For 3D face milling with CUT3DFD in combination with "Top Surface", the setting recommendations regarding "Top Surface" must be observed. Special test programs are provided (https://support.industry.siemens.com/cs/ww/en/view/ 109738423) in the SIOS portal for checking the set data. 3.3.3 3D circumferential milling taking into account a limitation surface (CUT3DCC,...
Page 264 W5: 3D tool radius compensation 3.3 Programming CUT3DCCD takes account of a limitation surface for a real differential tool that the programmed standard tool would define. The NC program defines the center-point path of a standard tool. CUT3DCC with the use of cylindrical tools takes account of a limitation surface that the programmed standard tool would have reached.
Page 265 W5: 3D tool radius compensation 3.3 Programming Example Program code Comment N10 $TC_DP1[1,1]=120 ; Cylindrical milling tool N20 $TC_DP6[1,1]=10 N30 $TC_DP15[1,1]=-3 ; Processing with cylindrical milling tool and CUT3DCCD N110 TRAORI ; Activation of the transformation. N120 A4=0 B4=0 C4=1 ;...
Page 266 W5: 3D tool radius compensation 3.3 Programming Example: Toroidal miller with reduced radius compared to the standard tool Tool type Shaft radius (R) Corner radius (r) Standard tool with corner rounding R = $TC_DP6 r = $TC_DP7 Real tool with corner rounding R' = $TC_DP6 + $TC_DP15 + r' = $TC_DP7 + $TC_DP16 OFFN...
Page 267 W5: 3D tool radius compensation 3.3 Programming Using cylindrical tools When cylindrical tools are used, infeed is only necessary if the machining surface and the surface of limitation form an acute angle (less than 90 degrees). If a toroidal miller (end mill with corner rounding) is used, tool infeed in the longitudinal direction is required for both acute and obtuse angles.
Page 268: Boundary Conditions
"Advanced Surface" or "Top Surface" function (requiring a license), the setting recommendations regarding "Advanced Surface" / "Top Surface" must be observed. Special test programs are provided in the SIOS portal for checking the set data: ● Test programs for Advanced Surface (https://support.industry.siemens.com/cs/ww/en/view/ 78956392) ● Test programs for Top Surface (https://support.industry.siemens.com/cs/ww/en/view/...
Page 269 W5: 3D tool radius compensation 3.5 Examples Program code Comment N20 T1 D1 ; Selection of the tool (radius=5). N30 TRAORI(1) ; Activation of transformation. N40 CUT3DC ; Selection of 3D TRC for circumferential milling. N50 ORIC ; Orientation changes at outside corners are super- imposed on the circle block to be inserted.
Page 270 W5: 3D tool radius compensation 3.5 Examples Program code Comment N75 M20 ; auxiliary function call N80 A3=1 B3=0 C3=1 ; change in orientation of external corner gener- ated from N70 and N90 N90 Y60 Blocks N75 and N80 are executed after N70. The circle block is then executed with the current orientation.
Page 271: Example 2: Orientation Change At Inside Corner During 3D Circumferential Milling
W5: 3D tool radius compensation 3.5 Examples Figure 3-14 ORID: Change in orientation and path movement consecutively 3.5.2 Example 2: Orientation change at inside corner during 3D circumferential milling Program code Comment N10 A0 B0 X0 Y0 Z0 F5000 N20 T1 D1 ;...
Page 272: Data Lists
W5: 3D tool radius compensation 3.6 Data lists Data lists 3.6.1 General machine data Number Identifier: $MN_ Description 18094 MM_NUM_CC_TDA_PARAM Number of TDA data 18096 MM_NUM_CC_TOA_PARAM Number of TOA data, which can be set up per tool and evaluated by the CC 18100 MM_NUM_CUTTING_EDGES_IN_TOA Tool offsets per TOA module...
Page 273: Channelspecific Machine Data
W5: 3D tool radius compensation 3.6 Data lists 3.6.2 Channelspecific machine data Number Identifier: $MC_ Description 20110 RESET_MODE_MASK Definition of the control basic setting after power-up and RESET / part program end 20120 TOOL_RESET_VALUE Definition of the tool from which the tool length compen‐ sation is selected during run-up and upon RESET or part program end, dependent upon MD 20110.
Page 274 W5: 3D tool radius compensation 3.6 Data lists Tools Function Manual, 06/2019, A5E47435126B AA...
Page 275: W4: Grinding-Specific Tool Offset And Tool Monitoring
W4: Grinding-specific tool offset and tool monitoring Grinding-specific tool data 4.1.1 Structure of tool data Grinding tools (tool type: 400 to 499) normally have specific tool and dresser data in addition to cutting edge data. The grinding wheel-specific data for the left and right wheel geometry can be stored under a T number in the tool cutting edges D1 and D2.
Page 276: Cutting Edge-Specific Parameters
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data <t>: T number <d>: D number Figure 4-1 Structure of the tool data for grinding tools 4.1.2 Cutting edge-specific parameters 4.1.2.1 List of cutting edge-specific parameters The cutting edge-specific tool parameters for grinding tools have the same meaning as those for turning and milling tools.
Page 277 W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data Tool parameter Meaning Comment Geometry - tool radius compensation $TC_DP6 Radius 1 $TC_DP7 Reserved $TC_DP8 Reserved $TC_DP9 Reserved $TC_DP10 Reserved $TC_DP11 Reserved Wear - tool length compensation $TC_DP12 Length 1 $TC_DP13 Length 2 $TC_DP14...
Page 278: Tc_Dp1
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.2.2 $TC_DP1 The parameter $TC_DP1 contains the 3-digit number of the grinding tool type: Number Grinding tool type Surface grinding wheel Surface grinding wheel with monitoring with tool base dimension for GWPS Surface grinding wheel without monitoring without tool base dimension for GWPS Surface grinding wheel with monitoring without tool base dimension for GWPS Facing wheel...
Page 279: Tool-Specific Parameters
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.3 Tool-specific parameters 4.1.3.1 List of tool-specific parameters The tool-specific parameters are automatically set up with every new grinding tool (tool type: 400 to 499). Note Tool-specific parameters have the same characteristics as a cutting edge. This is to be taken into account when the number of cutting edges is specified: MD18100 $MN_MM_NUM_CUTTING_EDGES_IN_TOA When all the cutting edges of a tool are deleted, the associated tool-specific parameters are...
Page 280: Tc_Tpg1
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.3.2 $TC_TPG1 The spindle number is entered in parameter $TC_TPG1. The grinding wheel circumferential velocity is then monitored for this spindle. 4.1.3.3 $TC_TPG2 The tool parameters of the two cutting edges D1 and D2 are entered in parameter $TC_TPG2, their values must always be the same.
Page 281: Tc_Tpg3, $Tc_Tpg4
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data Change becomes effective If parameter $TC_TPG2 becomes effective at a later point in time, the values of the tool parameters of the cutting edges are not automatically aligned immediately. The alignment is only made the next time that a tool parameter of both cutting edges is changed.
Page 282: Tc_Tpg6 And $Tc_Tpg7
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.3.6 $TC_TPG6 and $TC_TPG7 For grinding-specific tool monitoring (Page 298), theupper limit values of the grinding wheel are entered in the parameters: ● Parameter $TC_TPG6: Speed [rpm] ● Parameter $TC_TPG7: Circumferential/peripheral speed [m*s ] or [inch*s 4.1.3.7 $TC_TPG8...
Page 283: Tc_Tpg9
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.3.8 $TC_TPG9 Parameter $TC_TPG9 is used to define to which tool parameters the following functions should refer: ● Grinding-specific tool monitoring (Page 298) ● Constant grinding wheel peripheral speed (GWPS) (Page 301) Examples: $TC_TPG9 = <value>...
Page 284: Access To Tool-Specific Parameters
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data MD18096 $MN_MM_NUM_CC_TDA_PARAM NOTICE Loss of data due to reconfiguration Reconfiguration of the local static NC memory results in a loss of data on the active and passive file system. We therefore urgently recommend archiving or backing up all relevant data by creating a commissioning archive before activating a modified memory configuration.
Page 285: Examples
W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data 4.1.5 Examples Figure 4-3 Required offset data of a surface grinding wheel Tools Function Manual, 06/2019, A5E47435126B AA...
Page 286 W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data Figure 4-4 Required offset data for inclined wheel with implicit monitoring selection and without base dimension for GWPS Figure 4-5 Required offset data for inclined wheel with implicit monitoring selection and with base dimension for GWPS Tools Function Manual, 06/2019, A5E47435126B AA...
Page 287 W4: Grinding-specific tool offset and tool monitoring 4.1 Grinding-specific tool data Figure 4-6 Required offset data of a surface grinding wheel without base dimension for GWPS Figure 4-7 Required offset data of a facing wheel with monitoring parameters Tools Function Manual, 06/2019, A5E47435126B AA...
Page 288: Online Tool Offset
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Online tool offset 4.2.1 Function A grinding operation involves both machining of a workpiece and dressing of the grinding wheel. These processes can take place in the same channel or in separate channels. To allow machining to continue while the grinding wheel is being dressed, the reduction in the size of the grinding wheel caused by dressing must be transferred to the current tool in the machining channel as a tool offset that is applied immediately.
Page 289: Commissioning
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Additional properties ● An online tool offset can be activated for every grinding tool (tool type: 400 to 499) in each channel. ● The online tool offset is generally applied as a length compensation. Like geometry and wear data, lengths are assigned to geometry axes on the basis of the current plane as a function of the tool type.
Page 290: Programming
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset 4.2.3 Programming 4.2.3.1 Defining a polynomial function (FCTDEF) Certain dressing strategies (e.g. dressing roller) are characterized by the fact that the grinding wheel radius is continuously (linearly) reduced as the dressing roller is fed in. This strategy requires a linear function between infeed of the dressing roller and writing the wear value of each length.
Page 291: Write Online Tool Offset Continuously (Putftocf)
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Example Definitions ● Function number: 1 ● Lower and upper limit value: -100, 100 ● Gradient of the characteristic: a ● The operating point should be located at the center of the characteristic. Based on the setpoint position of axis XA in the WCS at the instant that the function is defined in the NC program, the characteristic must be shifted in the negative Y direction: a = -a...
Page 292: Write Online Tool Offset, Discrete (Putftoc)
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Syntax PUTFTOCF(<Func>,<RefVal>,<ToolPar>,<Chan>,<Sp>) Meaning PUTFTOCF(...): Write online tool offset, continuously block-by-block using the polynomial function defined with FCTDEF(...) Function number, defined in the function definition with FCTDEF(...) <Func>: Data type: Range of val‐...
Page 293: Activate/Deactivate Online Tool Offset (Ftocon/Ftocof)
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Number of the channel in which the online tool offset is to take effect. <Chan>: Note: Only required if the offset is not to take effect in the active channel. Data type: Number of the spindle for which the online tool offset is to take effect.
Page 294 W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Acceleration margin The active online tool offset is traversed through at JOG velocity, allowing for the maximum acceleration. In case of FTOCON the following channel-specific machine data is taken into account: MD20610 $MC_ADD_MOVE_ACCEL_RESERVE An acceleration margin can thus be reserved for the movement which means that the overlaid movement can be executed immediately.
Page 295: Examples
W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset 4.2.5 Examples 4.2.5.1 Example: Write online tool offset continuously ① Grinding disk ② Dressing roller Oscillating axis Infeed axis: Grinding disk Table axis Infeed axis: Dressing roller Figure 4-9 Surface grinding machine Specifications ●...
Page 296 W4: Grinding-specific tool offset and tool monitoring 4.2 Online tool offset Figure 4-10 Tool offset Program (section) for channel 1: Machining channel Program code Comment G1 G18 F10 G90 ; initial setting T1 D1 ; select actual tool S100 M3 X100 ;...
Page 297: Online Tool Radius Compensation
W4: Grinding-specific tool offset and tool monitoring 4.3 Online tool radius compensation Program code Comment V-0.05 G1 F0.01 G91 ; infeed motion of the V axis for dressing Online tool radius compensation Function When the longitudinal axis of the tool and the contour are perpendicular to each other, the offset can be applied as a length compensation to one of the three geometry axes (online tool length compensation).
Page 298: Grinding-Specific Tool Monitoring
W4: Grinding-specific tool offset and tool monitoring 4.4 Grinding-specific tool monitoring Boundary conditions ● A tool radius compensation, and thus also an online tool radius compensation, can be activated only when the selected tool has a radius other than "0". This means that machining operations cannot be implemented solely with a tool radius compensation.
Page 299 W4: Grinding-specific tool offset and tool monitoring 4.4 Grinding-specific tool monitoring The current wheel width is usually determined through the dressing cycle and can be entered in parameter $TC_TPG5 of a grinding tool. If monitoring is active, this entered value is compared to the value in parameter $TC_TPG4 (minimum wheel width).
Page 300: Commissioning
W4: Grinding-specific tool offset and tool monitoring 4.4 Grinding-specific tool monitoring 4.4.2 Commissioning Automatic activation If, when selecting the tool length compensation of a grinding tool with an odd tool type number, the grinding-specific tool monitoring is to be automatically activated, the following machine data must be set to "1": MD20350 $MC_TOOL_GRIND_AUTO_TMON (activation of tool monitoring) = 1 4.4.3...
Page 301: Constant Grinding Wheel Peripheral Speed (Gwps)
W4: Grinding-specific tool offset and tool monitoring 4.5 Constant grinding wheel peripheral speed (GWPS) Constant grinding wheel peripheral speed (GWPS) 4.5.1 Function For grinding wheels, generally the wheel peripheral speed is used instead of the spindle speed. The value to be set is determined by technological process parameters (e.g. grinding wheel characteristic, material combination).
Page 302: Commissioning
W4: Grinding-specific tool offset and tool monitoring 4.5 Constant grinding wheel peripheral speed (GWPS) Status The following interface signal can be used to determine whether or not the GWPS is active: DB31, ... DBX84.1 (GWPS active) New tool If GWPS is to be selected with a new tool for a spindle for which GWPS is already active, the active GWPS must first be deselected (otherwise an alarm is output).
Page 303: Programming
W4: Grinding-specific tool offset and tool monitoring 4.5 Constant grinding wheel peripheral speed (GWPS) MD35040 $MA_SPIND_ACTIVE_AFTER_RESET = 1 Note MD35040 only takes effect in the spindle mode open-loop control operation. 4.5.3 Programming 4.5.3.1 Switching constant grinding wheel peripheral speed (GWPSON, GWPSOF) on/off: With the predefined procedures GWPSON(...) and GWPSOF(...), the constant grinding wheel peripheral speed (GWPS) for grinding tools (tool type: 400 to 499) is switched on and off.
Page 304: Example
W4: Grinding-specific tool offset and tool monitoring 4.5 Constant grinding wheel peripheral speed (GWPS) 4.5.4 Example A constant grinding wheel peripheral speed is to be used for grinding tools T1 and T5. T1 is the active tool. Data of tool T1 (peripheral grinding wheel) $TC_DP1[1,1] = 403 ;tool type $TC_DP3[1,1] = 300...
Page 305: Data Lists
W4: Grinding-specific tool offset and tool monitoring 4.6 Data lists Program code Comment N65 GWPSOF(5) ; deactivate GWPS for tool 5 (spindle 2) Data lists 4.6.1 Machine data 4.6.1.1 General machine data Number Identifier: $MN_ Description 18075 MM_NUM_TOOLHOLDERS Maximum number of tool holders that can be defined 18094 MM_NUM_CC_TDA_PARAM Number of TDA...
Page 306 W4: Grinding-specific tool offset and tool monitoring 4.6 Data lists Tools Function Manual, 06/2019, A5E47435126B AA...
Page 307: Appendix
Appendix List of abbreviations Output ADI4 (Analog drive interface for 4 axes) Adaptive Control Active Line Module Rotating induction motor Automation system ASCII American Standard Code for Information Interchange: American coding standard for the exchange of information ASIC Application-Specific Integrated Circuit: User switching circuit ASUB Asynchronous subprogram AUXFU...
Page 308 Appendix A.1 List of abbreviations Computerized Numerical Control: Computer-Supported Numerical Control Connector Output Certificate of License Communication Compiler Projecting Data: Configuring data of the compiler Cathode Ray Tube: picture tube Central Service Board: PLC module Control Unit Communication Processor Central Processing Unit: Central processing unit Carriage Return Clear To Send: Ready to send signal for serial data interfaces CUTCOM...
Page 309 Appendix A.1 List of abbreviations Input Execution from External Storage Input/Output Encoder: Actual value encoder Compact I/O module (PLC I/O module) Electrostatic Sensitive Devices ElectroMagnetic Compatibility European standard Encoder: Actual value encoder EnDat Encoder interface EPROM Erasable Programmable Read Only Memory: Erasable, electrically programmable read-only memory ePS Network Services Services for Internet-based remote machine maintenance...
Page 310 Appendix A.1 List of abbreviations GSDML Generic Station Description Markup Language: XML-based description language for creating a GSD file Global User Data: Global user data Abbreviation for hexadecimal number AuxF Auxiliary function Hydraulic linear drive Human Machine Interface: SINUMERIK user interface Main Spindle Drive Hardware Commissioning...
Page 311 Appendix A.1 List of abbreviations Position Measuring System Position controller Least Significant Bit: Least significant bit Local User Data: User data (local) Media Access Control MAIN Main program: Main program (OB1, PLC) Megabyte Motion Control Interface MCIS Motion Control Information System Machine Control Panel: Machine control panel Machine Data Manual Data Automatic: Manual input...
Page 312 Appendix A.1 List of abbreviations Process Image Output Process Image Input Personal Computer PCIN Name of the SW for data exchange with the control PCMCIA Personal Computer Memory Card International Association: Plug-in memory card standardization PC Unit: PC box (computer unit) Programming device Parameter identification: Part of a PIV Parameter identification: Value (parameterizing part of a PPO)
Page 313 Appendix A.1 List of abbreviations R Parameter, arithmetic parameter, predefined user variable R Parameter Active: Memory area in the NC for R parameter numbers Roll Pitch Yaw: Rotation type of a coordinate system RTLI Rapid Traverse Linear Interpolation: Linear interpolation during rapid traverse motion Request To Send: Control signal of serial data interfaces RTCP Real Time Control Protocol...
Page 314 Appendix A.1 List of abbreviations Terminal Board (SINAMICS) Tool Center Point: Tool tip TCP/IP Transport Control Protocol / Internet Protocol Thin Client Unit Testing Data Active: Identifier for machine data Totally Integrated Automation Terminal Module (SINAMICS) Tool Offset: Tool offset Tool Offset Active: Identifier (file type) for tool offsets TRANSMIT Transform Milling Into Turning: Coordination transformation for milling operations on a...
Page 315 Appendix A.1 List of abbreviations Extensible Markup Language Work Offset Active: Identifier for work offsets Status word (of drive) Tools Function Manual, 06/2019, A5E47435126B AA...
Page 316 Appendix A.1 List of abbreviations Tools Function Manual, 06/2019, A5E47435126B AA...
Page 317: Index
Index Angle Clearance, 144 Holder, 144 Assignment tool/toolholder, 96 $AC_CUT_INV, 164 $AC_CUTMOD, 164 $AC_CUTMOD_ANG, 147, 164 $AC_CUTMODK, 164 $NT_ROT_AX_NAME, 161 Behavior at inside corners, 250 $P_AD, 163 $P_CUT_INV, 164 $P_CUTMOD, 164 $P_CUTMOD_ANG, 147, 164 CDOF, 77 $P_CUTMOD_ERR, 165 CDOF2, 77 $P_CUTMODK, 164 CDON, 77 $P_GWPS, 303...
Page 318 Index D function, 22 Holder angle, 144 D numbers Allocation of free ..., 27 DB31, ... DBX83.3, 299 Incrementally programmed compensation DBX83.6, 299 values, 168 DBX84.1, 302 Insertion depth, 239, 256 DELTOOLENV, 209 ISD, 239 Description of a rotation, 107 DISC, 71 Dressing, 288 Kinematic type, 99...
Page 319 Index MD20121, 22 MD20125, 146, 150 MD20126, 131, 151 MD20127, 151 NORM, 52 MD20180, 122 MD20184, 124 MD20188, 107 MD20190, 107 MD20202, 67 Offset number, 28 MD20204, 60 Online tool offset, 288 MD20210, 73, 241 Online tool radius compensation:, 297 MD20220, 71 ORIC, 241, 250 MD20230, 73, 241...
Page 320 Index Smooth approach and retraction Tool length compensation Significance, 57 calculate tool-specifically, example, 136 Sub-movements, 57 Geometry, 43 Storing angles in the toolholder data, 99 Wear, 46 Workpiece-specific calculation, 199 Tool monitoring grinding-specific, 298 Tool offset T function, 21 Offset in the NC, 25 TCARR, 122 Types, 98 TCOABS, 123...

Siemens SINUMERIK 840D sl Function Manual

1 Fundamental Safety Instructions

2 W1: Tool Offset

3 W5: 3D Tool Radius Compensation

4 W4: Grinding-Specific Tool Offset and Tool Monitoring

Appendix

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Summary of Contents for Siemens SINUMERIK 840D sl

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