DIE AND MOLD

s

Manual Edition 04/2004

sinumerikTool and Mold MakingSINUMERIK 810D/840D

References

Contents Page

4.1 Overview of higher-order functions 4.2

4.2 Index 4.10

SINUMERIK 810D/840DTool and Mold Making

Manual

Valid for

Control software versionSINUMERIK 840D 6

SINUMERIK 840DE (Export version) 6SINUMERIK 840D powerline 6

SINUMERIK 840DE powerline 6SINUMERIK 840Di 2

SINUMERIK 840DiE (Export version) 2SINUMERIK 810D 3

SINUMERIK 810DE (Export version) 3SINUMERIK 810D powerline 6SINUMERIK 810D powerline 6

04.04 Edition

sFirst for the

theory 1

Machine operators �

at the machine 2

Information for

programmers 3

References 4

© Siemens AG 2004 All rights reserved. SINUMERIK 840D Manual, Tool and Mold Making 04.2004

0.2

IntroductionPrinting history, Trademarks

SINUMERIK® Documentation

Printing history

Brief details of this edition and previous editions are listed below.The status of each edition is shown by the code in the �Remarks� column.

Status code in the �Remarks� column:

A .... New documentation.B .... Unrevised edition with new order no.C .... Revised edition with new status.

Any change to the technical content of a page as compared with the previousedition is indicated by the changed edition number in the header ofthe page concerned.

Edition Order No. Remarks--- --- ---

TrademarksSIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK and SIMODRIVE are registeredtrademarks of Siemens AG. Other names in this publication might be trademarks whose use by a third party for his own purposes may violate the rights of the registered holder.

More information is available on the Internet:http://www.ad.siemens.de/sinumerik

This document has been created using a number of layout andgraphics utilities.The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights,including rights created by patent grant or registration of a utility model or design, are reserved.

© Siemens AG 1995 - 2004. All rights reserved.

Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing.

We have checked the contents of this manual for agreement with the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information given in this publication is reviewed at regular intervals and any corrections that might be necessary are made in the subsequent printings. We welcome suggestions for improvement.

Subject to change without prior notice

Order No. 6FC5095-0AB10-0BP0Printed in the Federal Republic of Germany

Siemens Aktiengesellschaft

0


0.3

IntroductionContents

Contents

First for the theory

1.1 Introduction.......................................................................................... 1.2

1.2 What are the needs of tool and mold making? .................................... 1.3

1.3 Milling with 3 axes, 3 + 2 or 5 axes?.................................................... 1.6

1.4 What moves and how? ........................................................................ 1.8

1.5 Machine-independent CNC programs ............................................... 1.12

1.6 Theory of tool radius compensation .................................................. 1.14

1.7 What are frames? .............................................................................. 1.17

1.8 Precision, speed, surface quality....................................................... 1.19

1.9 Structure of CNC mold making programs.......................................... 1.22

1.10 Orientation in 5-axis applications....................................................... 1.23

Machine operators � at the machine

2.1 Workpiece � determining the zero point .............................................. 2.2

2.2 Gauging tools .................................................................................... 2.13

2.3 Program data transfer........................................................................ 2.16

2.4 Testing a program.............................................................................. 2.17

2.5 Calling and executing a program....................................................... 2.18

2.6 Interrupting a program ....................................................................... 2.20

2.7 High-speed settings � CYCLE832..................................................... 2.25

2.8 ShopMill ............................................................................................ 2.28

Information for programmers

3.1 Introduction.......................................................................................... 3.2

3.2 Kinematic-independent CNC programs............................................... 3.3

3.3 Five-axis transformation � TRAORI..................................................... 3.5

3.4 Tool orientation � A3= B3= C3=, ... ..................................................... 3.6

0


0.4

IntroductionContents

3.5 High-speed settings � CYCLE832....................................................... 3.9

3.6 Feedrate proÞ le � FNORM, FLIN, ... ................................................. 3.18

3.7 Orientation interpolation � ORI... ....................................................... 3.19

3.8 Tool offsets � CUT3DFS, ... ............................................................... 3.21

3.9 Programming at the machine ............................................................ 3.22

3.10 Example � bending device for pipes.................................................. 3.25

3.11 Example � motor cycle headlight....................................................... 3.36

References

4.1 Overview of higher-order functions...................................................... 4.2

4.2 Index.................................................................................................. 4.10

0

1

First for the theory

Contents Page

1.1 Introduction 1.2

1.2 What are the needs of tool and mold making? 1.3

1.3 Milling with 3 axes, 3 + 2 or 5 axes? 1.6

1.4 What moves and how? 1.8

1.5 Machine-independent CNC programs 1.12

1-6 Theory of tool radius compensation 1.14

1.7 What are frames? 1.17

1.8 Precision, speed, surface quality 1.19

1.9 Structure of CNC mold making programs 1.22

1.10 Orientation in 5-axis applications 1.23

© Siemens AG 0000-2004 All rights reserved. SINUMERIK 840D Brochure, Tool and Mold Making 04.2004

1.2

First for the theoryIntroduction1.1

1.1 Introduction

5-axis machining of complex parts, in tool and mold making in particular, is based on the CAD - CAM - CNC process chain.

The aim of this brochure is to help both CNC programmers at the CAM workstation and operators at the machine to do their job, and to simplify communication between the CAM station and the machi-ne.

Sinumerik 840D features powerful, sophisticated functions, the intelligent use of which greatly simpli-Þ es the entire 5-axis programming and machining process and improves production results.

Automotivetrim


1.3

1.2 What are the needs of tool and mold making?

Object design standards in all areas of applicati-on are becoming ever more demanding.Increasingly, ergonomics, air drag coefÞ cient or simply aesthetics call for rounded forms. In addition, processes have to be faster and even more accurate. The design comes primarily from CAD systems, the machining programs for freeform surfaces from CAM stations.

Nevertheless, the skilled machine tool operator still bears the technological responsibility for the quality of the mold and of the entire tool.

Sinumerik 840D from Siemens is a control sys-tem that is precisely tailored to the requirements of tool and mold making� in the traditional 2 ½ D range, in3-axis machining as well as in the 5-axis andhigh-speed range:

! good operability! user-friendly programming at the machine! optimum performance in the CAD � CAM � CNC process chain! maximum quality control at the machine

First for the theoryWhat are the needs of tool and mold making? 1.2

Prototype construction

Impeller

Valve


1.4

First for the theoryWhat are the needs of tool and mold making?1.2

Freeformsurface

Deep cavity

Inclined surfacewith hole

5-axis machining inmodern milling centers

The demands placed on molds, surface quality and machining speed for stock removal, in tool and mold making in particular,are rising dramatically:

To obtain optimum cutting conditions whenmachining surfaces with a three-dimensional curve "...

... to machine geometries anywhere in the area # (the setting angle of the tool axis must be able to be varied) ...

3 + 2 axes

... or to mill deep cavities $ ...

Dynamic 5-axis machining

In addition to the 3 linear axes X, Y and Z, 2 rotary axes A, B or C are alsorequired.

1

2

3


1.5

Machine movement

The linear axes X, Y and Z are used toapproach a tool position in the work area.

2 rotary axes, e.g. B and C, are used tochange the tool setting, the tool orientation.

Theoretically, with 3 linear axes and 2 rotary axes, any point in the area can be approached with the desired tool orientation.

CNC programming

A set position in the CNC program is described with the coordinate axes X, Y and Z. To describe the tool orientation we recommend using the direction vector A3, B3, C3, so that the orientati-on can be programmed independently from the kinematics.

For certain tasks a Þ xed orientation is perfectly adequate, e.g. on inclined planes. In many cases, ho-wever, it is desirable for the tool orientation to change during the traversing movement. This is known as 5-axis simultaneous machining. The control system has to interpolate 2 rotary axes in addition to the 3 linear axes. With modern 5-axis control systems like Sinumerik 840D you can program elements such as inclined holes and pockets with a Þ xed tool orientation directly on the machine and adjust the key machining parameters in CAM programs.

Directionvector for tool orientation

First for the theoryWhat are the needs of tool and mold making? 1.2

C3

A3 B3


1.6

First for the theoryMilling with 3 axes, 3 +2 or 5 axes?1.3

1.3 Milling with 3 axes, 3 + 2 or 5 axes?

Freeform surfaces with uniform convex curves in particular are conventionally produced with 3 controlled axes. For deep cavities or frequent curvature changes, however, 5 controlled axes are required.

Sinumerik 840D naturally supports all machining strategies.

1

In these machine tools the orientation of the tool or the position of the table can be altered, e.g. by resetting.

In the picture on the left the cutter is working with optimum cutting conditions. The cutting conditions deteriorate as the cutter moves up towards the top or to the side of the workpiece. In order to obtain optimum cutting conditions here too, the table is swiveled. To machine a freeform surface completely, the table often has to be swiveled several times in various directions.

" 3 axes Controlled path axes X, Y, Z

# 3 + 2 axes Controlled path axes X, Y, Z Fixed rotary axes, e.g. A, C (table)

The orientation of the cutter remains unchanged along the entire cutter path. The cutting conditions at the cutter tip are never perfect.


1.7

3

First for the theoryMilling with 3 axes, 3 +2 or 5 axes? 1.3

Advantage: The orientation of the tool can be optimized along the entire path, synchronously to the linear movement of the tool. In this way optimum cutting conditions are maintained throughout the path.

$ 5 axes: Controlled path axes X, Y, Z Controlled rotary axes, e.g. A, B


1.8

First for the theoryWhat moves and how?1.4

1.4 What moves and how?

The design of 5-axis milling machines

2

3

1


1.9

A 5-axis machine can control tool movements in 5 axes: the 3 familiarlinear axes plus an additional 2 rotary axes. The two rotary axes have different kinematic solutions. The most common ones are shown here diagrammatically. Machine tool manuf-acturers are constantly developing new kinematic solutions for different requirements. With Sinumerik 840D, thanks to the integral kinematic transformation, we can also control special kinematics. Howe-ver, we don�t want to go into detail about hexapods, etc. here.

* Term: If the rotary axis is not perpendicular to a linear axis, it is referred to as a � nutated� axis.

2 rotary axes in the head

2 rotary axes in the table

1 rotary axis in the head,1 rotary axis in the table

Fork

Rotate/swivel

nutated *

nutated *

" #

$

&

First for the theoryWhat moves and how? 1.4

4 5

'


1.10

First for the theoryWhat moves and how?1.4

Kinematic-independent programming

Depending on the machine kinematics, completely different machine movements may be required to machine the same surface. The machine kinematics in example 2 are much more suitable for the production of this workpiece.

ExampleMachining a cylinder jacket surface

"

#

Sequence of movements for head/headkinematicsTo describe a simple circumference, descri-be a semicircle in X/Y with radius = cylinder radius. During the movement the tool must rotate around the Z axis so that the cutter is always perpendicular to the surface.

Sequence of movements for table/table� Swivel 90° around A� C axis turns to position +90°, then 90°� Y axis moves in a linear direction

When programming on a machine with Sinumerik 840D there is generally no need to worry about machine kinematics and tool length. All you need to think about is the relative move-ment between the tool and the workpiece. The control system does the rest.

See below for details of how operation varies according to the machine kinematics.

CONCLUSION

1

2


1.11

Inß uence of a change in orientation on the movement of thelinear axes

Machine-independent CNC programs

The examples show that with 5-axis machining it is vital that the CNC programs are not speciÞ c to the machine or tool. This is why Sinumerik 840D features integral 5-axis transformation.

Inß uence of tool length on machine axis movement

Example

Note: Depending on the tool length, it can happen that the traversing range of an axis is overrun and the axis runs on to the limit switch, even though all values in the CNC program are within the work area. A distinction is made here between the �gross� and �net� work area.

The machine movements required for 5-axis machining depend on the tool length.

The longer the tool in the example, the larger the traversing movements of the axis slides. Each tool change would require the CNC program to be recalculated on the CAM system. When programming on a machine with Sinume-rik 840D, there is no need to worry about tool length if tool offset is enabled. The control system takes care of it automatically.

Simple movements can be transformed into a complex curve by simultaneously changing the tool orientation.

To mill a straight line with no change of orienta-tion, the tool holder describes a straight line. If the orientation changes at the same time, the tool tip describes a curve. This curve must be compensated so that the tool tip describes the desired straight line as the orientation changes.

First for the theoryWhat moves and how? 1.4


1.12

First for the theoryMachine-independent CNC programs1.5

1.5 Machine-independent CNC programs

TRAORI � Calling 5-axis transformation

Of course we want CNC programs that can be run on various machine kinematics with a range of tools. For this to be possible, the control system has to compensate the inß uences illustrated below.

Effects of the TRAORI command on Sinumerik 840D:! The correct traversing movements are generated from the position and orientation data in the

CNC program according to the machine kinematics.! The current tool length is taken into consideration when calculating the traversing movements.

ExampleIn the CNC program an orientation change is programmed with no other traversing movement. The orientation change can be programmed with A3, B3, C3, irrespective of the machine kinematics.

Without TRAORIThe control system disregards the tool length. It rotates around the center of rotationof the axis. The tool tip moves out of position and does not remain Þ xed.

With TRAORIThe control system only changes the orientation,the position of the tool tip remains Þ xed. The ne-cessary compensating movements in X, Y and Z are calculated automatically.

TRAORI is usually already called in the CNC program obtained from the CAM system. The CNC program then simply contains the points X, Y and Z which are to be approached, and the direction vector A3, B3, C3, which describes the tool orientation.

In other words, the CNC program contains only geometrical and orientation data.


1.13

Sample CNC program

Swivel.MPF ; Program nameN01 TRAORI ; Call 5-axis transformationN02 T1 F1000 S10000 M3 ; Technology data, tool, speed, etc.N03 G54 ; Zero offsetN04 G0 X0 Y0 Z5 ; Start point, A3=0 B3=0 C3=1 Tool parallel to Z axisN05 G1 Z-1 ; Travel command, infeedN06 X10 Y0 A3=1 C3=1 ; Linear movement with orientation change to 45° in the X/Z planeN07 TRAFOOF ; 5-axis transformation �off�N07 M30 ; End of program

In this example a straight line is milled from X0 to X10. The tool orientation changes from 90°to 45°.

With TRAORI there is no need to worry about the actual machine movement when program-ming a straight line. The end point is approached exactly, and the tool tip describes a straight line.NOTE

First for the theoryMachine-independent CNC programs 1.5


1.14

First for the theoryTheory of tool radius compensation1.6

1.6 Theory of tool radius compensationTool compensation makes a CNC program independent of the tool radius. Tool radius compensation in the 2 ½ D range is a familiar concept. In the 3D range, however, especially with 5-axis milling, it can be very different.

Inß uence of tool radius in face milling with CUT3DF

For radius compensation in face milling with CUT3DF, it is not enough simply to specify the cutter geometry. The compensation direction is also required. The compensation direction is calculated from the surface normal, the tool direction and the tool geometry. This perpendicular is known as the surface normal or surface normal vector. It is calculated from the current tool orientation and the perpendicular to the workpiece surface.

In the special case of a spherical cutter, for example:For a path in the work area the compensation must be made perpendicularly to the surface on which the path is running. This means that the compensation direction is described by the normal vector ", #of the surface at the inserti-on point.

The compensation options in Sinumerik 840D allow the tool offset to be calculated using the surface normal vector. Previously, very few CAM systems were capable of providing the surface normal with every CNC block.

If the surface normal, tool radius and also the geometry of the cutter tip are known, Sinumerik 840D can calculate the new tool insertion point PE if tool radius compensation (CUT3DF) is enabled.

The illustration shows all the dimensions used by the control system and the relevant geometri-cal data for the cutter tip. " End mill# End mill with corner radius$ Cylindrical die mill

FN Surface normalTCP Tool center pointPE Tool insertion pointTB Path tangentVK Compensation vector

1 2

2 31

Generally speaking, only small radius changes relative to the standard tool (radius used for calculations by the CAM program) can be corrected. A smaller cutter radius is easy to calcula-te but results in a different peak-to-valley height. With a larger radius there is a risk of collision between the tool and the workpiece contour.

NOTE


1.15

First for the theoryTheory of tool radius compensation 1.6

Inß uence of tool radius compensation in 5-axis circumferential mil-ling, taking account of the limitation surface ( CUT3DCC)

PE

" Standard tool (the tool speciÞ ed for the program)

# Tool with smaller radius

$ Machining surface, inner surface

' Limitation surface, base of pocket

& Correction to machining surface

( Correction to limitation surface

TCP

ExampleMilling a pocket with a smaller cutter

Compensation for 5-axis circumferential milling

If a cutter with a smaller radius than speciÞ ed is chosen, Sinumerik 840D can calculate the new path.

Here the control system has to take into ac-count not only that a compensation is required in the direction of the machining surface & but also that an infeed is required in the tool direction (.

A typical application for this function can be found in particular in structural components in

2

1

the aviation industry.

After radius compensation in the machining surface direction $ the tool tips TCP of the cutter with the smaller radius and the standard tool are at the same level if both tools, as in this illustration, are the same length.

At the same time the cutter engages axially ( so that the tool insertion point PE just touches the limitation surface. This compensation in the direction of the pocket base also requires an adjustment of the tool in the milling direction. This is illustrated here by the visible underside of the tool.

5

6

4

3


1.16

Overview of available tool compensations

You are already familiar with the standard tool radius compensations in Sinumerik 840D:G40 Disable tool radius compensation, G41 Tool radius compensation, compensation direction left of path in circumferential milling, G42 Tool radius compensation, compensation direction right of path in circumferential milling. G450/G451 deÞ nes the behavior at external corners.

Sinumerik 840D also offers other compensation functions, however, a few applications of which we have already seen on the previous pages. All variants of Sinumerik 840D tool radius compensation are enabled with G41/42 and disabled with G40.

See the documentation for Sinumerik 840D:

2 1/2D circumferential milling

CUT2D 2 1/2D compensation with compensation plane determined with G17 - G19

CUT2DF 2 1/2D compensation with compensation plane determined by frame

3D circumferential milling

CUT3DC Compensation perpendicular to path tangent and to tool orientation

ORID No orientation changes in inserted circle blocks at external corners. Orientation movement is executed in the linear blocks.

ORIC Travel path extended with circles. The orientation change is executed proportionately in the circle as well.

Face milling

CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the coordinate system deÞ ned with G17 - G19. Frames have no inß uence.

CUT3DFF Constant orientation (3-axis). Tool in Z direction of the coordinate system currently deÞ ned with frame.

CUT3DF 5-axis with variable tool orientation

3D circumferential milling with limitation surface (combined circumferential/face milling)

CUT3DCC NC program refers to the contour on the machining surface.

CUT3DCCD NC program refers to the tool center path.

The compensations are activated by appending the appropriate command G41/G42, e.g.: CUT3DC G41

First for the theoryTheory of tool radius compensation1.6


1.17

First for the theoryWhat are frames? 1.71.7 What are frames?

Coordinate systems

A 5-axis machine can also be used to work on surfaces that can be offset and rotated anywhe-re in the area.

The workpiece coordinate system can only be offset using frames and set in an inclined plane by rotation.

That is precisely why we need FRAMES. All the following traversing commands now relate to the workpiece coordinate system.

Machine coordinate system " with reference point, zero offset (G54, G55, ...) are familiar terms.

Frames can be used to offset, rotate, mirror and scale coordinate systems.

Frames are used to describe the position of a destination coordinate system by specifying coordinates and angles starting from the current workpiece coordinate system #. Possible fra-mes include

! Basic frame (basic offset)! Settable frames (G54...G599)! Programmable frames

Coordinate systems and traversing movements

2

1


1.18

Using frames

When settable zero offset is activated (G54, G55), the workpiece coordinate system is at workpiece zero.

With the exception of special machine kine-matics, the axes are now aligned parallel to the machine axes.

Using a FRAME this coordinate system can now be offset and rotated anywhere in the area.

When the coordinate system " is rotated into the inclined plane, a hole for example can be programmed simply by calling the drilling cycle.

First for the theoryWhat are frames?1.7

ExampleMachining on an inclined plane

1


1.19

1.8

CAD systems construct higher-order surfaces ".

For example, in order to be able to mill an entire surface, or for collision checking, the CAM sys-tem generally converts the CAD surfaces into a polyhedron.

In other words, the smooth design surface is approximated by numerous tiny planes #.

This inevitably produces some minor deviations.

The CAM programmer overlays this polyhedron with tool paths, which the postprocessor uses to create CNC blocks within the speciÞ ed error tolerances. These usually comprise numerous short straight lines, G1 X Y Z $.

That is why the machining result is a polyhed-ron, i.e. the small planes can be visibly mapped on the surface.

This can mean that rework is necessary, howe-ver, which is undesirable.

First for the theoryPrecision, speed, surface quality

1.8 Precision, speed, surface quality

CAM ) CNC

CAD ) CAM

1

2

CAD -> CAM -> CNC process chain

Many CNC programs for freeform surface machining come from CAM systems. The CAM system obtains the workpiece geometry from a CAD system.

The CAD -> CAM -> (post-processor) -> CNC process chain is particularly important in the machi-ning of freeform surfaces.

3

G1G1

G1

G1


1.20

First for the theoryPrecision, speed, surface quality

Sinumerik 840D includes various functions which can help to avoid rework.

One of these is deÞ ned corner rounding at block boundaries. This involves inserting geometrical elements ' at the corners, the tolerance of which can be altered.

Compressor function

Linear interpolation at the block transitions leads to acceleration jumps in the machine axes, which in turn can cause resonance in the machi-ne elements and can ultimately be detected on the workpiece surface as a beveled pattern " or as vibration #.

Analogously to the speciÞ ed tolerance band " the compressor combines a sequence ofG1 commands # and compresses them to form a spline $, which is directly executable by the control system.

This makes the surface much smoother, since the machine axes can move more harmoniously and machine resonance is avoided.

This allows higher traversing speeds and redu-ces the load on the machine.

1.8

1

2

4

1 32

Programmable corner rounding


1.21

High-speed setting cycle

With Sinumerik 840D, COMPCAD spline com-pression " can now be easily switched on and off in CYCLE832.

The CAM program sequence can be inß uenced with CYCLE832. It provides technological support for the machining of freeform contours (surfaces) in the 3- and 5-axis high-speed machi-ning range. More information about its use can be found in subsequent chapters.

First for the theoryPrecision, speed, surface quality 1.8

NOTE If the tolerance band for the CAM system is known, this or a slightly higher value should be used for the compressor tolerance.

In COMPCAD this value is typically between 1.2 and 1.5 of the programmed chord tolerance of the CAM system. If this value is not known, the default setting for CYCLE832 should be used as a starting value.

1


1.22

Subroutinecall

High-speed setting cycle

Zero pointStart position

Technology

Tool call

1.9 Structure of CNC mold making programs

A CNC program for machining freeform surfaces is made up of many CNC blocks and is generally not edited on the CNC control system.

Structure of a CNC mold making program

The most clearly structured CNC program is one in which the CAM programmer uses the following program structure:

First for the theoryStructure of CNC mold making programs1.9

The subroutines contain the typical traversing blocks, which owing to the complexity of the programs should not be changed.The zero offset, all technology values, start point and high-speed settings are deÞ ned in the main program. The high-speed setting parameters can be used to inß uence the quality of the workpiece.

A well structured CNC program can also be resumed from a chosen point after a program interrupti-on.

N10 T1D1

N20 M3 M8 S8000 F1000

N30 G0 G54 X10 Y10 Z5 ;Settable zero offset

N40 CYCLE832(0.01) ;CYCLE832 sets the compressor tolerance and deÞ nes other path conditions.

N50 EXTCALL �Roughing�; Calls the �Roughing� subroutine, which contains the geometry of the CAM program.

Main program with subroutine callExample


1.23

1.10 Orientation in 5-axis applications

Just as in the 2D range between 2 points, there are any number of paths between 2 orientations.

In 2D interpolation we are limited to! Straight line (G1) " ! Circle (G2, G3) #! Polynomial, B-spline $ or Fig.

21

A 5-axis machine can position the tool in any orientation to the workpiece, subject of course to the machine kinematics. In order to move from one orientation to another, intermediate positions must be interpolated. The path from the start to the end orientation is described in this way.

First for the theoryOrientation in 5-axis applications 1.10

This means that the orientation vector does not describe a deÞ ned surface.

This interpolation is therefore not always suitable for circumferential milling.

The movement can be very similar to the surface of a cone, so it is important not to confuse the function with conical surface interpolation.

Linear interpolation ORIAXES

In linear interpolation from a start " to an end orientation # the necessary rotary axis movements are broken down into equidistant sections.

21

In orientation interpolation we have a choice of linear interpolation, great circle interpolation, conical surface interpolation and curve interpolation.


1.24

Great circle interpolation ORIVECT/ORIPLANE

In this interpolation process the path from the start " to an end orientation # is interpolated in such a way that the orientation vector runs in the plane that is spanned by the starting vector and the Þ nal vector.

Each rotary axis approaches equidistant angles. This type of orientation interpolation can be used for the precise machining of inclined, plane walls in one block, for example.

Applications:Structural components in the aviation industry. ORIVECT should also be used for face milling in mold making applications.

21

1.10 First for the theoryOrientation in 5-axis applications

ORICONCW Interpolation on the peripheral surface of a cone in the clockwise direction with speciÞ cation of the end orientation and taper direction or aperture angle of the cone.

ORICONCCW Interpolation on the peripheral surface of a cone in the counterclockwise direction with speciÞ cation of the end orientation and taper direction or aperture angle of the cone.

ORICONIO Interpolation on the peripheral surface of a cone with speciÞ cation of the end orientation and an intermediate orientation.

ORICONTO Interpolation on the peripheral surface of a cone with tangential transition and speciÞ cation of the end orientation.

Conical surface interpolation ORICONCW

In conical surface interpolation from a start " to an end orientation # the tool moves on a program-mable peripheral surface of a cone anywhere in the area.

21


1.25

1.10First for the theoryOrientation in 5-axis applications

ExampleLet�s have a look at an example:

In great circle interpolation the orientation should change from start A3 = sx, B3 = sy, C3 = sz to end A3 = ex, B3 = ey, C3 = ez. No value is zero, i.e. the orientation is inclined (s = start orientati-on, e = end orientation).

Reorientation in great circle interpolation takes place in a plane $. The line on the cone is referred to as a great circle '. In the illustration the C axis rotates through 85°. The A axis swivels from 60° to 30°. Speed control for the reorientation is continuous.

" = start orientation, # = end orientation

2

1

C = 85°

A = 60°

A = 30°

4

3


1.26

Example The situation is quite different if interpolation goes through the point &. This is the case if for example sx = 0 and ex = 0, i.e. the start and end orientationare parallel to the Y/Z plane.

In this example the A axis should not be allowed to swivel.

What happens next? The C axis starts at 0°, the A axis at 45°, for example.

During the orientation interpolation C remains at 0°, while the A axis approaches the position &. Here the position of the C axis is undeÞ ned,but just one interpolation phase later C must rotate abruptly to 180°,A moves away from point & and C remains at 180°.

To maintain the orientation speed, i.e. in position &, theC axis would have to accelerate inÞ nitely, which of course is not possible. In this case we speak of a pole. In conventional 5-axis machines the deÞ nition of a pole is that when the Þ rst rotary axis rotates, the tool orientation remains unchanged. In CA kinematics A=0 corresponds to the pole orientation. To avoid such an extreme speed control, in the vicinity of the pole Sinumerik 840D switches to linear interpolation.

First for the theoryOrientation in 5-axis applications1.10

5


1.27

First for the theoryOrientation in 5-axis applications

Example: When milling a pocket with a45° incline $ the A and C axis rotate harmo-niously when traversing from one corner to the other - everything is OK.

In this example the incline is now 85° '.

What happens? The steeper the tool angle, the faster the C axis has to rotate in the center of the path in order to sustain the orientation on the second half of the path.

3

4

Example

Let�s take another look at great circle interpolation in the vicinity of the pole in practice:

Certain machine kinematics, especially the commonly used fork head, feature poles or singularities.

NOTE

Incidentally, the pole situation is a physics problem rather than a control technology problem. In fact Sinumerik 840D alleviates the problem substantially.

Poles can be avoided by appropriate clamping. For example, an inclined chuck can be helpful.

1.10


1.28

Curve interpolation ORICURVE ( spline orientation)

In curve interpolation the movement of the orientation vector is described by the paths at the tool tip (spline curve ") and the path of a second point on the tool (spline curve #).

To machine an inclined surface by circumferential milling, for example, the upper and lower contour would be described. This type of interpolation results in a faster path speed and improved surface quality.

First for the theoryOrientation in 5-axis applications1.10

1

2

For an overview of orientation interpolation, see section 3.7.

2

Machine operators -at the machine

Contents Page

2.1 Workpiece - determining the zero point 2.2

2.2 Gauging tools 2.13

2.3 Program data transfer 2.16

2.4 Testing a program 2.17

2.5 Calling and executing a program 2.18

2.6 Interrupting a program 2.20

2.7 High-speed settings - CYCLE832 2.25

2.8 ShopMill 2.28


2.2

Machine operators - at the machineWorkpiece – determining the zero point2.12.1 Workpiece - determining the zero point

Determining the zero offset and basic rotation of the workpiece about the workpiece axis

Function

Once the machine has been switched on and the reference point approached, the axis positions rela-te to the machine coordinate system. The position of the workpiece in the machine coordinate system is signaled to the control system by the zero offset.

Previously, the workpiece was clamped, manually aligned paraxially to the machine axes, and then the zero offset was determined, e.g. by scratching. By looking at two examples that commonly occur in practice, we can see how much easier it is with probes and SINUMERIK cycles. We will show how the control system compensates the basic rotation of the workpiece, eliminating the need for time-consuming, manual alignment.

Example Determining the zero point + measuring the basic rotation about the tool axis

Task assignment

After being clamped, the workpiece is rotated relative to the machine coordinate system in the wor-king area. You have to determine the zero offset and the position of the coordinate system, in other words the basic rotation.

P1

P2

P4

P3


2.3

Machine operators – at the machineWorkpiece – determining the zero point 2.1Prerequisites

! Probe is calibrated, active and clamped in the spindle; tool offset is valid! Measuring cycles are installed! Workpiece is clamped

If only one workpiece is to be machined, as is usually the case in tool and mold making, measurement takes place in JOG mode (as described below). If several similar parts are to be machined in the same device, two measuring cycles are used in automatic mode (the approxi-mate zero point must be set up).

Determining the zero offset and basic rotation

Select the �Machine� operating area.

Call �Jog� mode at the machine control panel.

Call �Measure workpiece�.

Call �Corner� measurement.

Machine

Measureworkpiece

Corner

Select zero offset " for data transfer, e.g. G54, G55, G56 or G57. In this example G54 was used.

Choose a corner as a reference point by toggling # and then pressing �Select�.

NOTE

2

1 G54


2.4

Machine operators – at the machineWorkpiece – determining the zero point2.1

Using the �axis keys�, position the probe in front of the touch point P1 on theworkpiece.

Press �NC Start�. The measuring operation proceeds automatically: the probe approaches the workpiece, trips, and returns to the start position.

Save touch point P1.

For touch points P2, P3 (P4) position the probe in front of the workpiece again and proceed as for P1. Note: Point P4 is only required for non-rec-tangular workpieces.

Press �Calculate corner�:

The control system calculatesa) the X and Y values for the zero offset from the intersection of the two

straight linesb) the basic rotation of the workpiece coordinate system about the Z axis.c) The values are entered in the zero point table, zero offset G54, taking

into consideration the basic zero offset.

An offset in the X-Y plane and a basic rotation about �Z� has now been determined.

Save P1

Save P3

Calculatecorner

P1

P2

P4

P3

To measure a corner in the G17 plane, an offset is measured in X, Y and a rotation in Z for zero offset. To measure an edge in the Z direction, an offset is measured in Z for zero offset. The result of the measuring operation is a frame comprising offset and rotation.

Save P2


2.5

Go back one level in �Measure workpiece�.

Call �Edge� measurement.

Choose the Z axis.

In the screen form choose G54.

Choose the upper side of the workpiece as the measuring edge.Position the probe above the workpiece.

Press �NC Start� to start the measuring operation. The Z value is added to the zero point table.

Machine operators – at the machineWorkpiece – determining the zero point 2.1Determining the Z value for the zero offset

Measureworkpiece

Depending on the machine kinematics, two situationsare now possible:

� Effect of zero offset on machines with a rotary axis in the table

� Effect of zero offset on machines without a rotating table

Z

Edge

Determination of the zero point and basic rotation for a 3-axis machine is now complete. If the basic rotation is not equal to zero, the control system converts programmed, paraxial movements into corre-sponding XY movements.

If the machine has a fourth axis, e.g. C axis, and the workpiece is to be machined paraxially to the machine coordinate system, the basic rotation of the workpiece must be compensated with the C axis.


2.6

Machine operators – at the machineWorkpiece – determining the zero point2.1Offset and basic rotation on machines with aC axis in the table. Moving the C axis value manually into position

Machine

MDA

After the probing operation go to the zero offset table.

Select basic rotation table.

The Z axis Þ eld contains the measurement result for the rotation. Copy this value into the C axis Þ eld. First overwrite the value for �Z� with 0.

Align the workpiece paraxially to the machine coordinate system with a program in �MDA� mode:

Call the �Machine� operating area.

Call �MDA� mode and enter the program.

N01 G54 ; Call zero offset.N02 T27D1N03 G0C0 ; Paraxial alignment of C axis.N04 M30

Parameter

Zero offset

Rotation

X [degrees]0

Y [degrees]0

Z [degrees]24,894G54

X [mm]238,968

Y [mm]172,384

Z [mm]25,728

C [degrees]24,894G54

Offset

Axes +

Press �NC Start�. The turntable rotates about C = 24.894° and aligns the workpiece paraxially to the machine coordinate system.

Call the zero offset table to transfer the display to the rotary axes.

Enter the value from �Z� under �C�.

X [degrees]0

Y [degrees]0

Z [degrees] 0G54


2.7

Machine operators – at the machineWorkpiece – determining the zero point 2.1

N01 G54 ; Call zero offset.N02 T27D1N03 G0X0Y0Z10 ; Approach zero point with a clearance of 10 mm.N05 M30

Repeat the entire measuring procedure from page 2.3 onwards, but this time on the paraxially aligned workpiece. This is necessary because the rotation means that the X, Y values are no longer correct and need to be determined again. The Z value has not changed.

Start by selecting the �Measure workpiece� and �Corner� functions. Then continue as before.

The angle of rotation that was entered manually under �C� in the zero point table is not overwritten.

To check whether paraxial traversing is possible, a short program could again be created in MDA.

Measureworkpiece

Corner

When you press �NC Start�, the zero point is approached in �Z� with a safety clearance.

Example Production � Machine kinematics �with� and �without� a C axis in the table

21

In production the same CNC program results in different movements of the machine axes, depending on the machine kinematics.

" Machine with C axis in the table The table was rotated. Milling paths running parallel to the edges of the workpiece also run paraxially to the machine coordinate system. When programming the X axis, the machine axis also moves in X.

# Machine without C axis In machines without a rotating table, the machine puts together milling paths running parallel to the workpiece edges through traversing movements. When programming the X axis the machine axes X and Y traverse by rotation around Z.


2.8

Example Overview - Measuring function for tool and mold making with reference to � Spigots�

Overview of advanced measuring functions

On request, the �Measure workpiece� function in Sinumerik 840D can include measuring functions tailored to speciÞ c tool and mold making requirements.

Spigots


These can include the �Spigots� function, which makes zero point deter-mination much easier on cast parts with no deÞ ned workpiece edges. This function is used when it is not possible to touch the workpiece edges.


2.9

Machine operators – at the machineWorkpiece – determining the zero point 2.1Zero offset with swiveling of working plane

Requirements

! Swivel cycle CYCLE800 set up! AUTOMATIC mode selected

Task, function

To determine the zero point for a workpiece with an inclined plane" and rectangular base. According to the CAM program the tool must be aligned perpendicularly to this plane for the subsequent opera-tions. The entire sequence can be divided into 4 individual steps. The approximate zero offset must be known.

Sequence Measure inclined plane" � CYCLE998, Measure angle:

Using 3-point measurement in CYCLE998 the position of the inclined plane is determined in the machine coordinate system. To this end the control system automatically calculates 2 angles which clearly deÞ ne the incline. In the subse-quent machining the angles are written to the active zero offset, e.g. G54.

3-point measurement can be used up to an ang-le of about 20°. For larger angles, e.g. 48°, the working plane is Þ rst swiveled to 45° with CYCLE800. 3-point measurement is then used to determine the exact angle, but as the difference from 45°, so in this case it would be 3°.

Swivel the working plane# - CYCLE800, Swivel:

Now swivel the working plane with CYCLE800 so that the tool is perpendicular to this working plane.

To do this, call CYCLE800 in the program with �Rotation equals zero�. CYCLE800 automatically takes the angle determined by CYCLE998 and swivels the working plane so that it is perpendi-cular to the tool.

Machine kinematics with two rotary axes in the table:The table swivels about the A and C axis. The working plane is aligned to the tool.

1

2


2.10

Measure corner $ - CYCLE961, Measure corner:

Use CYCLE961 to touch 3 points to determine the X and Y value of the new zero point. Since the base is rectangular, 3 points are sufÞ cient to determine the corner.

Result:The translatory values X and Y and the basic rotation of the tool axis Z for zero offset are determined.

Determine the Z value % - CYCLE978, Measu-re edge:

Using CYCLE978 touch the working plane perpendicular to the probe in the Z direc-tion.

Note:This operation is entirely unrelated to the machi-ne kinematics.

3

4



2.11

Programming

Example N01 G56 ; Call zero offset.

N02 T1D1 ;Use the �Measure�, �Mill�, �Measure workpiece�, �Measure angle� soft-keys to call the cycle. Select the measuring function as shown in the screen form below and enter all parameters.

N03 CYCLE998 ; Press �OK� to add the cycle to the program.

; Press �Mill�, �>>�, �Swivel cycle� to call the cycle. Do not make any changes to the next screen form.


ProgramCall the �Program� operating area.

Press the Input key.

Open the program.

Machine operators – at the machineWorkpiece – determining the zero point 2.1

170


2.12

; Use the �Measure�, �Mill�, �Measure workpiece�, �Corner� softkeys to call the cycle, select measuring functions as shown in the screen form below and enter all parameters.


; Use the �Measure�, �Mill�, �Measure workpiece�, �Surface� softkeys to call the cycle, select measuring functions as shown in the screen form below and enter all parameters.

N06 CYCLE978 ;Press �OK� to add the cycle to the program.

N07 M30 ;End of program

Start swiveling.


NOTE To change the parameters, use the cursor to highlight the cycle in the pro-gram and press the �Recompile� softkey. The parameters are copied back into the screen form for the cycle, the screen form is opened and you can make your changes.

Recompile


2.13

Function

The tool magazine is loaded, the tool numbers T1, T2, etc. " entered in the tool table and the tools assigned a tool offset D # - consisting of radius �R� and length �L1� - in the usual way.

The CAM programmer speciÞ es the tool type andgeometry. You specify the tool length in the associated tool parameter.

Regarding the tool length, you must check whether the CAM programmer has included the tool tip( = tool center point or TCP) in L1. Depending on the tool shape, some CAM programmers position the TCP higher up the tool. If that is the case, this distance must be taken into account in the tool length.

Depending on the tool type, you can specify additional tool data for face milling.

In a CNC program the control system uses this data and the path corrections G41, G42 deÞ ned in the program to execute the necessary path and length corrections.

Machine operators – at the machineGauging tools 2.22.2 Gauging tools

T1

L1

D11

Ball end millType 111

End millType 120, 130

End mill withcorner radiusType 121, 131

Radius millType 110

Truncated cone mill withcorner radiusType 156

Tapered die millType 157

Truncated cone millType 155

L1 L1

2

TCP TCPTCP

Taperbase

NOTE Come to an agreement with the CAM programmer: to avoid major tool deß ection, the CAM programmer should choose as short a tool length as possible.


2.14

Machine operators – at the machineGauging tools2.2Operation - manually entering tool offset data

Using a tool presetting device the tool offset data �L� and �R� has been determined externally and the tool placed in the tool magazine. The tool offset data is then entered:

Tooloffset

Parameter Select the �Parameters� operating area.

Select �Tool offset�.

Select tool or

select offset data.

Enter new values.

T no.+

D no.+

7& *

8(

9

4$ %

5^

6

1!

2@ #

3

--

0) .>

Operation - tool offset data with tool probe

An easier option is to use a tool probe in JOG or AUTOMATIC mode and the tool gauging cycle CY-CLE971. The measurement data �L� or �R� can be determined in a single operation and automatically stored in the tool offset memory.


2.15

1

Machine operators – at the machineGauging tools 2.2To do this, call CYCLE971 in the program, select radius or length and the appropriate measurement strategy, and enter the parameters. If you call the tool offset memory after the probing operation, the offset data for the active tool will have been entered automatically.

!L

Sinumerik 840D also offers measuring functions in �Machine� mode.


2.16

Machine operators – at the machineProgram data transfer2.32.3 Program data transfer

Hardware conÞ guration

The program data storage is deÞ ned in conjunc-tion with the network administrator and Siemens. Sinumerik 840D supports a number of options,including:

! TCP/IP Ethernet, serial interface RS232/V.24! Hard disk with PCU 50, Compact Flash Card with PCU 20! PCMCIA, ß oppy disk

Setting data

In the setting data & the path to the swapped out program data is deÞ ned in close consultation with the network administrator.

CNC programs are saved on the HMI control unit ", loaded into the NCK CNC memory # and executed with the machine.

In the case of mold making programs consisting of technology and geometry programs, however, at up to 100 MB the geometry program is often too large for the NCK CNC memory and so has to be swapped out onto a server $, for example,

Program data transfer

In the main program ' an EXTCALL command is programmed, which calls the swapped out geometry program ( in accordance with the net-work path on the server, the PCMCIA card, etc.

Production

The EXTCALL ensures that the program data is gradually transferred to the NCK CNC memory.

Advanced

LAMP.MPF...N 50 EXTCALL �FIXTURE.SPF�...

FIXTURE.SPF...N5120 X Y Z A3 B3 C3N5130 X Y Z A3 B3 C3...

Setting data...Server/disk drive/directory/.....

HMI/PCU hard disk

Production

PCU 50PCU 20

and gradually loaded onto the control unit via a network connection %.

3

7

6

5

4

1

NCK CNC memory

TCP/IP Ethernet

2

DirectoryServer

Disk drive


2.17

Machine operators – at the machineTesting a program 2.42.4 Testing a program

Testing a program

User interface - DIN/ISO standard:

Before machining, the CAM program can be checked for syntax errors. This is done in the �Machine� operating area in �Auto� mode by calling the program and pressing the �Program control� softkey. Then highlight �Program test� in this screen form.

When �NC Start� is pressed, the program is executed at an accelerated feed rate but the machine does not perform any axis movements.

If a syntax error is found, the program test is interrupted and the incorrect block is highligh-ted. Press the �Program correction� softkey to display the incorrect block " in a program editor, where it can be overwritten #, for example.

Press �OK� to close the editor and then press �NC Start� again. The program test continues to the end of the program.

Programcontrol

2

1

Checking the machine

The machine must be checked at regular inter-vals to discover whether it is producing errors in the mechanical system. This is done by approa-ching a , with TRAORI enabled and with widely diverging orientations.

Since the sphere diameter is known, it is also very easy to create a short test program con-taining points on the peripheral surface of the sphere. If the dial gauge shows no deviation in traversing movement, starting position and destination position, everything is Þ ne. If errors outside the speciÞ ed machine tolerances are found, however, the machine manufacturer should be informed.

Note Alternatively the dial gauge can of course be Þ xed to the table and the sphere clamped in the tool spindle.


2.18

2.5 Calling and executing a program

Machine operators – at the machineCalling and executing a program2.5

Ideal program structure

A main program " containing all the technology data is obtained from the CAM station. The main program calls one or more subroutines #, $, which contain the geometry data for the workpiece. The breakdown into subroutines is determined by the tool change.

Call.MPF (Aufruf.MPF)N1 G55

N2 T1 D1 ;Tool changeN3 M3 S15000N4 CYCLE832 (0.1,103)N5 EXTCALL �CAM_Roughing� ;The search path for ;the swapped out programs ;must already be deÞ ned in ;the setting data. All ;programs should be located ;in the same directory. N6 T2 D2 ;Tool changeN7 M3 S20000N8 CYCLE832 (0.01,102001)N16 EXTCALL �CAM_Finishing�N17 M30

CAM_Roughing.SPF (CAM_Schrupp.SPF)N1 G90N2 G0 X0 Y0 Z10

N3 G1 Z0 F500N4 G1 X-1.453 Y0.678 F10000N17 G1 X-1.814 Y0.842N18 G1 X-1.879 Y0.684 Z-0.001...N5046 G1 X-4.118 Y-11.442N5047 G0 Z10N5048 Z50N5049 X10.663 Y-3.67 A3=0.34202 B3=0 C3=0.939693N5050 Z2.868 A3=0.34202 B3=0 C3=0.939693N5051 G1 Z-2.132 A3=0.34202 B3=0 C3=0.939693 F5000...N6582 G1 X7.609 Y3.555 A3=0.34202 B3=-0 C3=0.939693N6583 G0 Z50 A3=0.34202 B3=-0 C3=0.939693N6584 M17

CAM_Finishing.SPF (CAM_Schlicht. SPF)N1 G90N2 G0 X0 Y0 Z10 A3= B3= C3=.... .......

2

3

45

6

7

8

9

1Main program

Subroutine

Subroutine


2.19

Selecting/starting/stopping/interrupting/continuing a program


Select �Automatic� mode.

Select �Program overview�, �Workpiece overview�. Highlight the �Workpiece directory� you require and open it.

In the workpiece directory highlight the part program " - in this case the program �CALL.MPF� (AUFRUF.MPF) - and press �Select�.

Press �NC Start� to start the part program. This calls the geome-try programs �ROUGHING.SPF� (CAM_SCHRUPP.SPF) # and �FINISHING.SPF� (CAM_SCHLICHT. SPF), which are loaded block by block onto the control system from the external drive during the machining process. Press �NC Stop� to stop the part program.

Press �Reset� to interrupt the part program.

Programoverview

A part program interrupted with �NC Stop� can be continued by pressing �NC Start�. A part program interrupted with �Reset� is executed from the beginning if �NC Start� is pressed.

Machine operators – at the machineCalling and executing a program 2.5

2 1

Machine

AUTO

Workpieces

Select

Note

Main program: The main program contains the two key functions for milling, CYCLE832 % and EXTCALL&.CYCLE832 %: CYCLE832 was developed speciÞ cally for the program structure illustrated here, with separation of technology and geometry data. The machining technology for 5-axis milling is deÞ ned in CYCLE832. For the roughing program �CAM_ROUGHING� (CAM_SCHRUPP.SPF) with T1, the parameters in CYCLE832 have been set to favor high speed. For the Þ nishing program �CAM_FINIS-HING� (CAM_SCHLICHT. SPF), the parameters have been set to favor high precision. TRAORI can also be called in CYCLE832. The current zero offset is retained. See section 2.7 below for more information about CYCLE832.EXTCALL&: Since CAM programs are generally very large, they are swapped out to an external storage device. EXTCALL calls the subroutines from the external storage device.

Subroutine: In the subroutine G90 for absolute programming is immediately followed by the geomet-ry blocks. In our example these are blocks for 3-axis milling(, followed by blocks for 5-axis simultane-ous milling ), identiÞ ed by the vector details A3, B3 and C3.


2.20

REPOS - repositioning after an interruption

Function

When a program is interrupted with �NC Stop�, the tool can be moved away from the contour in JOG mode, e.g. to perform a measurement. The control system saves the breakpoint coordinates. The differential travel of the axes is displayed.

Operation

2.6 Interrupting a program

Machine operators – at the machineInterrupting a program2.6

Initial situation: program interrupted with �NC Stop�.


Select �JOG� mode.

Repositioning after program interrupt.

Select axes.

Move the axes to the breakpoint according to the differential travel display-ed. The breakpoint cannot be overrun.

Switch from �JOG� mode to �Automatic� mode.

Continue machining.

JOG

AUTO

TOROT - retraction from an inclined hole or undercut

Function

When 5-axis transformation is enabled, TOROT generates a frame whose Z axis coincides with the current tool orientation. This allows the tool to be retracted in a 5-axis program, after a tool breakage, for example, without the risk of collision, by retracting the Z axis. After tool orientation has been pro-grammed with TOROT, all the programmed geometry axis movements refer to the frame generated by this programming.

Machine

2


2.21

Machine operators – at the machineInterrupting a program 2.6

MDA


Select �MDA� mode.Enter the program as follows:

Basiccoordinate system

Settable frame(programmed frame)

Currentworkpiece orien-tation

Tool retraction along the Z axis

N10 TRAORI ; Transformation ONN20 TOROT ;Calculate and select retraction frameN30 G1 G91 Z50 F500 ;Straight retraction movement in Z direction by 50 mmN40 M17 ;End of subroutine

Select single block. Start the program block by block.

Machine

Workpiececoordinate system

As an alternative to incremental retraction in MDA mode, the tool can be retracted in JOG mode by pressing the direction key in the tool direction.

Notice: For retraction in JOG mode the machine must be conÞ gured accordingly(Z axis as the geometry axis).

TOROT must be deselected before the start of the next program: TOROTOFNOTE


2.22

Initial situation: program interrupt with �Reset�.

Accelerated external block search without calculation


Function

This function was developed speciÞ cally for programs called with EXTCALL. It is therefore ideal for large programs obtained from a CAM station.

If machining has been interrupted with the �Reset� key, the �Accelerated external block search without calculation� function can be used to select any point in the part program from which to start or conti-nue machining.

Operation

Blocksearch

Breakpoint

Call.MPF (Aufruf.MPF)N1 G54 N2 T1 D1N3 M3 S15000N4 CYCLE832 (0.1,103)N5 EXTCALL �CAM_Roughing�N6 T2 D2 N7 M3 S20000N8 CYCLE832 (0.01,102001)N16 EXTCALL �CAM_Finishing�N10 M30

CAM_Roughing.SPF (CAM_Schrupp.SPF)N1 G90N2 G0 X0 Y0 Z10

N3 G1 Z0 F500N4 G1 X-1.453 Y0.678 F10000N17 G1 X-1.814 Y0.842N18 G1 X-1.879 Y0.684 Z-0.001

CAM_Finishing.SPF (CAM_Schlicht.SPF)N1 G90

Press the �Block search� softkey.

Press the �Search pointer� softkey.

Press the �Breakpoint� softkey.

Example 1

1

3

Search pointer


2.23

2

3

1

Overstoring

1

Externalwithout calc.

Pressing the �Breakpoint� softkey inserts the entire program sequence " up to the breakpoint into the screen form.

In this example the main program �Call.MPF� (Aufruf.MPF) calls the subroutine�CAM_Roughing.SPF� (CAM_Schrupp.SPF). The EXTCALL for the subroutine is loca-ted in block N16 $. Block 3044 in �CAM_Roughing.SPF� (CAM_Schrupp.SPF) is where the program was interrupted.

There are now two possibilities:

1. Jump directly to the breakpoint in the sub-routine:

Press the �External without calc.� softkey. The program jumps directly to block 3044.

2. Jump to any point in the subroutine: To do this you must select a (search) type

# - for �External without calc.� you can choose between �1-Block number� and

�5-Line number� - and then enter the type number followed by the desired block or line number.

Press the �External without calc.� softkey.

The function combines all activeM commands and loads them at the destination block.

Continue machining at the destination block.

Corrections

During input the �Overstore� function can be used to correct the destination block before star-ting the program.

A typical case is shown here, where the com-pressor tolerance needs to be changed. CYC-LE832 is called and the compressor tolerance manually changed to 20 µm". This can be done by entering just one parameter (tolerance = 0.02). CYCLE832 is now executed before the main program is started.

The tolerance is activated by pressing NC Start.

Machine operators – at the machineInterrupting a program 2.6


2.24

Quick View

Function

Quick View can be used to view mold making part programs containing G01 blocks. Program loops, polynomials, transformations and G02/03 blocks are not supported.Four views # are available: 3D view ", X/Y


QuickView

1

Call the �Quick View� function.

Choose the view you require - in this case theX/Z plane.

Use the cursor to select a point in the graphic. The associated block is displayed in the editor line.

Call the block, e.g. to change it in the program.

2

3

4

The following functions are also available:

! Search for a speciÞ c block! Zoom in/out! Shift, rotate! Measure between two points! Edit the NC part program displayed

Simulation

plane, X/Z plane, Y/Z plane

The two editor lines $ display the block current-ly highlighted in the graphic. Scrolling through the editor window automatically highlights the position in the graphic %.


2.25

2.7 High-speed settings - CYCLE832

Function

The CAM program sequence can be inß uenced with CYCLE832. It provides technological support for the machining of freeform contours (surfaces) in the 3- and 5-axis high-speed machining range.

Speed

Surface quality

Precision

Machine

Operation

Call the �Programs� operating area.

Show other softkeys.

Press �High-speed settings�. The cycle iscalled.

>>

High-speed settings

Machine operators – at the machineHigh-speed settings – CYCLE832 2.7

The cycle combines the essential G codes and machine and setting data that are required for HSC machining. These are speciÞ ed in the parameter Þ elds. Depending on the parameter choice " the trend triangle # shows a trend towards either �Speed� or �Precision�.

2

1


2.26

Machining ! Finishing (default) ! PreÞ nishing ! Roughing ! Deselection

Tolerance_Tol. ! Chord tolerance Tolerance of linear/rotary axes, default settings: (chord tolerance should -> 0.01 mm/ 0.08° (Þ nishing) be taken from the CAM -> 0.05 mm/ 0.4° (preÞ nishing) system or weighted with -> 0.1 mm/ 0.08° (roughing) a factor of 1,2 ... 1.5) -> 0.1 mm/ 0.1° (deselection)

Transformat. ! TRAFOOF -> Transformation �off� ! TRAORI -> First transformation �on� ! TRAORI(2) -> Second transformation �on�

Adaptation ! yes -> Subsequent Þ elds can be modiÞ ed ! no -> Subsequent Þ elds are locked The Þ elds are unlocked by the machine manufacturer

Compression ! no (COMPOF) -> Compressor OFF ! COMPCAD (default) -> Compressor ON, constant acceleration for mold making applications ! COMPCURVE -> Jerk-free for circumferential milling ! B-SPLINE -> Spline interpolation

Continuous-path ! G64 -> Continuous-path modecontrol ! G641 -> Programmable rounding clearance ! G642 -> Corner rounding with single axis tolerances ! G643 -> Block-internal corner rounding with single axis tolerances ! G644 -> Speed-optimized corner rounding with settable tolerances

Feedforward ! FFWON-SOFT -> With feedforward control, with jerkcontrol limitation ! FFWOF-SOFT -> Without feedforward control, with jerk limitation ! FFWOF-BRISK -> Without feedforward control, without jerk limitation

Parameters for the high-speed setting cycle

The user simply chooses between Þ nishing, preÞ nishing and roughing in the Machining Þ eld and enters a value in the Tolerance Þ eld. The values in all other Þ elds have already been entered by the machine manufacturer. The machine manufacturer can enable the other Þ elds by means of the Adap-tation Þ eld.

Machine operators – at the machineHigh-speed settings – CYCLE8322.7


2.27

If changes are made you should be guided by the tolerance value speciÞ ed in the CAM pro-gram. Smaller tolerances than those speciÞ ed there are not recommended. Transformation TRAORI is used for 5-axis simultaneous milling. If TRAORI is already included in the NC pro-gram, there is no need to specify it here.

Please bear in mind that the Þ elds are inter-dependent: for example, if Compression is switched off, various types of rounding can be selected under Continuous-path control. The preset for Feedforward control is deÞ ned by the machine manufacturer. Since machines

Machine operators – at the machineHigh-speed settings - CYCLE832 2.7

Programming

CYCLE832 is ideally programmed in the hig-her-order NC control program which calls the geometry program. In this way you can apply the cycle to the entire geometry or, depending on the transparency of the CAM program, to indivi-

are becoming more and more rigid, feedforward control is used less and less. It allows following errors to be reduced almost to zero.

More information can be found in Chapter 3, which contains detailed descriptions of the indivi-dual parameters.

Note

Fast cycle call

The following call options with reduced parameter transfer can be used for CYCLE832:

! CYCLE832() Corresponds to selecting the �Machining� screen form, �Deselection�! CYCLE832(0.01) To enter the tolerance value. The active G commands are not changed in the cycle.

A detailed explanation of these parameters can be found in Chapter 3.

dual program sections or freeform surfaces. See also the programming examples in the previous chapter.


2.28

2.8 ShopMill

ShopMill:

Simple operation andprogrammingin the workshop

Machine operators – at the machineShopMill2.8

Standard DIN/ISO:

multifunctional user interfacefor production machines

Switching by machinemanufacturer function

In Sinumerik 840D, software version 6.4, the user-friendly ShopMill interface provides a real alternative to the universal Sinumerik 840D stan-dard DIN/ISO user interface.

ShopMill features many additional mold making functions, greatly simplifying its use for mold makers.

As a consequence, ShopMill is now no longer

restricted to sequencer programming by means of partial machining steps and even supports demanding 5-axis applications.

A complete description of the ShopMill functions can be found in�Sinumerik 810D/840D Using andProgramming ShopMill (SW06) 11/036FC5298-6AD10-0AP2 (German)�

ShopMill user interface


2.29

Machine operators – at the machineShopMill 2.8

ShopMill functions

SetupPowerful setup functions in ShopMill ensure rapid and accurate detection of the component position. Any offsets are compensated automati-cally by the control system.

" Edge# Corner$ Hole% Spigot

SequencerShopMill sequencer programming allows easy programming of simple2 1/2D machining tasks directly on the machine. An ideal add-on for mold makers.

" Program# 2D representation$ 3D representation

G code editorShopMill comes with a powerful G code editor, which easily supports mold making programs of up to 100 MB in size, eliminating the need to switch to the standard DIN/ISO interface.

�High-speed setting� cycleThe �High-speed setting� cycle now also comes as standard with the ShopMill user interface.

" Program editor# CYCLE832, high-speed settings

2

3

1

4

21

3

2

1


2.30

Machine operators – at the machineShopMill2.8

Block searchThe extended block search function described in section 2.6 also now comes as standard with ShopMill.

" �External without calc.� block search

3D viewingShopMill also allows simple viewing of 3D forms. Cutouts can also be deÞ ned.

" Workpiece# 2D representation$ 3D representation

Tool managementShopMill tool management is clearly structured and supports various tool types, tool names in plain text, sister tools and tool geometry with length, radius and number of cutters.

EthernetThe ShopMill program manager allows direct access to external drives via a high-speed Ethernet connection. Extensive mold making programs can be stored

! on the HMI hard disk (PCU 50 ) or ! on the Flash Card (PCU 20)

" Network access function

1

1

2

3

1

3

Information forprogrammers

Contents Page

3.1 Introduction 3.2

3.2 Kinematic-independent CNC programs 3.3

3.3 Five-axis transformation - TRAORI 3.5

3.4 Tool orientation - A3= B3= C3=, ... 3.6

3.5 High-speed settings � CYCLE832 3.9

3.6 Feedrate proÞ le - FNORM, FLIN, ... 3.18

3.7 Orientation interpolation - ORI... 3.19

3-8 Tool offsets - CUT3DFS, ... 3.21

3-9 Programming at the machine 3.22

3-10 Example - bending device for pipes 3.25

3-11 Example - motorcycle headlight 3.36


3.2

Information for programmersIntroduction3.13.1 IntroductionIntroduction

In the programming of freeform surfaces, the entire CAD/CAM/CNC process chain is of vital importance.

The CAD system generates the geometry of the desired workpiece. On the basis of this geometry Þ le the CAM system generates the corresponding processing strategy with associated technology information.

The initial data format from the CAM system is usually an APT or CL data Þ le, which in the postprocessor is converted into executable CNC code.

The postprocessor is of the utmost importancein gaining the maximum beneÞ t from thecapabilities of Sinumerik 840D.

The postprocessor has to ensure that the higher-order functions of Sinumerik 840D are activated in the best possible way. An overview of all higher-order Sinumerik 840D functions can be found in Chapter 4.

CAD software(design creation)

CAM software(NC programming)

PP software(NC programming)

CAD software(machining)

Geometry Tool pathAPT source

NC program Workpiece


3.3

3.2 Kinematic-independent CNC programs

1. Tool orientation and TRAORI

Programming with Sinumerik 840D independently of the machine kinematics simply requires a few conventions to be followed.

The TRAORI ! command is used to call 5-axis transformation. The control system is then re-sponsible for converting position and orientation data into machine movements (see Chapter 2).

When TRAORI is enabled, the positional data X, Y, Z " relate to the tool tip (TCP, tool center point).

To program orientation on a 5-axis machine, we do not recommend programming the machine axes A, B or C directly. An NC program of that type is dependent on the kinematics of the machine.

Instead, the directional vectors with addresses A3, B3 and C3 # should be programmed in conjunction with TRAORI.

When TRAORI is activated, we recommend starting swivel movements close to the proÞ le in order to keep within the conÞ gured work area limits.

N15 TRAORIN16 G1 X Y Z A3= B3= C3=

1

3

A3 B3

C3

G1

2

G1

G1

Information for programmersKinematic-independent NC programs 3.2

N16 G1 X Y Z

N16 G1 X Y Z A3= B3= C3=

TRAORI


3.4

2. Tool gauging

In machine kinematic-neutral programs, the tool data are calculated directly from the tool Þ le.

Freeform surfaces are generally machined with-out radius compensation in the CNC.Although Sinumerik 840D does offer correspond-ing compensation options, we are working on the assumption here that the necessary data are rarely available. For that reason we recommend outputting the tool center point.

This also simpliÞ es tool gauging at the machine.

3. Inß uencing speed and quality

High-speed settings CYCLE832

To simplify programming and to improve pro-gram structure, we have combined all these technology functions into a single cycle.

The feedrate proÞ le is not part of CYCLE832 and has to be programmed separately.

Information for programmersKinematic-independent NC programs3.2

L1

Tolerance band

Compressor

Continuous-path control:

Corner rounding

Velocity feedforward control+ Jerk limitation

4. Feedrate proÞ le

Feedrate proÞ le


3.5

Information for programmersFive-axis transformation – TRAORI 3.3

Function

To obtain optimum cutting conditions when ma-chining surfaces with a three-dimensional curve, the setting angle of the tool must be able to be varied.

In addition to the three linear axes X, Y, Z, this requires at least one or two rotary axes. The NC blocks are extended with the orientation informa-tion A3, B3, C3.

When transformation is enabled, the positional data (X, Y, Z) always relate to the tip of the tool (TCP). Changing the position of the rotary axes involved in the transformation causes so many compensating movements of the remaining machine axes that the position of the tool tip is unchanged.

! without 5-axis transformation" with 5-axis transformation

Note: Depending on the conÞ guration, TRAORI can reset the zero offset.

Programming

TRAORI(n)TRAFOOF

Explanation of the commands

TRAORI Activates the Þ rst programmed orientation transformation ____________________________________________________________________________ TRAORI(n) Activates the orientation transformation programmed with n ____________________________________________________________________________ n Transformation number (n = 1 or 2), TRAORI(1) corresponds to TRAORI. ____________________________________________________________________________ TRAFOOF Switches transformation off

3.3 Five-axis transformation � TRAORIProgramming TRAORI offers several advantages. In particular: the program is independent of the tool length and machine kinematics; the feedrate relates to the tool center point, and compensation movements to compensate the rotary axis movements are performed automatically.

2

1

TIP Fluctuating orientation changes should be avoided along the tool paths.


3.6

Information for programmersTool orientation - A3= B3= C3=, ... 3.4

We recommend using directional vectors to program the tool orientation. Sinumerik 840D supports all types that are relevant in practice for programming the tool orientation. Orientation transformation TRAORI must be activated.

Programming

G1 X Y Z A3= B3= C3=


G1 X Y Z A B C Direct programming of the movement of the rotary axes A, B or C. The rotary axes are moved synchronously to the tool path. ____________________________________________________________________________ ORIEULER Orientation programming on the basis of Euler angles (default) ORIRPY Orientation programming on the basis of RPY angles. This is only effective if $MC_ORI_DEF_WITH_G_CODE = 1 is set. Otherwise deÞ ned on the basis of machine data.

G1 X Y Z A2= B2= C2= Programming on the basis of Euler angles or RPY angles (roll pitch yaw)

The interpretation is deÞ ned on the basis of machine data

Programming in Euler or RPY angles via A2, B2, C2 or programming of directional vector. The directional vector points from the tool tip towards the tool holder.

G1 X Y Z A3= B3= C3= Programming of the directional vector (recommended) ____________________________________________________________________________ G1 X Y Z A4= B4= C4= Programming of the surface normal vector at start of block This information is used by CUT3DF for 5-axis machining. Lead and Tilt can also be used to program the tool orientation. The lead and tilt angle relates to the normal vector A4 B4 C4.

G1 X Y Z A5= B5= C5= Programming the surface normal vector at end of block ____________________________________________________________________________ LEAD Lead angle for programming tool orientation. Angle relative to the surface normal vector in the plane spanned by the path tangent and surface normal vector. TILT Tilt angle for programming tool orientation. The TILT angle describes the rotation of the lead angle about the surface normal vector (see illustration on p. 3.8).

3.4 Tool orientation - A3= B3= C3=, ...


3.7

Programming the directional vector

The components of the directional vector ! are programmed with A3, B3, C3. The vector points towards the toolholder; the length of the vector is meaningless. Vector components that have not been programmed are set equal to zero.

The resolution should be set as high as possible. Experience shows that 8 to 10 decimal places produce good results.

ORIVECT.MPF N020 TRAORI N030 G60 F10000 X0 Y0 Z0 N050 A3=0 B3=0 C3=1 N060 A3=0 B3=1 C3=0 N070 A3=1 B3=0 C3=0 N080 A3=1 B3=1 N090 A3=1 B3=1 C3=1 N100 A3=1 B3=0 C3=1 N110 A3=0 B3=1 C3=1 N160 A3=0 B3=-1 C3=0 N170 A3=-1 B3=0 C3=0 N180 A3=-1 B3=-1 N190 A3=-1 B3=-1 C3=1 N200 A3=-1 B3=0 C3=1 N210 A3=0 B3=-1 C3=1 N888888 M30

Programming in RPY angles

The values programmed with A2, B2, C2 for ori-entation programming are interpreted as an RPY angle (in degrees).Starting from the normal position !: The orienta-tion vector results from turning a vector in the Z direction Þ rstly with C2 around the Z axis ", then with B2 around the new Y axis # and lastly with A2 around the new X axis. In contrast to Euler angle programming, all three values here have an effect on the orientation vector.

ORIRPY.MPF N020 TRAORI N030 G60 F10000 X0 Y0 Z0 N050 C2=0 B2=0 N060 C2=90 B2=90

2

1

C3

A3 B3

2

3

1

where C2 = 90°rotated about the Z axis

where B2 = +45°rotated about therotated Y axis

Variants for deÞ ning the tool setting

This section covers only the most important functions. More information can be found on the DOCon-CD.

Information for programmersTool orientation – A3= B3= C3=, ... 3.4

Example

Example


3.8

Information for programmersTool orientation – A3= B3= C3=, ... 3.4

2

1

N070 C2=0 B2=90 N080 C2=45 B2=90 N090 C2=45 B2=45 N100 C2=0 B2=45 N110 C2=90 B2=45 N160 C2=90 B2=-90 N170 C2=0 B2=-90 N180 C2=-135 B2=90 N190 C2=-135 B2=45 N200 C2=0 B2=-45 N210 C2=90 B2=-45 N888888 M30

Programming the tool orientation with Euler angles

Programming in Euler angles is analogous to programming in RPY angles.

.... N020 TRAORI N030 G60 F10000 X0 Y0 Z0 N050 A2=0 B2=0 C2=0 N060 A2=0 B2=-90 C2=0 ...

Programming the tool orientation with LEAD and TILT in conjunction with ORIPATH

The resulting tool orientation is determinedfrom:$ the path tangent$ the surface normal vector$ the lead angle LEAD !$ the tilt angle TILT " at end of block

LEAD describes the angle between the surface normal and the new tool orientation, in the direc-tion of the path tangent. If the tool is also rotated about the surface normal from this position, this corresponds to the TILT angle.

.... N100 G54 N110 G64 N120 ORIWKS N130 CUT3DF N110 ORIC N120 START: ROT X=R20 N130 G0 X=260 Y0 A3=1 B3=0 C3=0 N140 G1 Z0 LEAD=5 TILT=10 G41 N150 X240.000 Y0.000 A5=1 B5=0.000 C5=0.000 ...

Example

Example


3.9

3.5 High-speed settings � CYCLE832To simplify programming and clarify program structure, Sinumerik 840D includes CYCLE832, which contains the most important functions for freeform surface milling. CYCLE832 also makes it easier for the machine operator to inß uence the program.

Programming

CYCLE832(_TOL,_TOLM) Programming the cycle

CYCLE832() Abbreviated program call. Corresponds to selecting the �Machining� screen form �Deselection�.

CYCLE832(0.01) Abbreviated program call. To enter the tolerance value. The active G commands are not changed in the cycle.

Explanation of the parameters

_TOL real Tolerance on machining axes -> unit: mm/inches; degrees _____________________________________________________________________________ _TOLM 7 integer Mode tolerance Decimal place 2) Input __________________________________________________ 0 0 = Deselection 1 = Finishing (default)1)

2 = PreÞ nishing 3 = Roughing __________________________________________________ 1 0 = 1 = __________________________________________________ 2 0 = TRAFOF (default)1) 1 = TRAORI(1) 2 = TRAORI(2) __________________________________________________ 3 0 = G64 1 = G641 2 = G642 (default)1)

3 = G643 4 = G644 __________________________________________________ 4 0 FFWOF SOFT (default)1)

1 FFWON SOFT 2 FFWOF BRISK __________________________________________________ 5 0 = COMPOF 1 = COMPCAD (default)1)

2 = COMPCURV 3 = B spline __________________________________________________ 6 Reserved 7 Reserved

1) Setting can be changed by machine manufacturer. 2) Sequence of parameters (CYCLE832(_TOL,76543210)

Information for programmersHigh-speed settings – CYCLE832 3.5


3.10

Decimal place 0Tolerance (_TOL)Tolerance of the axes used for machining. The tolerance value applies with G642 and COMP-CURV or COMPCAD. If the machining axis is a rotary axis, the tolerance value is written to MD 33100: COMPRESS_POS:_TOL (AX) for the rotary axis with a factor (default factor = 8).

With G641 the tolerance value corresponds to the ADIS value. On initial input the tolerance is preset with the following values:0 Deselection: 0.1 (linear axes) 0.1 degrees (rotary axes) Measurement system mm/inches is taken into account1 Finishing: 0.01 (linear axes) 0.08 degrees (rotary axes)2 PreÞ nishing: 0.05 (linear axes) 0.4 degrees (rotary axes)3 Roughing: 0.1 (linear axes) 0.8 degrees (rotary axes)If the tolerance value is also to apply to the rotary axes, 5-axis transformation must be set up by the machine manufacturer.

Decimal place 2Transformation (_TOLM)The Transformation input Þ eld is only displayed if the NC option is set (5-axis machining package set).0 TRAFOOF CAM programs with open rotary axis positions are supported1 TRAORI2 TRAORI (2)Deselection of the transformation number of the manufacturer cycle to call 5-axis transformation. The parameter is used in conjunction with the following GUD7 variable _TOLT2.This can be followed by the name of a manufac-turer cycle which calls the manufacturer trans-formation cycle. If _TOLT2 is empty (�default�), selecting transformation 1, 2 ... calls 5-axis transformation with TRAORI(1), TRAORI(2).

Adaptation, technology adaptation$ yes$ noIf CYCLE832 is programmed via the screen form on the control system, the following input parameters can only be modiÞ ed if Adaptation is set to �yes�.

Decimal place 3Continuous-path control (_TOLM)0 G64 (default)1 G641 Corner rounding with ADIS, ADISPOS2 G642 Corner rounding with single-axis tolerance3 G643 Block-internal corner rounding4 G644 Speed-optimized corner roundingWith the NC block compressor with COMPCAD, COMPCURV, G642 is always selected.

Decimal place 4Compression, NC block compressor (_TOLM)0 FFWON SOFT with feedforward control, with jerk limi-tation1 FFWOF SOFT without feedforward control, with jerk limitation2 FFWOF BRISK without feedforward control, without jerk limitationIn order for feedforward control (FFWON) and jerk limitation (SOFT) to be selected, the control system and machining axes must have been optimized by the machine manufacturer.

Decimal place 5Compression, NC block compressor (_TOLM)0 none (COMPOF)1 COMPCAD2 COMPCURV3 B splineIn order for feedforward control (FFWON) and jerk limitation (SOFT) to be selected, the control system and machining axes must have been optimized by the machine manufacturer.


In order for these functions to be used, the CNC/machine must have been optimized by the machine manufacturer in the proper manner.TIP


3.11

Example of CYCLE832 call

N01 T1 D1 N02 G54 N03 M3 S12000 N04 CYCLE832(0.2,110003)* ;0.2 tolerance value ;1003 from back to front: ;3 = Roughing, 0 = TRAFOF, ;0 = G64, 1 = FFWON SOFT, 1 = COMPCAD N05 EXTCALL �CAM_Mold_Roughing� ; �Roughing� subroutine call N06 CYCLE832(0.01,102001)* ; 0.01 = tolerance value ;102001 from back to front: ;1 = Finishing, 0 = TRAFOF, ;2 = G642, 0 = FFWOF SOFT, ;1 = COMPCAD N07 EXTCALL �CAM_Mold_Finishing� ;�Finishing� subroutine call N08 M02

CYCLE832 combines the essential G codes and machine and setting data that are required for HSC machining.

A distinction is made in CYCLE832 between three machining technologies:

$ Finishing$ PreÞ nishing and$ Roughing

In CAM programs in the HSC range the three machining types have a direct bearing on the precision and speed of the path contour. By specifying a tolerance value the operator/programmer can weight these factors accordin-gly.

Different tolerances and settings (technology adaptation) can be assigned to the three machi-ning types.

The cycle is positioned ahead of the geome-try subroutine in the main program (see call example below). The various interpretations of the tolerance values are taken into account. For example, with G641 the tolerance value is trans-ferred as ADIS=, and with G642 the axis-speciÞ c machine data MD 33100 $MA_COMPRESS_POS_TOL (AX) is updated.

Calling the �Machining deselection� cycle resets the modiÞ ed machine/setting data to the machi-ne manufacturer�s value.

Example


Speed

Surface quality

Precision

Using the high-speed setting cycle

*Note: Decimal place 1 has no function. (0.2,110003)

Decimal place 0Decimal place 1


3.12

Information for programmersHigh-speed settings – CYCLE832 3.5 Compressor - COMPCAD, COMPCURV, ...

The compressor is ideally called in CYCLE832. To program it separately you should use the following procedure.

Programming

COMPCURVCOMPCADCOMPOF


COMPCURV Compressor on:

Approximation by polynomial, 5th degree. G1 blocks are approximated by a polynomial. The block transitions are jerk-free.

Preferably for circumferential milling ______________________________________________________________________________ COMPCAD Compressor on: COMPCAD smoothes the point proÞ le before approximation (B spline) and at high path speed offers maximum precision with constant-acceleration transitions (compression rate unlimited, but max. path length 5 mm)

Preferably for the milling of freeform surfaces (recommended) ______________________________________________________________________________ COMPOF Compressor off

Additional commands for a combination of path and orientation axes:

UPATH Parameter settings for the orientation axes correspond to those for the path axes X, Y, Z. This means that for the movement of a synchronous axis, A = f(u), where u denotes the path parameter for the path movement. UPATH is recommended for programming. ______________________________________________________________________________ SPATH Parameter settings for the synchronous axes follow the arc length for the path axes. This means that for the movement of an orientation axis A, A= f(s) where s denotes the arc length for the path movement.


3.13


N010 FGROUP (X, Y, Z) ; Feed relates to the path axes N020 UPATH G642 N020 $MA_COMPRESS_POS_TOL [X] = 0.01 ; Path tolerance setting N030 $MA_COMPRESS_POS_TOL [Y] = 0.01 ; Path tolerance setting N040 $MA_COMPRESS_POS_TOL [Z] = 0.01 ; Path tolerance setting N050 $MA_COMPRESS_POS_TOL [A] = 0.08 ; Rotary axis tolerance setting N060 $MA_COMPRESS_POS_TOL [B] = 0.08 ; Rotary axis tolerance setting ; (The value for the rotary axes should be ; factor 8 - 10 of the path tolerance.) N070 NEWCONF N080 COMPCAD ;Compressor on N090 G1 X.37 Y2.9 F600 ;G1 before end point and feed! N100 X16.87 Y-4.698 A3=0.1736482 B3=-0.84950947 C3=0.49817663 N110 X16.865 Y-4.72 A3=0.1736482 B3=-0.84950664 C3=0.49818147 N120 X16.91 Y-4.799 A3=0.17364925 B3=-0.84774706 C3=0.5011695 ... N1037 COMPOF ;Compressor off ...

Example

Notes on programming

If the high-speed setting cycle CYCLE832 is not available, then the compressor should be programmed as follows. This is the case with software versions prior to 6.4.

Function of the spline compressor

According to the speciÞ ed tolerance band ! the compressor combines a sequence of G1 com-mands " and compresses them into a spline #, which is directly executable by the control system.

This makes the surface much smoother, since the machine axes can move more harmoniously and machine resonance is avoided.

This allows higher traversing speeds and redu-ces the load on the machine.

1 32

Writing of machine data [MA] must be unlocked by the machine manufacturer.


3.14

Information for programmersHigh-speed settings – CYCLE832 3.5 Continuous-path mode, Look ahead - G64, G642, G643

If continuous-path mode is called within CYCLE832, the ADIS value in G641 corresponds to the tole-rance value TOL_. If you are programming without CYCLE832, you should include the ADIS value.

Programming the retraction clearance with ADIS

G64G642 ADIS=� or ADISPOS=�G643 ADIS=� or ADISPOS=�


G64 Continuous-path mode - Look ahead with braking at corners only ______________________________________________________________________________ G642 Corner rounding with axial tolerance (recommended) Look ahead with additional corner rounding corresponding to MD 33100 (machine data) For G642 and G643 there are 2 ways of specifying the tolerance. 1. Specifying single axes - see programming example on the previous page or 2. Programming the retraction clearance with ADIS Preferably for the milling of freeform surfaces ______________________________________________________________________________ G643 Block-internal corner rounding Look ahead with additional block-internal corner rounding corresponding to MD33100) ______________________________________________________________________________ G644 Speed- and acceleration-optimized corner rounding for rapid positioning outside the contour ______________________________________________________________________________ ADIS= Rounding clearance for path functions G1, G2, G3 ______________________________________________________________________________ ADISPOS= Rounding clearance for rapid traverse G0 (not suitable for free form surfaces)

Use of G64, ..., G644

The purpose of continuous-path control is to increase speed and harmonize traversing perfor-mance. In path control function G64, etc., this is achieved with two functions.

Look ahead - look-ahead speed control !The control system calculates several CNC blocks ahead and determines a modal speed proÞ le. The way in which this speed control is calculated can be set with functions G64, etc.

G1 G1 G1G1

1

2

G1 G1


3.15


G1 G1

1

2

3

Corner rounding "The look ahead function also means that the control system is able to round the corners it detects. The programmed corner points are therefore not approached exactly. Sharp corners are rounded.

These two functions mean that the contour is created with a uniform path velocity proÞ le. This establishes better cutting conditions, improves the surface quality and reduces the machining time.

To round sharp corners #, the continuous-path commands G642 and G643 form transition elements !, " at the block boundaries. The continuous-path commands differ in the way they form these transition elements.

With G641, G642, G643 you can deÞ ne the de-gree of rounding " with the ADIS value.

G642 inserts constant-curve transition polynomi-als. This avoids acceleration jumps at the block boundaries. We recommend G642 for mold making applications.

G643 inserts constant-curve transition polyno-mials. It does not form intermediate blocks but rounds the corners within the blocks.


3.16

Feedforward control and jerk limitation - FFWON, SOFT, ...

Feedforward control and jerk limitation can only be called in CYCLE832 as a combination of the two functions. This is because this combination offers ideal conditions for freeform surface milling. Both functions can of course also be programmed separately.

Programming

FFWON/FFWOFBRISKSOFT


FFWON Feedforward control �on� ______________________________________________________________________________ FFWOF Feedforward control �off� ______________________________________________________________________________ BRISK Without jerk limitation Brisk acceleration of path axes ______________________________________________________________________________ SOFT With jerk limitation Soft acceleration of path axes Axial jerk limitation (maximum jerk in machine data JOG_AND_PS_MAX_JERK (jog and positioning) MAX_AX_JERK (path mode)

Jerk limitation function


To make acceleration as gentle on the machine as possible, the acceleration proÞ le of the axes can be inß uenced by means of the commands Soft, Brisk. If Soft is activated, the acceleration behavior does not change abruptly but is incre-ased by a linear characteristic. This reduces the load on the machine. It also has a beneÞ cial effect on the surface quality of workpieces, since machine resonance is excited far less frequently.

BRISK:Acceleration behavior: abrupt acceleration of the path axes according to the speciÞ ed machine data

The axis slides travel with maximum accelerati-on until the feedrate is reached. BRISK enables time-optimized machining, but with jumps in the acceleration curve.


3.17


SOFT:Acceleration behavior: soft acceleration of path axes.

The axis slides travel with constant acceleration until the feedrate is reached. SOFT acceleration enables higher path accuracy and less wear and tear on the machine.

Feedforward control function

Following errors cause contour violation !. The inertia in the system means that the cutter tends to leave the setpoint contour " tangentially, i.e. the actual contour # that is produced deviates from the setpoint contour. Following errors are due to a combination of the system (positioning control) and the speed.

Feedforward control FFWON reduces speed-de-pendent following errors when contouring almost to zero. Traversing with feedforward control permits higher path accuracy and thus improved machining results.

Recommendations

CYCLE832 includes the followingcombinations:

FFWON SOFTThe emphasis is on high path accuracy. This is achieved by a soft speed control which is largely free from following errors.

FFWOF SOFTHigh path accuracy is not a priority. Additional rounding is achieved by means of following er-rors. For use with older part programs/machines.

FFWON BRISKnot recommended

FFWOF BRISKFor use in roughing and when maximum speed is required.

Feedforward control

FFWONwithoutfollowing errors/tolerance

FFWOFwithfollowing errors/tolerance

Acceleration

BRISKhigh acceleration

SOFTgentle acceleration

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3.18

3.6 Feedrate proÞ le - FNORM, FLIN, ...

Programming

F� FNORMF� FLINF� FCUBF=FPO(endfeed, quadf, ufb)


FNORM Basic setting. The feedrate is applied over the entire path of the block and is subsequently regarded as the modal value. _______________________________________________________________________________ FLIN Path velocity proÞ le linear: The feedrate is traversed linearly from the current value at the beginning of the block to the end of the block and is subsequently regarded as the modal value. _______________________________________________________________________________ FCUB Path velocity proÞ le cubic: The non-modally programmed F values, relative to the end of the block, are connected through a spline. The spline starts and ends tangentially to the previous or following feedrate setting. If the F address is missing from a block, the last programmed F value is used. _______________________________________________________________________________ F=FPO... Polynomial path velocity proÞ le: The F address denotes the feedrate proÞ le via a polynomial from the current value to the end of the block. The Þ nal value is subsequently regarded as the modal value. _______________________________________________________________________________ endfeed: Feedrate at block end _______________________________________________________________________________ quadf: Quadratic polynomial coefÞ cient _______________________________________________________________________________ ubf: Cubic polynomial coefÞ cient

Function

What is a feedrate proÞ le?To allow a more ß exible programming of the feedrate proÞ le, linear and cubic characteristics have been added to the feedrate programming in accordance with DIN 66025. The cubic characteristics can be programmed either directly or as interpolating splines. These additional characteristics make it possible to pro-

Information for programmersFeedrate profi le – FNORM, FLIN, ...3.6

gram continuously smooth velocity characteris-tics depending on the curvature of the workpiece to be machined.

These speed characteristics make it possible to program limiting acceleration changes and the-reby to produce uniform workpiece surfaces.


3.19

Information for programmersOrientation interpolation – ORI... 3.73.7 Orientation interpolation - ORIVECT, ...Programming

N.. ORIMKS Reference system for orientationN.. ORIWKS_________________________________________________________________________N.. ORIAXES/ORIVECT/... Type of orientation interpolationN.. G1 X Y Z A B C


Orientation reference

ORIMKS The reference system for the orientation vector is the machine coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0 it is also identical to ORIAXES ORIWKS The reference system for the orientation vector is the workpiece coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0 it is also identical to ORIVECT

Orientation interpolation Axis interpolation

ORIAXES Linear interpolation of the machine axes or interpolation of the rotary axes using polynomials (if POLY is active) ______________________________________________________________________________

Vector interpolation

ORIVECT Interpolation of the orientation vector in one plane (great circle interpolation)

ORIPLANE Interpolation in one plane (great circle interpolation), synonym of ORIVECT

ORIPATH Tool orientation relative to the path. A surface is spanned with the normal vector and path tangent, which deÞ nes the meaning of LEAD and TILT at the end point. This means that the path reference applies only for the deÞ nition of the end orientation vector. Great circle interpolation is performed from the start to the end orientation. LEAD and TILT do not simply mean lead and tilt angle. They are deÞ ned as follows: LEAD describes the rotation in the plane that is spanned by the normal vector and path tangent; TILT then deÞ nes the rotation around the normal vector. In other words they both have the meaning of theta and phi in a spherical coordinate system, with the normal vector as the Z axis and the tangent as the X axis.

ORICONCW Interpolation on the peripheral surface of a cone in the clockwise direction

ORICONCCW Interpolation on the peripheral surface of a cone in the counterclockwise direction. Also required in both cases: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation


3.20

Rotary axis of the cone: A6, B6, C6 Aperture angle: NUT=�

ORICONIO Interpolation on the peripheral surface of a cone with intermediate orientation setting with A7=... B7=... C7=....

Also required: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation

ORICONTO Interpolation on the peripheral surface of a cone with tangential transition

Also required: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation

With POLY, PO[PHI]=..., PO[PSI]=... can also be programmed here. This is a generalization of great circle interpolation, in which the polynomials for lead and tilt angle are programmed. The polynomials have the same meaning in conical interpolation as in great circle interpolation for the given start and end orientations. The polynomials can be programmed with ORIVECT, ORIPLANE, ORICONCW, ORICONCCW, ORICONIO, ORICONTO.

ORICURVE Orientation interpolation with deÞ nition of the movement of the tool tip and of a second point on the tool. The path of the second point is deÞ ned with XH=... YH=... ZH=..., in conjunction with BSPLINE as the control polygon with POLY as the polynomial:

PO[XH] = (xe, x2, x3, x4, x5) PO[YH] = (ye, y2, y3, y4, y5) PO[ZH] = (ze, z2, z3, z4, z5) If additional BSPLINE or POLY information is not available, simple linear interpolation is performed accordingly from the start to the end orientation.

The main orientation interpolations

Information for programmersOrientation interpolation - ORI...3.7

2

3 4

1 Orientation interpolation functions are described in section 1.10.

! Linear interpolation ORIAXES" Great circle interpolation ORIVECT# Conical surface interpolation ORICONCW& Curve interpolation ORICURVE


3.21

3.8 Tool offsets - CUT3DFS, ...


G40 Deactivation of all variants G41 Activation in circumferential milling compensation direction left G42 Activation in circumferential milling compensation direction right G450 Circles at external corners (all compensation types) G451 Intersection traveling at external corners (all compensation types)

2 ½D circumferential milling

CUT2D 2 1/2D COMPENSATION with compensation plane determined with G17 - G19 ______________________________________________________________________________ CUT2DF 2 1/2D COMPENSATION with compensation plane determined by frame


CUT3DC Compensation perpendicular to path tangent and to tool orientation ______________________________________________________________________________ ORID No orientation changes in inserted circle blocks at external corners. Orientation movement is executed in the linear blocks. ______________________________________________________________________________ ORIC Travel path extended with circles. The orientation change is executed proportionately in the circle as well.

Face milling

CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the coordinate system deÞ ned with G17 - G19. Frames have no inß uence. ______________________________________________________________________________

CUT3DFF Constant orientation (3-axis). Tool in Z direction of the current coordinate system deÞ ned with frame. ______________________________________________________________________________ CUT3DF 5-axis with variable tool orientation

3D circumferential milling with limitation surface (combined circumferential/face milling) CUT3DCC CNC program refers to the contour on the machining surface. ______________________________________________________________________________ CUT3DCCD The CNC program refers to the tool center path.

Information for programmers3D tool offsets - CUT3DFS 3.8


3.22

With the user-friendly functions in Sinumerik 840D the program can be easily programmed at the control system.

%_N_slide N10 T1 N20 S1000 M3 N30 M8 M60 N40 ORIWKS TRAORI N50 ORIVECT N60 G54 ;Zero point at !. N70 TRANS X25 Y10 Z70 ;Coordinate system moved to ". N80 AROT Y+60 ;Coordinate system rotated into inclined plane. From this point ;the static transformation is calculated automatically. N90 G0 X20 Y15 Z5 ;Approach Þ rst drilling position and with A3, B3, C3 tool A3=0 B3=0 C3=1 ;parallel to Z axis, i.e. tool perpendicular to the plane. N110 Drilling cycle :From this point you can carry on programming as for ;a 2 ½D situation. The 840D does everything else ;for you. ... N200 M30 ;End of program

Example

3.9 Programming at the machine

Machining inclined surfaces or holes

Programmers can also program 5-axis movements at the machine.

Example: Inclined holesTo produce 4 holes on an inclined slide in a large tool.

2

1

Information for programmersProgramming at the machine3.9


3.23

Example of orientation interpolation

Pocket with draft

In the following program we have assumed that the pocket has already been produced with straight walls, so only the programming of the inclines is described here.The programming is carried out in G90, the tool starts parallel to the Z axis.The contour at the base of the pocket is programmed.

N110 TRAORI(1) ;Activate TRAFON120 G54 ;Select tool zero pointN130 TRANS X 80 Y80 ;Move tool zero point to center of pocket !/N140 AROT Z .. ;(rotate pocket if necessary)N150 ORIWKS ;Tool orientation in WCSN160 ORIVECT ;Great circle interpolation of orientationN170 CUT3DC ;3D tool radius compensation (TRC)N180 ISD=0 ;Engaged length of tool = 0 The contour was programmed on the workpiece surface, not on the pocket base (then ISD = 41, 231), see also notes at end of CNC program.N190 G0 X0 Y-40 Z-39 ;Approach path "N200 G1 G41 X0 Y-50 Z-40 A3=0 B3= - 10 C3=40 ;As the contour is approached, the orientation changes

Example

Information for programmersProgramming at the machine 3.9

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3.24

This pocket can be produced with various strategies:

1. If the contour of the pocket is programmed at the pocket base, ISD = 0 mm, where ISD is the depth of engagement of the tool.

2. The pocket contour can also be programmed at the workpiece surface. In this case the cutter must be plunged in with an ISD of 41.231 mm, which corresponds to the wall length. The radii should be adjusted.

In this example the depth of engagement is calculated using Pythagoras� theorem:

; Select TRC and approach 1st machining position with ;required orientation. ;The components of the orientation vector ;can be taken directly from the ;drawing. #N210 X20 ;1. machining step. Traverse to the corner. &N220 ORICONCCW ;Selects conical surface interpolation for the orientation ;interpolationN230 A6=0 B6=0 C6=1 ;DeÞ nes the taper axis (parallel to the Z axis of the ;TCS). DeÞ nition that the taper is perpendicular to the Z ;axis.N240 G3 X30 Y-40 CR=10 A3=10 B3=0 C3=40 ;Pocket rounding with radius programming ;Orientation change on the conical surface 'N250 ORIVECT ;Great circle interpolationN260 G1 Y40 ;from this point the individual machining steps are repeated (N270 ORICONCCWN280 A6=0 B6=0 C6=1N290 G3 X20 Y50 CR=10 A3=0 B3=10 C3=40N300 ORIVECTN310 G1 X-20 ;)N320 ORICONCCW N330 A6=0 B6=0 C6=1N340 G3 X-30 Y40 CR=10 A3= - 10 B3=0 C3=40N350 ORIVECTN360 G1 Y-40N370 ORICONCCWN380 A6=0 B6=0 C6=1 ;*N390 G3 X-20 Y-50 CR=10 A3=0 B3= - 10 C3=40N400 ORIVECTN410 G1 X0 ;+N420 G40 Y-40 Z-39 A3=0 B3=0 C3=1 ;Deselects TRCN430 G0 Z100 ;RetractionN440 TRAFOOF ;Switch off TRAFO (if necessary)

Information for programmersProgramming at the machine3.9

402 + 102 = 41, 231ISD:


3.25

Information for programmersExample – bending device for pipes 3.10

4

BENDINGRADIUS.SPF

GUIDESLOT.SPFHOLES.SPF

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3.10 Example - bending device for pipes


3.26

Information for programmersExample – bending device for pipes3.10Workpiece

Milling work is required on a bending device for pipes:

! Bending radius, die (BENDINGRADIUS.SPF, 5-axis simultaneous milling of a freeform surface)" Holes (HOLES.SPF, 3-axis drilling with frame shifting)# Guide slot (GUIDESLOT.SPF, 3-axis milling with frame shifting)

On the lower side of the workpiece is a central threaded hole & for clamping the device in the ben-ding machine. The threaded hole should also be used in the milling machine for clamping or at least centering. This allows a reproducible clamping for other parts. All key dimensions relate to this hole and as a consequence the tool coordinate system & is also positioned in the hole by adjustable zero offset G54 '.

Machine kinematics

In our example the workpiece is machined with a rotating/swivel head. The machine zero is outside the table. The axes of the machine( and workpiece coordinate system & are parallel to one another in this case. G54 therefore comprises only translatory values. Any 5-axis machine with any machine kinematics can be used for milling.

The prerequisite is of course that the necessary orientations can be achieved. For example, the tool in point * must be able to adopt a swivel angle of A = �90°.

Between each subroutine call a tool change position ) is approached, which is positioned so that the tool can approach the machining position along a straight path without colliding with the workpiece. The safe position is at the very top of the work area at X0 Y0 Z999.

The procedure is the same for all three basic kinematics (see Chapter 1). The same program can be run on all three machine types.

CNC program

The postprocessor in a CAM system generates the CNC program, which consists of a main program and subroutines. A CAM system is not necessary for the holes " and guide slot #, however. Both machining operations can easily be programmed with Sinumerik 840D.

The subroutines correspond to the machining positions !, " and #. The program structure is therefore very clear for machine operators. The main program contains the workpiece coordinate system &, to which two temporary axis systems (frames) refer, which use the subroutines �Holes.spf� and �Guideslot.spf�. These temporary axis systems are deÞ ned with the commands TRANS and AROT. TRANS and AROT deÞ ne the workpiece coordinate system for programming.

Subsequent changes can be made by the machine operator. A few tips are included in our comments on the subroutines. The standard version of the postprocessor only generates a program with no main program and subroutine technology.

Note:The programs shown here are not complete. They are intended only to illustrate the structure of the programs from a technological perspective.


3.27

Mainprogram.mpfN10 G17 G54 G90 ; Working plane, absolute dimensions ; Zero offset from machine to workpiece ; coordinate system, in the threaded hole on the ; lower side of the workpiece ; The frame deÞ nitions in �Holes.spf� and ; �Guideslot.spf� relate to this ; workpiece zero.N20 MSG (�CAM program�)______________________________________________________________________________

; Note: ; The swivel movement in the approach position does ; not occur in the subroutine. ; Feedrates are programmed in the subroutines. N30 MSG (�1st OPERATION: ; Comment by CAM programmer on the type of 5-AXIS MACHINING�) ; subroutineN40 T1 D1 ; Approach the tool change position and tool ; change. This is a simpliÞ ed version only, ; depending on the machine manufacturer other ; commands are necessary.N50 S16800 M3 ; Spindle speed, clockwiseN60 CYCLE832(0.05,112101) ; High-speed settings �on�, settings are as follows: ; 0.05 = Tolerance of machining axes 0.05 mm ; 112101 = COMCAD, FFWON SOFT, G642, ; TRAORI(1), FinishingN70 EXTCALL�BENDINGRADIUS.SPF� ; Call the �BENDINGRADIUS.SPF� subroutine.N80 CYCLE832() ; Deselect high-speed settings since they are not ; required for the subsequent program �holes.spf�. ______________________________________________________________________________

; Note: ; The swivel movement in the working position is ; included here in block N170. ; CYCLE832 is not programmed, since it is only ; useful for 3-axis and 5-axis transformations

N90 MSG (�2nd OPERATION: ; Comment by CAM programmer on the type of Drilling with frame support�) ; subroutineN100 T2 D2 ; Approach the tool change positionN110 S850 M3 ; Spindle speed, clockwiseN120 TRAORI() ; Selects 5-axis transformationN130 G54 ; Select zero offset againN140 TRANS X45 Y-69.529 Z109.393 ; Frame deÞ nition, translatory component ; From the lower side of the workpiece to the center of ; the top hole

Main program

The main program contains only the technology data. The geometry data are all contained in the subroutines. The frame deÞ nitions for the two subroutines �Holes.spf� and �Guideslot.spf� are also included in the main program.



3.28

N150 AROT X45 ;Frame deÞ nition, rotary componentN160 AROT Z-60 ;The frame was positioned so that after rotation ;both holes lie on the same axis, namely ;the X axis. The required clearance of ;26 mm between the two drill holes can clearly ;be seen in the program. ;This makes it easier to modify the hole ;positions in the program at a later date. ;The frame offset is carried out with TRANS and ROT, ;since they have to be based on G54. N170 G0 A3=0 B3=0 C3=1 ;Tool orientation perpendicular to the machining ;plane

N180 EXTCALL�HOLES.SPF� ; Call the �holes.spf� subroutine.N190 TRANS ;Translation and rotation off. Since TRANS ;clears all transformations (ROT, SCALE, MIRROR, ;TRANS), a CNC block �N22 ROT� to ;switch off rotation is not required.

______________________________________________________________________________ ;Note: ;The swivel movement in the working position is ;included here in block N280.

N200 MSG (�3rd OPERATION: Contour ;Comment by CAM programmer on the type of milling with frame support�) ;subroutineN210 G0 A3=0 B3=0 C3=1 ;To avoid collision with the workpiece ;(TRAORI is still enabled)N220 T3 D3 ; Approach the tool change positionN230 S10500 M3 ;Spindle speed, clockwise

N240 TRANS X75 Y0 Z0 ;Frame deÞ nition, translatory component. From the ;lower side of the workpiece to the lower side of the ;side wall.N250 AROT Z90 ;Frame deÞ nition, rotary component. The frameN260 AROT X90 ;is positioned so that the Z axis in this frame ;corresponds to the infeed direction and the main ;direction of movement to the Y axis.

N270 CYCLE832(0.05,112101) ;High-speed settings �on�, settings are ;as follows: ;0.05 = Tolerance of machining axes 0.05 mm ;112101 = COMCAD, FFWON SOFT, G642, ;TRAORI(1), Þ nishingN280 G0 A3=0 B3=0 C3 =1 ;Tool orientation perpendicular to the ;machining planeN290 EXTCALL�GUIDESLOT.SPF� ;Call the �GUIDESLOT.SPF� subroutine

N300 CYCLE832() ;Deselect high-speed settingsN310 TRANS ;Translation (TRANS) and rotation (ROT) off, see ;CNC block N240N320 A3=0 B3 =0 C3=1 ;Tool parallel to Z axis in G54 coordinate ;systemN330 TRAFOOF ;Transformation off______________________________________________________________________________

Information for CAM programmersExample – bending device for pipes3.10


3.29

N340 G0 G53 Z999 D0 ;Move in rapid traverse to the safe position at the ;top of the work area in the machine coordinate ;system at Z999. ;After G53 all subsequent movements relate ;not to G54 but to the ; machine coordinate system. ;Since G54 is modal, the command is used ;if further blocks follow. Otherwise ;the CAM system could also simply output ;the non-modal command SUPA: ;SUPA Z999 D0 ;D0 clears the existing tool offset ;N220 T3 D3. N350 M30 ;End of program



3.30

BENDINGRADIUS.SPF subroutine

Machining strategy:The milling paths ! were generated by the CAM program. They run parallel to the Y axis in the work-piece coordinate system.

Milling with 3+2 axes or with 5-axes simultaneously? Both types of machining are possible here.5-axis simultaneous milling has the clear advantage, however:

$ Much better cutting conditions in 5-axis simultaneous milling. The result is a higher cutting speed and improved surface quality.$ In contrast to milling with 3+2 axes, the tool can be kept shorter. In order to reach the convex contour on the extreme left and right, 3+2 axis milling would require a very long tool.$ In 5-axis simultaneous milling the work can be completed in a single machining operation. 3+2 axis milling would require milling for the left, right and center die or radius segment with 2 or 3 machining operations.

Sequence:The tool moves in a straight line, without risk of collision, from the tool change position " to the approach position #. The approach position # and retraction position & are at safe positions outside the workpiece. From there the tool moves down vertically to the start position (.

Machine operators:

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3.31

BENDINGRADIUS.SPFN10...180 ;Not relevant, user-speciÞ c CNC blocksN190 G0 A3=0.1736482 B3=-0.84951514 C3=0.49816696 ;Swiveling of the tool to the tool change ;position "N200 G0 X-20.54042 Y-117.80997 Z175 ;Approach position #N210 G0 Z63.87603 ;Moving down to the start position (N220 G1 X-21.40866 Y-113.5624 Z61.3852 F8500 ;Start of modal G1 blocks and call ;for feed______________________________________________________________________________N230 N370 CIP X-21.89062 Y-109.77512 Z63.23548 I1=AC(-21.74533) J1=AC(-111.5367)K1=AC(61.4569) ;Programming of a quadrant via CIP ;(see SINUMERIK 840D documentation, Circular ;interpolation through intermediate point, CIP)____________________________________________________________________________N380 X-21.86959 Y-109.74489 Z63.60494 A3=0.1736482 B3=-0.84951231 C3=0.4981718 ;5-axis simultaneous milling with permanent ;change of tool setting with A3, B3, C3N390 X-21.84803 Y-109.71466 Z63.9744 A3=0.1736482 B3=-0.84950947 C3=0.49817663N400 X-21.82647 Y-109.68443 Z64.34386 A3=0.1736482 B3=-0.84950664 C3=0.49818147N410 X-21.79376 Y-109.63744 Z64.82612 A3=0.17364925 B3=-0.84774706 C3=0.5011695...N281930 X21.86959 Y-109.74488 Z63.60495 A3=-0.17364815 B3=-0.84951232 C3=0.4981718N281940 X21.89115 Y-109.77511 Z63.2355 A3=-0.17364815 B3=-0.84951515 C3=0.49816697_____________________________________________________________________________N281950 Y-109.94584 Z62.85898 ;Soft retraction from the contour on a quadrant, ;with no change of tool setting, i.e. the ;vector A3, B3, C3 does not change.

N281960 X21.87787 Y-110.20695 Z62.44206 ...N282080 X21.4767 Y-113.18568 Z61.28948 N282090 X21.40867 Y-113.56239 Z61.3852 _____________________________________________________________________________N......... ;End position)N282100 G0 Z175 ;Move up to the retraction position/safety ;plane & above the workpieceN282110 M17 ;End of program, return to main program

TIP

In contrast to the �Holes.spf� and �Guideslot.spf� subroutines, all positions refer to the workpiece coor-dinate system ' and not to the coordinate systems deÞ ned in these subroutines.

If as in this case the workpiece coordinate system and subroutine are clearly identiÞ ed in the CNC program, the accuracy of the movements can be roughly checked at the machine before the start of the program. Compare the clamped workpiece, e.g. with the main milling direction in the CNC program. By way of example we have highlighted the Y values ( in the program which correspond to the main milling direction. Compare: the values increasein the Þ rst tool path since they lead from the negative range from -y to +y.

5-axis simultaneous milling makes it almost impossible for the machine operator to modify the subrou-tine.

The program can only be executed with a tool of the deÞ ned radius, since the CAM system includes the tool radius in the calculation of the travel.

Information for CAM programmersExample – bending device for pipes 3.10


3.32

21

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�HOLES.SPF� subroutine

Machining strategy:In the main program, using TRANS and AROT in the workpiece coordinate system G54 !, a tem-porary frame " was placed in the position of the Þ rst hole, in which the Z axis corresponds to the infeed direction of the drill. Using this temporary frame a drilling pattern can very easily be program-med on the inclined surfaces.

Sequence:The tool swivels to the tool change position # in the tool orientation for the subsequent machining - see CNC block N15 in the main program. From there it moves to the start position above the Þ rst hole &, drills, then moves with a clearance of 50 mm from the workpiece surface to the second hole ', where it executes the drilling cycle again. In this example the drilling cycle �CYCLE81� is used.

Machine operators:Since both holes are on the X axis in the current tool coordinate system, the hole positions can be easily corrected or the drilling cycle modiÞ ed subsequently.

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3.33

HOLES.SPFN1 G0 X0 Y0 Z50 ;In rapid traverse to the Þ rst hole with a safety ;clearance Z=50 &N2 F50 ;DeÞ nition of the drilling feed = infeed movement ;The traversing movement from hole to hole takes place ;in rapid traverse (deÞ ned by the drilling cycle).N3 MCALL CYCLE81 (50,0.5,-20) ;DeÞ nition of the drilling cycle = no movement yet ;(Safety plane, surface, safety clearance, ;drilling depth). MCALL calls CYCLE81 modally.N4 X0Y0 ;Drills the Þ rst hole at position X0Y0 &N5 X26 ;Moves to the second hole 50 mm above the ;workpiece ' and drills at X26N6 MCALL ;Deselects the modal CYCLE801N7 M17 ;End of program, return to main ;program



3.34

�GUIDESLOT.SPF� subroutine

Machining strategy:In the main program a temporary frame " was placed by the workpiece coordinate system G54 ! on the lower edge of the workpiece using TRANS and rotated by 90° about Z and X using AROT, since the guide slot was measured from here in accordance with the tool drawing (. The Z axis again corresponds to the infeed direction of the cutter. All traversing movements relate to the temporary frame. The main milling direction ' runs parallel to the Y axis of the frame ".

Since the contour was programmed with active tool radius compensation (see block N330 G42), the machine operator can use a milling tool of any diameter. The maximum possible diameter of the milling tool is calculated from the smallest radius of the con-tour to be milled (see block N360, lower semicircle radius 10 mm)

Sequence:The tool swivels to the tool change position # in the tool orientation for the subsequent machining - see CNC block N280 in the main program. From there it moves to the start position &, which is outside the open side of the groove, outside the tool.From the start position the cutter Þ rst moves down. Infeed takes place 5 times in the Z direction.

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3.35


GUIDESLOT.SPF N10 ... N290 ;Not relevant, user-speciÞ c CNC blocksN300 G0 X-2 Y126 Z50 ;& Approach start position = safety planeN310 Z1______________________________________________________________________________N320 G1 G64 Z-2 F575 ;) The cutter is moved from top to bottom and ;is now exactly at the start of machining. ;This is point X-2 and Y126 (see N300, X-2, ;Y126 still modally valid). ;Infeed rate = 575 mm/minN330 G42 Y132 F6333 ;Tool radius compensation right of contour ;Switch to machining feedrate = 6333 mm/minN340 G2 X10 Y120 I0 J-12 ;Soft approach to contour along quadrantN350 G1 Y40 ;Description of contour (slot)N360 G2 X-10 I-10 J0 ; - � -N370 G1 Y120 ; - � -N380 G2 X2 Y132 I12 J0 ;Soft retraction from contour along quadrantN390 G40 ;Deselection of tool radius compensationN400 G1 Y126N410 G0 Z-1 ;Retract by 1 mm in the tool axis directionN420 X-2 ;Positioning at start point (see N300)______________________________________________________________________________N430 G1 Z-4 F575 ;Infeed to Z-4 at infeed rate...______________________________________________________________________________..._____________________________________________________________________________N860 M17 ;End of program, return to main program



3.36

3.11 Example - motorcycle headlight

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G54

Information for CAM programmersExample – motorcycle headlight3.11


3.37

Workpiece

The mold for a motorcycle headlight casing is milled in two clamps.

In clamp 1 ! the lower side of the housing is milled from a block with 4 subroutines. In clamp 2 " the top and front side of the housing are each milled with 4 subroutines. ! Clamp 1 - lower side of lamp

a) Lower side of housing 1x (1_CLAMP_1.SPF, 3-axis plane roughing) b) Lamp holder (1_CLAMP_2.SPF, 3-axis plane Þ nishing) c) Lower side of housing 2x (1_CLAMP_3.SPF, 3-axis plane Þ nishing) d) Small surface (1_CLAMP_4.SPF, 3-axis proÞ le Þ nishing) " Clamp 2 - top of lamp

e) Top of housing 1x (2_CLAMP_1.SPF, 3-axis plane roughing) f) Top of housing 2x (2_CLAMP_2.SPF, 3-axis plane Þ nishing) g) Constriction (2_CLAMP_3.SPF, 3-axis, equidistant Þ nishing) h) Top of housing 3x (2_CLAMP_4.SPF, 5-axis ISO machining)

# i) Reß ector ring 1x (2_CLAMP_5.SPF, 5-axis ISO machining) j) Reß ector ring 2x (2_CLAMP_6.SPF, 5-axis, equidistant Þ nishing) k) Reß ector internal incline (2_CLAMP_7.SPF, 5-axis, equidistant Þ nishing) l) Reß ector base (2_CLAMP_8.SPF, 5-axis, equidistant Þ nishing)

Machine kinematics

The axes in the machine ( and workpiece coordinate system & are not parallel to one another. G54 ' consists of a translation and a rotation about the Z axis.

Between each subroutine call a tool change position ) is approached, which is positioned so that the tool can approach the machining position along a straight path without colliding with the workpiece.

CNC program

The postprocessor in a CAM system generates all subroutines. The main program that calls the subroutines is created by the machine operator (see next page).

In the second clamp the workpiece coordinate system remains at the same X/Y/Z position but is rotated so that the tool axis and Z axis are parallel to one another.This does not apply to subroutines i) onwards, in which infeed takes place along the Y axis. Program changes at the machine should only be made during the Þ rst NC blocks of the subroutine, before the NC blocks for freeform surface milling begin.

Just a few of the subroutines are set out on the following pages, since the structure of the subroutines is similar.


Information for CAM programmersExample – motorcycle headlight 3.11


3.38

Main program

The main program contains only the technology data. The geometry data are contained in the subrou-tines. The frame deÞ nitions for the two subroutines �Holes.spf� and �Guideslot.spf� are also included in the main program.

Mainprogram.mpfN10 G17 G54 G90 ; Working plane, absolute dimensions ;Zero offset from machine to workpiece ;coordinate system, zero point down ;Milling of Þ rst clamp, workpiece lower ;side______________________________________________________________________________N20 T01 D01 ;Tool: Radial cutter, Ø 20, corner radius 1.0 ;Approach the tool change positionN30 S4200 M3 M8 ;Spindle speed, clockwise, coolant onN40 CYCLE832 (0.10.300220) ;High-speed settings �on�, roughing valuesN50 EXTCALL�1_CLAMP_1.SPF� ;Call subroutine a, 3-axis program______________________________________________________________________________N60 T30 D30 ;Tool: Radial cutter, Ø 12, corner radius 1.5 ;Approach the tool change positionN70 S12.400 M3 ;Spindle speed, clockwiseN80 CYCLE832(0.1, 300220) ;Change high-speed settings, roughing valuesN90 EXTCALL�1_CLAMP_2.SPF� ;Call subroutine b, 3-axis program______________________________________________________________________________...______________________________________________________________________________N510 CYCLE832() ;Set default valuesN340 G0 G53 Z999 D0 ;Move in rapid traverse to the safe position at the ;top of the work area in the machine coordinate ;system at Z999 ;After G53 all subsequent movements relate ;not to G55 but to the ; machine coordinate system. ;Since G55 is modal, the command is used ;if further blocks follow. ;Alternatively, the CAM system could also ;simply output the non-modal command SUPA: ;SUPA Z999 D0 ;D0 clears the existing tool offset ;N220 T3 D3. N350 M30 ;End of program



3.39

Clamp 1a) Lower side of housing 1x (1_Clamp_1.SPF, 3-axis plane roughing)

Sequence:In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane to the start point #. From the start point in rapid traverse towards the workpiece and then plunge into the material at milling feedrate on a helical path &. Roughing one layer at a time ' without changing the cutter orientation.

2

3

4

5

1

1_CLAMP_1.SPFN10 G0 G54 Z115 M08 ;In rapid traverse to the safety plane = Z115"N40 X110.54685 Y-37.6 ;Along the X/Y safety plane to the start point #N50 Z106.205 ;Infeed in rapid traverse in the Z directionN60 G1 Z101.205 F800 ;At milling feedrate in the Z directionN70 G1 X111.6 Z101.11286 F3650 ;Plunge with helix &N80 G1 X111.79875 Y-37.58005 Z101.09539 ;Helix with X/Y/Z valuesN90 G1 ... ;Surface machining... ;Surface machiningN332070 G1 ... ;Surface machiningN332080 G0 Z115 ;Retraction movement in rapid traverse to safety ;plane = Z115 "N332090 M17 ;End of program

Safety plane Z115



3.40

1_CLAMP_3.SPFN10 G0 G54 Z115 M08 ;In rapid traverse to the safety plane = Z115"N40 X5.24099 Y17.78397 ;Along the X/Y safety plane to the start point #N50 Z86.40075 ;Infeed in rapid traverse in the Z directionN60 G1 Z81.40075 F1850 ;Infeed at milling feedrate in the Z direction &N70 G1 X5.10055 Y17.28025 F2600 ;Start Þ nishingN80 G1 X5.04972 Y16.75979 ;Finishing with clockwise and counterclockwise traver-sing N90 G1 ... ;Surface machining... ;Surface machiningN1388690 G1 ... ;Surface machiningN1388700 G0 Z115 ;Retraction movement in rapid traverse to safety ;plane = Z115 "N1388720 M17 ;End of program

2

3

45

1

Clamp 1c) Lower side of housing 2x (1_Clamp_3.SPF, 3-axis plane Þ nishing)

Sequence:In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane to the start point #. From the start point in rapid traverse towards the workpiece and then at milling feedrate onto the surface &. Finishing ' with clockwise travel, back to the safety plane (, plunge again and counterclockwise milling.

6

Safety plane Z115



3.41

Information for CAM programmersExample – motorcycle headlight

Clamp 2h) Top of housing 3x (2_Clamp_4.SPF, 5-axis ISO machining)

Sequence:In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane to the start point #. During this movement the tool swivels into the orientation for the subsequent machi-ning. From start point in rapid traverse & below the safety plane. Finishing ' with 5-axis machining.

2_CLAMP_4.SPF...N40 G0 G54 Z50 M08 ;In rapid traverse to the safety plane = Z50 "N50 X-90.69083 Y-7.39829 A3=-1 B3=0.000618 C3=0.000008 ;Along the X/Y safety plane to the start point #N60 Z-50.11765 A3=-1 B3=0.000618 C3=0.000008 ;In rapid traverse in Z direction, without orientation ;change &N70 G1 X-85.69083 Y-7.40138 A3=-1 B3=0.000618 C3=0.000008 F1000 ;Plunge at milling feedrate in X directionN80 G1 ... ;5-axis surface machining... ;5-axis surface machiningN162960 G1 ... ;5-axis surface machiningN162970 G0 Z50 A3=1 B3=0.000618 C3=0.000008 ;Retraction movement in rapid traverse to safety ;plane = Z50 "N162980 A3=0 B3=0 C3=1 ;Tool is parallel to Z axis and is therefore ;ready for the next tool change. Block ;must already have been programmed in the main program.N162990 M17 ;End of program

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Safety plane Z50

3.11


3.42

2_CLAMP_7.SPFN10 ...N30 ;User-speciÞ c CNC blocksN40 G0 G54 Z-64.91412 M08 ;In rapid traverse to Z component of start position "N50 X2.10222 Y30 A3=-0.000864 B3=0.987688 C3=0.156432 ;In rapid traverse to start point # along safety ;plane = Y30N60 Y8.44899 A3=-0.000864 B3=0.987688 C3=0.156432 ;In rapid traverse in Y direction, without orientation ;change &N70 G1 X2.10654 Y3.51055 Z-65.69628 A3=-0.000864 B3=0.987688 C3=0.156432 F1850 ;Plunging at milling feedrate, 5-axis machining 'N80 G1 ... ;5-axis machining... ;5-axis machiningN687620 G1 ... ;5-axis machiningN687630 G0 Y30 A3=-0.00987 B3=0.987688 C3=0.156123 ;Retraction movement in rapid traverse to safety ;plane = Y30 "N687640 A3=0 B3=0 C3=1 ;Tool is parallel to Z axis and is therefore ;ready for the next tool change.N687650 M17 ;End of program

Clamp 2k) Reß ector internal incline (2_Clamp_7.SPF, 5-axis, equidistant Þ nishing)

Sequence:In rapid traverse from the tool change position ! to the Z coordinate of the start point ", then along the safety plane to the start point #. During this movement the tool swivels into the orientation for the subsequent machining. Infeed from start point in rapid traverse & in Y direction. Finishing ' with 5-axis machining.

Operators:The same tool is used for the next program l) (see main program). A tool change is therefore unne-cessary and could be deleted from the main program.

2

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4

1

5

Safety plane Y30



3.43

Clamp 2l) Reß ector base (2_Clamp_8.SPF, 5-axis, equidistant Þ nishing)

Sequence:In rapid traverse from the tool change position ! to the Z coordinate of the start point ", then along the safety plane to the start point #. During this movement the tool swivels into the orientation for the subsequent machining. Infeed from start point in rapid traverse & in Y direction. Finishing ' with 5-axis machining.

2_CLAMP_8.SPF...N40 G0 G54 Z-43.3831 M08 ;In rapid traverse to Z component of start position "N50 X-2.10801 Y30 A3=0 B3=0.965926 C3=0.258819 ;In rapid traverse to start point # along safety ;plane = Y30N60 Y-7.79506 A3=0 B3=0.965926 C3=0.258819 ;In rapid traverse in Y direction, without orientation ;change &N70 G1 Y-12.62469 Z-44.67719 A3=0 B3=0.965926 C3=0.258819 F1850 ;Plunging at milling feedrate, 5-axis machining 'N80 G1 ... ;5-axis surface machining... ;5-axis surface machiningN177680 G1 ... ;5-axis surface machiningN177690 G0 Y30 A3=0 B3=0.965926 C3=0.258819 ;Retraction movement in rapid traverse to safety ;plane = Y30N177700 A3=0 B3=0 C3=1 ;Tool is parallel to Z axis and is therefore ;ready for the next program start.N177710 M17 ;End of program

2

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1

5

Safety plane Y30



3.44

3.11 Information for CAM programmersExample – motorcycle headlight

4

References

Contents Page

4.1 Overview of higher-order functions 4.2

4.2 Index 4.10


4.2

ReferencesOverview of higher-order functions4.14.1 Overview of higher-order functions

The higher-order functions of 840D for mold making and aerospace are set out on the following pages. This gives you an overview of the commands that go beyond the requirements laid down in DIN 66025 and allow signiÞ cant improvements in the areas of aerospace and mold making.

4.1.1 Traversing commands

Conventional

G00, G01, G02, G03 Rapid traverse, linear interpolation, circular interpolation, counterclockwise circular interpolation

Additional circular interpolation programming

CIP Circular interpolation through intermediate point CIP X� Y� Z� I1=� J1=� K1=� CT Circle with tangential transition CT X� Y� Z� TURN Number of full circles to be traversed G3 X� Y� I� J� TURN =

Additional parameters: CR= Circle radius

I1, J1, K1 Intermediate points in Cartesian coordinates (in X, Y, Z direction)

AP= End point in polar coordinates, polar angle, also in linear interpolation RP= End point in polar coordinates, polar radius, also in linear interpolation AR= Aperture angle

Involutes

INVCW Travel on an involute path in clockwise direction INVCW X... Y... Z... I... J... K... CR=... INVCW I... J... K... CR=... AR=... INVCCW Travel on an involute path in counterclockwise direction INVCCW X... Y... Z... I... J... K... CR=... INVCCW I... J... K... CR=...AR=... I J K Center point of base circle in Cartesian coordinates CR= Radius of base circle AR= Arc angle (angle of rotation)

840D spline variants

CSPLINE Activation of cubic interpolating spline ASPLINE Activation of Akima spline


4.3

ReferencesOverview of higher-order functions 4.1

Start and end condition BNAT/ENAT Zero curvature BTAN/ETAN Tangential transition BAUTO/EAUTO Constant C3 at Þ rst and last spline segment transition

BSPLINE Activation of B spline SD=... B spline order (max. 3) PL=... Interval length (vector node), �non uniformity� PW=... Weights, i.e. denominator of rational B spline in polynomial representation

Example N20 BSPLINE X... Y... SD=... PL=... PW=...

POLY Activation of polynomial interpolation, B spline representation in polynomial form SD=... B spline order (max. 5!! -> different from BSPLINE) PL=... Interval length (vector node), �non uniformity�

Syntax PO[axis] = (block end position, a2 (quadratic coefÞ cient), a3 (cubic coefÞ cient), a4, a5) -> numerator polynomial PO[ ] = (Nend of block, b2, b3, b4, b5) -> denominator polynomial

Example N10 POLY PO[X] = (0.25,0.5,0) PO[Y] = (0.433,0,0) PO[] = (1,1,0)

Compressors COMPON Constant-speed transitions COMPCURV Constant-acceleration and jerk-free transitions COMPCAD Surface-optimized compressor (constant acceleration)

With corresponding single-axis tolerances: $MA_COMPRESS_POS_TOL[X] = �

Or in later software versions with the following tolerances:

$SC_COMPRESS_CONTOUR_TOL: maximum tolerance for the contour $SC_COMPRESS_ORI_TOL: maximum angular displacement for the tool orientation $SC_COMPRESS_ORI_ROT_TOL: maximum angular displacement for the angle of rotation of the tool (only available on 6-axis machines).

The machine data $MC_COMPRESSOR_MODE can be used to set the way in which tolerances can be deÞ ned:

0: axial tolerances with $MA_COMPRESS_POS_TOL for all axes (geometry axes and orientation axes).

1: contour tolerance with $SC_COMPRESS_CONTOUR_TOL, tolerance for orientation via axial tolerances with $MA_COMPRESS_POS_TOL.


4.4

ReferencesOverview of higher-order functions4.1 2: maximum angular displacement for tool orientation with $SC_COMPRESSORITOL, tolerance for contour via axial tolerances with

$MA_COMPRESS_POS TOL

3: contour tolerance with $SC_COMPRESS_CONTOURTOL and maxi-mum angular displacement for tool orientation with

$SC_COMPRESS_ORI_TOL.

Additional commands for a combination of path and synchronous axes UPATH Parameter settings for the synchronous axes correspond to those for the

path axes, i.e., for the movement of a synchronous axis A: A = f(u), where u denotes the path parameter for the path movement

SPATH Parameter settings for the synchronous axes follow the arc length for the path axes, i.e. for the movement of a synchronous axis A: A= f(s) where s denotes the arc length for the path movement.

4.1.2 Dynamic behavior

Look Ahead

G60, G60n Exact stop at block end

G601 Block change on reaching the Þ ne positioning window G602 Block change on reaching the coarse positioning window G603 Block change at end of interpolation

G64 Overrun of block end G64n Corner rounding

G641 ADIS = � rounding clearance ADISPOS =� Rounding clearance for G0, constant speed G642 Corner rounding with single-axis tolerances ($MA_COMPRESS_POS_

TOL[X] = �) or ADIS, ADISPOS with intermediate blocks, constant-acce-leration

G643 Block-internal corner rounding with single-axis tolerances ($MA_COM-PRESS_POS_TOL[X] = �) or ADIS, ADISPOS, constant-acceleration

G644 Speed-optimized corner rounding with settable tolerances ($MA_COM-PRESS_POS_TOL[X] = �. ADIS, ADISPOS) or maximum frequency ($MA_LOOKAH_FREQUENCY), constant-acceleration

G60, G64, G641, G code group 10 G642, G643, G644

G601 � G603 Internal G code group (group 12), i.e., G64n replace G64, G60n, do not replace G60


4.5

ReferencesOverview of higher-order functions 4.1Speed programming

Conventional non-modal speed programming via G94 inches, mm/min G93 inverse time G95 inches, mm per spindle rotation G96 Constant cutting rate

Programming of speed proÞ les FLIN Linear F-word interpolation inches, mm/min FCUB Cubic spline interpolation for F-word inches, mm/min F=FPO(�) Speed proÞ le in polynomial form inches, mm/min

Path reference FGROUP(X, Y, Z,�) DeÞ nes the path axes with regard to the feedrate, i.e. overall feedrate refers to the axes deÞ ned here. Example: FGROUP(X, Y), then:

Acceleration

ACC[axis]=� Programmable acceleration as a percentage of the maximum acceleration

Jerk

SOFT Jerk limitation (maximum jerk in machine data) JOG_AND_POS_MAX_JERK (jog and positioning) MAX_AX_JERK, MAX_PATH_JERK (path mode) BRISK Without jerk limitation

Feedforward control

FFWON Feedforward control on FFWOF Feedforward control off

4.1.3 5-axis functions

Transformation

TRAORI Enable transformation 1 TRAORI(1) Enable transformation 1 TRAORI(2) Enable transformation 2 TRAORI(1, �, �, �) Enable transformation 1, generic transformation, additional 3 parameters for basic orientation vectors TRAORI(2, �, �, �) Enable transformation 2, generic transformation, additional 3 parameters for basic orientation vectors TRAFOOF Disable transformation


4.6

ReferencesOverview of higher-order functions4.1Orientation programming

ORIEULER Orientation programming on the basis of Euler angles (default) ORIRPY Orientation programming on the basis of RPY angles Both are only effective if $MC_ORI_DEF_WITH_G_CODE = 1 is set.

Otherwise deÞ ned on the basis of machine data. In older systems the only difference is the machine data $MC_ORIENTATI-

ON_IS_EULER.

A2=� B2=� C2=... Euler or RPY angle A3=� B3=� C3=... Cartesian orientation vector XH=�, YH=�, ZH=� In ORIVECT or ORIPLANE synonymous with A3=... etc. Extended meaning in conjunction with ORICURVE, here either with BSPLI-

NE as control polygon, or in conjunction with POLY polynomial deÞ nition, otherwise linear interpolation for the upper straight line,

geometrical great circle, but not speed-related.

LEAD, TILT Lead/tilt angle relative to normal vectors and path tangent. The normal vec-tors at the start and end of the block are deÞ ned by A4=� B4=� C4=... and A5=� B5=� C5=...

Only in conjunction with ORIPATH.

Orientation reference

ORIMKS The reference system for the orientation vector is the basic coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0, it is also identical to ORI-AXES.

ORIWKS The reference system for the orientation vector is the workpiece coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0, it is also identical to ORI-VECT.

Orientation interpolation

The following G codes are only effective if $MC_ORI_IPO_WITH_G_CODE = 1 is set.

Axis interpolation ORIAXES Linear interpolation of the machine axes, or interpolation of the rotary axes

using polynomials (if POLY is enabled)

Vector interpolation ORIVECT Interpolation of the orientation vector in one plane (great circle interpolati-

on) ORIPLANE Interpolation in one plane (great circle interpolation), synonymous with

ORIVECT ORIPATH Tool orientation relative to the path. Here a surface is spanned with the

normal vector and path tangent, which deÞ nes the meaning of LEAD and TILT at the end point. This means that the path reference applies only for the deÞ nition of the end orientation vector. Great circle interpolation is per-formed from the start to the end orientation. LEAD and TILT do not simply mean lead and tilt angle. They are deÞ ned as follows: LEAD describes the rotation in the plane which is spanned by the normal vector and path tangent, TILT then deÞ nes the rotation around the normal vector. In other words, they both have the meaning of theta and phi in a spherical coordi-nate system with the normal vector as the Z axis and the tangent as the X axis.


4.7

ReferencesOverview of higher-order functions 4.1 ORICONCW Interpolation on the peripheral surface of a cone in the clockwise direction ORICONCCW Interpolation on the peripheral surface of a cone in the counterclockwise

direction Also required in both cases: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation rotary axis of

the cone: A6, B6, C6 Aperture angle: NUT=� ORICONIO Interpolation on the peripheral surface of a cone with speciÞ cation of an

intermediate orientation via A7=� B7=� C7=�. Also required: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation ORICONTO Interpolation on the peripheral surface of a cone with tangential transition Also required: A3=� B3=� C3=... or XH=�, YH=�, ZH=� end orientation

With POLY, PO[PHI]=..., PO[PSI]=... can also be programmed here. This is a generalization of great circle interpolation, in which the polynomials for lead and tilt angle are programmed. The polynomials have the same mea-ning in conical interpolation as in great circle interpolation for the given start and end orientations. The polynomials can be programmed in ORIVECT, ORIPLANE, ORICONCW, ORICONCCW, ORICONIO, ORICONTO.

ORICURVE Orientation interpolation with deÞ nition of the movement of the tool tip and of a second point on the tool

The path of the second point is deÞ ned with XH=... YH=... ZH=... , in con-junction with BSPLINE as control polygon with POLY as the polynomial:

PO[XH] = (xe, x2, x3, x4, x5) PO[YH] = (ye, y2, y3, y4, y5) PO[ZH] = (ze, z2, z3, z4, z5) If additional BSPLINE or POLY information is not available, simple linear

interpolation is performed accordingly from the start to the end orientation.

4.1.4 Tool radius correction

G40 Deactivation of all variants G41 Activation in circumferential milling, compensation direction left G42 Activation in circumferential milling, compensation direction right

G450 Circles at external corners (all compensation types) G451 Intersection traveling at external corners (all compensation types)

2½ D circumferential milling

CUT2D 2 1/2D COMPENSATION with compensation plane determined with G17 - G19 CUT2DF 2 1/2D COMPENSATION with compensation plane determined by frame


CUT3DC Compensation perpendicular to path tangent and to tool orientation

ORID No orientation changes in inserted circle blocks at external corners. Orien-tation movement is executed in the linear blocks.

ORIC Travel path extended with circles. The orientation change is executed pro-portionately in the circle as well.


4.8

ReferencesOverview of higher-order functions4.1Face milling

CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the coordinate system deÞ ned with G17-G19. Frames have no inß uence.

CUT3DFF Constant orientation (3-axis), tool in Z direction of the coordinate system currently deÞ ned with frame

CUT3DF 5-axis with variable tool orientation

3D circumferential milling with limitation surface - combined circumferential/face milling

CUT3DCC NC program refers to the contour on the machining surface. CUT3DCCD NC program refers to the tool center path.

5. FRAMES

Programmable frames

TRANS X� Y� Z� Absolute offset ATRANS X� Y� Z� Incremental offset, relative to the currently active frame ROT X� Y� Z� Absolute rotation AROT X� Y� Z� Incremental rotation, relative to the currently active frame ROTS X� Y� Absolute rotation described by two angles. The angles are the angles of

the lines of intersection of the inclined plane with the main planes against the axes.

AROTS X� Y� Incremental rotation, relative to the currently active frame, angles as for ROTS

RPL=� Rotation in the plane MIRROR X� Y� Z� Absolute mirroring AMIRROR X� Y� Z� Incremental mirroring, relative to the currently active frame SCALE X� Y� Z� Absolute scaling ASCALE X� Y� Z� Incremental scaling, relative to the currently active frame

Frame operators

Frame operators can be used to deÞ ne frame variables as a chain of indivi-dual frame types:

CTRANS (X� Y� Z�) Absolute offset CROT (X� Y� Z�) Absolute rotation CROTS (X� Y� Z�) Absolute rotation CMIRROR (X� Y� Z�)Absolute mirroring CSCALE (X� Y� Z�) Absolute scaling FRAME = CTRANS(�) : CROT (X� Y� Z�) : CMIRROR (X� Y� Z�)


4.9

ReferencesOverview of higher-order functions 4.1Special frames

TOFRAME Tool frame, coordinate system with Z axis in tool direction, zero point is tool tip TOFRAMEX Tool frame, coordinate system with X axis in tool direction, zero point is tool tip TOFRAMEY Tool frame, coordinate system with Y axis in tool direction, zero point is tool tip TOFRAMEZ Tool frame, coordinate system with Z axis in tool direction, zero point is tool tip, identical to TOFRAME TOROT Tool frame, coordinate system with Z axis in tool direction, contains only

the rotation component of TOFRAME. The zero point remains unchanged. TOROTX Tool frame, coordinate system with X axis in tool direction, contains only

the rotation component of TOFRAME. The zero point remains unchanged. TOROTY Tool frame, coordinate system with Y axis in tool direction, contains only

the rotation component of TOFRAME. The zero point remains unchanged. TOROTZ Tool frame, coordinate system with Z axis in tool direction, contains only

the rotation component of TOFRAME. The zero point remains unchanged. Identical to TOROT.


4.10

ReferencesIndex4.24.2 Index

A

ADIS 3.14

B

Block search 2.22BRISK 3.17

C

CAM 1.19Compressor 1.20, 3.12Conical surface interpolation

ORICONCW 1.24Continuous path mode 3.14Coordinate systems 1.17Corner measurement

CYCLE961 2.10Corner rounding 1.20Curve interpolation

ORICURVE 1.28CUT3D... 3.21CUT3DCC 1.15CUT3DF 1.14CYCLE800 2.9, 2.11CYCLE832 1.21, 2.25, 3.9CYCLE961 2.10, 2.12CYCLE971 2.15CYCLE978 2.10, 2.12CYCLE998 2.9, 2.11

E

Ethernet 2.16EXTCALL 2.16, 2.22

F

Feedforward control 3.16Feedrate proÞ le 3.18Frame 2.21Frames 1.17

G

Gauging tools 2.13Great circle interpolation 1.25

ORIVECT 1.24H

High-speed setting cycle 1.21High-speed settings 2.25, 3.9

I

Inclined plane measurementCYCLE998 2.9

Interruption 2.20

J

Jerk limitation 3.16

K

Kinematic-independent programmingMachine-independent programming 1.10

L

LEAD 3.8Linear interpolation

Oriaxis 1.23M

Machine kinematicsMachine kinematics 1.9

Measuring functions 2.8Measuring sphere 2.17

N

Network connection 2.16Nutated axis 1.9

O

ORIAXES 1.23ORICONCCW 1.24ORICONCW 1.24ORICONIO 1.24ORICONTO 1.24Orientation 1.23, 3.6, 3.19

ORIVECT 1.24P

PCU 20 2.16PCU 50 2.16Pole 1.26Pole 1.26Program structure 1.22, 2.18Process chain

CAD CAM CNC 1.19Q

Quick View 2.24


4.11

R

Radius changes 1.14REPOS 2.20Retraction 2.21

S

Serial interface 2.16ShopMill 2.28SOFT 3.17Spigots 2.8Spline orientation 1.28Subroutine 1.22Surface normal 1.14Surface normal vector 3.6Swivel cycle

CYCLE800 2.9T

Testing a program 2.17Tool probe 2.2TCP

Tool center point 1.15, 2.13TILT 3.8Tool offset 3.21Tool offset data 2.14Tool compensations 1.16Tool radius compensation 1.14Tool type

Cutter types 2.13TOROT 2.20TOROTOF 2.21TRAORI 1.12

Z

Zero point 2.2

ReferencesIndex 4.2


4.12

ReferencesIndex4.2

© Siemens AG 2004Subject to change without prior notice

Order no.: 6FC5095-0AB10-0BP0

Printed in the Federal Republic of Germany

Siemens AGAutomation and DrivesMotion Control SystemsP.O. Box 3180, D � 91050 ErlangenFederal Republic of Germany

www.siemens.com/automation/mc

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