Siemens SINUMERIK 808D User manual

Sinumerik 808D Programming and Operating
Procedures for Milling
Version 2013-01
s
Training manual

Operating and Programming — Milling Page 2 808D
Notes
s

808D Page 3 Operating and Programming — Milling
s
Create Part
Program
Part 2
Pages 39~51
ISO Mode
Pages 97~106
Contents
End
Switch On and
Referencing
Pages 9~10
Test
Program
Pages 57~58
Additional
Information
Part 1
Pages 69~75
Tool Setup
Pages 13~20
Additional
Information
Part 2
Pages 77~85
Machine
Pieces
Pages 61~63
Appendix
Pages 109~112
Program
Restart
Pages 65~66
Simulate
Program
Pages 53~54
Workpiece
Setup
Pages 23~27
Preparation
Pages 5~7
Sample
Program
Pages 87~94
Create Part
Program
Part 1
Pages 29~36
Basic knowledge of programming for milling is required,
before operating of a machine !

Operating and Programming — Milling Page 4 808D
Index
s
Absolute incremental dimensioning 32
Editing part program 31
Executing M function 20
Calculator 85
Changing time 74
Contour editor 46
Creating and measuring tools 13
Creating zero offsets 24
Cycles 40
Dry run 58
Jogging spindle 20
Manual start spindle 23
Manual face milling 72
List of programming functions 109
Tool wear 63
Manual tool change 15
MDA 77
Moving axis with handwheel 16
Part programming 29
Protection levels 7
Program execution 57
Block search 65
Reference point 10
RS232c and USB 69
Saving data 74
Simulation 53
Timers/counters 61
Sample program 87
Subprograms 78
ISO mode 97

808D Page 5 Operating and Programming — Milling
Preparation s
Content
Unit Description
This unit describes the 808D PPU and MCP functionality, the coordinate
system of a milling machine and how to enter passwords to access the
system.
Unit Content
PPU
Function of
keyboard
MCP mode
Changing
MCP
Moving axis
MCP
OEM
keys
Machine
coordinate
system
User
interface
Passwords
PPU
Function of
keyboard
The 808D panel pro-
cessing unit (PPU) is
used to input data to
the CNC and to navi-
gate to operating
areas of the system.
Menu navigation Operating area
navigation
MCP mode
Changing
Mode Navigation
The 808D machine
control panel (MCP) is
used to select the
machine operating
mode :
JOG - MDA - AUTO
Basic Theory
End

Operating and Programming — Milling Page 6 808D
Preparation s
MCP
Moving axis
Axis remove
The 808D machine control
panel (MCP) is used to con-
trol manual operation of the
axis.
The machine can be moved
with the appropriate keys.
MCP
OEM
keys
OEM
keys
The 808D machine control
panel (MCP) is used to con-
trol OEM machine functions.
The machine functions can
be activated with the appro-
priate keys.
User
interface
808D (PPU) has
eight vertical softkeys
(abbr. SKs) on the
right of the screen.
These SKs can be
activated with the
corresponding button
(located on the right).
808D (PPU) has eight horizontal SKs on the bottom
of the screen. These SKs can be activated with the
corresponding button (located below).

808D Page 7 Operating and Programming — Milling
Preparation s
Machine
coordinate
system
The Sinumerik 808D uses a
coordinate system which is
derived from the DIN 66217
standard.
The system is an international
standard and ensures com-
patibility between machines
and coordinate programming.
The primary function of the
coordinate system is to en-
sure that the tool length and
tool radius are calculated
correctly in the respective
axis.
Passwords
Passwords at the control are used to set the user’s
right to access the system. Tasks such as ”Basic Op-
erating”, “Advanced Operating” and commissioning
functions all depend on the passwords.
No password
Customer’s password
Manufacturer’s password
Customer’s password = CUSTOMER
Manufacturer’s password = SUNRISE
Changing
password
Step 1
The service mode is opened
with the appropriate key
combination.
In the service mode, the
password can be activated
and deactivated.
Step 2
Enter customer’s or manufacturer’s password
Change customer’s or manufacturer’s password
Delete customer’s or manufacturer’s password
End
Usually the machine operator does not need
to change the password.
+
Machine operator
Advanced operator
OEM engineer
SEQUENCE

Operating and Programming — Milling Page 8 808D
Notes
s

808D Page 9 Operating and Programming — Milling
Switch On
and
Referencing
s
Content
Unit Description
This module describes how to switch the machine on and reference it.
Unit Content
Switch on
the
machine
Reference
the
machine
Please note the explicit switching on rules as specified by
the machine manufacturer.
Turn on the main switch of the machine.
The main switch is usually
at the rear of the machine.
Release all the EMERGENCY STOP
buttons on the machine!
Make sure you perform the following operation!
Step 1
Step 2
End
Switch on
the
machine
End
SEQUENCE

Operating and Programming — Milling Page 10 808D
Switch On
and
Referencing
s
Step 3
After completing the referencing
procedure for all axes, the refer-
enced symbol is displayed next to
the axis identifier.
End
After returning to JOG mode, use
the axis traversing keys to move the
machine manually.
The machine can now be operated
in JOG mode.
During normal operation (JOG),the
referenced symbol is not shown on
the screen.
After power on, the machine must first
be referenced!
Step 1
After power on, the machine will be
in the reference point approach
mode (default).
If the axis is not referenced, the non-
referenced symbol (circle) is dis-
played between the axis identifier
and the value.
Step 2
The axes are referenced with the
corresponding axis traversing keys.
The traversing direction and keys
are specified by the machine manu-
facturer.
Reference
the
machine
SEQUENCE

808D Page 11 Operating and Programming — Milling
Notes
s

Operating and Programming — Milling Page 12 808D
Notes
s

808D Page 13 Operating and Programming — Milling
Tool Setup s
Content SEQUENCE
Unit Description
This unit describes how to create and set up tools.
Unit Content
Create tool
Load tool
into active
position
Measure
tool
Move ma-
chine with
handwheel
JOG
spindle
Execute M
function
Start
spindle
Create tool A tool must have been created and
measured before executing the pro-
gram.
Step 1
Press “Offset” on the PPU.
Please make sure the system is in JOG mode.
Create tool
edge
Press the “Tool list” SK on the PPU.
End

Operating and Programming — Milling Page 14 808D
Tool Setup s
Step 2
Press the “New tool” SK on the PPU.
Enter “1” at “Tool No.”
Press the “OK” SK on the PPU.
Enter the ”Radius” of the milling tool.
Select the type of tool required.
Press the “Input” button on the PPU.
Create tool
edge
Step 1
Press the “Offset” key on the PPU.
A tool must have been created and
selected before creating a tool edge!
Press the “Edges” SK on the PPU.
Use “D” code to specify the tool edge. The system activates tool
edge no. 1 per default at the start.
Use direction keys to select the tool
which needs to add a tool edge.Or
Press the “New edge” SK on the PPU.
Press the “Tool list” SK on the PPU.
The range of tool numbers which can be created
by this system is 1 ~32000.
The machine can be loaded with a maximum of
64 tools / 128 tool edges.
SEQUENCE

808D Page 15 Operating and Programming — Milling
Tool Setup s
Press the “Machine” key on the PPU
Press the “T.S.M” SK on the PPU
Enter tool number “1” in “T”
Press “CYCLE START” on the MCP
Load tool
into Spindle
Press the “Back” SK on the PPU
A tool must have been created in the
system before it can be loaded into the
active position.
Press the “JOG” key on the MCP
Step 2
The red circle shows the actual active tool and tool edge,the purple circle
shows how many tool edges have been created and the related data for
each tool edge.
A new tool edge can be added in this way and different lengths and radii
can be entered as required.
A maximum of nine tool edges can be created for each
tool!
Different tool lengths and radii can be saved in different
tool edges as required.
Please select the right tool edge for machining according
to requirement!
SEQUENCE

Operating and Programming — Milling Page 16 808D
Tool Setup s
The tool are usually loaded manually into the spindle.
The tool will be automatically loaded into the spindle with an automatic
tool changer.
Move ma-
chine with
handwheel
A handwheel can control the axis motion instead of the “JOG” button.
Press the “Machine” key on the PPU
Make sure there is no obstruction when
moving the tool to avoid a crash.
Press the “Handwheel” key on the MCP
Select the required override increment
according to the buttons on the right
（this selection fits all axes）
The selected axis can now be moved with the handwheel.
Press “JOG” on MCP to end the function
of “Handwheel”.
The override increment is
“0.001 mm”
The override increment is
“0.010 mm”
The override increment is
“0.100 mm”
Select the required
axis on the right of
the PPU; the se-
lected axis is
shown with a √
Notes：If set the MD14512[16]=80, the system will deactivate the
function of MCP for selecting the axis of handwheel, the user will
have to activate “Handwheel” function with PPU softkey.
Select the axis you want to move with
the appropriate keys. on the MCP
Under “WCS” or “MCS” state, a handwheel
will be shown beside the axis symbols,
showing the axis is chosen, and can be
controlled with a handwheel.
SEQUENCE

808D Page 17 Operating and Programming — Milling
Tool Setup s
Press the “CYCLE START” key on
the MCP
Press the “Back” SK on the PPU
Press “Reset” on the MCP to stop the
spindle rotation
A tool must have been created and
loaded before it can be measured!
Measure
tool
Step 1
Press the “Meas. tool” SK on the PPU
Press the “Measure manual” SK on the
PPU
Press the “Machine” key on the PPU
Press the “JOG” key on the MCP
Measure length
Press the “Machine” key on the PPU
Press the “T.S.M” SK on the PPU
Enter “500” at “Spindle speed”
Select “M3” using the “Select” key
on the PPU
Start the spindle before adjusting tools as follows:
A tool must have been loaded and ro-
tated to the position.
Start
spindle
SEQUENCE

Operating and Programming — Milling Page 18 808D
Tool Setup s
Press the “Set length” SK on the PPU
Enter “0” for “Z0”
(If the setting block is used, then the
value would be thickness a)
Press the “Handwheel” key on the
MPC and position the tool at location
Z0 or a of the workpiece.
or
Move directly to zero point Use a setting block.
a
Press the “Diameter” SK on the PPU
Step2 Measure diameter
Press the axis keys on the MCP to
move the tool to the set position
above the workpiece.
The measured tool length is now shown in “Length (L)”. This value is
also saved in the length value column of the corresponding tool list at the
same time.
Note: The following text describes the
required settings in the workpiece coordi-
nate system
“X / Y / Z” zero points as:“X0” / “Y0” / “Z0”
Use “SELECT” key to set the refer-
ence point as “workpiece” (In real
measurement, the reference point
can be set as either “workpiece” or
“ fixed point” if required.
SEQUENCE

808D Page 19 Operating and Programming — Milling
Tool Setup s
Press the ”Set diameter” SK on the PPU
Press the “Back” SK on the PPU
Enter “0” at “X0”
Enter “0” at “Y0”
(This is the value of the width of a
setting block if it is used.Select one of
X0/Y0 according to requirement.)
Press the “Handwheel” key on the
MCP and position the tool at the
location X0 or a of the workpiece.
or
Move directly to zero point Use a setting block.
a
Press the axis keys on the MCP to
move the tool to the set position.
SEQUENCE

Operating and Programming — Milling Page 20 808D
Tool Setup s
Press “Spindle stop” on the MCP to stop
the spindle.
Press “Spindle left” on the MCP to start the
spindle in the counter-clockwise direction.
Press “Spindle right” on the MCP to start
the spindle in the clockwise direction.
Press the “Machine” key on the PPU.
Press the “T.S.M” SK on the PPU.
Use the direction key to move the
highlighted cursor to “Other M func-
tion” and enter “8”. This will start the
coolant.
Press “CYCLE START” on the MCP.
Press the “Back” SK on the PPU.
Please make sure all the machine axes
are in safe positions before executing
the M function!
Execute M
function
Press the “Reset” key on the MCP to
stop the coolant function.
The coolant function button on MCP is
active.
Jog spindle
Press the “Machine” key on the PPU.
A tool must be loaded to the spindle.
Press the “JOG” key on the MCP.
Press the spindle direction key on the
MCP to start/stop the spindle.
SEQUENCE