Siemens SINUMERIK 808D User manual

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Manual Machine Plus (Turning)
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SINUMERIK
SINUMERIK 808D
Manual Machine Plus (Turning)
Programming and Operating Manual
Valid for:
SINUMERIK 808D Turning (software version: V4.4.2)
Target group:
End users and service engineers
12/2012
6FC5398-3DP10-0BA0
Preface
Turning on, Reference Point
Approach
1
Setting-up
2
Manual machining
3
Machining the machining
step program manually
4
Messages
5

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-3DP10-0BA0
Ⓟ 12/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 3
Preface
SINUMERIK 808D documentation
The SINUMERIK 808D documentation consists of the following components:
● Operating Instructions
– Mechanical Installation Manual
– Electrical Installation Manual
– PLC Subroutines Manual
– Function Manual
– Parameter Manual
● Diagnostics Manual
● Commissioning Manual
● Programming and Operating Manual (Turning)
● Programming and Operating Manual (Milling)
● Manual Machine Plus (Turning)
● Online Help for Programming and Operating (Turning)
● Online Help for Programming and Operating (Milling)
● Online Help for Manual Machine Plus (Turning)
My Documentation Manager (MDM)
Under the following link you will find information to individually compile your documentation
based on the Siemens content:
www.siemens.com/mdm
Target group
This manual is intended for the following audience:
● End users of turning machines installed with SINUMERIK 808D control systems,
including operators, programmers and maintenance engineers
● Service engineers of the machine tool manufacturer
Benefits
This manual provides information about programming and operating the SINUMERIK 808D
CNC on turning machines.

Preface
Manual Machine Plus (Turning)
4 Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0
Standard scope
This documentation only describes the functionality of the standard version. Additions or
revisions made by the machine manufacturer are documented by the machine manufacturer.
Other functions not described in this documentation might be executable in the control.
However, no claim can be made regarding the availability of these functions when the
equipment is first supplied or in the event of servicing.
For the sake of simplicity, this documentation does not contain all detailed information about
all types of the product and cannot cover every conceivable case of installation, operation, or
maintenance.
Technical support
Hotline: [phone]
Service and Support China:
www.siemens.com.cn/808D
Worldwide:
http://support.automation.siemens.com
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://support.automation.siemens.com
Here, enter the number 15257461 as the search term or contact your local Siemens office.
Licensing provisions
The SINUMERIK 808D software is protected by national and international copyright laws and
agreements. Unauthorized reproduction and distribution of this software or parts thereof is
liable to prosecution. It will be prosecuted both according to criminal and civil law and may
result in severe punishment or demands for compensation.
In the SINUMERIK 808D software, open source software is used. The licensing provisions
for this software are included on the Toolbox DVD and are to be observed accordingly.

Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 5
Table of contents
Preface ...................................................................................................................................................... 3
1 Turning on, Reference Point Approach...................................................................................................... 7
1.1 Entry to the "Manual Machine Plus" operating area ......................................................................7
2 Setting-up .................................................................................................................................................. 9
2.1 Measuring tools..............................................................................................................................9
2.2 Limit stops....................................................................................................................................12
2.2.1 Setting and activating/deactivating limit stops .............................................................................12
2.2.2 Turning against a stop .................................................................................................................15
2.3 Setting the workpiece zero...........................................................................................................17
3 Manual machining.................................................................................................................................... 19
3.1 Fundamentals of manual machining............................................................................................19
3.2 Display and operator control options in the main screen.............................................................20
3.2.1 Toggling the display .....................................................................................................................23
3.2.2 Machining with the handwheels...................................................................................................24
3.2.3 Setting the increment weighting for the handwheel.....................................................................24
3.2.4 Machining with axis direction switch ............................................................................................25
3.2.5 Spindle advance/reverse .............................................................................................................25
3.2.6 Tool change .................................................................................................................................26
3.2.7 Changing the feedrate/spindle value ...........................................................................................28
3.2.8 Changing the feedrate/spindle type .............................................................................................29
3.2.9 Change the speed limitation for constant cutting rate .................................................................31
3.3 Manual machining with machining types .....................................................................................32
3.3.1 Axis-parallel traversal...................................................................................................................32
3.3.2 Manual taper turning ....................................................................................................................33
3.3.3 Manual radius turning ..................................................................................................................35
3.3.3.1 Radius turning type A...................................................................................................................37
3.4 Manual machining using cycles (functions) .................................................................................38
3.4.1 Principle operating sequence.......................................................................................................38
3.4.2 General parameters .....................................................................................................................41
3.4.3 Manual drilling centered...............................................................................................................43
3.4.4 Manual thread tapping .................................................................................................................46
3.4.5 Manual grooving/parting ..............................................................................................................48
3.4.5.1 Groove cycle - single ...................................................................................................................48
3.4.5.2 Groove cycle - multiple ................................................................................................................51
3.4.5.3 Extended grooving .......................................................................................................................53
3.4.5.4 Multiple extended grooving..........................................................................................................57
3.4.6 Manual thread cutting ..................................................................................................................58
3.4.6.1 Thread cutting ..............................................................................................................................59
3.4.6.2 Thread recutting...........................................................................................................................63
3.4.7 Roughing cycles...........................................................................................................................65
3.4.7.1 Roughing cycle A .........................................................................................................................66

Table of contents
Manual Machine Plus (Turning)
6 Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0
3.4.7.2 Roughing cycle B ........................................................................................................................ 69
3.4.7.3 Roughing cycle C ........................................................................................................................ 72
3.4.7.4 Roughing cycle D ........................................................................................................................ 75
3.4.7.5 Roughing cycle E ........................................................................................................................ 78
3.4.7.6 Roughing cycle F ........................................................................................................................ 81
3.4.7.7 Roughing cycle, free contour: ..................................................................................................... 83
3.4.7.8 Execute a roughing cycle............................................................................................................ 86
4 Machining the machining step program manually.................................................................................... 87
4.1 Tool change in the machining step program............................................................................... 91
4.2 Teach In ...................................................................................................................................... 93
4.3 Simulate machining..................................................................................................................... 95
4.4 Executing the machining step program.......................................................................................96
5 Messages ................................................................................................................................................ 99
Index...................................................................................................................................................... 101

Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 7
Turning on, Reference Point Approach 1
1.1 Entry to the "Manual Machine Plus" operating area
Note
If the controller has already been preconfigured to "Manual Machine Plus" by the machine
manufacturer, the operating area "Manual Machine Plus" is activated once the controller has
been started up.
The operating area "Manual Machine Plus" runs only in SIEMENS mode instead of ISO
mode.
Operating sequence
Note that if MD1105 = 1, after power on the control system automatically opens the main
screen for "Manual Machine Plus".
1. Press <JOG> on the machine control panel to open the "Jog" window.

Turning on, Reference Point Approach
1.1 Entry to the "Manual Machine Plus" operating area
Manual Machine Plus (Turning)
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"Manual" 2. Press "Manual" to open the "Manual Machine Plus" operating area.
3. If the axes have not approached the reference point, press <REF. POINT>
to change to the "Ref. Point" window for reference point approaching
operation; otherwise, skip this step.
Refer to the topics "Turning on, reference point approach", "JOG mode -
"Machine" operating area", and "Assigning handwheels" in the
Programming and Operating Manual (Turning) for more description of
reference point approaching.
"CNC" 4. To exit the "Manual Machine Plus" operating area, press "CNC".
Note
The pictures in the parameterization screenforms depend on the setting of the machine data
by the machine manufacturer, i.e. display of the tool position before or behind the center of
rotation with regards to the turret head.

Manual Machine Plus (Turning)
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Setting-up 2
2.1 Measuring tools
Functionality
You can measure tools manually in the "Manual Machine Plus" operating area. In this case,
the manual tool measurement function accesses the tool list data.
Note
You can access the tool list by pressing the hardkey <OFFSET> and softkey "Tool list".
NOTICE
Tool breakage or workpiece damage
An uncalibrated or incorrectly calibrated tool can lead to dimensional errors or to incorrect
cutting values. If the values entered are very different from the actual tool values, there is a
risk that the tool may break or the mechanism or workpiece may be damaged.
Requirement
Load the tool beforehand or enter the tool number in the "T" field. After confirming the input,
a dialog will prompt you to press the <CYCLE START> key. If this key is pressed, the tool
will be changed.
Note
First approach a machine position where the tool change can be performed without danger.

Setting-up
2.1 Measuring tools
Manual Machine Plus (Turning)
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Operating sequence
Proceed as follows to measure the tool for the X axis of the loaded turning tool.
1. Press the "Meas. tool" softkey. The following screen appears:
Figure 2-1 Measure a turning tool
2. Press the "X" softkey.
The screen for measuring the X axis (L1) appears.
3. Check that the current tool number appears in the display field for the tool, since the
calibration operation will relate to this tool.
4. Carefully "scratch" a workpiece by an X handwheel infeed when the spindle is turning.
5. Move the slide slightly (without changing the X position) along the Z axis (longitudinal
turning) with the handwheel.
6. Switch the spindle off.
7. Enter the diameter measured on the workpiece in entry field "d1".
8. Accept the value by pressing the <INPUT> key.
The controller then automatically calculates the corresponding tool offset (in the radius)
and displays this as value "L1" in the screen form.

Setting-up
2.1 Measuring tools
Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 11
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9. Press the "Set length" softkey.
The modified tool offset for the selected tool is applied in the X axis. Provided that the
"scratch position" in the X axis has not been moved, the measured diameter is now
displayed as the actual position in the position display of the tool measurement screen.
Figure 2-2 Measurement of turning tool in X axis completed
10.Press the "Z" softkey.
The screen for measuring the Z axis appears.
The Z axis can be measured in the same way as the X axis.
When measuring the tool in the Z axis, you may define a distance between the workpiece
and the turning tool tip in input field "a1" to avoid surface damage on the workpiece.
11.To return to the main screen for "Manual Machine Plus", select softkey "Back".
NOTICE
New offset settings lost
If you exit the screen form at Point 8, the new offset will not take effect.

Setting-up
2.2 Limit stops
Manual Machine Plus (Turning)
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2.2 Limit stops
Functionality
Limit stops are used to stop the axes in a specific position.
If an axis stops in the limit stop position, it cannot be moved again until the triggering limit
stop is reset.
By setting the limit stops, in the "Manual Machine Plus" operating area, it is possible to turn
simple shoulders (including tapers) without the need for any further cycle parameterization.
Supplementary conditions
● The limit stop position is always an absolute dimension, which in turn always corresponds
to the position in the absolute actual value display on the "Manual Machine Plus"
interface. A relative limit stop position is not possible.
● A limit stop position can be entered/accepted only when the axes are stationary.
Otherwise, an error message appears.
2.2.1 Setting and activating/deactivating limit stops
Functionality
In the main screen "Manual Machine Plus", limit stops can be entered into the input fields "-
X/-Z/+X/+Z".
In the following screen, the cursor is located in the input field "Endstop of axis X+" (with an
orange background).
Figure 2-3 Endstop of axis X+

Setting-up
2.2 Limit stops
Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 13
Parameter
Parameter Description
ON The limit stop is activated.
OFF The limit stop is deactivated.
- X Negative absolute position of the limit stop of the X axis.
The axis stops automatically when both of the following are met:
The limit stop is active.
The specified axis traverses in the negative direction and reaches the absolute limit stop position.
+X Positive absolute position of the limit stop of the X axis.
The axis stops automatically when both of the following are met:
The limit stop is active.
The specified axis traverses in the positive direction and reaches the absolute limit stop position.
-Z Negative absolute position of the limit stop of the Z axis.
The axis stops automatically when both of the following are met:
The limit stop is active.
The specified axis traverses in the negative direction and reaches the absolute limit stop position.
+Z Positive absolute position of the limit stop of the Z axis.
The axis stops automatically when both of the following are met:
The limit stop is active.
The specified axis traverses in the positive direction and reaches the absolute limit stop position.
All of the limit stops are set in the following screen.
Figure 2-4 All limit stops set

Setting-up
2.2 Limit stops
Manual Machine Plus (Turning)
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Operating sequences
You can use the following methods to enter a limit stop position:
● Direct position entry:
– Select the input field of the relevant limit stop with the <Cursor keys>.
– Now use the <Numeric keys> to enter the absolute position you require.
– Press the <INPUT> key to accept the value.
● Accepting the current actual position:
– Select the input field of the relevant limit stop with the <Cursor keys>.
– Traverse to the required position using the axis direction switch (e.g. <-Z> or <+X/-
X/+Z>).
– Press the "Set stop" softkey.
The current actual position of the relevant axis is transferred to the input field.
Activating/disabling limit stops
The limit stops are activated/deactivated individually using the <SELECT> key.
You can select between ON and OFF.

Setting-up
2.2 Limit stops
Manual Machine Plus (Turning)
Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 15
2.2.2 Turning against a stop
Example:
The following example explains the operating principle of limit stops using the axis direction
keys.
You can also use the handwheel to perform the machining operation.
Task
The following shoulder with a finishing allowance of 0.2 mm must be turned:
● 100 mm in the Z direction
● 50 mm final diameter in the X direction
The end face starts at 0 mm in the Z direction. The blank diameter is 70 mm.
Operating sequences for infeeding to stop
1. Position the axes in front of the workpiece (e.g., X +75 mm/Z +5 mm).
2. Check the machining technology data.
3. Set the following limit stops:
– -X at 50.4 mm
– -Z at –99.8 mm (due to finishing allowance)
– +Z at +5 mm
4. Delete the limit stop for +X; it is not required.
5. Start the spindle.
6. Using the handwheel, infeed to the 1st depth of cut in the X direction.
7. Start machining in the Z axis in the negative direction using the axis direction switch.
When the limit stop position in Z –99.8 mm is reached, the Z axis stops automatically.
The message "Limit stop –Z reached" is displayed.
8. Switch-out the axis direction switch.
9. Using the handwheel, retract the tool from the workpiece in the X direction.
10.Using the axis direction switch and rapid traverse override, move the tool in a positive Z
direction towards the workpiece until the axis stops.
The message "Limit stop +Z reached" is displayed.
11.Switch-out the axis direction switch.
12.Using the handwheel, infeed to the next depth of cut in the X direction.
13.Start machining in the Z axis in the negative direction using the axis direction switch.
Repeat the procedure until the depth of rough cut is reached.
The message "Limit stop -X reached" is displayed as the tool is fed in.
Once this cut has been completed, adjust the limit stops to the finished dimension,
provided that the axes are positioned in front of the workpiece.

Setting-up
2.2 Limit stops
Manual Machine Plus (Turning)
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Operating sequences for adjusting to finished dimension
1. Adjust the limit stops to the finished dimension: -X to 50.0 mm/-Z to –100.0 mm
2. Using the handwheel, infeed in the X direction until the "Limit stop -X reached" message
appears.
3. Start machining in the Z axis in the negative direction using the axis direction switch.
When the limit stop position in Z –100.0 mm is reached, the Z axis stops automatically.
The message "Limit stop –Z reached" is displayed.
4. Switch-out the axis direction switch in the Z direction and start in the positive X direction
(finishing the end face).
5. Switch-out the axis direction switch in the X direction as soon as the tool tip leaves the
workpiece.

Setting-up
2.3 Setting the workpiece zero
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Programming and Operating Manual, 12/2012, 6FC5398-3DP10-0BA0 17
2.3 Setting the workpiece zero
Functionality
The "Set the workpiece zero" function can be used to specify the reference point for
machining the workpiece.
Typical application/procedure:
1. Parameterize all the machining steps (cycles) for the workpiece in relation to a "virtual
zero point" (e.g., an end face).
2. Clamp the blank.
3. Scratch the relevant surface which corresponds to the "virtual zero point".
4. Use the "Set WO" function to adapt the workpiece coordinate system to the
parameterized machining operation.
Make sure that the axis does not exit from the approached position.
Additional information
The following operations are performed automatically when you select softkey "Set WO":
● The work offset is automatically calculated according to the current axis position in the
longitudinal axis (Z), entered in the NC memory as the basic offsetand activated.
● This will also set the position displayed for the longitudinal axis (Z) to 0.000, as this
always corresponds to the workpiece coordinate system.
● If the workpiece zero is reset, the value "0.000" will be automatically entered in the NC
memory as the basic offset. The workpiece coordinate system display will change to
reflect this.
DANGER
Notice: Setting the workpiece zero affects the absolute machining position of all
machining steps that have been parameterized in the controller!! -> All machining steps
will now be performed in relation to the zero point that has just been set!!
Setting/resetting the workpiece zero without due care and attention can result in serious
damage to the tool, workpiece or machine!!

Setting-up
2.3 Setting the workpiece zero
Manual Machine Plus (Turning)
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Operating sequences
Press the "Set WO" softkey in the main screen for "Manual Machine Plus".
Figure 2-5 Set workpiece zero point
This screen displays the currently programmed Z value of the basic work offset.
The setting options in this screen are selected with softkeys. The softkey meanings are as
follows:
This function is used to set the "workpiece zero".
The workpiece coordinate system of the longitudinal axis (Z) displays the value "0.000".
The required work offset is computed automatically and stored in the appropriate place in the
NC.
This function resets the work offset that is currently stored on the NC. The value "0.000" is
entered in the basic offset memory location. However, all other offsets and the active tool
offset remain unchanged.

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Manual machining 3
3.1 Fundamentals of manual machining
Functionality
You can perform the following machining operations manually:
● Axis-parallel traversal
● Taper turning
● Radius turning
● Drilling - centered
● Tapping
● Groove cycles/Expan. groove
● Thread cutting
● Rough turning of contours
Fundamentals
The following operations must be performed before manual machining can proceed:
● Axes referenced
● Tools measured
● Limit stops set
● Set workpiece zero point

Manual machining
3.2 Display and operator control options in the main screen
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3.2 Display and operator control options in the main screen
Functionality
Note
If the controller has already been preconfigured to "Manual Machine Plus" by the machine
manufacturer, the operating area "Manual Machine Plus" is activated once the controller has
been started up. If you have not yet executed a reference point approach, you will be in the
operating mode Reference point approach after start-up.
You can reference the axes in the Siemens standard user interface as well as in the
operating area "Manual Machine Plus".
You have referenced the axes and pressed the "Manual" softkey in the "MACHINE"
operating area. The following screen represents the main screen of the "Manual Machine
Plus" operating area.
Figure 3-1 Main screen for "Manual Machine Plus", position display absolute
Note about the position display in the main screen for "Manual Machine Plus"
● Absolute position display active:
The position value displayed in the large-size font is the absolute position. No additional
value is shown.
● Relative position display active (see following diagram):
The position value displayed in the large-size font is the relative position. The position
value displayed next to it in the small-size font is the absolute position.