Siemens SINUMERIK 808D User manual

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Milling Part 1: Operation
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SINUMERIK
SINUMERIK 808D
Milling Part 1: Operation
Programming and Operating Manual
Valid for:
SINUMERIK 808D Milling (software version: V4.4.2)
Target group:
End users and service engineers
12/2012
6FC5398-4DP10-0BA0
Preface
Introduction
1
Turning on, reference point
approach
2
Setting-up
3
Part programming
4
Automatic machining
5
System
6
Data backup
7
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6FC5398-4DP10-0BA0
Ⓟ 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.

Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 3
Preface
Purpose of the manual
This manual provides information about programming and operating the SINUMERIK 808D
CNC on milling machines.
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 milling machines installed with SINUMERIK 808D control systems, including
operators, programmers and maintenance engineers
● Service engineers of the machine tool manufacturer
Standard scope
This manual only describes the functionality of the standard version. Extensions or changes
made by the machine tool manufacturer are documented by the machine tool manufacturer.
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.

Preface
Milling Part 1: Operation
4 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Documentation components
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)

Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 5
Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction................................................................................................................................................ 7
1.1 SINUMERIK 808D operator panels ...............................................................................................7
1.2 Machine control panels ................................................................................................................10
1.3 Coordinate systems .....................................................................................................................13
1.4 Software interface ........................................................................................................................17
1.4.1 Screen layout ...............................................................................................................................17
1.4.2 Protection levels...........................................................................................................................20
1.4.3 The help system...........................................................................................................................22
2 Turning on, reference point approach...................................................................................................... 25
3 Setting-up ................................................................................................................................................ 27
3.1 Setting up tools ............................................................................................................................28
3.1.1 Creating a new tool ......................................................................................................................28
3.1.2 Creating a new cutting edge ........................................................................................................29
3.1.3 Entering the tool offsets ...............................................................................................................30
3.1.4 Activating the tool and starting the spindle ..................................................................................31
3.1.5 Assigning the handwheel.............................................................................................................32
3.1.6 Measuring the tool (manually)......................................................................................................33
3.1.7 Measuring the tool with a probe (auto) ........................................................................................36
3.1.8 Calibrating the tool probe.............................................................................................................38
3.2 Setting up the workpiece..............................................................................................................40
3.2.1 Entering / modifying work offsets.................................................................................................40
3.2.2 Measuring the workpiece .............................................................................................................41
3.3 Entering / modifying the setting data ...........................................................................................44
3.4 Setting the R parameters.............................................................................................................47
3.5 Other settings in "JOG" mode......................................................................................................48
3.5.1 Setting the relative coordinate system (REL) ..............................................................................49
3.5.2 Face milling..................................................................................................................................50
3.5.3 Setting the JOG data ...................................................................................................................52
4 Part programming.................................................................................................................................... 53
4.1 Creating files or folders ................................................................................................................54
4.2 Editing part programs...................................................................................................................55
4.3 Managing part programs..............................................................................................................57
4.4 Calculating contour elements.......................................................................................................60
4.5 Free contour programming ..........................................................................................................65
4.5.1 Programming a contour ...............................................................................................................66
4.5.2 Defining a start point ....................................................................................................................67

Table of contents
Milling Part 1: Operation
6 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
4.5.3 Programming contour element.................................................................................................... 68
4.5.4 Parameters for contour elements................................................................................................ 71
4.5.5 Specifying contour elements in polar coordinates ...................................................................... 75
4.5.6 Cycle support .............................................................................................................................. 78
4.5.7 Programming example for milling ............................................................................................... 78
5 Automatic machining ............................................................................................................................... 87
5.1 Performing the simulation ........................................................................................................... 88
5.2 Program control........................................................................................................................... 90
5.3 Program test................................................................................................................................ 91
5.4 Starting and stopping / interrupting a part program .................................................................... 92
5.5 Executing / reading in a part program from external................................................................... 93
5.6 Machining at a specific point....................................................................................................... 96
6 System..................................................................................................................................................... 99
7 Data backup .......................................................................................................................................... 101
A Appendix................................................................................................................................................ 103
A.1 Pocket calculator....................................................................................................................... 103
A.2 Editing Chinese characters ....................................................................................................... 105
Index...................................................................................................................................................... 107

Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 7
Introduction 1
1.1 SINUMERIK 808D operator panels
Elements on the PPU (Panel Processing Unit) front





 





① Vertical and horizontal softkeys
Calls specific menu functions
⑦ On-board assistant key
Provides step-by-step guides on basic commissioning
and operation procedures
② Return key
Returns to the next higher-level menu
⑧ Help key
Calls help information
③ Menu extension key
Reserved for future use
⑨ Cursor keys *
④ Alphabetic and numeric keys
To enter the upper character on the key, hold down the
following key:
⑩ Operating area keys *
⑤ Control keys * ⑪ USB interface *
⑥ Alarm cancellation key
Cancels alarms and messages that are marked with
this symbol
⑫ Status LEDs *
* For more information, refer to the table below.

Introduction
1.1 SINUMERIK 808D operator panels
Milling Part 1: Operation
8 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Further information
Deletes a character selected to the left of the cursor
Deletes the selected file or character
Indents the cursor by several characters
Toggles between the input field and the selected program name
Control keys
Confirms your entry of a value
Opens a directory or program
Reserved for future use
Moves the cursor to the end of a line
Scrolls upwards on a menu screen
Scrolls downwards on a menu screen
Cursor keys
Toggles between entries in the input field
Enters the "Set-up menu" dialog at NC start-up
To open the system data management operating area, press the following
key combination:
+
Operating area keys
Enables user's extension application, for example, to generate user dialogs
with the EasyXLanguage function.
For more information about this function, refer to the SINUMERIK 808D
Function Manual.
LED "POK"
Lights up green: The power supply for the CNC is switched on.
LED "RDY"
Lights up green: The CNC is ready for operation.
Status LEDs
LED "TEMP"
Unlit: The CNC temperature is within the specified range.
Lights up orange: The CNC temperature is out of range.
USB interface Connects to a USB device, for example:
An external USB memory sticker, to transfer data between the USB
sticker and the CNC
An external USB keyboard which functions as an external NC keyboard

Introduction
1.1 SINUMERIK 808D operator panels
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 9
Key combinations
Key combination Description
<ALT> + <X> Opens the machining operating area:
<ALT> + <V> Opens the program editing operating area:
<ALT> + <C> Opens the offset parameters operating area:
<ALT> + <B> Opens the program management operating area:
<ALT> + <M> Opens the diagnostics operating area
<ALT> + <N>
 +
Opens the system data management operating area:
<ALT> + <H> Calls the online help system
<ALT> + <L> Enables input of lowercase letters
<ALT> + <S> Applicable only when the user interface language is Chinese
Calls the input method editor for entering Chinese characters
<=> Calls the pocket calculator.
Note that this function is not applicable in MDA mode.
<CTRL> + <B> Selects text in program blocks
<CTRL> + <C> Copies the selected text
<CTRL> + <D> Shows pre-defined slides on the screen
<CTRL> + <P> Captures screens
<CTRL> + <R> Restarts the HMI
<CTRL> + <S> Saves start-up archives

Introduction
1.2 Machine control panels
Milling Part 1: Operation
10 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
1.2 Machine control panels
Elements on the MCP (Machine Control Panel) front



① Emergency stop key
Stops all machine motions immediately
⑥ User-defined keys *
(all with LED status indicators)
② Handwheel key
(with LED status indicator)
Controls the axis movement with external handwheels
⑦ Axis traversing keys *
③ Tool number display
Displays the current tool number
⑧ Spindle control keys
④ Operating mode keys
(all with LED status indicators)
⑨ Program state keys *
⑤ Program control keys *
(all with LED status indicators)
⑩ Feedrate override switch
Traverses the selected axis at the specified feedrate
override
* For more information, refer to the table below.
Further information
Disables the output of setpoints to axes and the spindle. The control
system only "simulates" the traverse movements in order to verify the
correctness of the program.
Stops the program at every block in which miscellaneous function M01 is
programmed
Adjusts axis feedrate override
Program control keys
Activates single block execution mode

Introduction
1.2 Machine control panels
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 11
Pressing this in any operating mode switches on/off the lamp.
LED lit: The lamp is switched on.
LED unlit: The lamp is switched off.
Pressing this key in any operating mode switches on/off the coolant
supply.
LED lit: The coolant supply is switched on.
LED unlit: The coolant supply is switched off.
When all axes and the spindle stop operation, pressing this key unlocks
the safety door.
LED lit: The safety door is unlocked.
LED unlit: The safety door is locked.
Pressing this key rotates the magazine clockwise (active only in JOG
mode).
LED lit: The magazine rotates clockwise.
LED unlit: The magazine stops clockwise rotation.
Pressing this key approaches the magazine to the reference point
(active only in JOG mode).
LED on: The magazine is reference point approached.
LED off: The magazine is not yet referenced
Pressing this key rotates the magazine counterclockwise (active only in
JOG mode).
LED on: The magazine rotates counterclockwise.
LED off: The magazine stops counterclockwise rotation.
Pressing this key in any operating mode starts the forward rotation of the
chip remover (active only in JOG mode).
LED lit: The chip remover starts forward rotation.
LED unlit: The chip remover stops rotation.
User-defined keys
Keeping pressing this key in any operating mode rotates the chip
remover in reverse order. Releasing the key changes the chip remover
to the previous forward rotation or stop state (active only in JOG mode).
LED lit: The chip remover starts reverse rotation.
LED unlit: The chip remover stops reverse rotation.
Traverses the selected axis at rapid traverse speed while pressing the
relevant axis key
No function is assigned to this key.
Axis traversing keys
Incremental feed keys (with LED status indicators)
Sets increments desired for the axis to traverse
Stops the execution of NC programs Program state keys
Starts the execution of NC programs

Introduction
1.2 Machine control panels
Milling Part 1: Operation
12 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Resets NC programs
Cancels alarms that meet the cancel criterion
Pre-defined insertion strips
The MCP (machine control panel) package includes two sets (six pieces each) of pre-
defined insertion strips. One set is for the turning version of the control system and is pre-
inserted in the back of the MCP. The other set is for the milling version of the control system.
For a milling version of the control system, replace the pre-inserted strips with the milling-
specific insertion strips.

① Insertion strips for turning version of the control system
② Insertion strips for milling version of the control system
Customized insertion strips
The MCP package also includes an A4-sized blank plastic sheet with detachable strips. You
can customize insertion strips if the pre-defined strips can not meet your needs.
In the \04040000\examples\MCP folder of the Toolbox DVD for the SINUMERIK 808D, there
is a symbol library file and an insertion strip template file. To make customized insertion
strips, follow the steps below:
1. Copy the desired symbols from the symbol library file to the desired locations in the
insertion strip template.
2. Print the template to the A4-sized blank plastic sheet.

Introduction
1.3 Coordinate systems
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 13
3. Detach the insertion strips from the blank plastic sheet.
4. Pull out the pre-inserted strips from the MCP.
5. Insert the customized strips on the back of the MCP.
Note
This manual assumes an 808D standard machine control panel (MCP). Should you use a
different MCP, the operation may be other than described herein.
1.3 Coordinate systems
As a rule, a coordinate system is formed from three mutually perpendicular coordinate axes.
The positive directions of the coordinate axes are defined using the so-called "3-finger rule"
of the right hand. The coordinate system is related to the workpiece and programming takes
place independently of whether the tool or the workpiece is being traversed. When
programming, it is always assumed that the tool traverses relative to the coordinate system
of the workpiece, which is intended to be stationary.
The figure below illustrates how to determine the axis directions.
90°
90°
90°
;
=
<
;
=
<
Machine coordinate system (MCS)
The orientation of the coordinate system relative to the machine depends on the respective
machine types. It can be rotated in different positions.
The directions of the axes follow the "3-finger rule" of the right hand. Seen from the front of
the machine, the middle finger of the right hand points in the opposite direction to the infeed
of the spindle.

Introduction
1.3 Coordinate systems
Milling Part 1: Operation
14 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
;
=
<
The origin of this coordinate system is the machine zero.
This point is only a reference point which is defined by the machine manufacturer. It does not
have to be approachable.
The traversing range of the machine axes can be in the negative range.
Workpiece coordinate system (WCS)
To describe the geometry of a workpiece in the workpiece program, a right-handed, right-
angled coordinate system is also used.
The workpiece zero can be freely selected by the programmer in the Z axis. In the X axis, it
lies in the turning center.
The figure below shows an example of the workpiece coordinate system.
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:
=
<
;

Introduction
1.3 Coordinate systems
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 15
Relative coordinate system (REL)
In addition to the machine and workpiece coordinate systems, the control system provides a
relative coordinate system. This coordinate system is used to set reference points that can
be freely selected and have no influence on the active workpiece coordinate system. All axis
movements are displayed relative to these references.
Clamping the workpiece
For machining, the workpiece is clamped on the machine. The workpiece must be aligned
such that the axes of the workpiece coordinate system run in parallel with those of the
machine. Any resulting offset of the machine zero with reference to the workpiece zero is
determined along the Z axis and entered in a data area intended for the settable work offset.
In the NC program, this offset is activated during program execution, for example, using a
programmed G54 command.
The figure below shows an example of the workpiece clamped on the machine.
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=
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=
PDFKLQH
;
PDFKLQH
<
PDFKLQH
HJ*
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Introduction
1.3 Coordinate systems
Milling Part 1: Operation
16 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Current workpiece coordinate system
The programmed work offset TRANS can be used to generate an offset with reference to the
workpiece coordinate system, resulting in the current workpiece coordinate system.
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:
=
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;
3URJUDPPDEOHRIIVHW
75$16
=
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FXUUHQW

Introduction
1.4 Software interface
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 17
1.4 Software interface
1.4.1 Screen layout











Status area Application area
① Active operating area ⑧ Actual value window
② Active operating mode ⑨ T, F, S window
③ Alarm and message prompt area ⑩ Operating window with program block
display
④ Current time and date Tip and softkey area
⑤ Program file name ⑪ Information line
⑥ Program status indication ⑫ Horizontal softkey bar
⑦ Active program control modes ⑬ Vertical softkey bar

Introduction
1.4 Software interface
Milling Part 1: Operation
18 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Status area




Display Meaning
Machining operating area
System data management operating area
Program editing operating area
Program management operating area
Offset parameters operating area
① Active operating
area
Diagnostics operating area
"REF POINT" mode
"JOG" mode
Incremental traverse in "JOG" mode
"MDA" mode
② Active operating
mode
"AUTO" mode

Introduction
1.4 Software interface
Milling Part 1: Operation
Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0 19
Display Meaning
Displays active alarms with alarm text
The alarm number is displayed in white lettering on a red
background. The associated alarm text is shown in red
lettering.
An arrow indicates that several alarms are active. The
number to the right of the arrow indicates the total number
of active alarms.
When more than one alarm is active, the display scrolls
through the alarms in sequence.
An acknowledgement symbol indicates the alarm cancel
criterion.
③
Alarms and
messages
Displays messages from NC programs
Messages from NC programs do not have numbers and
appear in green lettering.
④ Current time and date
⑤ File name of the current part
program
Program state
RESET Program canceled / default state
RUN Program is running
⑥
STOP Program stopped
⑦ Program control in "AUTO" mode
Tip and softkey area
1
4
5
2 3
Screen item Display Description
①
Return symbol
Returns to the next higher-level menu with the following key:
② Information line
Displays notes and information for the operator and fault states

Introduction
1.4 Software interface
Milling Part 1: Operation
20 Programming and Operating Manual, 12/2012, 6FC5398-4DP10-0BA0
Screen item Display Description
③ HMI status information
ಯ/ಯ
Lowercase letter input active
RS232 connection active
Connection to PLC Programming Tool
④ Horizontal softkey bar
⑤ Vertical softkey bar
1.4.2 Protection levels
Protection levels
SINUMERIK 808D provides a concept of protection levels for enabling data areas. Different
protection levels control different access rights.
The control system delivered from SIEMENS is set by default to the lowest protection level 7
(without password). If the password is no longer known, the control system must be
reinitialized with the default machine data. All passwords are then reset to default passwords
for this software release.
NOTICE
Before you boot the control system with default machine data, make sure that you have
backed up your data; otherwise, all data is lost after rebooting with the default machine
data.
Protection level Locked by Area
0 Siemens password Siemens, reserved
1 Manufacturer password Machine manufacturers
2 Reserved
3-6 End-user password
(Default password: "CUSTOMER")
End users
7 No password End users