Siemens SINUMERIK 840D sl User manual

SINUMERIK Operate - 
Turning
_
_________________
_
_
_________________
_
_
___________
_
______
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
__________________
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
_
_________________
_
SINUMERIK 840D sl
SINUMERIK Operate - Turning
Control system overview
for machine tools' sales people
09/2012
Preface
Introduction
1
System overview
2
CNC operation in manual
mode (JOG)
3
Tool management
4
User memory
5
Data transfer
6
Graphical support functions
7
CNC operation in automatic
mode (AUTO)
8
CNC performance capability
and optimization functions
9
CNC programming methods
10
Simulation
11
CNC technology cycles
12
Complete machining
13
Multi-channel machining
14
PC software
15
Integrated safety functions
16
Option list for the
SINUMERIK package
17
Summary of unique features
18

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ⓟ 09/2012 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.

SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 3
Preface
Scope of validity
This document provides you with an overview of the range of functions included in the
SINUMERIK 840D sl Version 4.5 for turning machines.
The document is focusing on vendors and dealers of machine tools.
Organization of the information
● Of the varied functional features of the SINUMERIK products, only those are listed which
are of direct value to the machine user.
● All functions contained in the machine's basic configuration will be identified as follows:
☑ Basic configuration
● All functions not contained in the machine's basic configuration will be identified as
follows:
☑ Option: ...
● You can find a summary of the most important unique selling points of the SINUMERIK
840D sl in the chapter "Summary of highlights".
● For information on marketing options through the machine manufacturer, please see the
technical description of each machine.
Subject to change without prior notice
Contact person at machine manufacturer
Marketing & Sales
Phone: +49 xxx xxx
Fax: +49 xxx xxx
Email: [e-mail]
Service
Phone: +49 xxx xxx
Fax: +49 xxx xxx
Email: [e-mail]
Homepage:
http://www.machinemanufacturer.com

Preface
SINUMERIK Operate - Turning, SINUMERIK 840D sl
4 Control system overview for machine tools' sales people, 09/2012
Contact person at Siemens
Country Name e-mail Phone
Argentina Santiago Fernandez Veron [e-mail] [phone]
Belgium Pieter Vanderhaeghen [email protected] [phone]
Bosnia and Herzegovina Helmut Stralz [email protected] [phone]
Brazil Gustavo Marino marino.gusta[email protected] + 55 (11) 3908-1752
Bulgaria Helmut Stralz helmut.s[email protected] [phone]
China Hong Xia Mu [e-mail] [phone]
Denmark Stefan Karlstrand [email protected] [phone]
Germany (Headquarters) Gerhard Micka [email protected] [phone]
Finland Juha Meriaho [e-mail] [phone]
France François Chevalier francoi[email protected] [phone]
Great Britain Tony Bennison tony[email protected] [phone]
India Narayanan Shankar naray[email protected] [phone]
Indonesia Andy Lesmono [email protected] [phone]
Italy Nicodemo Megna nicodemo.m[email protected] [phone]
Canada Sagar Arora sagar.aro[email protected] [phone]
Korea Kim Sung Hyun [email protected] + 82 55 268 1906
Croatia Matjaz Mlinsek [email protected] [phone]
Lithuania Juha Meriaho juha.meri[email protected] [phone]
Malaysia Ridwan Aziz ridwan_az[email protected] [phone]
Mexico Marco Lopez [e-mail] [phone]
Netherlands Frank de Korte frank[email protected] [phone]
Norway Stefan Karlstrand [email protected] [phone]
Austria Helmut Stralz helmut.s[email protected] [phone]
Portugal Molaguero Godoy juan.mol[email protected] [phone]
Romania Matjaz Mlinsek [email protected] [phone]
Russia Alexander Kudinov [email protected] [phone]
Sweden Stefan Karlstrand [email protected] [phone]
Switzerland Hans-Peter Kueng hans[email protected] [phone]
Serbia Montenegro Helmut Stralz [email protected] [phone]
Slovakia Matjaz Mlinsek [email protected] [phone]
Slovenia Matjaz Mlinsek matjaz.m[email protected] [phone]
Spain Molaguero Godoy [email protected] [phone]
Taiwan Jerry Lin [email protected] [phone]
Thailand Rajeev Madhyastha rajee[email protected] [phone]
Czech Eva Klocova eva.kloc[email protected] [phone]
Turkey Taner Okayi [e-mail] [phone]
Hungary Istvan Joo istvan.j[email protected] [phone]
USA Jon Cruthers [email protected] [phone]
Vietnam Pham-Vu Trung pham-vu.tr[email protected] [phone]
Homepage:
For further information please visit ...
http://www.siemens.de/cnc4you
http://www.automation.siemens.de/doconweb

SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 5
Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction................................................................................................................................................ 9
1.1 Application......................................................................................................................................9
1.2 Machine spectrum........................................................................................................................10
2 System overview...................................................................................................................................... 11
2.1 SINUMERIK 840D sl....................................................................................................................11
2.2 Operator panel fronts...................................................................................................................12
2.3 Operator panel equipment ...........................................................................................................16
3 CNC operation in manual mode (JOG).................................................................................................... 19
3.1 TSM universal cycle.....................................................................................................................19
3.2 Positioning cycle ..........................................................................................................................20
3.3 Stock removal cycle .....................................................................................................................21
3.4 Measure tool ................................................................................................................................22
3.5 Measure workpiece......................................................................................................................23
3.6 Work offsets .................................................................................................................................24
4 Tool management.................................................................................................................................... 25
4.1 Tool table .....................................................................................................................................25
4.2 Monitoring of tool life and workpiece count..................................................................................26
4.3 Replacement tools .......................................................................................................................27
4.4 Setup data....................................................................................................................................27
5 User memory ........................................................................................................................................... 29
5.1 Buffered CNC work memory........................................................................................................29
5.2 CompactFlash card......................................................................................................................29
5.3 Hard disk......................................................................................................................................30
5.4 Card reader..................................................................................................................................30
5.5 USB Hub 4 ...................................................................................................................................31
6 Data transfer............................................................................................................................................ 33
6.1 Program manager ........................................................................................................................33
6.2 Data transfer using the USB memory stick..................................................................................34
6.3 RCS Commander.........................................................................................................................34
6.4 Ethernet networking .....................................................................................................................35

Table of contents
SINUMERIK Operate - Turning, SINUMERIK 840D sl
6 Control system overview for machine tools' sales people, 09/2012
7 Graphical support functions ..................................................................................................................... 37
7.1 Animated Elements ..................................................................................................................... 37
7.2 Onboard documentation.............................................................................................................. 38
8 CNC operation in automatic mode (AUTO).............................................................................................. 39
8.1 Block search................................................................................................................................ 39
8.2 Basic block display...................................................................................................................... 40
8.3 Program control........................................................................................................................... 41
8.4 Simultaneous recording .............................................................................................................. 42
9 CNC performance capability and optimization functions..........................................................................43
9.1 80bit NANOFP accuracy............................................................................................................... 43
9.2 Jerk limitation .............................................................................................................................. 44
9.3 Dynamic feedforward control ...................................................................................................... 45
9.4 Look Ahead ................................................................................................................................. 46
10 CNC programming methods .................................................................................................................... 47
10.1 Overview of programming methods ............................................................................................ 47
10.2 programGUIDE and SINUMERIK CNC programming ................................................................ 48
10.2.1 Introduction ................................................................................................................................. 48
10.2.2 Program editor ............................................................................................................................ 48
10.2.3 Languages .................................................................................................................................. 49
10.2.4 programGUIDE input support...................................................................................................... 50
10.3 ShopTurn..................................................................................................................................... 51
10.3.1 Introduction ................................................................................................................................. 51
10.3.2 Sequence editor .......................................................................................................................... 51
10.3.3 Interlinking of sequences ............................................................................................................ 52
10.3.4 Broken-line graphics ................................................................................................................... 53
10.4 Online ISO dialect interpreter...................................................................................................... 54
11 Simulation................................................................................................................................................ 55
11.1 2D simulation .............................................................................................................................. 55
11.2 3D simulation .............................................................................................................................. 56
12 CNC technology cycles............................................................................................................................ 57
12.1 Highlights of machining cycles.................................................................................................... 58
12.1.1 Stock removal along contour with blank contour ........................................................................ 58
12.1.2 Engraving cycle........................................................................................................................... 59
12.1.3 Counterspindle cycle................................................................................................................... 60
12.2 Residual material detection......................................................................................................... 61
12.2.1 Residual material detection during turning.................................................................................. 61
12.2.2 Detection of residual material when milling................................................................................. 62
12.3 In-process measuring for workpieces and tools.......................................................................... 63

Table of contents
SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 7
13 Complete machining................................................................................................................................ 65
13.1 End face machining (TRANSMIT)................................................................................................65
13.2 Peripheral surface machining (TRACYL).....................................................................................66
14 Multi-channel machining.......................................................................................................................... 67
14.1 Overview ......................................................................................................................................67
14.2 programSYNC job list ..................................................................................................................68
14.3 Double editor................................................................................................................................69
14.4 Simulation ....................................................................................................................................70
15 PC software............................................................................................................................................. 71
15.1 CAD reader for PC.......................................................................................................................71
15.2 SinuTrain......................................................................................................................................72
15.3 Computer-based training .............................................................................................................72
16 Integrated safety functions....................................................................................................................... 73
17 Option list for the SINUMERIK package .................................................................................................. 75
18 Summary of unique features.................................................................................................................... 77
Index........................................................................................................................................................ 79

Table of contents
SINUMERIK Operate - Turning, SINUMERIK 840D sl
8 Control system overview for machine tools' sales people, 09/2012

SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 9
Introduction 1
1.1 Application
With the SINUMERIK 840D sl and the operating software SINUMERIK Operate you have a
tailored solution for all CNC turning machines used worldwide.
When operating the machine tool, you are supported by graphic help screens and Animated
Elements.
The functions in the manual mode enable a quick, practical machine set-up. More
specifically, this consists of calculating the workpiece position in the machine, as well as the
maintenance and dimensioning of the tools in use.
You have three different options when programming:
● programmGUIDE and SINUMERIK CNC programming, with a wide selection of
technology cycles for medium series and large series production.
● ShopTurn, with automatic cascading (linking) of associated machining steps for small
series production.
● ISO dialect and SINUMERIK CNC programming language with IOSO dialect interpreter.
The SINUMERIK 840D sl with the operating software SINUMERIK Operate offers a control
configuration that covers all of the required application areas without subsequent
commissioning and training costs:
● Easy-to-use interface for all machine functions
● DIN/ISO programming on the machine or offline via the CAD/CAM system
● Graphic programming
● Complete machining
● In-process measuring for workpieces and tools

Introduction
1.2 Machine spectrum
SINUMERIK Operate - Turning, SINUMERIK 840D sl
10 Control system overview for machine tools' sales people, 09/2012
1.2 Machine spectrum
The SINUMERIK 840D sl with the operating software SINUMERIK Operate is perfectly
suited for the following types of machines:
1. Single-slide turning machines with X and Z axes
– Turning operations
– Centric drilling on the end face
2. Like 1.) with rotating tools (C axis mode)
– Any drilling or milling on the end face and outer surface
3. Like 1.) or 2.) with additional Y axis
– Any drilling or milling on the end face and outer surface
4. Like 1.), 2.) or 3.) with additional counterspindle for front and rear machining

SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 11
System overview 2
2.1 SINUMERIK 840D sl
SINUMERIK 840D sl is open, flexible and powerful and offers a standard and integrated
structure for operator control, programming and visualization. Integrated into the new,
especially compact and reliable SINAMICS S120 drive system, it constitutes a completely
digital system. It is best-suited for medium and high performance ranges.
● Digital drive controller
● Modular design for drive controller and power unit
● Up to 31 axes/spindles in up to 10 processing channels
● Intelligent control functions meeting the highest standards of machining technology
You can find further information in catalog NC 61
Highlights
● Flexible application and guaranteed future through modular design and
comprehensive CNC functions
● Best dynamics, precision and surface quality through use of
high performance processors
● Integrated, certified safety functions for man and machine are possible with
Safety Integrated

System overview
2.2 Operator panel fronts
SINUMERIK Operate - Turning, SINUMERIK 840D sl
12 Control system overview for machine tools' sales people, 09/2012
2.2 Operator panel fronts
These operator panel fronts have an integrated CNC keyboard. We offer matched machine
control panels for the version with mechanical keys (protection class IP54) and the version
with membrane keys (protection class IP65). You have two choices:
OP 010C
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
with frontal USB port for memory stick,
version with mechanical keys,
separate machine control panel
Highlights
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick

System overview
2.2 Operator panel fronts
SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 13
OP 010
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
with frontal USB port for memory stick,
version with membrane-type keys,
separate machine control panel
Highlights
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick
OP 010S
Operator panel 310mm wide, 10.4" display, mechanical keyboard,
with frontal USB port for memory stick,
separate CNC keyboard and machine control panel
Highlights
● Option of especially slim design
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, balanced and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick

System overview
2.2 Operator panel fronts
SINUMERIK Operate - Turning, SINUMERIK 840D sl
14 Control system overview for machine tools' sales people, 09/2012
OP 015
Operator panel 483mm wide, 15" display, membrane keys,
with frontal USB port for memory stick,
separate CNC keyboard and machine control panel
Highlight
● Option of large display for better readability and graphic display, especially for high-
performance machines
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, harmonized and high-quality design of operator components
● Simple data handling with easily accessible USB memory stick

System overview
2.2 Operator panel fronts
SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 15
OP 019
Operator panel 483 mm wide, 19" display with resolution 1280*1024,
membrane keys, can also be operated with gloves,
capacitive sensors for fast key initiation,
integrated key lock to protect against operator errors,
USB 2.0 connector socket for mounting in control desks,
separate CNC keyboard and machine control panel
Highlight
● New operator panel front with especially large display for better readability and graphic
display, especially for high-performance machines
● All relevant functions at a glance, thanks to horizontal and vertical softkeys
● Brilliant color display, harmonized and high-quality design of operator components

System overview
2.3 Operator panel equipment
SINUMERIK Operate - Turning, SINUMERIK 840D sl
16 Control system overview for machine tools' sales people, 09/2012
2.3 Operator panel equipment
TCU
The Thin Client Unit (TCU) for a distributed configuration allows the SINUMERIK operator
panel front to be spatially separated and/or permits several operator panels to be connected
to one SINUMERIK NCU.
● Fewer parts for specifically flat design
● Competitive purchase price and inexpensive replacement parts
Highlights
● Rugged and cost-optimized solution, as there is no hard disk
● Signal transmission between PCU/NCU and operator panel front via Industrial Ethernet

System overview
2.3 Operator panel equipment
SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 17
PCU 50
We offer the PCU 50 for customers who specify a hard disk and/or supplementary Windows-
based software.
● Windows XP operating system
● Additional CNC memory through hard disk
● Additional PCI slots
● Additional CF card slot
● DVI interface
Highlights
● Flexible software expansion on Windows platform
● Flexible hardware expansion via PCI slots

System overview
2.3 Operator panel equipment
SINUMERIK Operate - Turning, SINUMERIK 840D sl
18 Control system overview for machine tools' sales people, 09/2012

SINUMERIK Operate - Turning, SINUMERIK 840D sl
Control system overview for machine tools' sales people, 09/2012 19
CNC operation in manual mode (JOG) 3
3.1 TSM universal cycle
☑ Basic configuration
A universal cycle is available in the setup for the most commonly used machine functions:
● Tool change with direct access via the tool table (T)
● Spindle speed and direction (S)
● M functions (M)
● Activation of work offsets
Highlight
● Take over and change in tools directly from the tool table

CNC operation in manual mode (JOG)
3.2 Positioning cycle
SINUMERIK Operate - Turning, SINUMERIK 840D sl
20 Control system overview for machine tools' sales people, 09/2012
3.2 Positioning cycle
☑ Basic configuration
The machine axes can be positioned directly via input screens in the setup:
● Linear axes / spindles
● Feedrate / rapid traverse
Highlight
● Simple axis positioning without manual input, directly over the dialog screen