Siemens SINUMERIK 840D User manual

SINUMERIK
SINUMERIK 840D sl/828D
Milling
Operating Manual
Valid for
Control System
SINUMERIK 840D sl/840DE sl/828D
Software Version
CNC software for 840D sl/ 840DE sl/828D 2.6 SP1
with SINUMERIK Operate for PCU/PC 2.6 SP1
03/2010
6FC5398-7CP20-1BA0
Preface
Introduction
1
Setting up the machine
2
Execution in manual mode
3
Machining the workpiece
4
Simulating machining
5
Creating G code program
6
Creating a ShopMill program
7
Programming technological
functions (cycles)
8
Multi-channel view
9
User variables
10
Teaching in a program
11
Tool management
12
Program management
13
Setting up drives
14
HT 8
15
Easy Message (828D only)
16
Easy Extend (828D only)
17
Service Planner (828D only)
18
Ladder Viewer and Ladder
add-on (828D only)
19
A
larms, error messages, and
system alarms
20
Appendix
A

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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 for the specific task, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the 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.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
order number: 6FC5398-7CP20-1BA0
Ⓟ 05/2010
Copyright © Siemens AG 2010.
Technical data subject to change

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Operating Manual, 03/2010, 6FC5398-7CP20-1BA0 3
Preface
Structure of the documentation
The SINUMERIK documentation is organized in three parts:
● General documentation
● User documentation
● Manufacturer/service documentation
Information on the following topics is available at
http://www.siemens.com/motioncontrol/docu:
● Ordering documentation
Here you can find an up-to-date overview of publications.
● Downloading documentation
Links to more information for downloading files from Service & Support.
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWEB.
● Compiling individual documentation on the basis of Siemens contents with the My
Documentation Manager (MDM), refer to http://www.siemens.com/mdm.
My Documentation Manager provides you with a range of features for generating your
own machine documentation.
● Training and FAQs
Information on our range of training courses and FAQs (frequently asked questions) is
available via the page navigation.
Target group
This documentation is intended for users of milling machines running the SINUMERIK
Operate software.
Benefits
The operating manual familiarizes users with the operator controls and operating commands.
It instructs users on how to respond to faults and take corrective action.
Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.

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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.
Terms
The meanings of some basic terms are given below in this documentation.
Program
A program is a sequence of instructions to the CNC which combine to produce a specific
workpiece on the machine.
Contour
The term contour refers generally to the outline of a workpiece. More specifically, it refers to
the section of the program that defines the outline of a workpiece comprising individual
elements.
Cycle
A cycle, e.g. milling a rectangular pocket, is a subprogram defined in SINUMERIK Operate
for executing a frequently repeated machining operation.
Technical Support
If you have any technical questions, please contact our hotline:
Europe/Africa
Phone [phone]
Fax [phone]
0.14 €/min. from German landlines, max. 0.42 €/min for calls from a mobile phone
Internet http://www.siemens.com/automation/support-request
Americas
Phone [phone]
Fax [phone]
E-mail mailto:[email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-mail mailto:support.asia.automatio[email protected]

Preface
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Note
Country-specific telephone numbers for technical support are provided under the following
Internet address:
http://www.automation.siemens.com/partner
Questions about the manual
If you have any queries (suggestions, corrections) in relation to this documentation, please
fax or e-mail us:
Fax [phone]
E-mail mailto:[email protected]m
A fax form is available in the appendix of this document.
Internet address
http://www.siemens.com/motioncontrol

Preface
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Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction.............................................................................................................................................. 17
1.1 Product overview .........................................................................................................................17
1.2 Operator panel fronts ...................................................................................................................18
1.2.1 Overview ......................................................................................................................................18
1.2.2 Keys of the operator panel...........................................................................................................20
1.3 Machine control panels................................................................................................................26
1.3.1 Overview ......................................................................................................................................26
1.3.2 Controls on the machine control panel ........................................................................................26
1.4 User interface...............................................................................................................................29
1.4.1 Screen layout ...............................................................................................................................29
1.4.2 Status display...............................................................................................................................30
1.4.3 Actual value window ....................................................................................................................33
1.4.4 T,F,S window ...............................................................................................................................34
1.4.5 Current block display ...................................................................................................................35
1.4.6 Operation via softkeys and buttons .............................................................................................36
1.4.7 Entering or selecting parameters.................................................................................................37
1.4.8 Pocket calculator..........................................................................................................................40
1.4.9 Context menu...............................................................................................................................41
1.4.10 Touch operation ...........................................................................................................................42
1.4.11 Changing the user interface language.........................................................................................42
1.4.12 Entering Asian characters............................................................................................................43
1.4.13 Protection levels...........................................................................................................................45
1.4.14 Online help in SINUMERIK Operate............................................................................................47
2 Setting up the machine............................................................................................................................ 51
2.1 Switching on and switching off.....................................................................................................51
2.2 Approaching a reference point.....................................................................................................52
2.2.1 Referencing axes .........................................................................................................................52
2.2.2 User agreement ...........................................................................................................................53
2.3 Operating modes .........................................................................................................................55
2.3.1 General ........................................................................................................................................55
2.3.2 Modes groups and channels........................................................................................................57
2.3.3 Channel switchover......................................................................................................................57
2.4 Settings for the machine ..............................................................................................................58
2.4.1 Switching over the coordinate system (MCS/WCS) ....................................................................58
2.4.2 Switching the unit of measurement..............................................................................................59
2.4.3 Setting the work offset .................................................................................................................60
2.5 Measuring the tool .......................................................................................................................62
2.5.1 Measuring a tool manually...........................................................................................................62
2.5.2 Measuring the tool length with the workpiece as reference point................................................63
2.5.3 Measuring radius or diameter ......................................................................................................64
2.5.4 Fixed point calibration ..................................................................................................................65
2.5.5 Measuring a tool with an electrical tool probe..............................................................................66

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2.5.6 Calibrating the electrical tool probe............................................................................................. 68
2.6 Measuring the workpiece zero .................................................................................................... 69
2.6.1 Overview ..................................................................................................................................... 69
2.6.2 Sequence of operations .............................................................................................................. 72
2.6.3 Examples with manual swivel ..................................................................................................... 73
2.6.4 Calibrating the electronic workpiece probe................................................................................. 74
2.6.5 Setting the edge .......................................................................................................................... 76
2.6.6 Edge measurement..................................................................................................................... 78
2.6.7 Measuring a corner ..................................................................................................................... 80
2.6.8 Measuring a pocket and hole...................................................................................................... 83
2.6.9 Measuring a spigot...................................................................................................................... 90
2.6.10 Aligning the plane........................................................................................................................ 95
2.6.11 Defining the measurement function selection............................................................................. 97
2.6.12 Corrections after measurement of the zero point ....................................................................... 98
2.7 Work offsets .............................................................................................................................. 100
2.7.1 Display active zero offset .......................................................................................................... 101
2.7.2 Displaying the work offset "overview" ....................................................................................... 102
2.7.3 Displaying and editing base zero offset .................................................................................... 103
2.7.4 Displaying and editing settable zero offset ............................................................................... 104
2.7.5 Displaying the zero offset details. ............................................................................................. 105
2.7.6 Deleting a work offset................................................................................................................ 106
2.7.7 Measuring the workpiece zero .................................................................................................. 107
2.8 Monitoring axis and spindle data .............................................................................................. 108
2.8.1 Specify working area limitations................................................................................................ 108
2.8.2 Editing spindle data................................................................................................................... 109
2.9 Displaying setting data lists....................................................................................................... 110
2.10 Handwheel assignment............................................................................................................. 111
2.11 MDA .......................................................................................................................................... 113
2.11.1 Loading an MDA program from the Program Manager ............................................................ 113
2.11.2 Saving an MDA program........................................................................................................... 114
2.11.3 Executing an MDA program...................................................................................................... 115
2.11.4 Deleting an MDA program......................................................................................................... 116
3 Execution in manual mode..................................................................................................................... 117
3.1 General...................................................................................................................................... 117
3.2 Selecting a tool and spindle ...................................................................................................... 117
3.2.1 T, S, M windows........................................................................................................................ 117
3.2.2 Selecting a tool.......................................................................................................................... 119
3.2.3 Starting and stopping a spindle manually ................................................................................. 120
3.2.4 Position spindle ......................................................................................................................... 121
3.3 Traversing axes......................................................................................................................... 122
3.3.1 Traverse axes by a defined increment...................................................................................... 122
3.3.2 Traversing axes by a variable increment .................................................................................. 124
3.4 Positioning axes ........................................................................................................................ 125
3.5 Swiveling ................................................................................................................................... 126
3.6 Simple face milling of workpiece...............................................................................................130
3.7 Default settings for manual mode ............................................................................................. 133
4 Machining the workpiece ....................................................................................................................... 135

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4.1 Starting and stopping machining................................................................................................135
4.2 Selecting a program...................................................................................................................136
4.3 Testing a program......................................................................................................................137
4.4 Displaying the current program block ........................................................................................138
4.4.1 Current block display .................................................................................................................138
4.4.2 Displaying a basic block.............................................................................................................139
4.4.3 Display program level ................................................................................................................140
4.5 Correcting a program .................................................................................................................141
4.6 Repositioning axes.....................................................................................................................142
4.7 Starting machining at a specific point ........................................................................................143
4.7.1 Use block search .......................................................................................................................143
4.7.2 Continuing program from search target .....................................................................................145
4.7.3 Simple search target definition...................................................................................................145
4.7.4 Defining an interruption point as search target..........................................................................146
4.7.5 Entering the search target via search pointer............................................................................147
4.7.6 Parameters for block search in the search pointer ....................................................................148
4.7.7 Block search mode ....................................................................................................................149
4.8 Intervening in the program sequence ........................................................................................151
4.8.1 Program control..........................................................................................................................151
4.8.2 Skip blocks.................................................................................................................................153
4.9 Overstore ...................................................................................................................................154
4.10 Editing a program.......................................................................................................................156
4.10.1 Searching in programs...............................................................................................................157
4.10.2 Replacing program text..............................................................................................................158
4.10.3 Copying/pasting/deleting a program block.................................................................................159
4.10.4 Renumber program....................................................................................................................160
4.10.5 Opening a second program .......................................................................................................160
4.10.6 Editor settings ............................................................................................................................162
4.11 Displaying G Functions and Auxiliary Functions........................................................................163
4.11.1 Selected G functions..................................................................................................................163
4.11.2 All G functions............................................................................................................................165
4.11.3 Auxiliary functions ......................................................................................................................166
4.12 Displaying the program runtime and counting workpieces........................................................169
4.13 Setting for automatic mode........................................................................................................170
5 Simulating machining............................................................................................................................. 173
5.1 Overview ....................................................................................................................................173
5.2 Simulation before machining of the workpiece ..........................................................................179
5.3 Simultaneous recording before machining of the workpiece .....................................................181
5.4 Simultaneous recording during machining of the workpiece .....................................................182
5.5 Different views of a workpiece ...................................................................................................183
5.5.1 Plan view....................................................................................................................................183
5.5.2 3D view ......................................................................................................................................183
5.5.3 Side views..................................................................................................................................184
5.6 Editing the simulation display.....................................................................................................185
5.6.1 Entering blank details.................................................................................................................185

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5.6.2 Showing and hiding the tool path.............................................................................................. 185
5.7 Program control during the simulation ...................................................................................... 186
5.7.1 Changing the feedrate............................................................................................................... 186
5.7.2 Simulating the program block by block ..................................................................................... 187
5.8 Changing and adapting a simulation graphic............................................................................ 188
5.8.1 Enlarging or reducing the graphical representation .................................................................. 188
5.8.2 Panning a graphical representation .......................................................................................... 189
5.8.3 Rotating the graphical representation....................................................................................... 190
5.8.4 Modifying the viewport .............................................................................................................. 191
5.8.5 Defining cutting planes.............................................................................................................. 192
5.9 Displaying simulation alarms..................................................................................................... 193
6 Creating G code program ...................................................................................................................... 195
6.1 Graphical programming............................................................................................................. 195
6.2 Program views .......................................................................................................................... 196
6.3 Program structure ..................................................................................................................... 199
6.4 Basics........................................................................................................................................ 200
6.4.1 Machining planes ...................................................................................................................... 200
6.4.2 Current planes in cycles and input screens .............................................................................. 200
6.4.3 Programming a tool (T) ............................................................................................................. 201
6.5 Generating a G code program .................................................................................................. 202
6.6 Blank input ................................................................................................................................ 203
6.7 Machining plane, milling direction, retraction plane, safe clearance and feedrate (PL, RP,
SC, F)........................................................................................................................................ 205
6.8 Selection of the cycles via softkey ............................................................................................206
6.9 Calling technology functions ..................................................................................................... 211
6.9.1 Hiding cycle parameters............................................................................................................ 211
6.9.2 Setting data for cycles............................................................................................................... 211
6.9.3 Checking cycle parameters....................................................................................................... 212
6.9.4 Changing a cycle call ................................................................................................................ 212
6.9.5 Additional functions in the input screens................................................................................... 213
6.10 Measuring cycle support ........................................................................................................... 214
7 Creating a ShopMill program ................................................................................................................. 217
7.1 Program views .......................................................................................................................... 218
7.2 Program structure ..................................................................................................................... 222
7.3 Basic information....................................................................................................................... 223
7.3.1 Machining planes ...................................................................................................................... 223
7.3.2 Polar coordinates ...................................................................................................................... 224
7.3.3 Absolute and incremental dimensions ...................................................................................... 224
7.4 Creating a ShopMill program ....................................................................................................226
7.5 Program header ........................................................................................................................ 227
7.6 Generating program blocks....................................................................................................... 228
7.7 Tool, offset value, feed and spindle speed (T, D, F, S, V) ........................................................ 229
7.8 Defining machine functions....................................................................................................... 231