Siemens SINUMERIK 808D User manual

© Siemens AG 2017. All rights reserved
01/2017 1
SINUMERIK
SINUMERIK 808D, SINUMERIK 808D ADVANCED
Programming and Operating Manual (Manual Machine Plus
(MM+), Turning)
User Manual
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.

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Preface
Applicable products
This manual is valid for the following control systems:
Control system
Software version
SINUMERIK 808D ADVANCED T (Turning)
SINUMERIK 808D ADVANCED M (Milling)
V4.7.4: PPU161.3/PPU160.2 with spindle/feed servo system
SINUMERIK 808D (Turning)
SINUMERIK 808D (Milling)
V4.7.4: PPU141.2 with feed servo system
Documentation components and target audience
End-user documentation
Target audience
Programming and Operating Manual (Turning) Programmers and operators of turning machines
Programming and Operating Manual (Milling)
Programmers and operators of milling machines
Programming and Operating Manual (ISO Turning/Milling)
Programmers and operators of turning/milling machines
Programming and Operating Manual (Manual Machine Plus
(MM+), Turning)
Programmers and operators of turning machines
Diagnostics Manual Mechanical and electrical designers, commissioning engi-
neers, machine operators, and service and maintenance
personnel
Manufacturer/service documentation
Target audience
Commissioning Manual Installation personnel, commissioning engineers, and ser-
vice and maintenance personnel
Function Manual
Mechanical and electrical designers, technical professionals
Parameter Manual
Mechanical and electrical designers, technical professionals
Service Manual Mechanical and electrical designers, technical profession-
als, commissioning engineers, and service and maintenance
personnel
Readme file
Third-party software - Licensing terms and copyright information
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
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
Country
Hotline
1)
Further service contact information:
•Worldwide Web site:
https://support.industry.siemens.com/cs/ww/en/
•Chinese Web site:
http://www.siemens.com.cn/808D
Germany
[phone]
China [phone]
1) You can find more hotline information at the worldwide Web site given above.
EC Declaration of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at
http://www.siemens.com/automation/service&support.
Here, enter the number "
67385845
" as the search term or contact your local Siemens office.

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Table of contents
Preface...................................................................................................................................................................2
1 Fundamental safety instructions ..............................................................................................................................4
1.1 General safety instructions......................................................................................................................4
1.2 Industrial security ....................................................................................................................................4
2 Turning on, Reference Point Approach....................................................................................................................5
3 Setting-up...............................................................................................................................................................6
3.1 Measuring tools .......................................................................................................................................6
3.2 Limit stops ...............................................................................................................................................8
3.2.1 Setting and activating/deactivating limit stops .........................................................................................9
3.2.2 Turning against a stop...........................................................................................................................11
3.3 Setting the workpiece zero ....................................................................................................................12
4 Manual machining................................................................................................................................................. 13
4.1 Fundamentals of manual machining......................................................................................................13
4.2 Display and operator control options in the main screen.......................................................................13
4.2.1 Toggling the display...............................................................................................................................16
4.2.2 Machining with the handwheels.............................................................................................................18
4.2.3 Setting the increment weighting for the handwheel...............................................................................18
4.2.4 Machining with axis direction switch......................................................................................................18
4.2.5 Spindle advance/reverse.......................................................................................................................19
4.2.6 Tool change...........................................................................................................................................19
4.2.7 Changing the feedrate/spindle value.....................................................................................................20
4.2.8 Changing the feedrate/spindle type.......................................................................................................21
4.2.9 Change the speed limitation for constant cutting rate............................................................................22
4.3 Manual machining with machining types ...............................................................................................23
4.3.1 Axis-parallel traversal ............................................................................................................................23
4.3.2 Manual taper turning..............................................................................................................................24
4.3.3 Manual radius turning............................................................................................................................25
4.3.3.1 Radius turning type A ............................................................................................................................27
4.3.3.2 Radius turning type B ............................................................................................................................27
4.3.3.3 Radius turning type C............................................................................................................................28
4.4 Manual machining using cycles (functions) ...........................................................................................28
4.4.1 Principle operating sequence ................................................................................................................28
4.4.2 General parameters...............................................................................................................................31
4.4.3 Manual drilling centered ........................................................................................................................32
4.4.4 Manual thread tapping...........................................................................................................................35
4.4.5 Manual grooving/parting........................................................................................................................37
4.4.5.1 Groove cycle - single .............................................................................................................................37
4.4.5.2 Groove cycle - multiple..........................................................................................................................39
4.4.5.3 Extended grooving ................................................................................................................................41
4.4.5.4 Multiple extended grooving....................................................................................................................44
4.4.6 Manual thread cutting............................................................................................................................45
4.4.6.1 Thread cutting .......................................................................................................................................46
4.4.6.2 Thread recutting ....................................................................................................................................49
4.4.7 Roughing cycles ....................................................................................................................................51
4.4.7.1 Roughing cycle A ..................................................................................................................................52
4.4.7.2 Roughing cycle B ..................................................................................................................................55
4.4.7.3 Roughing cycle C ..................................................................................................................................57
4.4.7.4 Roughing cycle D ..................................................................................................................................59
4.4.7.5 Roughing cycle E ..................................................................................................................................61
4.4.7.6 Roughing cycle F...................................................................................................................................63
4.4.7.7 Roughing cycle, free contour.................................................................................................................65
4.4.7.8 Execute a roughing cycle ......................................................................................................................68
5 Machining the machining step program manually...................................................................................................69
5.1 Tool change in the machining step program..........................................................................................73

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5.2 Teach In................................................................................................................................................ 75
5.3 Simulate machining............................................................................................................................... 77
5.4 Executing the machining step program................................................................................................. 78
6 Messages .............................................................................................................................................................80
1
Fundamental safety instructions
1.1
General safety instructions
WARNING
Danger to life if the safety instructions and residual risks are not observed
If the s
afety instructions and residual risks in the associated hardware documentation are not observed, accidents involving
severe injuries or death can occur.
•Observe the safety instructions given in the hardware documentation.
•
Consider the residual risks for the risk evaluation.
WARNING
Danger to life or malfunctions of the machine as a result of incorrect or changed parameterization
As a result of incorrect or changed parameterization, machines can malfunction, which in turn can lead to injuries or death.
•Protect the parameterization (parameter assignments) against unauthorized access.
•
Respond to possible malfunctions by applying suitable measures (e.g. EMERGENCY STOP or EMERGENCY OFF).
1.2
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial secur
ity functions that support the secure operation of plants,
systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement
– and
continuously maintain
– a holistic, state-of-the-
art industrial security concept. Siemens products and solutions only represent
one component of such a concept.
The customer is responsible for preventing unauthorized access to its plants, systems, machines and networks. Systems,
machines and components should only be connected to the enterprise network or the internet if and to the extent necessary
and with appropriate security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into account. For more information about
industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions
undergo continuous development to make them more secure. Siemens strongly
recommends to apply product updates as soon as available and to always use the latest product versions. Use of product
versions that are no longer supported, and failure to apply lat
est updates may increase customer’s exposure to cyber
threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).

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WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe operating states in your system that
may lead to death, serious injury, and property damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the
installation or machine.
•Make sure that you include all installed products into the holistic industrial security concept.
•Protect files stored on exchangeable storage media from malicious software by with suitable protection measures, e.g.
virus scanners.
2
Turning on, Reference Point Approach
Note
If the controller has already been preconfigured
to Manual Machine Plus (MM+) by the machine manufacturer, the desired
operating area is activated once the controller has been started up.
This operating area 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 MM+.
1.
Press this key on the machine control panel to open the "JOG" window.

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2.
Press this softkey to open the MM+ operating area.
3.
If the axes have not approached the reference point, press this key to change to the
"REF.POINT" window for reference point approaching operation; otherwise, skip this step.
For more information on refer
ence point approaching, see Chapter "Switching on and refer-
encing
" of the SINUMERIK 808D/SINUMERIK 808D ADVANCED Programming and Oper-
ating Manual (Turning).
4.
Press this softkey to exit the operating area.
Note
The pictures in the parameterization screenforms depend on the
setting of the machine data by the machine manufacturer,
that is, display of the tool position before or behind the center of rotation with regards to the turret head.
3
Setting-up
3.1
Measuring tools
Functionality
You can measure tools manually in the MM+ operating area. In this case, the manual tool measurement function accesses
the tool list data.
Note
To access the tool list, proceed as follows:
→

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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 following hardkey. If this key is pressed, the tool will be changed.
Note
First approach a machine position whe
re the tool change can be performed without danger.
Operating sequence
Proceed as follows to measure the tool for the X axis of the loaded turning tool.
1.
Press this softkey. The following screen appears.
2.
Press this softkey.
The screen for measuring the X axis (L1) appears.
3.
Check that the current tool number appears in the display fiel
d for the tool, since the calibra-
tion 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 (longitudin
al turn-
ing) 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 this hardkey.
The controller then automatically calculates the corresponding tool offset (in the radius) and
displays this
as value "L1" in the screen form.

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9.
Press this 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 di
s-
played as the actual position in the position display
of the tool measurement screen.
10.
Press this softkey.
The scr
een 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.
Press this so
ftkey to return to the main screen for MM+.
Note
New offset settings lost
If you exit the screen form in step 8, the new offset will not take effect.
3.2
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 MM+ 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 MM+ 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.

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3.2.1
Setting and activating/deactivating limit stops
Functionality
In the main screen of MM+, limit stops can be entered into the input fields "-X/-Z/+X/+Z".
In the following screen, the cursor is located in the desired input field (with an orange background).
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.

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All of the limit stops are set in the following screen.
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 above hardkey 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 (for example, <-Z> or <+X/-X/+Z>).
–Press the above 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 above hardkey.
Here, you can select ON or OFF.
Note
After activating a limit stop, set MD201
52[59] = 1 to retain the current setting even after you press the following key.