SINUMERIK – the turning and milling solution for the shopfloor

Answers for industry.

How can workpieces be machinedquickly and even more cost-effectively?

Contents

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CNC solutions for the shopfloor using SINUMERIK 03

SINUMERIK – from simple up versatile, the perfect CNC platformSINUMERIK 828D – compact, powerful, simply brilliantSINUMERIK 840D sl – open, flexible, powerful – packed with innovations

0405

SINUMERIK Operate – the new user interface Operation, programming and setup – same look and feel, whether turning or milling

06 – 10

Milling with SINUMERIK 10

Turning with SINUMERIK 12

Data and facts – milling functions, SINUMERIK Operate Data and facts – turning functions, SINUMERIK Operate

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Tips and tricks when using SINUMERIK Operate 16 – 19

Special expertise for the shopfloor

Behind SINUMERIK, there are machine tool control systems, drives and mo- tors, as well as complete solutions for machine tool automation. Used in many industries, this is the expertise that we have specifically implemented for the shopfloor and in turn, for your applications.

Two control systems for turning and milling

With SINUMERIK 828D and SINUMERIK 840D sl, Siemens offers you two numeri-cal controls from the SINUMERIK family of control CNCs. They combine the flexibil-ity and benefits of conventional machin-ing with the productivity and cost-effec-tiveness of a CNC machine. Designed for the typical shopfloor, these solutions will decisively improve opera- tions with CNC turning and milling machines.

SINUMERIK Operate

The new SINUMERIK Operate user inter-face is now even more transparent and intuitive. It combines the well-known HMI Advanced, ShopMill and ShopTurn under one standard, innovative operating and programming interface. SINUMERIK Operate is equipped with a multitude of new and powerful functions and sets new standards when it comes to operation to achieve perfect usability. Programming and operation have never been so simple, tailored to the require-ments of trained operators in the field and easy-to-use, even for beginners.

Do you want everything to run smoothly on your shopfloor? Do you want to schedule and process your orders while

meeting and exceeding quality standards? Do you want to manufacture small batch sizes economically? Then SINUMERIK®

is the right choice for you.

CNC solutions for the shopfloor using SINUMERIK

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SINUMERIK – from simple to versatile, the perfect CNC platform

SINUMERIK 828D – compact, powerful, simple, and simply brilliant

This panel-based numerical control has been tailored to address sophisticated turning and milling machines that are typically used on the shopfloor. The range of applications extends from vertical and basic horizontal machining centers, up to slant bed lathes with ma-chining slides, equipped with Y-axis and counter-spindle. Both the operator panel and CNC are combined in a rugged and maintenance-free unit. With extremely small dimen-sions, the SINUMERIK 828D offers powerful CNC functionality, which sets new standards in the compact CNC class. Equipped with a comprehensive CNC programming package, the SINUMERIK 828D is optimally prepared for every global machine tool market. Addition-ally, technology-specific, pre-configured system software and intelligent service functions allow the costs for commission-ing and maintenance of the machines to be drastically reduced.

SINUMERIK 828D – at a glance:

◾ Compact CNC operator panel with horizontal and vertical operator panel layout options

◾ Up to 6 axes/spindles (milling) and 8 axes/spindles (turning) in one machining channel

◾ 80 bit NANOFP precision ◾ Operator panel with 10.4” TFT color display

◾ Programming support, programGUIDE ◾ Machining step programming ShopMill/ShopTurn

◾ Operation and programming support using animated help graphics with moving images

◾ Setup with innovative measuring cycles ◾ SINUMERIK MDynamics for 3-axes (milling version)

◾ Customized system software versions for turning and milling with parameter pre-assignment

◾ Process monitoring using text messages (SMS)

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SINUMERIK 840D sl – open, flexible, powerful, and packed with innovation

SINUMERIK 840D sl offers modularity, openness and flexibility, as well as standard structures for operator control and programming. It provides a system platform with leading-edge functions for almost every technology.Integrated into the SINAMICS S120 drive, and supplemented by the SIMATIC S7-300 automation system, the SINUMERIK 840D sl is a complete, digital CNC system.SINUMERIK 840D sl sets itself apart as a result of the high degree of flexibility, highest dynamic performance and preci-sion, as well as optimum integration into networks.

SINUMERIK 840D sl – at a glance:

◾ Drive-based CNC for sophisticated and demanding solutions

◾ Ideal for up to 31 axes/spindles in 10 machining channels

◾ 80 bit NANOFP precision ◾ 7.5”/10”/12”/15” TFT operator panel fronts

◾ Programming support using programGUIDE

◾ Machining step programming ShopMill/ShopTurn

◾ Operator control and programming using animated graphics

◾ Setup using innovative measuring and setting-up cycles

◾ SINUMERIK MDynamics 3-axis/5-axis technology packages

◾ Several operator panels can be connected to a CNC

◾ Tool management functions ◾ SINUMERIK Safety Integrated safety functions

◾ Multi-channel programming – double editor – programSYNC for time synchronization

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SINUMERIK Operate – for efficient machine operation

Highest degree of operator-friendliness

The new SINUMERIK Operate user interface is equipped with a multitude of new and powerful functions. This allows machin-ing step and high-level language programming to be combined under one system interface; therefore, facilitating a very logical and intuitive NC programming and production planning.

Faster from the drawing to the finished workpiece

Whether you are setting up, programming or machining parts – with SINUMERIK Operate, you are supported by a visual, user-friendly display showing the various tasks as well as graphical help displays and animation when operating your machine.

With Animated Elements for milling and turning applications

SINUMERIK Operate – advantages at a glance:

◾ Standard user interface for all new SINUMERIK CNC systems

◾ Perfect operating and programming usability ◾ Transparent, can be intuitively used ◾ Optimum display using a modern Windows style ◾ With new powerful functions for setup, programming, tool and program management

◾ Programming solutions to address each and every requirement and the highest productivity

◾ New functions for complete machining

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Programming the way you like it

SINUMERIK high-level language with programGUIDE – CNC programming for the highest degree of productivity

The SINUMERIK high-level language with programGUIDE has been developed to provide the maximum degree of flexibility and short machining times. It is well-suited for medium- to large-batch sizes.

◾ programGUIDE guarantees a maximum of productivity and flexibility when it comes to programming, combined with innovative technology and machining cycles

◾ CNC language with high-level programming commands ◾ programGUIDE with graphic cycle support screens including tooltip (brief, context-related information)

◾ Online ISO dialect interpreter is available

Machining step programming with ShopMill and ShopTurn

ShopMill and ShopTurn machining step programming is the tailored programming solution for the production of individual parts and small-batch quantities. In addition to programGUIDE, the unique machining step programming allows the shortest programming times to be achieved.

◾ Machining steps are clearly displayed without requiring any knowledge about G-code

◾ Technology functions are simply linked using geometrical elements

◾ The workpiece is dynamically displayed during programming

SINUMERIK Operate offers unique programming methods

for every application. This includes the ShopMill/ShopTurn

machining step programming, as well as the SINUMERIK

high-level language with programGUIDE. ISO-code program-

ming is also supported.

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Intuitive programming, operation and setup – whether milling or turning

Parameters, which are entered into a CNC on a daily basis, control machine

motion. Using static help graphics, this motion can only be displayed with

some restrictions. This is the reason that SINUMERIK with Animated Elements

offers a completely new level of user-friendliness when it involves data

input. It completely redefines the term graphical programming and opera-

tion, thanks to a unique type of display using moving image sequences.

Transparent tool and program management also provide useful support.

Turning and milling with the same look and feel

Intelligent HMI functions support you with the highest effi- ciency in your daily work. The optimum display in the modern Windows style is also user-oriented. In addition, the user interface sets new standards when it comes to graphic support. In this case, Animated Elements provide a helpful function – they predict each machining step in the form of a graphically animated simulation. But the best is yet to come: whether mill-ing or turning, the user interface is almost identical and allows you to change between a turning and milling machine with extremely short training time, facilitating fast, productive entry into the system.

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Tool and program management made easy

SINUMERIK offers you a modern and transparent tool and program management functionality. The tool list has a con- figurable display and uses context-dependent functions with self-explanatory symbols that can be intuitively used and displayed – for efficient tool data management.

Using innovative program management, you can create sub- folders for workpieces in local drives and directly access external data storage media. Users benefit from fast program preview, user-friendly data transfer, as well as simple program handling.

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Our SINUMERIK controls, in conjunction with the new user inter-

face are precisely the right choice if you are looking for a solution

with comprehensive functions for milling. As a result of their

outstanding performance and flexibility, the controls are also ad-

mirably suited for the tool- and mold-making industries, and with

the SINUMERIK 840D sl, also five-axis simultaneous machining,

too. The SINUMERIK Operate user interface, ShopMill and

programGUIDE are designed so that machines can be simply

operated and workpieces easily programmed. You benefit from

standard and integrated CNC solutions with the same look and

feel, no matter if you are milling or turning.

Milling with SINUMERIK

Extended setup functions

With the right tools, machine tool setup is a simple procedure. The functions in manual operation mode allow the machine to be quickly set up for machining exactly what is required. For example, this includes determining the workpiece position in the machine, as well as measuring the tools used. Manual and automatic measuring functions are available to measure both workpiece and tool.

◾ Automatic measuring cycle in programGUIDE and ShopMill ◾ Input screen forms with graphic support and automatic logging of the measurement results

Swiveling during setup

Complex workpieces can be machined in one clamping opera-tion through simple and fast handling. Different kinematics can be very easily set up. Swiveling can be realized axis-by-axis and directly including the optional coordination rotation.

Measuring in JOG on a five-axis milling machineAligning the rotary axis over two holes

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Technology cycles for standard machining operations

Whether drilling, position pattern or milling – using the standard technology cycles, you can simply address a high percentage of the shopfloor programming requirements by parameterizing practical cycles. You can also effectively use special cycles from the CAM area – such as trochoidal milling and plunge milling. Using the new multi-edge cycle, by enter-ing the number of edges or width over flats, you can generate a multi-edge with any number of edges.

◾ Centering, drilling, reaming, tapping, thread-cutting ◾ Position pattern – line, grid and circle ◾ Milling cycles for pockets, holes, grooves, spigots and multi-edge

SINUMERIK MDynamics – milling expertise as a package

SINUMERIK MDynamics combines all of our expertise around milling, the powerful SINUMERIK CNC hardware, intelligent CNC functions and our unique CAD/CAM/CNC process-chain in technology packages for three-axis and five-axis milling. With Advanced Surface, SINUMERIK MDynamics guarantees perfect surfaces through innovative motion control and an optimized NC data compressor, fast adaptation to the workpiece, tool and program handling, and optimum machining using the flexible programGUIDE programming technique and ShopMill. This allows you to achieve the shortest programming times possible.

SINUMERIK Operate – milling at a glance

◾ User-friendly feature with a graphical machining step editor

◾ Perfect input support using animated elements ◾ Dynamic broken-line graphics for complete workpiece and cycle screen forms

◾ Wide selection of standard drilling, milling and turning cycles

◾ Contour computer makes it easy to input geometrical workpiece contours

◾ Cycles for contour milling with residual material detection

◾ Process measuring for workpiece and tool ◾ High-speed cutting (HSC) functions and complete machining with swivel and transformation

◾ Powerful 2-D and 3-D CNC simulation

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With the combination of modern CNC hardware and SINUMERIK

Operate, even sophisticated turning operations can be easily and

reliably mastered. Even for complex machines with B-axis and

counter-spindle, you always have operation and programming

under control. With the SINUMERIK Operate user interface, you

have various programming types available that you can use, such

as the ShopTurn machining step programming or the SINUMERIK

high-level language with programGUIDE. Our programGUIDE is the

perfect combination of SINUMERIK CNC programming language

and the parameterization of technology cycles. Even multi-channel

machining operations are now easy-to-program and synchronize

thanks to programSYNC.

Turning with SINUMERIK

Optimal support at your fingertips

Whether you are setting up, programming or machining, SINUMERIK Operate, and especially ShopTurn, optimally reflect the way the machine operator views the work sequence. Visual, user-orientated presentation of job tasks in line with user requirements support you when operating the system using graphical help displays and animation. The machining plan displays every step – such as roughing, finishing, drilling, mill-ing, tapping or grooving. Would you like additional support for operation and programming? Not a problem – complete docu-mentation can be called up at the control in a context-sensitive fashion so that you are always on top of the situation.

Setup is easy

With SINUMERIK Operate, tool and workpiece setup are straightforward thanks to the functions in manual mode. These include determining the workpiece zero points in the machine, as well as measuring the tools used. “Manual measuring” and “automatic measuring” are available as functions. After setup, all of the tools are clearly listed in a tabular form in the tool manager. You even have various views for the work offsets, e.g. all active offsets are displayed in one window.

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Contour computer in combination with turning/milling cycles

Special technology cycles are available for standard elements such as grooves. When things get a little bit more difficult, us-ing the contour calculator, you can generate any geometrical contours directly at the machine and then link these with the contour turning or contour milling cycles. Programming is completed in just two work steps.

◾ ”Painting by numbers“ – even for difficult contours ◾ Converting contours and position patterns into the DXF format using the CAD reader with further processing in the contour calculator

◾ Linking contours with stock removal cycles ◾ Automatic residual material detection

From the real environment – fast and effective plunge turning

Generally, difficult contours involving elements with negative gradients require a large number of tools, for example to machine from the left or right. This involves time and resources when making the appropriate measurements, and normally the number of tools is limited by the turret. With plunge and plunge turning cycles, you can machine the complete contour using just one tool and this is even more productive as setup and tool change are eliminated. When programming, just as usual, you generate the contour and then link this with the plunge turning cycle. No additional programming is required – and you move quickly from the drawing to the workpiece.

SINUMERIK Operate – turning at a glance

◾ User-friendly feature using a graphical machining step editor

◾ Perfect input help using animated elements ◾ Dynamic broken-line graphics for complete work-piece and cycle screen forms

◾ Wide selection of standard drilling, milling, turning and plunge turning cycles

◾ A geometry computer makes it simpler to input workpiece contours

◾ Contour turning and milling with residual material detection

◾ Process measuring for workpiece and tool ◾ Complete machining with counter-spindle and transformation at the face and peripheral surfaces, as well as machining inclined surfaces (B-axis)

◾ Powerful 2-D and 3-D CNC simulation ◾ programSYNC for multi-channel programming

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Milling functions SINUMERIK Operate – data and facts

Graphical programming, ShopMill•Transparent, clearly structured

programming in machining steps•Programming without DIN/ISO

know-how•Easily understandable symbols to

display the machining steps•Linking of contours with solid

machining cycles•Linking of drilling and milling

operations with position patterns•Automatic measuring cycles for

workpiece, tool•Simplemodification,insertionand

deletion of machining steps•Significantreductionofthepro-

gramming time when compared to DIN/ISO programming

•Dynamic broken-line graphics for displaying workpieces true-to-scale

• Dynamic help graphics as input support for cycle parameters

Contour programming• Powerful contour calculator for creating

contours in the milling plane• Automaticcalculationofpartiallydefined

geometrical elements• True-to-scale representation of contours with

up to 255 contour elements• ImportingDXFfilesviaanoptionalCADreader

is possible

Machining cyclesMilling cycles for free contours• Solid machining of contour pockets with

up to 12 isolated contours• Machining of contour spigots with up to

12 isolated contours• Automatic detection and follow-up machining

of residual material• Automaticormanualspecificationof

machining start point with possibility for pre-drilling

• Plunge strategy: linear, diagonal, helical

Milling cycles for standard contours• Multiple-edge spigots• Face milling cycle with lateral limitation• Rectangular and circular pockets with

different plunge strategies• Rectangular and circular spigots• Longitudinal and circular grooves• Thread milling

• Combined countersinking/thread milling• Engraving of any texts• Open groove for trochoidal milling and

plunge milling

Drilling cycles• Centering, reaming, boring• Boring with chip break and stock

removal function• Tapping with chip break and stock

removal function

High-speed settings• Moldmaking cycle for the selection of the

machining type and contour tolerance

Position pattern• Any position pattern in the milling plane• Position patterns such as line, circle or grid

Complete machiningSwivel cycle• Any drilling and milling machining in swiveled

machining planes on 5-axis milling machines• Flexible input of swivel angle in the workpiece

coordinate system (axis, solid or projection angle) or direct axis input

Multi-channel programming 840D sl• Double editor

DIN/ISO programming and programGUIDE• Fullprogrameditortoflexiblygenerate

DIN/ISO programs• programGUIDE for standard machining cycles• Input support for automatic measuring cycles

Simulation/simultaneous recording• 5-axis simulation• Powerful simulation of machining steps

and DIN/ISO programs• Presentation in plan view, 2-side view and

3-D view• Simultaneous recording in the automatic mode

Tools• Tool types shown as symbols• Tool and magazine data on one screen

including details• Tool name as plain text or number with

max. 24 characters• Efficientmanagementofthetooldata

including all the details and replacement tool handling

Program management• Direct access to external data storage media

including network drives• Part programs with plain text,

max. 24 characters• Subdirectories for workpieces in local drives• Program preview

Work offsets• All active – adjustable and programmable –

WO in one overview• Rotation, scaling, mirroring – also as screen• Display of the offsets of the active swivel

data set

Setup functions• Menu-prompted probing function to

determine work offset, also in swiveled machining planes

• Tool measurement using scratching or tool probe

• Face milling cycle for workpiece preparation• Swivel cycle for setup and measurement tasks

Automatic functions• Blocksearchalsofordefinedmachining

operations in position patterns• Traversing path display of machining steps

in G-code (basic block display)• Feed reduction using program control for

rapid traverse motion

Accessories• PC training and programming software• CAD reader for the PC

CNC systemsSINUMERIK Operate is available on the following CNC systems:• SINUMERIK840Dsl • SINUMERIK 828D

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Graphical programming•Transparent, clearly structured

programming in machining steps•Programming without DIN/ISO

know-how•Easily understandable symbols for

displaying the machining steps•Linking of contours with stock

removal cycles•Linking of drilling and milling

operations with position patterns•Automatic measuring cycles for

workpiece, tool•Simplemodification,insertionand

deletion of machining steps•Significantreductionofthe

programming time when compared to DIN/ISO programming

•Dynamic broken-line graphics for displaying workpieces to scale

• Dynamic help graphics as input support for cycle parameters

Contour programming• Powerful contour calculator for creating

turning and milling contours• Automaticcalculationofpartiallydefined

geometrical elements• Automatic calculation of grinding allowances,

also with negative values• ImportingDXFfilesviaanoptionalCADreader

is possible

Machining cyclesStock removal cycle• Stockremovalforfreelydefinablecontours• Axis- and contour-parallel roughing and finishing

• Automatic detection of residual material• Stock removal cycle for plunge cutting and plungeturningoffreelydefinablecontours

• Freelydefinableblankcontour

Grooving/undercut cycles• Grooving cycle for any trapezoidal grooves• Undercut cycle for any threads and DIN

threads• Undercut shape E, shape F

Thread-cutting cycle• Face, longitudinal and tapered threads• Constant and variable pitch• Linear and degressive infeed• Multiple-thread machining

Drilling cycles• Centering, deep-hole drilling and tapping

with stationary tools• Any drilled holes on face and peripheral

surfaces with driven tools

Milling cycles• Any milling operations on face and

peripheral surfaces• Standard geometry such as circular and

rectangular pockets• Multi-edge• Solid machining cycle for free geometries

with residual material detection• Engraving any texts• Open groove for trochoidal milling and

plunge milling

Position patterns• Any position patterns on face and peripheral

surfaces• Position patterns such as line, circle or grid

Counter-spindle machining• Counter-spindle cycle with graphic input• Automatic workpiece transfer

Swiveling B-axis• Milling and drilling on swiveled planes• Turning with swiveled tools

Multi-channel programming, 840D sl• Double editor and programSYNC

DIN/ISO programming and programGUIDE• Fullprogrameditorforflexiblecreationof

DIN/ISO programs• programGUIDE with standard machining

cycles• Input support for automatic measuring

cycles (optional)

Simulation• Powerful simulation of machining steps

and DIN/ISO programs• Presentation in turning plane, face and

3-D view

Program management• Direct access to external data storage

media including network drives• Part programs with plain text,

max. 24 characters• Subdirectories for workpieces in local drives• Program preview

Work offsets• All active – adjustable and programmable –

WO in one overview• Rotation, scaling, mirroring – also as screen

Tools• Tool types shown as symbols• Tool and magazine data on one screen

including details• Tool name as plain text or number with

max. 24 characters• Efficientmanagementofthetooldata

including all the details and replacement tool handling

Setup functions• Menu-prompted scratching function to

determine work offset• Tool measurement by scratching or with probe• Universal turning cycle for applications such

as hollowing out soft end pieces

Automatic functions• Blocksearchalsofordefinedmachining

operations in position patterns• Display of traversing paths of machining steps

in G-code (basic block display)

Accessories• PC training and programming software• CAD reader for the PC

CNC systemsSINUMERIK Operate is available on the following CNC systems:• SINUMERIK840Dsl • SINUMERIK 828D

Turning functions SINUMERIK Operate – data and facts

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Tips and tricks for SINUMERIK Operate

See exactly how the helpful functions of SINUMERIK Operate

can make your production environment even more efficient.

The best tips and tricks for the new SINUMERIK user interface

are explained.

Language-independent help can be called up in every screen using the Help key.

Vertical softkeys on the right-hand side can all be used as switch-on/switch-off element.

”Grayed-out softkeys“ indicate that the function cannot be presently used.

Tips as ”simple“ help in every screen are displayed in red when incorrect entries are made on screen.

Using short film sequences, animated elements offer a high degree of user-friend-liness when it comes to operation and programming.

Select option with the insert key and/or using any other key.

Undo function with ”Insert“ – as long as an input key has not been pressed or data have not been accepted in the fields.

INSERT

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Calculator function can be called using the “=” function.

All cycles can be recompiled using the right arrow key.

Cycles can be edited without recompiling using:

INSERTSHIFT

Zero offsets can be written from the ShopTurn program header.

ShopTurn and ShopMill cycles can also be defined using parameters.

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Functions – softkeys – shortcut keys

Your overview of the most important shortcut keys

Insert key

INSERT

Edit mode of input fields or selection mode of combo boxes and toggle fields.These can be exited without any change by pressing Insert again.

INSERT

Undo function, as long as an input key has not been pressed or data have not been accepted in the fields.

Toggle key

SELECT

You can also directly change over toggle fields using the toggle key (Select) without opening them. You can scroll through them backwards using Shift-Toggle.

Cursor keys

Open/close folder, open/close program, open/close cycle

Various

INSERTSHIFT

Commenting out cycles and directly editing programGUIDE cycles

Calculator function

Help function

Control key

CTRL P Create screenshot

CTRL L Toggle between languages

CTRL C Copy

CTRL X Cut

CTRL V Insert

CTRL Y Repeat input (editor functionality)

CTRL ZUndo function – max. 5 lines in the editor (editor functionality)

CTRL A Select all (editor functionality)

CTRL Go to the start of program.

CTRL END Go to the end of program.

CTRL ALT DBackup log files on USB or Compact Flash (CF) card

Simulation/simultaneous recording

Shift: Shift cursor up/down and rotate in the 3-D screen

Shift cutout

CTRLor

Override +/– (simulation)

CTRL S Single block on/off (simulation)

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Want more information?

Everything you want to know about SINUMERIK CNC:www.siemens.com/sinumerik

Everything about shopfloor manufacturing:www.siemens.com/cnc4you

Information about CNC training:www.siemens.com/sinumerik/training

www.siemens.com/sinumerik

Subject to change without prior notice Order No.: E20001-A850-P610-V1-7600 Dispo 06311 WÜ/29070 GD.MC.MT.STAN.52.1.06 WS 01115.0Printed in Germany © Siemens AG 2011

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteris tics shall only exist if expressly agreed in the terms of contract.

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