spf arbeitsheft 6 0 eng - deliver.cnc-keller.net3.3 the sinumerik 802c control system...

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2nd edition 2015

All rights reservedReproducing or transferring even excerpts of text, pictures or diagrams without the prior written consent of the publisher is forbidden. This applies both to reproduction by photocopying or any other method and to transmission via films, tapes, records, working transparencies or other media.

Publisher: CNC KELLER GmbH, Vorm Eichholz 2, 42119 Wuppertal GermanyAuthor: Siegfried KellerUpdate and revision: Klaus ReckermannGraphics and typesetting: CNC KELLER GmbH

Order No.: HD-E-KSF600

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© CNC KELLER GmbH2

Table of contentsA General information ........................................................................................................................................ 4A.1 The four training levels ...................................................................................................................................... 4A.2 Operating modes in the training levels ................................................................................................................ 5B Operating instructions ................................................................................................................................... 6B.1 The start wizard.................................................................................................................................................. 6B.2 Symbols at the top right of the header ............................................................................................................. 6B.3 Additional functions ............................................................................................................................................ 6B.4 Mouse functions ................................................................................................................................................. 7B.5 Various operating concepts ............................................................................................................................... 71 The virtual 3D learning environment ....................................................................................................... 81.1 Shopfloor ............................................................................................................................................................ 91.1.1 Tour ............................................................................................................................................................... 91.1.2 How to measure and check! ...................................................................................................................... 101.1.3 Theoretical and practical aspects of the torque ....................................................................................... 141.1.4 Mechanical and hydraulic clamping .......................................................................................................... 161.2 Machine ............................................................................................................................................................ 181.2.1 Getting familiar with a CNC milling machine ............................................................................................ 181.2.2 This is how it works! ................................................................................................................................... 191.2.3 The 802C keyboard ................................................................................................................................... 211.3 Operation .......................................................................................................................................................... 221.3.1 Operating the CNC milling machine ......................................................................................................... 221.3.2 Programming and manufacturing.............................................................................................................. 251.4 How to prevent accidents ................................................................................................................................ 262 Programming with PALplus ....................................................................................................................... 282.1 Toggling between thetraining levels ............................................................................................................... 292.2 The operating mode DIN Multimedia / PAL Multimedia ................................................................................ 292.3 The G1/G2/G3 operating mode ...................................................................................................................... 302.3.1 G1 and G2/G3 with I and J ........................................................................................................................ 302.3.2 G1 and G2/G3 with R ................................................................................................................................. 302.3.3 Contour for importing into the PAL Simulator ........................................................................................... 312.4 The Setup operating mode .............................................................................................................................. 322.4.1 Invoking a tool ............................................................................................................................................ 322.4.2 Creating a tool ............................................................................................................................................ 322.4.3 Changing the magazine ............................................................................................................................. 332.4.4 Creating a magazine .................................................................................................................................. 332.5 The DIN Simulator / PAL Simulator operating mode ..................................................................................... 342.5.1 Cutting data for the tools ........................................................................................................................... 342.5.2 From operating mode G1/G2/G3 to the PAL Simulator ........................................................................... 352.5.3 The simulation types .................................................................................................................................. 362.5.3.1 The 2D simulation ................................................................................................................................. 362.5.3.2 The 3D simulation ................................................................................................................................. 372.5.4 Programming WITHOUT cycles ................................................................................................................ 382.5.4.1 Milling a rectangular pocket, circular pocket and grooves ................................................................ 412.5.4.2 Holes on drilling path and drilling circle .............................................................................................. 422.5.5 Programming WITH cycles ........................................................................................................................ 432.5.5.1 Cycles on one level .............................................................................................................................. 432.5.5.2 ZI, ZA and W for cycles on different levels ......................................................................................... 442.5.5.3 Milling and drilling cycles on different levels ....................................................................................... 452.5.6 Milling WITHOUT milling cutter radius correction .................................................................................... 462.5.6.1 Equidistant programming ..................................................................................................................... 462.5.6.2 Equidistant for non-tangential transitions ........................................................................................... 472.5.7 Milling WITH milling cutter radius correction (MRC) ................................................................................ 482.5.7.1 Basics of MRC ...................................................................................................................................... 482.5.7.2 Programming with MRC ....................................................................................................................... 492.5.7.3 MRC with linear approach and return function ................................................................................... 502.5.7.4 MRC with radial approach and return function ................................................................................... 512.5.8 Milling WITHOUT special contour functions............................................................................................. 522.5.9 Milling WITH special contour functions .................................................................................................... 53

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© CNC KELLER GmbH 3

2.5.9.1 Overview of contour functions ............................................................................................................. 532.5.9.2 Contour with rounding, chamfers, angles and radii ........................................................................... 542.5.9.3 Contour with absolute centre point and opening angle ..................................................................... 552.5.10 Determination of dimensions including adjusting dimensions on the workpiece .................................. 562.5.11 Milling with tool radius correction TR ........................................................................................................ 582.5.12 Program part repetition with G23 .............................................................................................................. 592.5.13 Milling with tool length correction TL ......................................................................................................... 602.5.14 Workpiece with contour functions, cycles and chamfer .......................................................................... 612.5.15 Subroutines ................................................................................................................................................. 622.5.16 The PAL-IHK final examination part II - sample 2008 ............................................................................. 642.5.17 Contour pocket with tenons ....................................................................................................................... 662.5.18 Complex workpieces .................................................................................................................................. 682.5.19 Setting up the machine .............................................................................................................................. 702.5.20 PAL turns into chips.................................................................................................................................... 742.5.20.1 General information .............................................................................................................................. 742.5.20.2 Cycles and subroutines ........................................................................................................................ 752.5.20.3 Data transfer ......................................................................................................................................... 752.5.21 Exam preparation ....................................................................................................................................... 763 Programming using control simulators ............................................................................................... 803.1 KELLER milling control simulators ................................................................................................................. 813.2 General information on the control system simulators .................................................................................. 823.3 The SINUMERIK 802C control system simulator .......................................................................................... 823.4 Examples of other milling control system simulators .................................................................................... 843.4.1 HEIDENHAIN iTNC 530* ........................................................................................................................... 843.4.2 SINUMERIK 840D ...................................................................................................................................... 864 Programming in the Graphical dialogue .............................................................................................. 884.1 KELLER CAD/CAM ......................................................................................................................................... 894.1.1 Structure ..................................................................................................................................................... 894.1.2 Pictographs for creating the geometry...................................................................................................... 894.1.3 Pictographs to create the workplan .......................................................................................................... 894.2 Workpiece GEO1 ............................................................................................................................................. 904.2.1 Programming with cycles ........................................................................................................................... 904.2.2 Graphical programming ............................................................................................................................. 914.2.2.1 Creating the GEO1 geometry .............................................................................................................. 914.2.2.2 Creating the workplan CAM1 ............................................................................................................... 924.2.2.3 Time saving due to automatic residual material detection ................................................................ 934.3 Workpiece GEO2 ............................................................................................................................................. 944.3.1 Creating the GEO2 geometry .................................................................................................................... 954.3.1.1 Creating the contour ............................................................................................................................. 954.3.1.2 Creating the circular pocket and the circle tenons ............................................................................. 974.3.1.3 Creating the drilling pattern .................................................................................................................. 974.3.2 Creating the workplan CAM2 .................................................................................................................... 984.3.2.1 Roughing surfaces................................................................................................................................ 984.3.2.2 Finishing contours .............................................................................................................................. 1004.3.2.3 Centring and drilling ........................................................................................................................... 1014.4 Workpiece GEO3 ........................................................................................................................................... 1024.4.1 Creating the GEO3 geometry .................................................................................................................. 1044.4.2 Creating workplan CAM3 ......................................................................................................................... 1064.5 From the workplan to the NC program ......................................................................................................... 1084.6 From the NC program to the machine .......................................................................................................... 1094.7 Exercises .........................................................................................................................................................1104.8 Applying CAD data .........................................................................................................................................1144.8.1 Applying the geometry ..............................................................................................................................1144.8.2 Workplan ....................................................................................................................................................1164.9 Work step: Partial contour ..............................................................................................................................1174.10 TeachIn / PlayBack .........................................................................................................................................1185 Clamping device ........................................................................................................................................... 120Keyboard assignment of the plus systems ................................................................................................. 122Glossary ....................................................................................................................................................................... 123

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Introduction

Since 1982, KELLER has been developing trendsetting CNC training software and has built up a proven track record as evidenced by nearly 6,000 customers and 90,000 systems supplied in over 76 countries.

We are pleased to be able to present the Version SYMplus 6.0, another new state-of-the-art software for turning and milling. SYMplus and the new workbooks combine to give you a product for CNC training that deserves to be termed innovative with regard to quality and quantity:

The 4-stage training pyramid provides a clear structure. In their redesigned and extended form, the work-books perfectly complement the various software systems.

This Virtual 3D learning environment consists of the operating modes Shopfl oor, Machine and Operation.The Shopfl oor operating mode provides interactive features to make you familiar with the environment of CNC machines, such as, e.g. measuring and inspection, clamping ...In the Machine operating mode, you can dismantle the machine completely and interactively learn to understand the functions of the individual components.The Operating mode is also particularly important: In this mode you can train almost as you would on a "real" machine and obtain important insights into practical CNC use, up to and including the virtual crash, which will really scare you.

In this training stage you will familiarise yourself with the basics of programming with G and M functions according to DIN 66025. PAL* defi nes coding with additional G commands and cycles using this standard as its basis.To make the introduction to CNC programming and exam preparation as easy and appealing for the learner as possible (hence the term "PALplus“), the training contents for programming in this stage are divided into three parts:The Multimedia operating mode offers interactive learning at your own pace. It includes a test to see how much you have learned, which you can repeat as many times as you wish.The G1 G2 G3 provides the best possible support for learning the elementary geometrical functions.The Simulator operating mode can be used for completely free programming and simulation. The scope of command in this mode can be set to 3 levels (see page 29).Note: The exercises contained in this workbook are based on the exam requirements accord-ing to "PAL 2009". This scope of commands is pre-set when the software is fi rst installed.A software expansion and an individual workbook are available for the expanded exam requirements according to "PAL 2012 with 3+2 axes".

This training stage provides the control system specifi c CNC advanced course.The control simulators are edited using the uniform, guided NC editor including numerous information images. The respective control systems can be learned perfectly in combination with the clear and comprehensible 3D simulation.

The CAD/CAM training level is an absolutely professional graphical programming system, which guarantees a smooth transition into production.Use the geometry section to enter even the most complicated contours in the least compli-cated manner with graphic support or transfer them from CAD (DFX or IGES 2D).In the CAM section, particular focus is put on the application of the automatic residual quantity detection: Ideal NC programs are available fast at a reduced machine run time despite com-plex tasks - due to the Graphical dialogue.

We hope you will enjoy working with the new Version SYMplus 6.0 in CNC theory, in virtual CNC practice and real production with CNC machines.

Siegfried Keller Wuppertal, Spring 2010

* PAL is a German exam standard for the CNC fi eld.

VIRTUAL SHOPFLOOR

PALplusMULTIMEDIA SIMULATOR

CONTROLSIMULATOR

CAD/CAM

VIRTUAL SHOPFLOOR


CONTROLSIMULATOR

CAD/CAM

VIRTUAL SHOPFLOOR


CONTROLSIMULATOR

CAD/CAM

VIRTUAL SHOPFLOOR


CONTROLSIMULATOR

CAD/CAM

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1.2.2 This is how it works!

decimal dual

5 0101

x 23 + x 22 + x 21 + x 20

Thus, the decimal value 0101 is:

+ + + =

Indirect measuring system

Pneumatic unit / tool clamp

Ball screw

Milling machine designs

Central lubrication / stick-slip effect

Knee-typeMilling machine

Cross slide tableMilling machine

+X

-X

+Y

-Y

+Z

-Z

Compare intake and exhaust air:

Advantages:

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© CNC KELLER GmbH22

1.3 Operation

1.3.1 Operating the CNC milling machine

Use and to switch to Operation mode.

Here you can set up the machine in the specifi ed fi xed order.If you are stuck: Place the mouse cursor on to fi nd out how to continue.

Attention: If you use the Windows Vista operating system, graphical errors may occur in this operating mode and the machine may be displayed incorrectly.In this case please go to Graphics settings to switch to DirectX 9.0.

Switching on

To the next menu point: Use your mouse to click on

How to continue?

1.2.3.

Now the machine is ready to move to the reference point.

Initial status

What to do?

Movements:

Machine is referenced.

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Exercise 4


N G X Y Z I J RN1 N2 G1 Z-2N3 N4 N5 N6 N7 N8 N9 N10 N11 N12 N13 N14 N15 N16 N17 N18 G0 Z1N19

Complete the geometry program.

Save this geometry under the name DIN1 in the folder My ISO programs:

Return to main menu File Save

(If the above-mentioned folder is not active,

activate it with Folder)

2.3.3 Contour for importing into the PAL Simulator

90

80

60

40

20

20 40 60 80 100 120

PR15

R15

Note:• Point P is approached at the

height Z1.

• Program the arcs of the fi rst'C' with I and Jand the arcs of the second'C' with R.

Exercise 5 The Z coordinate is also programmed in this exercise, as this geometry program will be imported into the PAL Simulator at a later date and then extended into an NC program.

TCP: X-10 / Y-10 / Z100

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2.5.12 Program part repetition with G23

For rough milling, TR0.1 is used to circumvent the contour with radius correction as required in practice.For fi nishing, the contour is circumvented again with radius correction without radius allowance.For this purpose, the traverse blocks can be repeated by means of the G23 function.

N WITHOUT program part repetitionN1 G54N2 T2 F480 S1000 M13 TR0.1

; Contour milling with allowanceN3 G0 X135 Y-15 Z1 Start positionN4 G0 Z-5 Milling depth in ZN5 G41 G45 ...

Contour description N.. ...N17 G46 G40

; Finishing without allowanceN18 TR0N19 G0 X135 Y-15 Z1 Start positionN20 G0 Z-5 Milling depth in ZN21 G41 G45 ...

Contour description N.. ...N33 G46 G40 ...N34 G0 X150 Y150 Z100 M9N35 M30

N WITH program part repetitionN1 G54N2 T2 F480 S1000 M13 TR0.1

; Contour milling with allowanceN3 G0 X135 Y-15 Z1 Start positionN4 G0 Z-5 Milling depth in ZN5 G41 G45 ...

Contour description N.. ...N17 G46 G40

; Finishing without allowanceN18 TR0N19 G23 N3 N17N20 G0 X150 Y150 Z100 M9N21 M30

The NC program is .......... due to G23

Practical work on the CNC machine

When measuring after roughing, a measured value of 70.22 mm results.Which is the value to be entered for TR for the fi nishing cut to ensure that the contour will be dimensionally accurate? Mark the correct solution with a cross:

+0.01 -0.01 +0.11 -0.11 +0.22 -0.22

Contour chamfering

The contour should receive a chamfer of a width of 1 mm. For this purpose, also circumvent the contour with the NC spot drill on station 1.The NC spot drill has a point angle of 90° and a cross cutter of 1 mm.The cross cutter should have a spacing of 1 mm from the contour.

Which is the depth at which the NC spot drill must circumvent the contour to achieve a chamfer width of 0.75 mm?

N Program N.. ...

N21 T1 F220 S3500 M13 TR1; Contour chamfering

N22 G0 X125 Y-15 Z1 Start positionN23 G0 Z Milling depth in ZN24 G23 N5 N17N25 G0 X150 Y150 Z100 M9N26 M30

Remark: For the program part repetition in block N24 take into account that you start with block N5 instead of N3 to ensure that the correct milling depth is used.

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2.5.18 Complex workpieces

CNC copying, drilling circles and circular grooves

Exercise 26 Create the NC program according to the 6 work steps shown on the right:

Grooves with LFR10 (G59 AR)

Circular pocket with LFR10 ...

... with tenon (G73 RZ)

Snap ring grooves with LFR10

1st Drilling circle with SPB08 (G77 H2)

2nd drilling circle with SPB08 (G77 H3)

V = 89.851 cm3

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4.1 KELLER CAD/CAM

4.1.1 Structure

4.1.2 Pictographs for creating the geometry

4.1.3 Pictographs to create the workplan

Graphical dialogue

Geometry creation

Workplan creation

Generate NC program

NC program simulation*

Transfer NC program

Post-processor

* When a suitable simulator is available

Because it is so easy to create contours using these pictographs, this Graphical dialogue can also be used to start learning CNC technology.

When no geometry was created beforehand

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Invoke operating mode ,

F1 File / F1 New / Set start wizard to:

Then the unfi nished part appears together with the GEO2 fi nished part:

4.3.2 Creating the workplan CAM2

1. Mill the contour pocket F1 Create / F1 Surface / F1 Finished part:

The red surface shows what the tool on station 2 (the fi rst surface tool in the magazine) could machine.

Due to Z=6 this tool is not suitable.

2. Tool selection Select F1 Magazine / T16: Ø 16mm / Z=2

Press the key to obtain an overview, of whether or not this milling cutter is suitable:

YES, continue with .

3. You can see on the top right in the dialogue that the setpoint depth is -5.However, more surfaces are to be milled:

Invoke F1 Multiple, click into the contour pocket and activate this volume at the depth -10 (see in the dialogue at the top right) with F1 Add.Then also add the circle pocket.

4. Apply the following dialogue windows and set the cut-in strategy to Helix:

At the depth of -10, residual material remains!

4.3.2.1 Roughing surfaces

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spf arbeitsheft 6 0 eng - deliver.cnc-keller.net3.3 the sinumerik 802c control system...

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