-0009500-0…

SINUMERIK 840D/810D

Operation/Programming

ShopMill

Manual Number: M-410 Part Number: M -0009500-0410

08.2000 Edition

SINUMERIK

840D/810D/FM-NC

SINUMERIK

Overview of SINUMERIK 840D/840Di/810D/FM-NC Documentation (08.00)

Brochure Catalog Ordering Info NC 60.1 *)Technical Info.NC 60.2

Description of Functions Drive Functions *)

Description of Functions– Basic Machine *) – Extended Functions– Special Functions

SINUMERIK

611D840D/810D

SINUMERIK

840D/840Di/810D/FM-NC

840D/840Di/810D/FM-NC/611

Accessories

CatalogAccessories NC-Z

SINUMERIKSIROTECSIMODRIVE

840D/840Di/810DFM-NC611D

Lists *)Installation &Start-up Guide *)– FM-NC– 810D– 840D/611D– MMC

SINUMERIK

840D

Description ofFunctionsDigitizing

SINUMERIK

SINUMERIK

840D/810D/FM-NC

Configuring KitMMC 100/101– Configuring

Syntax – Development Kit

SINUMERIK

840D/810D/FM-NC

Screen KitMMC 100/101SW Updateand Configu-ration

SINUMERIK

840D/840Di/810D/FM-NC

SINUMERIK

840D/840Di/810D

Operator Components(HW) *)

840D/840Di/810D/FM-NC

Description ofFunctionsSINUMERIKSafety Inte-grated

SINUMERIKSIMODRIVE

SINUMERIK

840D/810D/FM-NC611,Motors

SIMODRIVE

DOC ON CD *)The SINUMERIK System

General Documentation

Electronic Documentation

Manufacturer / Service Documentation


SINUMERIK

840D/810D/FM-NC

SINUMERIK

840D/810D

User Documentation

DiagnosticsGuide *)

Operator’s Guide– HT 6– HPU– Unit Operator

Panel

AutoTurn– Short Guide– Programming (1)– Setup (2)

SINUMERIK

840D/840Di/810D/FM-NC

Program. Guide– Short Guide– Fundamentals *)– Advanced *)– Cycles– Measuring Cycles

Description ofFunctions– ManualTurn– ShopMill

Description ofFunctionsSynchronized ActionsWood, Glass,Ceramics

840D/810D

SINUMERIK

Operator’s Guide– ManualTurn– Short Guide ManualTurn– ShopMill– Short Guide ShopMill

840D/810D


SINUMERIK

840D/810D

Descr. of Functions– Computer Link– Tool Data

Information System

*) These documents are a minimum requirement for the control

Operator’s Guide– Short Guide– Operator’s

Guide *)

SINUMERIK

840D/810D/FM-NC

Configuring (HW) *)– FM-NC– 810D– 840D

SINUMERIK

SINUMERIK

840D/810D

SINUMERIK

840D/810D/FM-NC

Description ofFunctionsOperatorInterface OP 030

Description ofFunctionsTool Manage-ment

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

SINUMERIKSIMODRIVE

840D611D

840D611D

Description ofFunctionsLinear Motor

SINUMERIKSIMODRIVESIROTEC

EMC Guidelines

Description ofFunctions– Hydraulics

Module– Analog Module

User Documentation

SINUMERIK

System Overview

840Di


SINUMERIK

Descr. of FunctionsISO Dialects for SINUMERIK

840D/810D

SINUMERIK

Descr. of FunctionsCAM IntegrationDNC NT-2000

SINUMERIK

Manual(HW + Installationand Start-up)

840Di

08.00 Edition


SINUMERIK 840D/810D

ShopMill

Introduction 1

Operation 2

Programming with

ShopMill3

Programming with

G Code4

Simulation 5

File Management 6

Alarms and Messages 7

Examples 8

Appendix A

Valid for

Control Software VersionSINUMERIK 810D/DE 3SINUMERIK 840D/DE 5

0 Contents 08.00 0

SINUMERIK® Documentation

Printing history

Brief details of this edition and previous editions are listed below.

The status of each edition is shown by the code in the "Remarks" column.

Status codes in the "Remarks" column:

A .... New documentation.

B .... Unrevised reprint with new order number.

C .... Revised edition with new status.

Edition Order No. Comment10.97 6FC5298-2AD10-0BP0 A11.98 6FC5298-2AD10-0BP1 C03.99 6FC5298-5AD10-0BP0 C08.00 6FC5298-5AD10-0BP1 C

This book forms part of the documentation available on CD ROM (DOCONCD)

Edition Order No. Comment10.00 6FC5298-6CA00-0BG0 C

TrademarksSIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK® and SIMODRIVE® are Siemenstrademarks. Other names in this publication might be trademarks whose use by a third party for his ownpurposes may violate the rights of the registered holder.

Further information is available at the following Internet website:http://www.ad.siemens.de/sinumerik

This publication was produced with WinWord V8.0and Designer V6.0.The reproduction, transmission or use of this document or its contents is notpermitted without express written authority. Offenders will be liable for damages.All rights, including rights created by patent grant or registration of a utility modelor design, are reserved.

© Siemens AG 1997 – 2000. All rights reserved

Other functions not described in this documentation might be executable in thecontrol. This does not, however, represent an obligation to supply such functionswith a new control or when servicing.

We have checked that the contents of this document correspond to the hardwareand software described. Nonetheless, differences might exist and we cannottherefore guarantee that they are completely identical. The information containedin this document is, however, reviewed regularly and any necessary changes willbe included in the next edition. We welcome suggestions for improvement.

Subject to change without prior notice.

Order No. 6FC5298-5AD10-0BP1Printed in the Federal Republic of Germany

Siemens Aktiengesellschaft

Siemens AG 2000. All rights reservedSINUMERIK 840D/810D, ShopMill Operation/Programming (BAS) – 08.00 Edition 0-5

0 08.00 Contents 0

Contents

Introduction 1-15

1.1 The ShopMill product................................................................................................... 1-16

1.2 Handling instructions ................................................................................................... 1-16

1.3 Operator components.................................................................................................. 1-171.3.1 OP 031 slimline operator panel ................................................................................... 1-171.3.2 OP 032S slimline operator panel................................................................................. 1-181.3.3 Important function keys ............................................................................................... 1-19

1.4 Control elements on the machine control panel .......................................................... 1-201.4.1 Emergency Stop .......................................................................................................... 1-201.4.2 Operating modes......................................................................................................... 1-211.4.3 Machine functions........................................................................................................ 1-211.4.4 Feed control................................................................................................................. 1-221.4.5 Spindle control............................................................................................................. 1-231.4.6 Keyswitch..................................................................................................................... 1-241.4.7 Program control........................................................................................................... 1-25

1.5 Mini handheld unit ....................................................................................................... 1-26

1.6 Graphics interface ....................................................................................................... 1-28

1.7 Fundamentals.............................................................................................................. 1-291.7.1 Rectangular coordinate system................................................................................... 1-291.7.2 Plane designations ...................................................................................................... 1-291.7.3 Polar coordinates......................................................................................................... 1-301.7.4 Absolute dimension ..................................................................................................... 1-301.7.5 Incremental dimension ................................................................................................ 1-311.7.6 Important softkeys for operation and programming .................................................... 1-311.7.7 Pocket calculator function ........................................................................................... 1-321.7.8 Inch/metric dimension system switchover ................................................................... 1-331.7.9 Switchover between machine and workpiece coordinate systems ............................. 1-34

Operation 2-35

2.1 Power ON and reference point approach.................................................................... 2-37

2.2 Manual mode and settings for manual mode .............................................................. 2-402.2.1 Traverse the machine axes ......................................................................................... 2-402.2.2 Load tool from list into spindle..................................................................................... 2-412.2.3 Enter a new tool in the list and load it to the spindle.................................................... 2-422.2.4 Enter a new tool in the list and load it in the magazine................................................ 2-432.2.5 Start, stop and position the spindle manually .............................................................. 2-432.2.6 Machine-specific functions .......................................................................................... 2-452.2.7 Switch over machining plane/tool axis......................................................................... 2-452.2.8 Switch over to mm or inches ....................................................................................... 2-46

2.3 Set a new position value (basic offset) ........................................................................ 2-47

2.4 Set up workpiece......................................................................................................... 2-48

Siemens AG 2000. All rights reserved0-6 SINUMERIK 840D/810D, ShopMill Operation/Programming (BAS) – 08.00 Edition

0 Contents 08.00 0

2.4.1 Accept a zero offset from the zero offset list............................................................. 2-482.4.2 Manual setup with an edge probe ............................................................................. 2-492.4.3 Manual setup with a 3D probe .................................................................................. 2-502.4.4 Calibrate the workpiece probe .................................................................................. 2-54

2.5 Measuring tools in Manual area ................................................................................ 2-562.5.1 Accept tool from the tool list ...................................................................................... 2-562.5.2 Measuring tools using scratching method................................................................. 2-562.5.3 Measuring tools with a tool probe ............................................................................. 2-572.5.4 Calibrate the tool probe............................................................................................. 2-58

2.6 Machining in Manual mode ....................................................................................... 2-592.6.1 Change settings ........................................................................................................ 2-592.6.2 Positioning................................................................................................................. 2-592.6.3 Face milling ............................................................................................................... 2-60

2.7 MDA mode ................................................................................................................ 2-61

2.8 Automatic mode ........................................................................................................ 2-622.8.1 Switchover between "T, F, S", "G functions" and "Auxiliary functions" displays........ 2-632.8.2 Select a program for execution ................................................................................. 2-632.8.3 Start/stop/abort program ........................................................................................... 2-642.8.4 Interrupt program ...................................................................................................... 2-652.8.5 Enter a program at any selected point ...................................................................... 2-662.8.6 Program control......................................................................................................... 2-682.8.7 Simultaneous recording before machining................................................................ 2-702.8.8 Simultaneous recording during machining................................................................ 2-71

2.9 Execute a trial program run....................................................................................... 2-722.9.1 Single block............................................................................................................... 2-722.9.2 Correct program........................................................................................................ 2-73

2.10 Tools and tool offsets................................................................................................ 2-742.10.1 Select the tool list ...................................................................................................... 2-762.10.2 Create a new tool ...................................................................................................... 2-772.10.3 Create tool offset block for tool edge1/2 ................................................................... 2-782.10.4 Change the tool name............................................................................................... 2-792.10.5 Create a replacement tool......................................................................................... 2-792.10.6 Manual tools.............................................................................................................. 2-792.10.7 Tool offsets ............................................................................................................... 2-802.10.8 Special tool functions ................................................................................................ 2-832.10.9 Create tool wear data................................................................................................ 2-842.10.10 Tool monitoring ......................................................................................................... 2-852.10.11 Magazine list ............................................................................................................. 2-862.10.12 Delete a tool .............................................................................................................. 2-872.10.13 Change the tool type ................................................................................................. 2-872.10.14 Load a tool ................................................................................................................ 2-872.10.15 Unload a tool ............................................................................................................. 2-882.10.16 Sort tools ................................................................................................................... 2-89

2.11 Zero offsets ............................................................................................................... 2-902.11.1 General ..................................................................................................................... 2-90


0 08.00 Contents 0

2.11.2 Display a zero offset .................................................................................................... 2-912.11.3 Select/deselect settable zero offset in Manual area.................................................... 2-93

2.12 Switch to CNC operation ............................................................................................. 2-94

2.13 Remote diagnosis........................................................................................................ 2-94

Programming with ShopMill 3-95

3.1 Fundamental programming principles ......................................................................... 3-97

3.2 Program structure...................................................................................................... 3-1003.2.1 Screen window in program ........................................................................................ 3-1013.2.2 Toggle between screen windows .............................................................................. 3-102

3.3 Create a ShopMill program........................................................................................ 3-1033.3.1 Create a new program; define a blank ...................................................................... 3-1033.3.2 Program new blocks.................................................................................................. 3-1063.3.3 Edit program blocks (change, delete, move, copy, paste) ........................................ 3-108

3.4 Program the tool, offset value and spindle speed ..................................................... 3-110

3.5 Contour milling........................................................................................................... 3-1113.5.1 Free contour programming........................................................................................ 3-1123.5.2 Description of softkeys for free contour programming function................................. 3-1153.5.3 Description of parameters for line/circle contour elements ....................................... 3-1173.5.4 Programming examples for freely defined contours.................................................. 3-1183.5.5 Path milling of open and closed contours.................................................................. 3-1203.5.6 Rough drilling in contour pockets .............................................................................. 3-1233.5.7 Machine (rough cut) pocket with islands ................................................................... 3-1263.5.8 Remove residual material.......................................................................................... 3-1273.5.9 Finish pocket with islands.......................................................................................... 3-129

3.6 Programing simple path motions............................................................................... 3-1313.6.1 Line............................................................................................................................ 3-1313.6.2 Circle with known center point................................................................................... 3-1333.6.3 Circle with known radius............................................................................................ 3-1343.6.4 Helix........................................................................................................................... 3-1353.6.5 Polar coordinates....................................................................................................... 3-1363.6.6 Polar line.................................................................................................................... 3-1373.6.7 Polar circle................................................................................................................. 3-1383.6.8 Programming examples for polar coordinates .......................................................... 3-139

3.7 Drilling........................................................................................................................ 3-1403.7.1 Centering ................................................................................................................... 3-1413.7.2 Drilling and reaming................................................................................................... 3-1423.7.3 Deep-hole drilling....................................................................................................... 3-1433.7.4 Boring ........................................................................................................................ 3-1453.7.5 Tapping...................................................................................................................... 3-1463.7.6 Thread cutting............................................................................................................ 3-1473.7.7 Position on freely programmable positions and position patterns ............................. 3-1503.7.8 Freely programmable positions ................................................................................. 3-1513.7.9 Line position pattern .................................................................................................. 3-152


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3.7.10 Matrix position pattern ............................................................................................... 3-1533.7.11 Full circle position pattern .......................................................................................... 3-1543.7.12 Pitch circle position pattern........................................................................................ 3-1563.7.13 Obstacle..................................................................................................................... 3-1573.7.14 Repeat positions ........................................................................................................ 3-1583.7.15 Programming examples for drilling ............................................................................ 3-159

3.8 Milling......................................................................................................................... 3-1613.8.1 Face milling................................................................................................................ 3-1613.8.2 Mill a rectangular pocket............................................................................................ 3-1643.8.3 Mill a circular pocket .................................................................................................. 3-1673.8.4 Mill rectangular spigots .............................................................................................. 3-1693.8.5 Mill circular spigots .................................................................................................... 3-1713.8.6 Mill longitudinal slots .................................................................................................. 3-1733.8.7 Mill circumferential slots on a full or pitch circle......................................................... 3-1753.8.8 Use of position patterns for milling ............................................................................ 3-177

3.9 Measurements ........................................................................................................... 3-1803.9.1 Workpiece zero point................................................................................................. 3-1803.9.2 Measure tool .............................................................................................................. 3-182

3.10 Miscellaneous functions............................................................................................. 3-1833.10.1 Subroutines and program section repeats................................................................. 3-1833.10.2 Alter the safety clearance or return plane.................................................................. 3-1843.10.3 Zero offsets................................................................................................................ 3-1853.10.4 Cylinder peripheral surface transformation................................................................ 3-1913.10.5 Swiveling.................................................................................................................... 3-1943.10.6 Define a new blank .................................................................................................... 3-199

3.11 Insert G code in a ShopMill program ......................................................................... 3-200

Programming with G Code 4-203

4.1 Create a G code program.......................................................................................... 4-204

4.2 R parameters (arithmetic parameters) ...................................................................... 4-207

4.3 User data ................................................................................................................... 4-208

4.4 ISO dialects ............................................................................................................... 4-211

Simulation 5-213

5.1 General ...................................................................................................................... 5-214

5.2 Start/abort program.................................................................................................... 5-214

5.3 Representation as a plan view................................................................................... 5-215

5.4 Representation as a 3-plane view ............................................................................. 5-216

5.5 Zoom a finished part viewport.................................................................................... 5-217

5.6 Three-dimensional representation of finished part .................................................... 5-2185.6.1 Change position of finished part ................................................................................ 5-2185.6.2 Cut open finished part................................................................................................ 5-219


0 08.00 Contents 0

5.6.3 Update finished part display ...................................................................................... 5-219

File Management 6-221

6.1 Function..................................................................................................................... 6-222

6.2 Directory structure ..................................................................................................... 6-222

6.3 "Directory" operating area (MMC 100.2) ................................................................... 6-2246.3.1 Select a file ................................................................................................................ 6-2246.3.2 Create a file ............................................................................................................... 6-2246.3.3 Execute a program .................................................................................................... 6-2256.3.4 Copy/rename files...................................................................................................... 6-2256.3.5 Delete files................................................................................................................. 6-2256.3.6 Set up the V.24 interface........................................................................................... 6-2266.3.7 Execute a program via the V.24 ................................................................................ 6-2276.3.8 Multiple clamping....................................................................................................... 6-2286.3.9 Back up tool/zero point data ...................................................................................... 6-2306.3.10 Read in tool/zero point data....................................................................................... 6-2316.3.11 Read out files............................................................................................................. 6-2326.3.12 Read in files............................................................................................................... 6-2336.3.13 Error log..................................................................................................................... 6-233

6.4 "Directory" operating area (MMC 103) ...................................................................... 6-2346.4.1 Basic display.............................................................................................................. 6-2346.4.2 Create files/directories............................................................................................... 6-2366.4.3 Open files/directories................................................................................................. 6-2376.4.4 Load and unload programs ....................................................................................... 6-2376.4.5 Select several programs............................................................................................ 6-2396.4.6 Copy/rename/insert files/directories .......................................................................... 6-2396.4.7 Delete/move files/directories ..................................................................................... 6-2406.4.8 Execute from hard disk.............................................................................................. 6-2406.4.9 Set up the V.24 interface........................................................................................... 6-2416.4.10 Multiple clamping....................................................................................................... 6-2426.4.11 Back up tool/zero point data ...................................................................................... 6-2446.4.12 Read in tool/zero point data....................................................................................... 6-2456.4.13 Read out files............................................................................................................. 6-2466.4.14 Read in files............................................................................................................... 6-2466.4.15 Error log..................................................................................................................... 6-247

Alarms and Messages 7-249

7.1 Cycle alarms and messages ..................................................................................... 7-2507.1.1 Error treatment in cycles............................................................................................ 7-2507.1.2 Cycle alarm overview ................................................................................................ 7-2507.1.3 Messages in cycles ................................................................................................... 7-254

7.2 Alarms for ShopMill ................................................................................................... 7-2557.2.1 Alarm overview.......................................................................................................... 7-2557.2.2 Select the alarm/message overview.......................................................................... 7-2567.2.3 Description of alarms................................................................................................. 7-257


0 Contents 08.00 0

Examples 8-265

8.1 Ex. 1: Machine with rectang./circ. pocket and circumf. slot ....................................... 8-266

8.2 Example 2: Shift and mirror a contour ....................................................................... 8-274

8.3 Example 3: Chamfer on circular spigot...................................................................... 8-277

8.4 Example 4: Cylinder surface transformation.............................................................. 8-280

8.5 Example 5: Slot side compensation .......................................................................... 8-283

8.6 Example 6: Swiveling................................................................................................. 8-287

Appendix A-295

A Abbreviations .............................................................................................................A-296

B Terms ........................................................................................................................A-299

C References ................................................................................................................A-307

D Index ..........................................................................................................................A-319


0 08.00 Preface

Structure of the manual 0

Structure of the

documentation

The SINUMERIK documentation is organized in 3 parts:

• General Documentation

• User Documentation

• Manufacturer/Service Documentation

Target group This documentation is intended for use by operators of verticalmachining centers or universal milling machines controlled by theSINUMERIK 810D/810D system.

Standard scope This Operating/Programming Guide describes the functionality of theShopMill operator interface. Extensions or changes made by themachine tool manufacturer are documented by the machine toolmanufacturer.

For more detailed information on SINUMERIK 840D/810D publicationsand other publications covering all SINUMERIK controls (e.g. universalinterface, measuring cycles...), please contact your local Siemensoffice.

Other functions not described in this documentation might beexecutable in the control. This does not, however, represent asobligation to supply such functions with a new control or whenservicing.

Validity This Operating/Programming Guide applies to ShopMill systems with

• SINUMERIK 810D (SW 3 and later)

• SINUMERIK 840D (SW 5 and later)


0 Preface 08.00

Rules for proper use 0

The following symbols with special significance are used in thedocumentation:

Notes The "Note" symbol is displayed in this document to draw your attentionto information relevant to the subject in hand.

In this documentation, you will find this symbol with a reference to anordering option. The function described is executable only if the controlcontains the designated option.

Warnings The following warnings with varying degrees of severity are used inthis document.

DangerThis symbol appears whenever death, severe bodily injury or

substantial material damage will occur if the appropriate precautions

are not taken.

CautionThis symbol appears whenever minor bodily injury or material damage

can occur if the appropriate precautions are not taken.

WarningThis symbol appears whenever death, severe bodily injury or

substantial material damage can occur if the appropriate precautions

are not taken.

References This symbol appears whenever specific information can be found inother literature.A complete list of available literature is included in the Appendix of thisOperator’s Guide.


0 08.00 Preface


Principle Your SIEMENS 840D/810D with ShopMill has been designed andconstructed according to state-of-the-art technology and approvedsafety regulations and standards.

Additional equipment SIEMENS offers special add-on equipment, products and systemconfigurations for the focused expansion of SIEMENS controls in yourfield of application.

Personnel Only suitably trained, authorized, reliable personnel should be

allowed to handle the equipment. Persons who are not qualifiedshould never be allowed to work on the control, even for a short time.

The relevant responsibilities of personnel who set up, operate and

maintain the equipment must be clearly defined and adherence to

these responsibilities monitored.

Procedure Before the control is started up, it should be ensured that the

Operator’ Guides have been read and understood by the people

responsible. The operator also has a permanent obligation to

continuously monitor the overall technical condition (externally

recognizable defects and damage and changes in the operatingbehavior) of the control.


0 Preface 08.00


Servicing Repairs must be carried out by personnel who are specially trained

and qualified in the relevant technical subject according to the

information supplied in the service and maintenance guide. Allappropriate safety specifications must be observed.

The following is deemed to be improper usage and exempts the

manufacturer from any liability:

Any application deviating from the above points or usage extending

beyond the given limits.

Cases where the control is not maintained in perfect technical

condition, or is operated without due regard to safety or danger, and

cases where any or all of the instructions in the Operator’s Guide havenot been observed.

If faults that might affect the safety of the equipment are not rectified

before the control is started up.

Any modification, bypassing or disabling of items of equipment on

the control that are required to ensure fault-free operation, unlimiteduse and active and passive safety.

Improper usage gives rise to unforeseen dangers to

• life and limb of personnel,

• the control, machine or other assets of the owner and the user.

1 08.00 Introduction 1


Introduction

1.1 The ShopMill product ................................................................................................ 1-16

1.2 Handling instructions................................................................................................. 1-16

1.3 Operator components ............................................................................................... 1-171.3.1 OP 031 slimline operator panel................................................................................. 1-171.3.2 OP 032S slimline operator panel .............................................................................. 1-181.3.3 Important function keys............................................................................................. 1-19

1.4 Control elements on the machine control panel ....................................................... 1-201.4.1 Emergency Stop ....................................................................................................... 1-201.4.2 Operating modes ...................................................................................................... 1-211.4.3 Machine functions..................................................................................................... 1-211.4.4 Feed control .............................................................................................................. 1-221.4.5 Spindle control .......................................................................................................... 1-231.4.6 Keyswitch.................................................................................................................. 1-241.4.7 Program control ........................................................................................................ 1-25

1.5 Mini handheld unit ..................................................................................................... 1-26

1.6 Graphics interface..................................................................................................... 1-28

1.7 Fundamentals ........................................................................................................... 1-291.7.1 Rectangular coordinate system ................................................................................ 1-291.7.2 Plane designations.................................................................................................... 1-291.7.3 Polar coordinates ...................................................................................................... 1-301.7.4 Absolute dimension................................................................................................... 1-301.7.5 Incremental dimension.............................................................................................. 1-311.7.6 Important softkeys for operation and programming.................................................. 1-311.7.7 Pocket calculator function......................................................................................... 1-321.7.8 Inch/metric dimension system switchover ................................................................ 1-331.7.9 Switchover between machine and workpiece coordinate systems........................... 1-34

1 Introduction 08.00

1.1 The ShopMill product 1


1.1 The ShopMill product

The ShopMill operating and programming software has been designedto perform 2½D milling operations on vertical and universal millingmachinery with a maximum of 5 axes (including 2 rotary axes) and 1spindle.The recommended hardware base for ShopMill is a SINUMERIK840D/810D control system with MMC100.2 and MMC103.ShopMill has been designed such that machine users can learnquickly and easily how to operate and program the SINUMERIK840D/810D CNC control system. The standard operator interfaceprovides access to the full functional scope of the SINUMERIK840D/810D. Workpieces are programmed graphically, i.e. the userdoes not need to have G code programming expertise.

Highlights • Dynamic input graphics (programming graphics) for contourelements and cycles

• Realtime simulation with zoom feature (online or in dry run mode)

• Contour pocket cycles with automatic residual material sensing(option)

• 3D graphics of finished-part contour

• Optimum adjustment of tool traversing paths taking account ofworkpiece contour and obstacles

• Powerful contour computer for entry of freely defined contours

• Measuring cycles for measuring tools and workpieces

1.2 Handling instructions

Caution

The operator panel/machine control panel may be opened only forservicing purposes by appropriately trained personnel.

Danger

When the operator panel/machine control panel is opened with thepower supply still connected, live parts are exposed which pose anextreme risk to the health and safety of operating personnel!

Warning

Failure to handle the electronic components inside theoperator/machine control panel correctly (in accordance with ESDguidelines) may cause them irreparable damage.

Before actuating any of the control elements on this panel:Please read all the relevant explanations in this document carefully!

1 08.00 Introduction

1.3 Operator components 1


1.3 Operator components

1.3.1 OP 031 slimline operator panel

OP 031 slimline operator

panel with machine

control panel A B C D E

F G H I J6

8 9 /

K L M N O31 2 - [P Q R S T= 0 . + ]U

Z ? ! –

. < >

$

"

V W X Y,\

End

1..n

1 2

A

C

B

A

4 5 63

D

(7

)4 5 *

A Graphics monitor, color

B Alphanumeric keypad

C Correction/cursor keypad with control keys and input key

D Machine control panel

1 Main menu key "Machine Manual"

2 Recall

3 Softkey menu (horizontal)

4 ETC key (menu extension)

5 Area switchover key

6 Softkey menu (vertical)




1.3.2 OP 032S slimline operator panel

Slimline operator panel

OP 032S

with CNC keyboard

(QWERTY)including keys "Program","Program Manager", "ToolOffset", "Alarm" from thesubstitute key set(US layout)

ToolOffset

Program

ProgramManager

Alarm

and machine control

panelwith keys "Manual" and"Auto" from the substitutekey set (US layout)

• Klicken Sie, um Texthinzuzufügen

100%

Auto

Manuell

Example of key assignments on an OP032S slimline operator panel




1.3.3 Important function keys

"Information" keyYou can use this key to

• display or conceal a programming help window, e.g. containing ahelp graphic

• toggle between two different screen displays when writingprograms(see Section "Screen window in program")

"Main Menu" keyYou can call the ShopMill main menu with this key:

MachineManual

MachineAuto

ProgramManager

CNC ISOProgram MessagesAlarms

ToolsZero

M "Machine" operating area keyYou can call the "Machine" main menu with this key.

Toggle keyIf a parameter has several different setting options, you can togglebetween them with the Toggle key. It has the same function as the"Alternative" key.

Home keyThis key moves the cursor

• to the first parameter setting field in an input form

• to the first block (program header) in a machining plan

EndEnd keyThis key moves the cursor

• to the last parameter setting field in an input form

• to the last block (program end) in a machining plan

Edit keyPress this key

• to switch the parameter setting field to Insert mode

• to activate pocket calculator mode

>ETC keyThis key calls the extended program editor (see Chapter"Programming").

DelDelete-Taste (OP 032S only)This deletes the value in a parameter field, leaving the field empty.

Backspace keyThis key performs the same function as the Delete key.

C tr l Ctrl-Taste (OP 032S only)Using key combination Ctrl + Pos1 or Ctrl + End, you can jump to theprogram beginning or program end respectively in the machining planand G code editor.


1.4 Control elements on the machine control panel 1


Operating area keys

OP 032S

When you press one of the following operating area keys, thecorresponding area will be displayed; all other operating areas andfunctions will be deselected at the same time.

AlarmPress this key to display the "Messages – Alarms" operating area. It isequivalent in function to the "Messages – Alarms" softkey.

ProgramPress this key to display the "Program" operating area. It is equivalentin function to the "Program" softkey.

ToolOffset

Press this key to display the "Tools" operating area. It is equivalent infunction to the "Tools Zero" softkey. You can access the operatingarea by pressing softkey "Zero offset".

ProgramManager

Press this key to display the "Directory" operating area. It is equivalentin function to the "Program Manager" softkey.

1.4 Control elements on the machine control panel

Operations on the machine tool such as axis traversal or "Startprogram" can only be initiated via a machine control panel.

A SIEMENS machine control panel or a machine control panelsupplied by the machine tool manufacturer can be connected to themachine tool.

1.4.1 Emergency Stop

Emergency Stop buttonPress the red pushbutton in emergency situations:1. If human life is at risk2. If there is a risk of damage to the machine tool or workpiece.Generally speaking, an Emergency Stop initiates a controlled stop ofall drives with the greatest possible braking torque.

Further or different reactions to Emergency Stop:See information provided by machine tool manufacturer!




1.4.2 Operating modes

The appropriate mode LED lights up to signal and confirm whichoperating mode is active.

Manua lMachine ManualMachine Jog mode implemented by

• continuous movement of axes via direction keys,

• incremental movement of axes via direction keys or

• the handwheel.

This key has the same function as the "Machine Manual" softkey.

AutoMachine AutoControl of the machine through automatic execution of programs.

This key has the same function as the "Machine Auto" softkey.

1.4.3 Machine functions

Manua l

ReposRepositioning, re-approach contour in "Machine Manual" mode

Manua l

RefApproach reference point in "Machine Manual" mode

Inc keys

Inc functions are activated in conjunction with "Machine Manual"mode:

Inc Var (Incremental Feed variable)

Incremental mode with variable increment size (see Section"Traversing machine axes").

... Inc (Incremental Feed)

Incremental mode with predefined increment size of1, ..., 10000 increments.

The increment value is evaluated as a function of a machine data.




1.4.4 Feed control

Feedrate/rapid traverse override

Control range:0% to 120% of programmable feedrate.100% of programmable feedrate is not exceeded in rapid traverse.

Feed Stop

When you press the "Feed Stop" key:

• Execution of the active program is halted

• The axis drives are shut down in a controlled manner

• The associated LED lights up as soon as the control accepts the"Feed Stop" command

• FST (=Feed Stop) is displayed in the header area (channel statusdisplay)

Feed Start

When you press the "Feed Start" key:

• The program is continued at the interruption block

• The feedrate is accelerated up to the programmed value

• The associated LED lights up as soon as the control accepts the"Feed Start" command

Axis keys

X ...

5These select the axis (X, Y, Z, 4 or 5) for traversal,

in the positive direction with the "+" key orin the negative direction with the "–" key.

Rapid traverse overrideThe axis travels in rapid traverse when you press this key togetherwith one of the direction keys displayed above.

MCS/WCSThis key toggles between the machine coordinate system and the toolcoordinate system.




1.4.5 Spindle control

Spindle override (spindle speed override switch)

• The rotary selector switch with scale markings allows you to lower

or raise the programmed spindle speed S (equals 100%).

• The set spindle speed value S is displayed as an absolute value

and a percentage in the "Spindles" screen display.

Control range:50% to 120% of programmed spindle speed

Alternative torotary selector switch Press the key

• "Spindle –" or "Spindle +" and lower or raise the programmedspindle speed "S" (equals 100%).

100%• "100%" and the programmed spindle speed is set.

Spindle Stop

When you press the "Spindle Stop" key:

• The spindle speed is reduced to zero

• The associated LED lights up as soon as "Spindle Stop" is

accepted by the control.

Example application:

• When you need to change a tool

• When you wish to enter spindle and machine functions during

setting up.

Spindle Start

When you press the "Spindle Start" key:

• The spindle speed is accelerated up to the programmed value

The associated LED lights up as soon as the control accepts the"Spindle Start" command

Alternative to Spindle Start

The spindle is rotating CCW or CW and is started.




1.4.6 Keyswitch

The keyswitch on the SINUMERIK 840D/810D has 4 settings to whichprotection levels 4 to 7 are assigned.The machine manufacturer or end user can allocate functions to thekeyswitch settings. Operator panel machine data can also beconfigured to set access to programs, data and functions inaccordance with user requirements.The keyswitch has three keys of different colors which can beremoved in the specified positions:

Key positionsPosition 0No keyProtection level 7

Position 1

Key 1 blackProtection level 6

Position 2

Key 1 greenProtection level 5

Position 3

Key 1 redProtection level 4

Lowest accessauthorization

↓Increasing

access authorization

↓Highest

access authorization

Changing the access

authorization

Changing the access authorization (e.g. by selecting a new keyswitchposition) does not cause the currently selected display to be rebuiltautomatically, but only when the next display is selected (e.g. when adirectory is closed and opened).When you execute a function, the currently valid access rights arechecked.

If the PLC is in the Stop state, the input image of the machine controlpanel is not scanned. The keyswitch positions are not thereforeevaluated during power-up.

Passwords To set access authorization levels, there is the additional option ofentering three passwords in the "Start-up" area of the standardoperator interface.The keyswitch positions are irrelevant when a password is set.

Please read the information provided by the machine manufacturer.




1.4.7 Program control

NC StartWhen you press the "NC Start" key, the selected part program (whoseprogram name is displayed in the header) is started at the currentblock. The associated LED lights up.

NC StopWhen you press the "NC Stop" key, the active part program is haltedand the associated LED lights up.You can restart the program by selecting NC Start again.

Single blockThis function offers you the option of executing a program block byblock. You can activate the "Single block" function in "Machine Auto"mode. When single block mode is active, the associated LED on themachine control panel lights up (see Section "Operation, singleblock").

Reset (Reset)

When you press the "Reset" key:

• Execution of the currently selected program is aborted.

• Messages from the monitoring function are erased (except for

alarms associated with POWER ON, NC Start and AcknowledgeAlarm).

• The channel is switched to the "Reset" state, i.e.

− the NC remains synchronized with the machine

− the control system is in the initial setting and ready for the next

program run.


1.5 Mini handheld unit 1


1.5 Mini handheld unit

A

B

C

H

D

F

G

E

I88 83,5

20 60 108

216

A Emergency Stop button, two-channelB Enabling key, two-channelC Axis selector switch for 5 axes and neutral positionD Function keys F1, F2, F3E Traversing keys, directions +, –F Rapid traverse key for high-speed travel with traversing keys or

handwheelG HandwheelH Magnets for attachment to metal partsI 1.5 m ... 3.5 m connecting lead

Control elements Emergency Stop buttonUse the Emergency Stop button in urgent situations, i.e.1. when human life is at risk or2. if there is a risk of damage to the machine tool or workpiece.

Enabling keyThe enabling key has 2 settings. It must be pressed to initiatetraversing movements.


1.5 Mini handheld unit 1


Axis selector switchYou can select up to 5 axes with the axis selector switch.

Function keysYou can activate machine-specific functions with the function keys.

Traversing keysThe + and – traversing keys can be pressed to move the axis selectedwith the axis selector switch.

HandwheelThe handwheel can be used to move the axis selected with the axisselector switch. The handwheel supplies 2 track signals with 100 l/V.

Rapid traverse keyThe rapid traverse key increases the traversing speed of the axisselected with the axis selector switch. The rapid traverse key acts bothon travel commands from the +/– keys and on the handwheel signals.


1.6 Graphics interface 1


1.6 Graphics interface

Screen layout

1 2

345

6

78

9

10

11

12

13

Explanation of display

elements

1 Operating modes: Machine Auto/Machine ManualOperating areas: Program/Directory/Messages/Tools

2 Alarm and message line3 Program name4 Reserved5 Channel status6 Program status7 Position display for max. 5 axes8 Status display for

• Tool

• Feed

• Spindle9 Status display, e.g. symbols denoting rotation10 Working window

• Section from the selection program

• Input area for various functions11 Dialog line in which additional explanations (Help) can be called12 Horizontal softkey menu with eight softkey functions13 Vertical softkey menu with eight softkey functions


1.7 Fundamentals 1


1.7 Fundamentals

1.7.1 Rectangular coordinate system

The principle of machining workpieces on a mill is based on arectangular coordinate system consisting of three coordinate axes – X,Y and Z – which are parallel to the machine axes.

The orientation of the coordinate system in relation to the machine isdependent on the machine type. The axis directions are governed bythe so-called "Right-hand rule" (according to DIN 66217).

Imagine you are standing in front of the machine with the middle fingeron your right hand pointing in the infeed direction of the main spindle.

• Your thumb is then pointing in direction +X,

• your index finger in direction +Y and

• your middle finger in direction +Z.

+Y

+Z

+X

Z

X

Y

Machine coordinate system and "Right-hand rule"

1.7.2 Plane designations

Each plane is defined by two coordinate axes. The third coordinateaxis (tool axis) in each case is perpendicular to this plane anddetermines the infeed direction of the tool (e.g. for 2½ D millingoperations).

When you program a workpiece,you must specify the plane inwhich you are working so thatthe control can calculate the tooloffset values correctly. The planeis also significant for certaintypes of circle programming andfor polar coordinates.

X

YZ

Y/Z

Z/X

X/Y


1.7 Fundamentals 1


Working planes are defined as follows:

Plane Tool axis

X/Y Z

Z/X Y

Y/Z X

1.7.3 Polar coordinates

The rectangular coordinate system is suitable in cases wheredimensions in the production drawing are orthogonal. For workpiecesdimensioned with arcs or angles, it is better to define positions usingpolar coordinates.

Polar coordinates have their zero point in the "pole".

Example:Using this system, points P1 andP2 could be defined as follows in

relation to the pole:

P1:Radius =100 plus angle =30°

P2:Radius =60 plus angle =75°

X

Y

P1P2

30°75°

Pole

15

30

60

100

1.7.4 Absolute dimension

With an absolute dimension, all position data always refer to thecurrently valid zero point. With respect to tool motion, this means:

The absolute dimension describes theposition to which the tool must move.

Example:The positions for points P1 to P3as absolute dimensions are as

follows in relation to the zero

point:P1: X20 Y35

P2: X50 Y60

P3: X70 Y20X

Y

7050

20

P2

P3

P1

6035

20


1.7 Fundamentals 1


1.7.5 Incremental dimension

In the case of production drawings in which dimensions refer to someother point on the workpiece rather than the zero point, it is possible toenter an incremental dimension.

With an incremental dimension input, a position specification refers ineach case to a point programmed beforehand.

Example:The positions for points P1 to P3as incremental dimensions are asfollows:P1: X20 Y35 ;(in relation to the

zero point)P2: X30 Y20 ;(in relation to P1)

P3: X20 Y-35 ;(in relation to P2) X

Y

P1

20 2030

P2

P3

2015

201.7.6 Important softkeys for operation and programming

"Cancel" softkeyReturns to next-higher menu. When you press "Cancel", a window isclosed without your inputs being stored.

"Back" softkeyReturns to next-higher menu.

"Alternat." softkeyThis softkey is displayed when the cursor is positioned on a parametersetting field for which one of several settings can be selected.

"OK" softkeyParameter settings you have entered are accepted and stored.

"Accept" softkeyParameters you have entered are transferred to the program andstored. The softkey will not be displayed if you have made aparameterization error.

Tools "Tools" softkeyYou can select the "Tools" softkey (in vertical softkey menu) in anyinput screenform with a tool input field in order to change to the tool listin the "Tools" operating mode.


1.7 Fundamentals 1


Zerooffset

"Zero offset" softkeyYou can select the "Zero offset" softkey (in vertical softkey menu) fromany screenform with a zero offset selection field in order to call thezero offsets list.

Toprogram

"To program" softkeyYou can return to the input screenform by selecting the "To program"softkey.

1.7.7 Pocket calculator function

Function

Precondition The cursor is positioned on a parameter field.

=

Press the Edit key (MMC 100.2)

orEquals key (MMC 103, and MMC 100.2 with SW 5 and later)

to activate pocket calculator mode.

To perform an arithmetic function on two values, press this key andthen enter the symbol for the relevant function (+, –, *, / ) followed by avalue.Then press the Input key and the second value to perform thecalculation.

Example application:A tool wear value in length L of + 0.1 must be included in a toolcalculation.

• Place the cursor in the appropriate parameter setting field,

• press the Equals key to open the parameter field and

• add the new wear value to the existing value,

e.g. 0.5 + 0.1

• Terminate calculation by pressing the Input key.Result: 0.6


1.7 Fundamentals 1


1.7.8 Inch/metric dimension system switchover

Function

This function enables you to switch between the metric and inchdimension systems depending on the dimension units used in yourproduction drawing.

Every dimension system switchover applies to the entire machine, i.e.all relevant measurement data are automatically converted to the newdimension system, e.g.

• Positions

• Tool offsets

• Zero offsets

Operating sequence

MachineManual

Change to the "Machine Manual" mode.

Settings Press softkeys "Settings" and "Inch"

Inch • Switch from metric to inches: Softkey is active

Inch • Switch from inches to metric: Softkey is not active

When you press the "Inch" softkey, a prompt box appears asking youto confirm the switchover operation.

The dimension system is adjusted correspondingly when you confirmwith the "OK" softkey.


1.7 Fundamentals 1


1.7.9 Switchover between machine and workpiece coordinate systems

Function

The machine coordinate system (MCS) is the original system of yourmachine. In contrast to the workpiece coordinate system (WCS), itdoes not allow for tool offsets, zero offset, scalings, etc.

Operating sequence

You can switch between the machine and workpiece coordinatesystems by following the sequence below:Press the key on the machine control panel

or

MachineManual

MachineAuto

select softkey "Actual value MCS" in the "Machine Manual" or"Machine Auto" operating areas.

Actual valueMCS

• Switch from WCS to MCS: Softkey is active.

Actualvalue MCS

• Switch from MCS to WCS: Softkey is not active.

�

2 08.00 Operation 2


Operation

2.1 Power ON and reference point approach ................................................................. 2-37

2.2 Manual mode and settings for manual mode ........................................................... 2-402.2.1 Traverse the machine axes ...................................................................................... 2-402.2.2 Load tool from list into spindle .................................................................................. 2-412.2.3 Enter a new tool in the list and load it to the spindle................................................. 2-422.2.4 Enter a new tool in the list and load it in the magazine............................................. 2-432.2.5 Start, stop and position the spindle manually ........................................................... 2-432.2.6 Machine-specific functions........................................................................................ 2-452.2.7 Switch over machining plane/tool axis ...................................................................... 2-452.2.8 Switch over to mm or inches..................................................................................... 2-46

2.3 Set a new position value (basic offset) ..................................................................... 2-47

2.4 Set up workpiece ...................................................................................................... 2-482.4.1 Accept a zero offset from the zero offset list ............................................................ 2-482.4.2 Manual setup with an edge probe............................................................................. 2-492.4.3 Manual setup with a 3D probe .................................................................................. 2-502.4.4 Calibrate the workpiece probe .................................................................................. 2-54

2.5 Measuring tools in Manual area................................................................................ 2-562.5.1 Accept tool from the tool list...................................................................................... 2-562.5.2 Measuring tools using scratching method ................................................................ 2-562.5.3 Measuring tools with a tool probe ............................................................................. 2-572.5.4 Calibrate the tool probe............................................................................................. 2-58

2.6 Machining in Manual mode....................................................................................... 2-592.6.1 Change settings ........................................................................................................ 2-592.6.2 Positioning ................................................................................................................ 2-592.6.3 Face milling............................................................................................................... 2-60

2.7 MDA mode................................................................................................................ 2-61

2.8 Automatic mode........................................................................................................ 2-622.8.1 Switchover between "T, F, S", "G functions" and "Auxiliary functions" displays ....... 2-632.8.2 Select a program for execution................................................................................. 2-632.8.3 Start/stop/abort program........................................................................................... 2-642.8.4 Interrupt program ...................................................................................................... 2-652.8.5 Enter a program at any selected point ...................................................................... 2-662.8.6 Program control ........................................................................................................ 2-682.8.7 Simultaneous recording before machining ............................................................... 2-702.8.8 Simultaneous recording during machining................................................................ 2-71

2.9 Execute a trial program run ...................................................................................... 2-722.9.1 Single block............................................................................................................... 2-722.9.2 Correct program........................................................................................................ 2-73

2.10 Tools and tool offsets................................................................................................ 2-742.10.1 Select the tool list...................................................................................................... 2-762.10.2 Create a new tool...................................................................................................... 2-77

2 Operation 08.00 2


2.10.3 Create tool offset block for tool edge1/2 ................................................................... 2-782.10.4 Change the tool name............................................................................................... 2-792.10.5 Create a replacement tool......................................................................................... 2-792.10.6 Manual tools.............................................................................................................. 2-792.10.7 Tool offsets ............................................................................................................... 2-802.10.8 Special tool functions ................................................................................................ 2-832.10.9 Create tool wear data................................................................................................ 2-842.10.10 Tool monitoring ......................................................................................................... 2-852.10.11 Magazine list ............................................................................................................. 2-862.10.12 Delete a tool .............................................................................................................. 2-872.10.13 Change the tool type ................................................................................................. 2-872.10.14 Load a tool ................................................................................................................ 2-872.10.15 Unload a tool ............................................................................................................. 2-882.10.16 Sort tools ................................................................................................................... 2-89

2.11 Zero offsets ............................................................................................................... 2-902.11.1 General ..................................................................................................................... 2-902.11.2 Display a zero offset.................................................................................................. 2-912.11.3 Select/deselect settable zero offset in Manual area.................................................. 2-93

2.12 Switch to CNC operation........................................................................................... 2-94

2.13 Remote diagnosis ..................................................................................................... 2-94

2 08.00 Operation

2.1 Power ON and reference point approach 2


2.1 Power ON and reference point approach

Switching control system

ON and OFF

Function

Power ON A variety of methods can be employed to switch on the power supplyto the control system or to the whole plant.

Please therefore read the information provided by the machinemanufacturer!

After power ON, the main "Machine Manual" display appears on thescreen

Main "Machine Manual" display

Power OFF For details on how to switch off the power supply to the control systemor the whole plant:

Please read the information provided by the machine manufacturer!

2 Operation 08.00



Reference point

approach

Function

The "Ref" function is used to synchronize the control system andmachine after power ON.Various reference point approach methods may be employed.Please read the information provided by the machine manufacturer!

• The reference point can be applied only with respect to machineaxes. The actual value display after power ON does not coincidewith the actual position of the axes.

• A reference point must be approached in cases where there is noabsolute measuring system installed on the machine!

Caution

If the axes are not positioned safely, then you must reposition themaccordingly.When doing so, please pay careful attention to the axis motionsdirectly on the machine!Ignore the actual value display until the axes have been referenced!Software limit switches are not operative!

Operating sequence

Operating mode "Machine Manual" is selected.

Select machine function "Ref" .

X ...

Select the axis that you wish to move and

then press the "+" or "–" key.

Your selected axis moves to the reference point. The direction orsequence is defined by the PLC program supplied by the machinemanufacturer.If you have pressed the wrong direction key, the input will not beaccepted and the axis does not move.The display now shows the reference point value.

No symbol is displayed for axes which are not yet referenced.

This symbol is displayed next to the axis when it has reached the reference point.

2 08.00 Operation



You can stop the axis you have started before it reaches the referencepoint.

X ...



Your selected axis moves to the reference point.

Caution

The machine is synchronized with the control once the axes havebeen referenced. The actual value display is set to the reference pointvalue. It shows the difference between the machine zero and the slidereference point. From this moment onwards, path limitations such assoftware limit switches are operative.

End the function via the machine control panel by selecting operatingmode "Machine Auto" or "Machine Manual".

• You can reference all axes simultaneously (depending on the PLCprogram supplied by the machine tool manufacturer).

• The feedrate override is operative.

Further notes

The machine tool manufacturer may specify the sequence in whichaxes must be referenced.

Only when all axes with a defined reference point have reached thispoint will you be able to activate NC Start in "Machine Auto".

2 Operation 08.00

2.2 Manual mode and settings for manual mode 2


2.2 Manual mode and settings for manual mode

2.2.1 Traverse the machine axes

Function

You can perform the following tasks in Manual mode:1. Synchronize the control system with the machine (reference point

approach).2. Set up the machine, i.e. activate manually controlled motions on

the machine using the keys and handwheels provided on themachine control panel.

3. Activate manually controlled motions on the machine using thekeys and handwheels provided on the machine control panel whilea part program is interrupted.

Traverse axes by keys

Operating sequence

By pressing the increment keys, you can move the selected axis indefined increments in the appropriate direction every time you pressan "Axis key" in manual mode.The axes themselves traverse at the programmed setup feedrate.

Preset increments

...

• You can select preset increments by pressing keys[1], [10], ..., [10000]

• You can also define variable increments in the "Settings" menu:

Select with softkey Settings

Enter the increment of your choice in parameter "Variableincrement".

Using the "Inc Var" key, move the selected axis by the presetincrement with the "Axis key" in Manual mode.

Example: With an increment of 0.5 mm, set a variable

increment of 500.

Set setup feedrate The "Setup feedrate" parameter is also entered in the "Settings"menu. The setting in this parameter defines the feedrate (in mm/min)at which axes must traverse in setup mode.A limitation for the maximum feed velocity is programmed in amachine data.

2 08.00 Operation



X ...



The feedrate and rapid traverse override switches may be operative.

Depending on the PLC program, you may be able to select more thanone axis at a time.

Further notes

• After the control power supply has been switched on, it may bepossible to move axes into the limit zone of the machine as theyhave not yet been referenced. They may trigger emergency limitswitches in this zone.

• The software limit switches and working area limitation are not yet

operative!

• The feed enable signal must be set.

Traverse axes by means

of handwheelsPlease note the machine manufacturer's instruction manual withregard to the selection and mode of operation of handwheels.

2.2.2 Load tool from list into spindle

Operating sequence

Select with softkey MachineManual

T, S, M, ...

The cursor is positioned on the input field of tool parameter "T":

Toolszero pt.

Call the tool list via the softkey

or

ToolOffset

key

Select the tool of your choice in the tool list and

Back tomanual

confirm your selection.

2 Operation 08.00



The tool is accepted.You can select a cutting edgeD1/D2.

When you press the "NC Start"key, the tool is loaded into thespindle.

2.2.3 Enter a new tool in the list and load it to the spindle

Operating sequence

Prepare for loading

MachineManual

T, S, M, ... Go into the "Machine Manual" area and select function "T, S, M, ...".

The cursor is positioned on the input field of tool parameter "T":

Enter tool in tool list

ToolOffset

or Tools

Call the tool list by selecting key "Tool Offset" or softkey "Tools".

Select a free tool in the tool list and enter a new tool (as described inSection "Tools and tool offsets").

Back tomanual

Select the "Back to manual" softkey to return automatically to the"T,S,M,..." function. The tool name is now entered in the input field oftool parameter "T".

Execute tool change

operation

The tool change is enabled when you press "NC Start".

The loaded tool is marked by a spindle symbol in the tool list.

Now load the tool manually into the spindle as described in themachine manufacturer’s instruction manual.

2 08.00 Operation



2.2.4 Enter a new tool in the list and load it in the magazine

Operating sequence

Enter tool in tool list

ToolOffset

Call the tool list by selecting the "Tool Offset" key

Toollist

or select softkey "Tool list".

Select a free tool in the tool list and enter a new tool (as described inSection "Tools and tool offsets").

Newtool

Select softkey "New tool".

Cutter

... 3Dprobe

Select the tool type of your choice and enter a tool name. Enter thetool offsets if applicable.

Load tool to magazine

Toollist

Load If the magazine on your machine has variable location assignment,execute the "Load" function in the "Tool list" menu.

If it is a magazine with fixed location assignment, load the tool in therequired magazine location as described in the machinemanufacturer’s instruction manual.

2.2.5 Start, stop and position the spindle manually

Operating sequence

Set the spindle speed

MachineManual

T, S, M, ... Select the menu "T, S, M, ..." in the "Machine Manual" operatingmode.Enter the speed setting of your choice in the spindle speed input field.

Press the "NC Start" key.

If the spindle is already rotating, it will accelerate/decelerate to the newspeed setting. If the spindle is stationary, the value is stored as thesetpoint speed. The spindle remains stationary.

2 Operation 08.00



Start/stop the spindle

The "Spindle CCW" or "Spindle CW" keys start the spindle rotating atthe preset spindle speed and the currently valid spindle overrideweighting.

You can stop the spindle again by pressing the "Spindle Stop" key.

Alternative method

MachineManual

T, S, M, ... You can also select Start/Stop Spindle in the "Spindle" selection fieldin menu "T, S, M,...".

Clockwise spindle rotation:

CCW spindle rotation:

Spindle Stop:

and then execute by pressing "NC Start".

Position spindle You can use this function to position the spindle at a specific angle,e.g. during a tool change.

• A stationary spindle is positioned via the shortest possible route.

• A rotating spindle is positioned as it continues to turn in the samedirection.

Spindle positions are specified in degrees.

MachineManual

T, S, M, ... Select the menu "T, S, M, ..." in the "Machine Manual" operatingmode.

Select the symbol for spindleposition in the "Spindle" selectionfield. The "Stop Pos." input field isdisplayed in which you must entera spindle stop position.

The spindle is turned to the selected position when you press"NC Start".

Change the spindle speed

The spindle override switch can be used to set spindle speed S to

between 50 and 120% of the last speed setting.

Or you can use the following keys on the OP032S operator panel:

You can reduce or increase programmed spindle speed "S"(corresponds to 100%) using the "Spindle –" or "Spindle +" keys.

2 08.00 Operation



100%Press key "100%" if you wish to set the programmed spindle speed.

2.2.6 Machine-specific functions

Function

Gear stage

MachineManual

T, S, M, ... If your machine has a gear unit for the spindle, you can set the gearstage in selection field "Gear stage" in menu "T, S, M, ..."and then activate it by pressing "NC Start".

Other special functions The machine manufacturer determines which additional specialfunctions are available for your use.Please read the information provided by the machine manufacturer!

2.2.7 Switch over machining plane/tool axis

Function

MachineManual

T, S, M, ... If your machine has a swivel-mounted work spindle, you can select themachining plane in the "Tool axis" selection field in menu "T, S, M, ...".

This parameter is relevant for all screenforms in the Manual area, i.e.it influences the parameter displays for face milling or measurements.In addition, the plane setting determines how tool offsets arecalculated in workpiece and tool measurements.

For instructions on how to swivel the spindle, please refer toinformation supplied by the machine manufacturer.

2 Operation 08.00



2.2.8 Switch over to mm or inches

Function

The selected unit of measurement affects the actual value display anddistance-defining parameters.

MachineManual

T, S, M, ... You can switch over between mm and inches in the "Unit ofmeasurement" selection field in menu "T, S, M, ..." in the "MachineManual" operating mode

and then activate it by pressing "NC Start".

The setting applies to the Manual area and remains valid until youswitch to the other unit. In Automatic mode, the unit of measurementdisplayed in the program header is always activated.

Tool offsets and zero offsets remain in the original basic system inwhich the system is set.

2 08.00 Operation

2.3 Set a new position value (basic offset) 2


2.3 Set a new position value (basic offset)

Function

You can use the "Set basic ZO" function to enter a new position valuefor each individual axis in the actual value display.The difference between the position value in the machine coordinate

system MCS and the new position value in the workpiece coordinate

system WCS is entered in "Basic zero offset" in menu "Zero offset".

Operating sequence

Move the machine axes to the desired position (e.g. workpiecesurface).

MachineManual

Set basicZO

Select the "Set basic ZO" menu in operating mode "Machine Manual".

Basic offset menu

Set position value You can enter new position values in the following ways:

• Directly via the input keypad.Increase/decrease value via cursor keys. Terminate the input bypressing the "Input" key.

• Via softkeys if you want to set position values to 0.

Reset basic offset

Select with softkey Deletebasic ZO

The basic offset is reset again when you select softkey"Delete basic ZO".

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2.4 Set up workpiece 2


2.4 Set up workpiece

Function

ShopMill supports you in setting up workpieces, whether you are doingso manually or automatically. You can use both edge probes and 3Dprobes as sensing tools.

Set up

with an edge probe

When a workpiece is set up with an edge probe, it is assumed that theworkpiece position on the machine table is unknown, but that thedimensional variations of the probe are known. The position to bemeasured is approached manually, for example, by means of ahandwheel, allowing a corner point or the position of an edge to bemeasured.

Instead of an edge probe, you can also use any other tool of which youknow the radius and length.

Set up

with a sensor probe

Precondition: A 3D probe type tool is mounted in the spindle.A measuring cycle is called in automatic setup mode. Theapproximate position of the workpiece is known in this case. Themeasuring cycle automatically generates the measuring distances andintermediate positions from the starting point reached as a function ofpreset setpoints. All measuring points required to take themeasurement are approached. Once the measurements have beentaken, the result is automatically calculated (corner, center-point hole,spigot) in the cycle according to the selected measurement method.Prepositioning can be done manually or implemented in a program.

2.4.1 Accept a zero offset from the zero offset list

Operating sequence

You have already called the zero offset list.

Zero pointworkpiece

When you select softkey "Zero point workpiece", the selected zerooffset is entered under parameter "Zero offset" in the "Zero pointworkpiece" input screenform.

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2.4.2 Manual setup with an edge probe

Set a reference point in any axis

Operating sequence

Preconditions The edge probe has been loaded into the spindle.The spindle speed is set and the spindle is rotating.

Approach the workpiece Position the edge probe in the desired axis direction in front of theworkpiece, e.g. in direction X.

Select the functionwith softkeys

Zero pointworkpiece

Edge

X

... Z

Make settings in inputscreenform

• Set the calculated offset in whichthe measurement result must bestored:

− Basic zero offset

− or the zero offset transferredfrom the zero offset list

• Direction: Contact direction of

selected axis, e.g. in –X

• Enter setpoint of reference point

(edge).

Setzero offset

The zero offset is calculated when you press the "Set zero offset"softkey.

The tool radius is included in the edge measurement calculation.Example: Setpoint position X0 = 0

Contact direction +XTool radius = 2 mm

⇒ X = –2

Corner as reference

point

Operating sequence

Preconditions The edge probe has been loaded into the spindle.The spindle speed is set and the spindle is rotating.

Approach the workpiece Move edge probe to a selected position on the workpiece.


Zero pointworkpiece

Edge

2 Operation 08.00







• Position: Set the corner to be

applied as the reference point

• Enter the setpoint position of the

reference point (corner).

Approach the contact points Move edge probe to the first contact point P1 on the workpiece edge.

StoreP1

Store contact point P1

Repeat process for contact points P2 ... P4

Setposition

When you select softkey "Set position", the zero offset and rotation α0

are calculated.

Three contact points are sufficient to make the calculation on arectangular workpiece.

2.4.3 Manual setup with a 3D probe

Set a reference point in any axis

Operating sequence

Precondition The 3D probe is loaded in the spindle and already calibrated.

Approach the workpiece Position the 3D probe in the desired axis direction in front of theworkpiece, e.g. in direction X.


Zero pointworkpiece

Edge

X

... Z


• Set the offset in which themeasurement result must bestored:



• Direction: Set contact direction for

selected axis for which thereference point is to be set,e.g. in –X.

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• Enter setpoint of reference point (edge).

When you press "NC Start", the measuring process commencesautomatically at a measuring feedrate set via machine data.

• Sensor outputs "Measure now" signal

• Automatic retraction to start position at rapid traverse

• The calculated value is written into the zero offset.

Corner as reference

point

Operating sequence


Approach the workpiece Position the 3D probe at a selected corner of the workpiece.


Zero pointworkpiece

Edge





• Position: Set the corner to be

applied as the reference point

• Enter the setpoint position of the

reference point (corner).

Approach the contact points Position the 3D probe at the first contact point P1 on the workpiece

edge.

When you press "NC Start", the measuring process commencesautomatically at a measuring feedrate set via machine data.

• Sensor outputs "Measure now" signal

• Automatic retraction to start position at rapid traverse

The position values of contact point P1 are stored automatically.

Repeat "Approach contact points" for points P2 ... P4.

Calculatecorner

The zero offset is calculated when you select softkey "Calculatecorner".

• The sequence for approaching contact points P1...P4 must beobserved.

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• To obtain greater accuracy, it is advisable to repeat the measuring

process again. The angle α0 is taken into account for the second

measurement.

Arc center as reference point

The center points of holes and spigots can be used as referencepoints with a 3D probe.

Holes: ShopMill automatically contacts the inside wall of the hole in allfour coordinate axis directions.

Spigots: ShopMill automatically contacts the outside wall of the spigotin all four coordinate axis directions.

Holes

Operating sequence


Approach the workpiece Position the 3D probe in the approximate arc center of the hole.


Zero pointworkpiece

Holes




− or the zero offset transferred from the zero offset list

• Diameter: Enter the approximate

diameter of the hole. If you do notenter a diameter, the probecontacts the hole wall from thestarting point at the measurementfeedrate.

• Enter setpoint position of the

hole arc center.

The measuring process is executed automatically when you press"NC Start".The 3D probe contacts 4 points in succession around the inside wall ofthe hole.

When the measurement has been taken, the set offset is calculated.

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Spigots

Operating sequence


Approach the workpiece Position the 3D probe over the approximate arc center of the spigot.


Zero pointworkpiece

Circle





• Diameter: Enter the approximate

spigot diameter (check thediameter >0, safety clearance,allowance for probecompensations).

• Enter the setpoint position of the spigot center point.

• Enter the measurement infeed depth.

The measuring process is executed automatically when you press"NC Start".The 3D probe contacts 4 points in succession around the spigotoutside wall.When the measurement has been taken, the set offset is calculated.

2 Operation 08.00



2.4.4 Calibrate the workpiece probe

Function

On milling machines and machining centers, the probe is normallyloaded from a tool magazine into the spindle. This may cause errors tooccur in subsequent measurements as a result of the probe clampingtolerances in the spindle. In addition, the trigger point of the probe inrelation to the spindle center has to be calculated exactly.A calibration cycle is provided for this purpose. This allows the probeto be calibrated in any hole or on a surface.

Calibrate the workpiece

probe in any hole

You can use this cycle to calibrate the probe in any hole in a referencepiece, e.g. on the workpiece or in a setting ring gauge (see diagrambelow). The calculated trigger points are automatically loaded to thecorresponding data area of an internal module.

Operating sequence

Preconditions A 3D probe is mounted in the spindle. The exact radius of the probeball must be entered in the tool offset block.A setting ring gauge with known radius is used to calibrate the probe.

Approach the referencepiece

Position the 3D probe at the approximate hole center point in theselected measuring plane and at calibration depth within the hole.


Zero pointworkpiece

Calibrateprobe >

Radius


Enter the diameter ∅ of the reference

piece (in this case, the setting ringgauge).

The calibration process is executed automatically when you press "NCStart". The exact position of the center of the setting ring is determinedfirst. 4 trigger points inside the setting ring are then contacted.

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Calibrate the workpiece

probe on any surface

The measuring cycle permits the sensing probe to be calibrated onany surface, e.g. on the workpiece, for the purpose of calculating itslength.

Operating sequence

Preconditions A 3D probe is mounted in the spindle. The exact radius of the probeball must be entered in the tool offset block.

Approach the workpiece Position the 3D probe opposite the calibration surface of theworkpiece.


Zero pointworkpiece

Calibrateprobe >

Length


Enter the known reference point Z0 ofthe machine table.

The calibration process is executed automatically when you press "NCStart".The 3D probe outputs a "Measure now" signal.

The calculated length of the 3D probe is stored in the tool offset datablock.

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2.5 Measuring tools in Manual area 2


2.5 Measuring tools in Manual area

2.5.1 Accept tool from the tool list

Operating sequence

You have called the tool list and the tool to be measured is loaded inthe spindle.

Measuretool

When you press the "Measure tool" softkey, the tool is transferred tothe "Measure tool" input screenform.

2.5.2 Measuring tools using scratching method

The diameter or radius of a tool can be defined via a machine data.Please read the machine manufacturer’s instruction manual!

Operating sequence

Precondition The tool to be measured is loaded in the spindle.

Approach the workpiece Infeed the tool to a known reference point, e.g. an edge of theworkpiece.

Select whether you wish to measure the radius/diameter or length ofthe tool:

Select with softkey Measuretool

Radiusmanual or

Lengthmanual or

Measuretool

Diametermanual or

Lengthmanual

Measure tool radius/diameter Measure the tool length


• For tool radius/diameter: Enter the reference point, e.g. valuefor X0

• For tool length: Enter the reference point, e.g. a value for Z0

Start calculationSelect

Calculateradius or

Setlength or

Calculatediameter or

Setdiameter .

The tool geometry data for radius/diameter or length are calculatedand entered in the tool list.

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2.5.3 Measuring tools with a tool probe

Operating sequence

When you measure a tool with a tool probe (table contact system), youcan choose to measure either the radius or the length of the tool.

Precondition The tool probe has been calibrated.Enter the tool geometry data (length or radius/diameter) asapproximate values in the tool offset data block of the tool list.The tool to be measured is loaded in the spindle.You must preposition the tool in such a way that it can approach thetool probe without risk of collision.

Approach the tool probe Position the tool near the measuring surface of the tool probe.

Select whether you wish to measure the radius/diameter or length ofthe tool:


RadiusAuto or

DiameterAuto or

LengthAuto

Measure tool length Measure tool radius/diameter


• Specify the tool to be measured T and the corresponding tool offset

data block D1 or D2.

• Enter a length offset V (positive value), required, for example, for

ball end mills or mills with round tool inserts.

When you press "NC Start", the measurement is taken automaticallyat the measuring feedrate.

The tool geometry data for radius or length are calculated and enteredin the tool list.

2 Operation 08.00



2.5.4 Calibrate the tool probe

Function

Mechanical tool probes are typically cube-shaped or cylindrical. Theprobe is installed in the working area of the machine (on the machinetable) and must be aligned in relation to the machining axes.The "Calibrate probe" function uses the calibration tool to determinethe current distances between the machine zero and the tool probeand automatically stores them in an internal data area. Tool type 120(mill) can be entered as the calibration tool; no special calibration tooltype is provided.

Operating sequence

Preconditions The length and radius of the calibration tool must be stored in a tooloffset data block.The calibration tool is loaded in the spindle.

Approach the tool probe Move the calibration tool until it is positioned over the approximatecenter of the measuring surface of the tool probe.


Calibrateprobe

Enter the method of measurement in the input screenform:

• Calibrate length only

• Calibrate length and diameter

Calibrate length and diameter Calibrate length only

When you press "NC Start", calibration is executed automatically atthe measuring feedrate.

The current distance measurements between the machine zero andtool probe are calculated and stored in an internal data area.

2 08.00 Operation

2.6 Machining in Manual mode 2


2.6 Machining in Manual mode

2.6.1 Change settings

Operating sequence


Settings

Default settings are entered in this menu for

• Return planeThe return plane is the position above the workpiece approachedby a cycle in rapid traverse during, for example, face millingoperations.

• Safety clearanceThe safety clearance is the distance between the tool tip and theworkpiece surface. This position is approached in rapid traverse.The programmed cycle, e.g. face milling, is then executed at theprogrammed machining feedrate.

These settings remain valid until you change them.

2.6.2 Positioning

Operating sequence

In Manual mode, you can move the axes to certain positions for thepurpose of performing simple machining operations.

Select with softkeys MachineManual

Positioning

Select the axis/axes that you wish tomove and enter its/their target position/s.

Enter your selected setting for feedrate F,

e.g. 1000 mm/min.

Rapidtraverse

Alternatively, you can select this softkey to move the axes in rapidtraverse.

2 Operation 08.00

2.6 Machining in Manual mode 2


The axes are moved to the specified target position when you press"NC Start".

2.6.3 Face milling

Function

You can use this cycle to face mill any workpiece. The cycledistinguishes between rough cutting (repeated end milling of surfacewith depth infeed inside workpiece) and finish cutting (single end milloperation on surface with retraction of mill and depth infeed outsideworkpiece).

Select with softkeys MachineManual

Facemilling

Then select the desired direction of machining and enter parametersettings in input screenform.

Please also note instructions regarding face millingin Section "Programming – Face Milling".

Confirm your inputs with softkey "OK"

and go to the program view in the Manual area:

Example of face milling in the program view

Press the "NC Start" key to start the "Face milling" cycle.

2 08.00 Operation

2.7 MDA mode 2


2.7 MDA mode

Function

You can write and execute programs block by block in G code in"MDA" (Manual Data Automatic) mode. To do this, you enter specificmovements as individual program blocks in the control via thekeyboard.

The "MDA" program view displays position, feedrate, spindle and toolvalues as well as the contents of the MDA program.

Example of a program in the "MDA" program view

Start programThe control executes the blocks you have entered when you press the"NC Start" key.

Delete programDeleteMDA prog.

Programs written in MDA mode are automatically deleted as soon asthey have finished running. Alternatively, you can delete them byselecting softkey "Delete MDA program".

2 Operation 08.00

2.8 Automatic mode 2


2.8 Automatic mode

In the "Machine Auto" operating mode, you can execute machiningprograms and monitor the progress of the current machining operationonline on the screen.

Preconditions The preconditions for executing machining programs are as follows:

• You have already synchronized the control measuring system withthe machine (i.e. "approached" reference points).

• You have already written the program to be executed in ShopMill.

• You have checked or entered the necessary offset values, e.g.zero offsets and tool offsets.

• The required safety interlocks are already active.

Example of program view in "Machine Auto"

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2.8.1 Switchover between "T, F, S", "G functions" and "Auxiliary functions" displays

Function

You can switch from the "T, F, S" status display to the "G functions" or"Auxiliary functions" displays in the "Machine Auto" and "MachineManual" program views.

Operating sequence

G function The "G functions" box containing the active G functions is displayed.Every G group has a predefined position. The group number (No.) andthe current G function of the G groups are displayed only if a Gfunction is active.

Deselection You can switch back to the "T, F, S" status display by pressing softkey"G function" again.

Auxiliaryfunction

All active auxiliary functions are displayed in the "Auxiliary function"box. 5 M functions and 3 H functions are displayed in total.

Deselection You can switch back to the "T, F, S" status display by pressing softkey"Auxiliary function" again.

2.8.2 Select a program for execution

Operating sequence

Select with softkey ProgramManager

or keyProgramManager

Select a program in the "Directory" menu

Execute Press softkey "Execute"

The program is selected and you switch automatically to the "MachineAuto" operating mode.

If you select a machining program with contour pockets for the firsttime, the depths of cut for the contour pocket are calculatedautomatically. This process may take several seconds depending onthe complexity of the contour.

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2.8.3 Start/stop/abort program

Function

The following subsection describes how you can start and stopprograms or continue them after an abort command.

Operating sequence

Precondition No alarms are currently active.The program is selected.The feedrate enable signal is set.The spindle enable signal is set.

Start program

The program is started and executed.

Stop/abort program

Processing is interrupted in a block, i.e. the block is not executed tothe block end.You can restart the program by pressing "NC Start".

The active program is aborted.

2 08.00 Operation



2.8.4 Interrupt program

Retract tool from contourAfter you have interrupted a program ("NC Stop") in Automatic mode(e.g. in order to take a measurement on the workpiece and correct thetool wear values or after tool breakage), you can retract the tool fromthe contour in "Machine Manual" mode. In such cases, ShopMill storesthe coordinates of the interruption point and displays the differences indistance traveled by the axes in "Machine Manual" mode as a "Repos"(= Reposition) offset in the actual value window.

For details of how to traverse machine axes, please refer to Section"Traverse machine axes".

Reposition tool on

contourThe "Repos" function repositions the tool on the workpiece contourafter traversal of the machine axes during a program interruption inAutomatic mode.

Operating sequence

Precondition "Machine Manual" operating mode is selected.The axes have been moved away from the point of interruption.

Selects the "Repos" machine function.

X ...



You will not be able to move the axis beyond the point of interruption.The feed override is operative.

Warning

The rapid traverse override key is active.Non-adjusted Repos offsets will be adjusted automatically withprogram feedrate and linear interpolation when you switch over toAutomatic and press "NC Start".

2 Operation 08.00



2.8.5 Enter a program at any selected point

Block search

Function

The block search function allows you to run the program forward untilthe selected block is reached. You can use one of three searchmethods:

1. Calculation to contour:During a block search with calculation to contour, the samecalculations are performed as in normal program operation. Theentire target block is subsequently executed in an identical mannerto normal program execution.

2. Start calculation to end point/block search:During a block search with calculation, the same calculations areperformed as in normal program operation. The end point of thetarget block or the next programmed position is then approachedaccording to the interpolation mode programmed for the targetblock.

3. Without calculationNo calculations are performed during the block search.The internal control values are set to the states prior to the blocksearch.This variant is displayed as an extra option only for G codeprograms!

You can specify the search target by

• positioning the cursor directly on program blocks (technology andposition blocks)

• entering a text string.

Operating sequence

Precondition The program in which you want to find a block is selected in "MachineAuto" mode.

Direct search on program

blocks

Position the cursor on the desired target block.

Blocksearch

Switches to the "Block search" function to set a search target.

Select one of the available search methods.

2 08.00 Operation



You can select one of the following strategies to search for a block:

Tocontour

Startsearch run

ShopMill cycle If the search target is a position block, a window will be displayed inwhich you can choose the technology from the chained programblocks.

You can abort the selection by pressing "Cancel".

When you select "Accept", a window is displayed in which you canenter the start hole number from the chained position block for theselected technology.

G code program The available block search methods in G code program are as follows:

Tocontour

Startsearch run

Withoutcalculation

When you press NC Start, the axis travel motions calculated from theblock search are executed. The program is then processed starting atthis target block.

Abort block search

You can abort the block search by pressing "Reset".

Aborts the "Block search" function.

Search via a text string

Search You define the search target by entering a text string in a window. Youcan also select whether the search must start at the programbeginning or from the current cursor position.

Continuesearch

The search is continued until the next matching text string is found.

When you press NC Start, the axis travel motions calculated from theblock search are executed. The program is then processed starting atthis target block.

You can abort the block search by pressing "Reset".

2 Operation 08.00



2.8.6 Program control

Function

In "Machine Auto" and "MDA" modes, you can intervene in theexecution of a program using functions

• Conditional stop (M01),

• Program test/dry run feedrate (PRT/DRY),

• Skip (SKP)

• and single block fine (see Section "Execute a trial program run" fordetails).

Programcontrol

In "Machine Auto" mode you can enter the functions via the "Programcontrol" softkey; in "MDA" mode you must enter the functions as Gcode commands.

Conditional stop

Function

When this function is active, processing of the program ceases ateach block in which an "Optional stop" has been programmed."Stop: M0/M1 active" is then displayed on the screen.

Operating sequence

Precondition The program is selected in "Machine Auto" or "MDA" mode.

Select with softkeys Conditionalstop

Start the program again by pressing the "NC Start" key.

Deselect with softkey Conditionalstop

If this function is not active, the program is not stopped at special

function M01 (in program block).

Program testing

Function

When the "Program test" function is active, the control system checksprograms and program sections for the following errors withoutmoving the machine axes:

2 08.00 Operation



• Geometric incompatibilities

• Missing data

• Non-executable instruction sequences and jumps

• Violation of working area

The following functions can be used in "Program test" mode:

• Stop program with "Conditional stop"

• Graphic screen representation via "Simultaneous recording"(see Section "Simultaneous recording before machining").

Further notes

The machine and auxiliary functions provided for program testing areoutput by the NC and can be inhibited by the machine manufacturer.

Please read the machine manufacturer’s instruction manual!

Dry run feedrate

Function

When you press softkey "Dry run feed", the programmed feedrate isreplaced by a dry run feedrates defined in a machine data.

The dry run feedrate must also be set for graphic screenrepresentation of the machining operation (see Section "Simultaneousrecording before machining").

Skip block

Function

G code blocks which need not be executed in every program run canbe skipped. If you wish a block to be skipped, you must identify it byinserting a "/" (slash) character in front of the block number.

Select with softkeys Skip

You can deactivate the function by pressing the "Skip" softkey again.

2 Operation 08.00



2.8.7 Simultaneous recording before machining

Function

The "Program test" function offers you the option of graphicallysimulating a program run in Automatic mode before it is machined, i.e.without moving the machine axes.

This simulation function is optional.

The graphic displays a workpiece as if it were being machined with acylindrical tool.

Status displays The status displays in the graphic contain information about

• the current axis coordinates and

• the program block currently being processed.

Operating sequence

Precondition The program is selected in "Machine Auto" mode.

Programcontrol

Programtest

Dry runfeedrate

Select softkeys "Program control" and "Program test".

If you select softkey "Dry run feedrate" as well, the programmed feedvelocity is replaced by a dry run feedrate defined in a machine data.

Simultan.recording

Select softkey "Simultaneous recording" and

start the program with "NC Start".

You can still use the program control functions such as "NC Stop","Single block", "Feedrate override", etc.

Programview

When you press softkey "Program view", the display changes from the"Simultaneous recording" graphic to the program view in Automaticmode. The system continues to record graphic data as a backgroundfunction.

You can return to the graphic display by pressing one of the followingsoftkeys:

Plan view • plan view,

• representation in 3 planes or

• 3D representation (volume model).

2 08.00 Operation



Deletescreen

You can select softkey "Delete screen" to clear the machiningoperation graphic which has already been recorded while the programis executing. Recording of the machining operation will howevercontinue.

For further information about the principles and operation, please referto Section "Simulation".

2.8.8 Simultaneous recording during machining

Function

You can track the current machining operation on the machine toolsimultaneously by monitoring the graphic display on the controlscreen.This function is optional.

Operating sequence

Precondition Program test and dry run feedrate must not be selected.

Simultan.recording

Select softkey "Simultaneous recording" and

start the program with "NC Start".

The "simultaneous recording" function can be switched on at any timeduring machining.

An explanation of the functions available under "Simultaneousrecording" can be found in Sections "Simultaneous recording beforemachining" and "Simulation".

2 Operation 08.00

2.9 Execute a trial program run 2


2.9 Execute a trial program run

2.9.1 Single block

Function

When this function is active, the program is interrupted after everyblock which initiates some operation on the machine (these do noinclude arithmetic blocks).

Default setting The following defaults apply:

• A single block includes

• the whole machining operation in the case of drilling operations andthe machining operations on one plane in the case of pocket milling.

Select with softkey Singleblock fine

"Single block fine" active When the "Single block fine" function is active, each individual drillinfeed and pocket milling motion is executed as a separate block.

Select with softkey Singleblock fine

Single block via machine

control panel

Activate the "Single block" function in "Machine Auto" mode. It willallow you to process a program block by block. The appropriate LEDon the machine control panel lights up to indicate that single blockmode is active.

If you have selected single block machining,

• the text "Stop: Block ended in single block" is displayed in thechannel operating message line when the program is interrupted

• the current program block will not be executed until you press the"NC Start" key,

• the program stops automatically after a block has been processed,

• the following block will be processed when you press the "NC Start"key again.

Deselect single block mode

You can deselect the function by pressing the "Single block" keyagain.

2 08.00 Operation2.9 Execute a trial program run 2


2.9.2 Correct program

Function

As soon as the control detects a syntax error in the program, itinterrupts the program and displays the syntax error in the alarm line.In the event of such errors (program Stop status), you can correct theprogram in the program editor.

Operating sequence

Precondition The program is selected in "Machine Auto" mode.The program is in the Stop or Reset state.

Select with softkey Correctprogram

The program editor appears on the screen.

If an error has occurred, the errored block is marked. Press the "Input"key and then correct the block.

Press softkey "Accept" to transfer the correction to the currentprogram.

Machinefrom here

After you have made the correction, you can continue processing bypressing this softkey and "NC Start".

• NC Stop status:You can only modify blocks that have not yet been executed orread in by the NC.

• Reset status:You can modify any block.

2 Operation 08.00

2.10 Tools and tool offsets 2


2.10 Tools and tool offsets

ShopMill offers you a tool management facility based on the followinglist:

• Tool list

• Tool wear list

• Magazine list

Enter the tools and their offset data in the tool list or tool wear list. Youwill be able to identify in the magazine list which magazine locationsare disabled or not.

Depending on individual requirements, a tool list might consist of thefollowing:

• A tool change involving

− a spindle or dual gripper

− or a spindle with dual gripper

• at least one tool magazine

• and tools that are not assigned to any tool magazine.

For details of the functionality of your tool management system, pleaserefer to the machine manufacturer’s instruction manual.

Tool list The tool list displays all tools and their offset data stored as a tool datablock in the NC, irrespective of whether or not they are assigned to amagazine location. The tool list offers you all commonly used tools.You can assign geometric and technological tool data to tool types.Various different examples of each tool might exist to which you canassign the current offset data of the tool being used.

You can load and unload tools to and from a magazine via the tool list.When a tool is loaded, it is moved from its storage location to amagazine location. When it is unloaded, it is removed from themagazine and taken back to a storage location.This loading and unloading of tool magazines is defined in a machinedata.

2 08.00 Operation



Example of a tool list with variable location assignment

The main display of the "Tools" operating area shows the current toollist with the following data:

Location Location numberThe following designations/symbols are used for:

• The spindle location

• The locations for gripper 1 and gripper 2 (applies only when a

spindle with dual gripper is used)

• The magazine location numbersIf the configuration includes more than one magazine, themagazine number is specified first followed by the location numberin the magazine:e.g. 1/10 = Magazine 1 with location number 10

2/5 = Magazine 2 with location number 5

• Tools that are not assigned to a magazine in the tool list are storedin a location without location number.

Type Tool typeDepending on the tool type (represented by a symbol), only certain tooloffset data are enabled.

Tool name The name of the tool can be entered as text or a number (see Section"Change tool names").

DP Duplo number of twin tool (replacement tool)1st/2nd edge Tool offset data "Length", "Diameter/radius" and "Angle" for the 1st

and/or 2nd edge of a tool (if applicable).The "H" column is displayed only for ISO dialect0-M programs. EveryH number of an ISO dialect0-M program must be assigned to a tooloffset data record.

N Number of teeth on a millSpindle direction of rotation

2 Operation 08.00



Coolant supply 1 and 2 can be switched on and off

Tool-spec. fct 1...4 Other tool-specific functions such as additional coolant supply,monitoring functions for speed, tool breakage, etc.

The "Details" softkey displays the additional parameters "Roundingradius" or "Angle" for 3D tapered milling tools.

Tool wear list You can select which tool wear data (length and radius/diameter) areapplicable in the tool wear list. You can also set the followingmonitoring functions for a tool.

• Monitoring of actual time of use (service life, number ofworkpieces)

• Monitoring of number of tool load operations

• Other tool status data (disable tool, tool in fixed location, oversizedtool)

Tool magazine The magazine locations with tools are specified in the magazine list.The list also indicates whether the magazine location is disabled(location disable) and the properties (tool status) assigned to the tools.

Fixed/variable location

assignment

You can set a machine data to determine whether all tools must havea variable or fixed location assignment in the magazine.If you select a variable location assignment, the tools are taken to thenext available space in the magazine after a tool change. With a fixedlocation assignment, the tools are always taken back to the locationassigned specifically to them.Please refer to the machine manufacturer’s instruction manual fordetails about location assignments in the tool magazine!

2.10.1 Select the tool list

Operating sequence

Select with softkey Toolszero pt.

Toollist

or key ToolOffset

The tool list will appear on your screen.

2 08.00 Operation



2.10.2 Create a new tool

Function

You create new tools directly in the tool list. A selection of tool typesare displayed for this purpose. The tool type determines whichgeometry data are required and how they will be computed. Thefollowing common tool types are available:

Operating sequence

Select with softkeys Toollist

Newtool

Use the cursor keys to select the tool location you want

Cutter ...

3Dtools

and confirm your selected tool type with the softkey.

A new tool is then created.

3D tools In addition to the geometry data in the tool list, you must specifyfurther parameters for 3D tools.

Type Name Additional parameter

110 Cylindrical die mill -

111 Ball end mill Rounding radius

121 End mill with corner rounding Rounding radius

155 Bevel cutter mill Angle for tapered tools

156 Tapered mill with corner rounding Rounding radius, angle for tapered tools

157 Tapered die mill Angle for tapered tools

Details Press the "Details" softkey and enter the rounding radius or angle fortapered milling tools.

2 Operation 08.00



2.10.3 Create tool offset block for tool edge1/2

ShopMill allows you to assign different tool offset blocks to tools with 2edges, e.g. a counterbore, i.e. one block for each tool edge.

All the tool parameters which define a tool are stored in the tool offsetblock for edge 1 (D1) or 2 (D2).These parameters are the

• tool type (identical for edges 1 and 2)

• geometry values (length, radius, angle) and

• wear values (length, radius).

An H number must be specified for ISO programs (e.g. ISO dialect 1).This corresponds to a particular tool offset block.

When you create a new tool, the tool offset block for tool edge 1 isautomatically active.

Tool offset for 2nd tool

edge

Select softkey "2nd cutt. edge" to set up the offset data for a tool witha 2nd cutting edge.

Select with softkey 2ndcutt. edge

Enter the corresponding values in the list. The tool offset for the 2ndedge is set up.

2 08.00 Operation



2.10.4 Change the tool name

A newly created tool in the tool list is automatically assigned the nameof the selected tool group. You may change this designation as youplease to

• a tool name, e.g. "face_mill_120mm" or

• a tool number, e.g. "1" .A tool name may contain a maximum of 17 characters. You can useany letters, digits, the underscore symbol "_", dots "." and slashes "/".

2.10.5 Create a replacement tool

A replacement tool is one that can be employed to perform the samemachining operation as a tool that already exists (e.g. as a replace-ment after tool breakage).

When you create a tool as a replacement, you must give it the samename as an existing comparable tool.

Confirm the name with the "Input" key. The duplo number of thereplacement tool will be incremented by 1 automatically.

The order in which replacement tools are inserted in the spindle is

determined by duplo number DP.

2.10.6 Manual tools

Manual tools are tools which are needed during a machining operationbut which exist only in the tool list and not in the tool magazine. Toolsof this type have to be loaded and unloaded to and from the spindle byhand.

Further notes


2 Operation 08.00



2.10.7 Tool offsets

Function

Why do we need tool

offsets?

You do not have to take tool diameters and lengths into account whenwriting machining programs.You can program workpiece dimensions directly, e.g. as specified inthe production drawing.When a workpiece is machined, the tool paths are controlled as afunction of the relevant tool geometry in such a way that theprogrammed contour can be produced with any tool employed.

Tool path

Contour

The control system

corrects the traversing

path

Enter the tool data separately in the "Tool list" and "Tool wear" tables.When writing the program, you merely need to call the tool yourequire.While the program is being processed, the control fetches the offsetdata it requires from the tool table and corrects the tool pathindividually for different tools.

Correctedtool path

Programmed contour

What type of tool offsets

are available?

The offset memory of a tool includes the following:

• Tool typeThe tool type determines which tool data are required and how theymust be calculated (e.g. drill, centering tool, mill).

2 08.00 Operation



• Total size: Length, radius, angle (drill)These comprise several components (geometry, wear). The controlperforms calculations on the components to obtain a final size (e.g.total length, total radius). The relevant total dimension becomesvalid as soon as the offset memory is activated.

Radius

Leng

thTool length

compensation

This value compensates the differences in length between the toolsyou use.The tool length is interpreted to be the distance between the toolholderreference point and the tool tip. This length is measured and enteredin the tool list.The control uses this measurement and the wear values to calculatetravel movements in the infeed direction.

Tool radius

compensation

"Contour" and "Tool path" are not identical. The mill or tool edgeradius center point must travel along an equidistant to the contour.For this purpose, the programmed tool center point path is displaced –as a function of radius and machining direction – in such a way thatthe tool edge travels exactly along the programmed contour.

2 Operation 08.00



The tool radius must be entered in the tool list. While a program isrunning, the control fetches the radii it requires and uses them tocalculate the tool path.

Equidistant

Offset values for

milling tool (example)F

Z Length in ZRadius in X/Y

Y Length in YRadius in Z/X

Length in XRadius in Y/Z

X

F - Toolholderreference point

Rad

ius

Length

Infeed Geometry in plane

Offset values for

drill (example) Z Length in Z

Y Length in Y

Length in XXF - Toolholder reference point

Infeed Geometry in plane

F

Length

F Angle

Radius

Offset values are used in the simulation display and programminggraphic for the following tools:

• Drill: Angle and radius/diameter

• Centering tool: Radius/diameter

2 08.00 Operation



2.10.8 Special tool functions

Function

You can assign other functions to tool types in the tool list.

Number of teeth N Specify the number of teeth in this parameter. Parameter N is tool-

dependent and can be applied only for milling tools. The controlsystem calculates feedrate F internally if the feed is set in mm/tooth inthe program.

Using the "Alternat." softkey, you can activate and deactivate thespindle direction of rotation (CCW/CW) in parameter "Spindle".

The spindle rotates in theclockwise direction of rotation.

Select withsoftkey

The spindle rotates in thecounterclockwise direction ofrotation.

The spindle is stopped.

You can assign a supply of coolant to the tool in parameters "Coolant1" and "Coolant 2".

Switch coolant ON: Select with softkey

Do not switch coolantON:

Tool-specific functions You can also assign another four machine-specific actions to a tool.You can activate or deactivate these functions using the "Alternat."softkey. Tool-specific functions might include, for example, a 3rdcoolant supply or a tool breakage monitor.Please read the machine manufacturer’s instruction manual!

2 Operation 08.00



2.10.9 Create tool wear data

The wear data for an existing tool must be entered in the tool wear list.

Select with softkey Tool wear

The following menu will appear on your screen:

Example of a tool wear list with variable location assignment

Allowances for

length and radiiYou must enter the delta values for length (∆length) and radius

(∆radius) /diameter (∆∅) for tools in the tool wear list.

Please note that

• a positive delta value signifies allowance (e.g. for subsequent finishcuts) and

• a negative delta value signifies undersize (tool wear)

Length

Radius

DL>0DL<0

DL=DLength

Radius

DR>0

DR<0

DR=DRadius

Allowances/undersizes for a corner radius mill

The correction values entered in tables "Tool list" and "Tool wear"become operative immediately a tool is called and inserted in thespindle.

2 08.00 Operation



2.10.10 Tool monitoring

You can assign the following tool monitoring functions and features toevery tool in the tool wear list:

• Tool life

• No. of loadings

• Other tool properties

− Disable tool

− Tool in fixed location

− Oversized tool

Further notes

The tool monitoring functions are activated via a machine data.Please read the machine manufacturer’s instruction manual!

Select with softkey Toollist

Toolwear

Tool life T The tool life monitoring function is applied to the tool cutting edge(D1 or D2) that is currently in use. The monitoring function must beexplicitly activated for this purpose. Monitoring times are set on aminutes scale and can be entered accordingly.When the remaining tool life is = 0, the tool is set to "disabled". It will

be discarded after the next tool change.If a tool is programmed again following a tool change operation, thesystem checks whether the tool life has already expired. If it has, areplacement tool is inserted in its place (if available).

No. of loadings C The number of times that a tool may be loaded in the spindle toperform a machining operation must be entered in this parameter.If the number of spindle loading operations ("no. of loadings") hasreached zero, the tool is disabled.

You can activate the type of monitoring you want in parameter T/Cafter selecting the "Alternat." key. Enter the appropriate setting in therelevant input field.

Other tool properties You can assign the following additional properties to a tool:

• G: Disable tool, e.g. when the tool edge is worn.

• U: Tool oversized, i.e. half of each of the adjacent magazinelocations (to left and right of location in question) is disabled.

• P: Tool at fixed location, i.e. the tool is permanently assigned to aparticular magazine location (fixed-location-coded).

2 Operation 08.00



Select the function you require with the cursor keys and activate it withsoftkey "Alternat.".

2.10.11 Magazine list

The magazine locations with tools are specified in the magazine list.The list also indicates whether the magazine location is disabled(location disable) and the properties (tool status) assigned to the tools.


Magazine

Example of magazine with variable assignment

Disable magazine location Magazine locations can be reserved or disabled for specific tools, e.g.for oversized tools.

Select the magazine location you wish to disable.

Toggle with the "Alternat." softkey in the "Location disable" columnuntil a "G" (= disabled) is displayed in the correct field. This location isnow disabled. You will not be able to load any tool into this location.

Tool status The "Tool status" column lists the properties which have beenassigned to the currently active tool:

• G: Tool is disabled

• U: Tool is oversized

• P: Tool has a permanent location assignment

2 08.00 Operation



2.10.12 Delete a tool

Function

Tools can be deleted in the tool list.

Operating sequence

Select the tool that you wish to delete.

Deletetool

Delete Select the softkey "Delete tool" and confirm by selecting the "Delete"button. The tool data for the selected tool are deleted. The magazinelocation in which the tool was stored is enabled.

2.10.13 Change the tool type

Function

You can change a tool type into another tool type in the tool list.

Operating sequence

Select the tool that you wish to delete. The cursor is positioned oninput field "Type".

Press the "Alternat." key to select the new tool type.The input fields for the new tool type are displayed.

2.10.14 Load a tool

Function

You can load a tool directly to the spindle or to another free location inthe magazine from the tool list.

Operating sequence

Precondition The machine data for tool management with loading/unloading is set.

2 Operation 08.00



Further notes



Toollist

or keyToolOffset

The "Tool list" menu is displayed on the screen.

Select the tool that you wish to delete.

Load Select softkey "Load".

A window headed "Empty location" containing the number of the firstfree magazine location appears on the screen.You can now enter a new location number

or

Spindle load the tool directly into the spindle.

Starts the loading operation.

The tool is loaded to the specified magazine location.

Aborts the loading operation.

2.10.15 Unload a tool

Function

When a tool is unloaded, it is removed from the magazine and enteredin a store position in the tool list. The tool offset data block is notdeleted. The unloaded tool has no location number in the storeposition.

Operating sequence

Precondition The machine data for tool management with loading/unloading is set.

Further notes



Toollist

or key ToolOffset

2 08.00 Operation



The "Tool list" menu is displayed on the screen.

Select a tool.

Unload Select softkey "Unload".

The tool is removed from the magazine and taken back to a storagelocation.

2.10.16 Sort tools

Function

Tools can be sorted in the tool list or tool wear list according tomagazine assignment, tool name (alphabetic) or tool type. When theyare sorted according to magazine assignment, empty magazinelocations are displayed as well.

Operating sequence


sort > or

Tool wear

sort >

tomagazine or

toname or

totype

2 Operation 08.00

2.11 Zero offsets 2


2.11 Zero offsets

2.11.1 General

Machine/

workpiece zero

After referencing, the actual values are referred to the machine zero M

of the machine coordinate system MCS. The machining program for

the workpiece is referred to the workpiece zero W of the workpiece

coordinate system WCS.

The machine zero and workpiece zero do not have to be identical. Thedistance between the machine zero and workpiece zero may varydepending on the workpiece type and clamping method. This zerooffset is taken into account when the workpiece program is processed.

Z m

Xm

Ym

ZW

Xw

ZO1

Basic offset

Yw

MW ZO2

Example of a zero offset on a milling machine

The following offsets can be activated:

Basic offset You can use the basic offset to redefine the zero point of theworkpiece coordinate system within the machine coordinate system.

Settable zero offset The settable zero offsets can be used to set up a workpiece zeroreferred to the zero of the machine coordinate system in all axes. Thesettable zero offset is referred to the base offset.

Programmable offsets In addition to the basic offset and settable offset, programmableoffsets can also be applied in the called program:

• Active zero offsets

• Offset

• Rotation

• Scaling

• Mirroring

2 08.00 Operation

2.11 Zero offsets 2


The programmable zero offset refers to the settable zero offset.

Please also refer to the description in Section "Programming, zerooffsets".

DRF offset The DRF offset (Differential Resolver Function) generates anincremental zero offset in Automatic mode in conjunction with anelectronic handwheel.

Total offset The total offset is the sum of all offsets in the machine coordinatesystem.

Further notes

The number of settable zero offsets (up to 100) is defined by amachine data.Please read the machine manufacturer’s instruction manual!

2.11.2 Display a zero offset

Function

The "Zero offset" overview lists the following information:

• Current axis positions in the machine and tool coordinate systems,

• all existing zero offsets and

• the total offset.

Additionalaxes

By selecting softkey "Additional axes", you can display a further twoaxes (rotary axes) and their offsets. These additional axes are eachactivated via display machine data.


2 Operation 08.00

2.11 Zero offsets 2


Operating sequence


Zerooffset

The following menu will appear on your screen:

Example of a zero offset

Base The basic offset entered in "Machine Manual" mode and the "Basiczero offset" menu is displayed here for each axis. You can change thebasic offset in this window if necessary.

ZO 1 ... ZO n Enter the following in this window:

• The values of current zero offsets "ZO 1 ... ZO n" (for n= 4...100)for each axis and

• the rotation with which a coordinate system is rotated about anaxis.

DRF The generated handwheel offsets for each axis are displayed here.

Program The active values of the selected programmable zero offset aredisplayed here. They cannot be altered.

Scale The active scale factor for the relevant axis is displayed here. Theycannot be altered.

Mirror Displays axis in relation to which mirroring is performed.

Total The sum of all active settable and programmable offsets is displayedhere. They cannot be altered.

2 08.00 Operation

2.11 Zero offsets 2


2.11.3 Select/deselect settable zero offset in Manual area

Operating sequence


T, S, M...

The following window is displayed.

Select a zero offset

Position the cursor on parameter "Zero offset" and use softkey"Alternat." to set the zero offset you require.

When you press the "NC Start" key, the zero offset you have selectedwill be activated.

The active zero offset is also displayed in the "WCS" window.

ZO1e.g.

The offset values programmed in the "Zero offset" menu are also

taken into account in the tool coordinate system display WCS.

Deselect a zero offset

Place the cursor on the "Zero offset" parameter and set the field to "–"using the "Alternat." softkey.

When you press the "NC Start" key, the set active zero offset will bedeselected again.

2 Operation 08.00

2.12 Switch to CNC operation 2


2.12 Switch to CNC operation

CNC ISO You can switch from the ShopMill interface to the CNC standardoperator interface of the SINUMERIK 840D or 810D system bypressing softkey "CNC ISO".

Softkey "CNC ISO" will work only if the machine manufacturer hasimplemented the function internally via the PLC interface.Please read the machine manufacturer’s instruction manual!

If softkey "CNC ISO" is active, the following basic display of the CNCstandard operator interface appears on your screen:

ShopMill If you wish to return to the ShopMill operator interface, press softkey"ShopMill"."

Further notes If you are working in the CNC standard operator interface, please readthe User Documentation for the SINUMERIK 840D/810D system (seeAppendix, List of References).

2.13 Remote diagnosis

Function

The control system can be operated from an external PC by means ofa remote diagnostic function. You can use a modem to link the controlsystem and the external PC.

Remotediagnosis

The remote diagnostic function is activated on the CNC standardoperator interface in the Diagnosis operating area.

Remote Diagnosis is an option.

For further information about remote diagnosis, please refer todocument /FB/, Description of Functions, Extension Functions, F3.

�

3 08.00 Programming with ShopMill 3


Programming with ShopMill

3.1 Fundamental programming principles ...................................................................... 3-97

3.2 Program structure ................................................................................................... 3-1003.2.1 Screen window in program ..................................................................................... 3-1013.2.2 Toggle between screen windows............................................................................ 3-102

3.3 Create a ShopMill program..................................................................................... 3-1033.3.1 Create a new program; define a blank.................................................................... 3-1033.3.2 Program new blocks ............................................................................................... 3-1063.3.3 Edit program blocks (change, delete, move, copy, paste)...................................... 3-108

3.4 Program the tool, offset value and spindle speed................................................... 3-110

3.5 Contour milling ........................................................................................................ 3-1113.5.1 Free contour programming ..................................................................................... 3-1123.5.2 Description of softkeys for free contour programming function .............................. 3-1153.5.3 Description of parameters for line/circle contour elements..................................... 3-1173.5.4 Programming examples for freely defined contours ............................................... 3-1183.5.5 Path milling of open and closed contours ............................................................... 3-1203.5.6 Rough drilling in contour pockets............................................................................ 3-1233.5.7 Machine (rough cut) pocket with islands................................................................. 3-1263.5.8 Remove residual material ....................................................................................... 3-1273.5.9 Finish pocket with islands ....................................................................................... 3-129

3.6 Programing simple path motions ............................................................................ 3-1313.6.1 Line ......................................................................................................................... 3-1313.6.2 Circle with known center point ................................................................................ 3-1333.6.3 Circle with known radius ......................................................................................... 3-1343.6.4 Helix ........................................................................................................................ 3-1353.6.5 Polar coordinates .................................................................................................... 3-1363.6.6 Polar line ................................................................................................................. 3-1373.6.7 Polar circle .............................................................................................................. 3-1383.6.8 Programming examples for polar coordinates........................................................ 3-139

3.7 Drilling ..................................................................................................................... 3-1403.7.1 Centering ................................................................................................................ 3-1413.7.2 Drilling and reaming................................................................................................ 3-1423.7.3 Deep-hole drilling .................................................................................................... 3-1433.7.4 Boring...................................................................................................................... 3-1453.7.5 Tapping................................................................................................................... 3-1463.7.6 Thread cutting......................................................................................................... 3-1473.7.7 Position on freely programmable positions and position patterns .......................... 3-1503.7.8 Freely programmable positions .............................................................................. 3-1513.7.9 Line position pattern................................................................................................ 3-1523.7.10 Matrix position pattern............................................................................................. 3-1533.7.11 Full circle position pattern ....................................................................................... 3-1543.7.12 Pitch circle position pattern ..................................................................................... 3-1563.7.13 Obstacle.................................................................................................................. 3-1573.7.14 Repeat positions ..................................................................................................... 3-158

3 Programming with ShopMill 08.00 3


3.7.15 Programming examples for drilling ......................................................................... 3-159

3.8 Milling ...................................................................................................................... 3-1613.8.1 Face milling ............................................................................................................. 3-1613.8.2 Mill a rectangular pocket ......................................................................................... 3-1643.8.3 Mill a circular pocket................................................................................................ 3-1673.8.4 Mill rectangular spigots ........................................................................................... 3-1693.8.5 Mill circular spigots.................................................................................................. 3-1713.8.6 Mill longitudinal slots ............................................................................................... 3-1733.8.7 Mill circumferential slots on a full or pitch circle ...................................................... 3-1753.8.8 Use of position patterns for milling.......................................................................... 3-177

3.9 Measurements ........................................................................................................ 3-1803.9.1 Workpiece zero point .............................................................................................. 3-1803.9.2 Measure tool ........................................................................................................... 3-182

3.10 Miscellaneous functions .......................................................................................... 3-1833.10.1 Subroutines and program section repeats .............................................................. 3-1833.10.2 Alter the safety clearance or return plane ............................................................... 3-1843.10.3 Zero offsets ............................................................................................................. 3-1853.10.4 Cylinder peripheral surface transformation ............................................................. 3-1913.10.5 Swiveling ................................................................................................................. 3-1943.10.6 Define a new blank.................................................................................................. 3-199

3.11 Insert G code in a ShopMill program....................................................................... 3-200

3 08.00 Programming with ShopMill

3.1 Fundamental programming principles 3


3.1 Fundamental programming principles

Important! Please pay particular attention to the following fundamental

principles when writing programs for your machine tool!

Axes The 3 main axes on milling machines are designated as X, Y and Z.Axis Z is normally the tool axis.

Metric or inch

unit of measurement

The control system can process both metric and inch dimensions.Depending on the basic setting you choose, the control interprets allgeometric values as either metric or inch dimensions.Irrespective of the basic setting, you can set metric or inch dimensionsin the program header (define blank).All dimensions stated in this section are metric.

Absolute dimensioning With the absolute dimensioning method, dimensions refer to the zeropoint of the coordinate system of the total offset.

Incremental dimensioning With the incremental dimensioning method, the programmedpositional numerical value corresponds to the path to be traversed.The direction of travel is determined by the sign.

Tool T A tool must be programmed for every cutting operation. With theShopMill machining cycles, a tool selection is already integrated inevery parameterization screenform. Exception: You must select a toolbefore programming simple straight lines and circles.

Tool selections are modal, i.e. if the same tool is used in a successionof machining cycles, it only needs to be programmed in the first cycle.

Tool length compensation Tool length compensations take effect immediately the tool is loadedinto the spindle. Two different tool offset blocks (D1/D2) can beassigned to each tool with 2 edges.The tool length compensation of the spindle tool remains active evenafter the program has been executed (RESET).

3 Programming with ShopMill 08.00



Tool radius compensation The tool radius compensation is automatically included in the cyclesexcept for path milling. You can machine with or without radiuscompensation in conjunction with the "Path milling" and "Line"functions. In the case of the "Line" function, the tool radiuscompensation has a modal action, i.e. it is not automaticallydeactivated again.

Radius compensation left of contour

Radius compensation right of contour

Radius compensation off

Radius compensation is retainedas set

Spindle speed The spindle speed (S) determines the number of spindle rotations perminute. The CW/CCW setting is made in the tool list in ShopMill.

Programming:The spindle speed is input when a new tool is loaded into the spindle.As an alternative to spindle speed, a cutting rate (V) can be specifiedin m/min.

Spindle start/spindle stop:The spindle is started directly after a new tool has been loaded. It isstopped on Reset, end of program or tool change.

Cutting rate Peripheral speed at which the tool cutting edge machines theworkpiece. Cutting rates (V) are specified in m/min.

Cutting rate




Traverse at rapid rate The programmed path is traversed along a straight line at the fastestpossible velocity without the workpiece being machined. Rapidtraverse is a non-modal command, i.e. if you want the axis to traverserapidly in the next block, then you must enter "Rapid traverse" asfeedrate (F) again.If you do not program a feedrate or rapid traverse, the axis isautomatically traversed at the last programmed feed value (machiningfeedrate).

Traverse at feedrate

(machining feedrate)

The tool travels at the programmed feedrate F along a straight line oron a circle to the programmed end point and then machines theworkpiece. Machining feedrates (F) are specified in mm/min, mm/revor mm/tooth.

Feedrate in mm/toothMills are multi-edged tools. For this reason, a value must be foundwhich guarantees that each cutting edge can machine the workpieceunder the best possible conditions. Feed per tooth corresponds to thelinear path traversed by the mill when a tooth is engaged. Feed pertooth is also the effective distance covered by the table feed betweenthe engagement of two successive cutting edges.

Feedrate in mm/tooth

The machining feedrate is modal, i.e. even if the machining processchanges, you need not enter a new feedrate if the feedrateprogrammed in the preceding block is still appropriate. This applieseven if you have programmed a rapid traverse command in between.


3.2 Program structure 3


3.2 Program structure

The program is divided into 3 subsections:Program header, program blocks and program end.These subsections form a machining plan.

Program structure

Program header The program header contains the dimensions of the blank andparameters which are effective throughout the program, e.g.

• dimension in mm or inches

• tool axis X, Y or Z

• return plane, safety clearance, machining direction

Program blocks To obtain a finished part, you must first program the variousmachining operations, travel motions, machine commands, etc. Theprogram blocks represent this program.

Chained machining The control automatically chains the technology and position blocks.These blocks are identified by a square bracket immediately besidethe machining symbol. The brackets are inserted from the beginningto the end of the sequence of chained blocks.

Blocks N10 ... N25 are chained




3.2.1 Screen window in program

Machining plan

View of a programmed machining plan

Programming graphic

View of a programming graphic

Parameter input window

with programming graphic

Programming graphic with open parameter window

Parameter input window

with Help display

Help display for parameter inputs




Explanation of color symbols in the Help displays:Yellow circle = reference pointRed arrow = tool traversing rapidlyGreen arrow = tool traversing at machining feedrate

3.2.2 Toggle between screen windows

Key

You can use the Info key to toggle between the displayedscreen windows, i.e.

• from the machining plan to the programming graphic andback and

• to select and deselect a Help display when parameterwindows are open.


3.3 Create a ShopMill program 3


3.3 Create a ShopMill program

3.3.1 Create a new program; define a blank

New programs are set up in the "Program Manager" area.

Select with softkeys ProgramManager

Programs

New >

ShopMillProgram

Enter a program name Enter a program name.Program names may be a maximum of 24 characters in length. Youcan use any letters, digits or the underscore symbol (_). ShopMillautomatically changes lower case to upper case.

Confirm the program name by pressing

softkey or with the "Input" key .

The screenform for setting the "Program header" parameters thenappears.

Parameterize the program

header

Set the program header parameters

Parameter settings in the program header are valid throughout theentire program.




Parameters for input of a

blank• Workpiece corner point 1 (X0, Y0, Z0):

Workpiece corner point 1 is the reference point for the blankdimensions. It must be entered as an absolute value.

• Workpiece corner point 2 or dimensions(X1, Y1, Z1 or L, W, H):Workpiece corner point 2 is opposite workpiece corner point 1.It must be entered as an absolute value. The deviations are thelength, width and height of the blank.

Workpiece corner points 1 and 2 Workpiece corner point 1 and

deviations

• Definition of unit of measurement of program [mm or inch].• Tool axis: The tool length is calculated in the set axis.

• Return plane (RP and safety clearance (SC):

Planes above workpiece. )During machining the tool travels in rapid traverse from the toolchange point to the return plan and then to the safety clearance.The machining feedrate is activated at this level. When themachining operation is finished, the tool travels at machiningfeedrate away from the workpiece onto the safety clearancelevel. It travels from the safety clearance to the return plane andthen to the tool change point in rapid traverse.The return plane is entered as an absolute value.The safety clearance must be entered as an incremental value(without sign).

Return plane (RP) and safety clearance (SC)




X

Z

Safetyclearance (SC)

Return plane (RP)

Safety clearance for varying workpiece heights

• Machining direction:When machining a pocket, a longitudinal groove or a spigot,ShopMill applies the machining direction (climb or conventional)and the spindle rotation entered in the tool list. The pocket isthen machined in a clockwise or counter-clockwise direction.

Climb milling

Conventional milling

Machining pockets in climb or conventional milling operation with CW spindle

rotation

• Retraction with position patterns:

When working with optimized retraction, the tool travels in

relation to the contour across the workpiece at machining feedrate

and safety clearance (SC). On retraction to RP, the tool is retracted

to the return plane when the machining step is complete andinfeeds at the new position. Collisions with workpiece obstacles arethus prevented when the tool is retracted and fed in, e.g. whenholes in pockets or grooves are machined at different levels andpositions.

Optimized retraction Retraction to return plane RP




Store parametersSelect with softkey The parameters you have entered are stored. The machining plan isthen displayed. You can now program further machining operations.

3.3.2 Program new blocks

Create program blocks Once you have defined the blank, you can define machiningoperations, feedrates and positions in individual program blocks.You will be supported by "Help" displays for individual machiningoperations.

Note New programming blocks are always inserted after the selected

block. You cannot program blocks before the program header or afterprogram end.

Parameter input fields

Feedrate:If you do not program a value for feedrate (F) (empty field), the systemuses the last programmed feedrate.

Clear an input field:Use the DEL key (or Backspace key) to clear an input field, i.e. todelete the programmed value.

Preset (default) or empty parameter fields :You must always enter a value in fields with a preset default. If youclear a default field, softkey "Accept" disappears from the display!

"Alternat." softkey and toggle key:If the cursor is positioned on an input field with various setting options,softkey "Alternat." is automatically displayed on the vertical softkey bar(see softkey "Alternat." in Section "Important softkeys for operationand programming").

Roughing/finishing:Every cycle can be programmed with roughing or finishing. If you wishto rough cut the workpiece first and then finish cut it, you must call thecycle a second time. The programmed values do not change if you callthe cycle again.

Some cycles offer roughing and finishing as a complete machining

operation, i.e. you need only call the cycle once.




Approach a cycle • Approach the programmed cycles with ShopMill

− Tool is above the return plane (RP) :The tool is positioned in rapid traverse in the X/Y plane and thenin the Z direction to the return plane (RP)

X

ZSafetyclearance (SC)

Returnplane (RP)

Tool change point

Rapid traverse

Machining feedrate

Approach a cycle above the return plane

− or tool is below the return plane (RP) :The tool is positioned in rapid traverse first in the Z direction tothe return plane (RP) and then in rapid traverse in the X/Y plane

X

ZSafetyclearance (SC)

Returnplane (RP)

Tool changepoint

Rapid traverse

Machining feedrate

Approach a cycle below the return plane

• Tool axis travels in rapid traverse to safety clearance (SC)

• The cycle is then processed at the programmed machiningfeedrate

• On completion of machining, the tool travels to the cycle center inthe X/Y plane at machining feedrate and then moves away from theworkpiece with the tool axis until it reaches safety clearance

• The tool axis then retracts to the return plane in rapid traverse

• The tool change point is approached from the return plane in rapidtraverse




3.3.3 Edit program blocks (change, delete, move, copy, paste)

Function

Change a program block Program blocks generated with the ShopMill programming syntax canbe reconverted to the corresponding ShopMill interactive screenformsagain.When you select a block with the cursor keys, an "Open" key appearsin the block.

Change a program block

When you select the key on the operator panel, the interactivescreenform of the selected program block is opened. You can nowchange the cycle parameters.

Transfer the changes to the program by selecting the key.

Edit a program block You can use the extended program block editor to delete, copy andpaste program blocks. You can also sort block numbers in ascendingorder.

Select with key "etc." >

Use the cursor keys to select the block to be edited. Then press theappropriate softkey, e.g. Copy.

Delete a program blockCut

Copy and paste a program blockCopy Insert

Move a program blockCut Insert

The program block to be inserted is always pasted in after the marked(selected) program block.

Edit more than one

program block

Use the arrow keys to select the first or last program block to be editedand then press softkey "Mark". Then select the remaining blocks to beedited using the cursor keys.

Delete program blocksMark

Cut




Copy and paste program blocksMark

Copy

Insert

Move program blocksMark

Cut

Insert

Copy program blocks to

another program• First copy the blocks that you want to paste to another program

(see "Mark, copy blocks").

• Then open the program into which you want to paste them andselect the extended program editor:

ProgramManager

Programs

>

• Use the cursor keys to select the block under which you wish toinsert the previously copied blocks and then press softkey "Paste".

Find You can set the following search criteria:

• Find block number

• Find text (e.g. straight line, drill, X=50, etc.)

• Search from program beginning (default) or search from currentcursor position. The option is selected with the toggle key.

Select with softkey Search >

Example Find block number 10

• Press Search >

• Enter the value "10"

• Press

Find Next You can continue the search by selecting the "Find next" key.

Select with softkey Findnext

Number blocks in

ascending sequence

If you paste a new or copied program block in between two existingprogram blocks, ShopMill automatically generates a new blocknumber. This number might be higher than the block number in thenext block.You can sort the block numbers in ascending sequence again bypressing softkey "Renumber".

Select with softkey: Renumber

Exit the extended program

editor You can exit the extended program editor by selecting softkey

.


3.4 Program the tool, offset value and spindle speed 3


3.4 Program the tool, offset value and spindle speed

General When you program cycles, you will find the tool displayed in thescreenform. When you program a line or a circular arc, you will haveto select a tool beforehand.

Select with softkeys: StraightCircle

Tool

Programming

a tool

Select parameter field "T". ShopMill allows you to enter tools in severaldifferent ways:1. Possibility: Enter the name or number of a tool via the keyboard.2. Possibility: Press area key "Tool, offset", select a tool with

the cursor keys and select softkey

toprogram .

The tool is transferred to the parameter field.

Offset value (D1/D2) You can select whether to apply offset value D1 or D2 for eachprogrammed tool. The tool offsets are stored in the tool list.You must program D1 and D2 for certain tools (counterbore withspigot, stepped drill, etc.) to avoid risk of collisions (see also Sections"Programming examples for drilling" and "Tools and tool offsets").

Spindle speed (S) or

cutting rate (V)

In ShopMill you can program either the spindle speed (S) or the cuttingrate (V). You can toggle between them using the "Alternat." key.

• Spindle speed and cutting rate remain valid until you program anew tool.

• Spindle speeds are programmed in rev/min.

• Cutting rates are programmed in m/min

• You can set the direction of rotation of a tool in the tool list.

Allowance (DR) You can program an allowance on the tool radius in this parameterinput field. A finishing allowance is then left when the contour ismachined (see also Section "Tools and tool offsets").

Example You want to leave a finishing allowance of 0.5 mm on a contour. DRmust then be programmed with 0.5 mm.With a setting of DR=0, the programmed contour is cut without afinishing allowance.


3.5 Contour milling 3


3.5 Contour milling

Function

You can program the following machining operations using the contourmilling cycles.

Free contour programming When programming a freely defined contour, you can input a contourand assign it a contour name. The geometry processor integrated inShopMill offers the following functions:

• Input of contours with up to 99 elements (including transitionelements chamfer and radius). At least two elements create adefined contour.

• Input of incompletely dimensioned elements

• Addition of chamfers and radii (transition elements)

• Tangential transitions

Select with softkeys Newcontour >

Path milling Path milling is a machining cycle with which you can machine openand closed contours. The most important functions are:

• Approach and retract strategies

• Finishing allowances for XY plane and Z direction (tool axis)

• Cut segmentation in Z direction (tool axis)

Select with softkey Pathmilling >

Rough-drilling The rough-drilling function can be used on contour pockets beforethey are removed. The machining cycle comprises a centering cycleand the actual rough-drilling cycle.

Select with softkey Rough-drilling >

Remove pocket with

islands

This is a cycle that can machine pockets with or without islands. Thepocket and island contours are programmed as a freely definedcontour. The cycle offers the following functions:

• Definition of insertion strategy

• Finishing allowances for XY plane and Z direction (tool axis)

• Cut segmentation in Z direction (tool axis)

Select with softkey Residualmaterial >

Remove residual material This cycle allows residual material to be removed with a small cutter. Itcan be useful in cases where the use of a tool with a large diameterhas left residual material along the contour, for example, in corners.

Select with softkeys: Residualmaterial >




Finish a pocket

with island

This cycle can be used to finish cut the base of a pocket or the pocketand island contours.

Select with softkeys: Remove >

3.5.1 Free contour programming

Function

You can create simple or complex contours and then machine themwith "Path milling" or "Solid machining" cycles.An integrated geometry processor calculates any parameters that aremissing provided that it can derive them from other parameters.

The programmed contours are stored at the end of the currentprogram.

Program a new contour and

define the starting point Select with softkeys Contourmilling

Newcontour >

Enter a contour name. This must be a unique name.

You can also copy contours to other programs.

When entering a contour, start at a position you know and enter thisas the starting point. Then define the tool axis. If you alter the tool axis,ShopMill will automatically alter the associated starting point axes.

The starting point is stored with softkey .

Transfer the contour to

the machining plan

Transfer the programmed contour to the machining plan by pressingsoftkey "Accept". You can then machine the contour using themachining cycles.

Free contour

programming

Beginning at the starting point, enter the first contour element, e.g.straight line. Enter all data specified in the workshop drawing: Lengthof line, end position, transition to next element, angle of lead, etc.By pressing softkey "All param.", you can display additional parameterinput fields for the contour element.




If you do not enter values in some parameter input fields, ShopMillassumes that you do not know what the settings should be and tries tocalculate the settings from other parameters.

Additional commands You can enter any additional commands in the form of G code foreach contour element. Additional commands (max. 40 characters) areentered in the Start form and under softkey "All param." for individualcontour elements.For example, you can program deceleration and exact stop for circularcontour element "G9".

When a contour is "path milled", it is always machined in theprogrammed direction. By programming the contour in a clockwise orcounter-clockwise direction, you can determine whether the contour ismachined in a synchronized operation or reverse rotation operation(see following table).

Outside contourDesired

machining direction

CW spindle rotation CCW spindle rotation

Synchronized operation Programmed in clockwise directionCutter radius compensation CCW

Programmed in counter-clockwisedirection, cutter radius comp. CW

Reverse rotation Programmed in counter-clockwisedirection, cutter radius comp. CW

Programmed in clockwise directionCutter radius compensation CCW

Inside contour:Desired

machining direction

CW spindle rotation CCW spindle rotation

Synchronized operation Programmed in counter-clockwisedirection, cutter radius comp. CCW

Programming in clockwise directionCutter radius compensation CW

Reverse rotation Programming in clockwise directionCutter radius compensation CW

Programmed in counter-clockwisedirection, cutter radius comp. CCW

Contours as pockets

or islands

Contours for pockets or islands must be closed, i.e. the starting andend points of the contour are identical.

Transition element

Chamfer/radius

You can use a transition element whenever there is an intersectionbetween two successive elements which can be calculated from inputvalues. Otherwise you must use a line or circle contour element.

Transition element in

closed contours

In a closed contour, you can program a transition element from thelast to the first element in the contour. The contour starting point liesoutside the contour after you have programmed the transition.




Parameters with gray

background

These parameters have been calculated by ShopMill and cannot bealtered by the user.When you alter the programmable parameter input fields (whitebackground), the control calculates new data which are thenimmediately displayed again in the input form.

Input value is already

calculated

If you over-define a contour, ShopMill may automatically calculate avalue that you would normally be required to input yourself.This may cause problems if the input value calculated by the controldoes not tally with the workshop drawing. If this is the case, you mustdelete the values from which the control is deriving the incorrect inputvalue. You can then enter the exact setting from the workshopdrawing.

Programming graphic The contour you have programmed is displayed in the programminggraphic. Contour elements can be displayed in different line styles andcolors:

• Black: Programmed contour

• Red: Current contour element

• Yellow: Alternative element

• Continuous line: Fully defined element

• Dotted line: Partially defined element

• Dashed line: Alternative element

The programming graphic displays as much of the contour as thecontrol can interpret on the basis of parameter inputs. If your contouris not displayed in the programming graphic, then you need to entermore data. Check the contour elements you have alreadyprogrammed if necessary. You may have omitted to enter settingswhich you know.




3.5.2 Description of softkeys for free contour programming function

Vertical line

Horizontal line

Diagonal line

Circle / Arc

Cylinder peripheral surface

transformation

When the "Cylinder peripheral surface transformation" function isactive, the lengths (in circumferential direction of cylinder peripheralsurface) of contours can be defined on a cylinder in the form ofangular measurements. Depending on the selected axis (in a displaymachine data), the start form and forms for contour elements display

the input in degrees for Xα, Iα or for Yα, Jα (see also Section

"Cylinder peripheral surface transformation").

Please read the machine tool manufacturer’s instruction manual!

Tangent to preceding

element

The contour element has a tangential transition to the precedingelement, thereby setting the angle to the preceding element (α2) to0 degrees. The status "tangential" appears in the input field of

parameter α2.

Select with softkeys: Tangent toprec. elem.

Additional parameter

displays

If your drawing contains other data (dimensions) for an element, youcan display further input options by pressing softkey "All param.".

Select with softkeys: Allparam.

Descriptions of individual parameters can be found in Section"Description of contour element parameters".

Select a dialog If your contour involves parameter constellations which permit morethan one contour characteristic, the system will request you to select adialog. Make the correct selection (continuous black line) using softkey"Alternat." and confirm with softkey "Accept".

Select with softkeys: Dialogselection

Acceptdialog

Alter the selected

dialog

If you wish to alter your selected dialog, you must select the contourelement for which the dialog selection was made.When you press softkey "Change selection", both dialog alternativesare displayed again. Make the selection again.

Select with softkeys: Changeselection

Dialogselection

Acceptdialog

If the selection has been made implicitly from other input values, thesystem will not request you to make a selection.




Clear a parameter input

field

You can clear the programmed value again with the DEL key.

Store a contour element If you have set all necessary parameters for a contour element orselected the required contour with softkey "Dialog select", store thecontour element by pressing softkey "Accept".

Select with softkeys:

You can now program the next contour element.

Change a contour element Select the programmed contour element that you wish to alter with thecursor keys. Press the "Input" key to display a parameter screenformshowing the magnified contour element. You can now change theelement parameters and then save them.

Delete a contour element Select the contour element you wish to delete with the cursor keys.The selected contour symbol and appropriate contour element in theprogramming graphic are highlighted in red. Then press softkeys"Delete element" and "OK".

Select with softkeys: Deleteelement

Close the contour When you press softkey "Close contour", ShopMill inserts a straightline between your current position and the starting point, thus closingthe contour.

Select with softkeys: Closecontour

Close and store

a contour

Once you have closed the contour, press softkey "Accept" to exit fromfree contour programming mode. The programmed contour istransferred to the machining plan at the same time.

Select with softkeys:




3.5.3 Description of parameters for line/circle contour elements

Parameters Description of "Straight line" contour element Unit

X absoluteX incremental

Absolute end position in X directionIncremental end position in X direction

mmmm

Y absoluteY incremental

Absolute end position in Y directionIncremental end position in Y direction

L Length of line mm

α1 Lead angle in relation to X axis Degrees

α2 Angle to preceding element, tangential transition: α2=0 Degrees

Transition tofollowingelement

Transition element to next contour is a chamfer (FS)Transition element to next contour is a radius (R)FS=0 or R=0 means no transition element.

mmmm

Additionalcommand

Any additional command in G code form

Parameters Description of "Circle" contour element Unit

X absoluteX incremental

Absolute end position in X directionIncremental end position in X direction

mmmm

Y absoluteY incremental

Absolute end position in Y directionIncremental end position in Y direction

α1 Start angle in relation to X axis Degrees

α2 Angle to preceding element, tangential transition: α2=0 Degrees

β1 End angle in relation to X axis Degrees

β2 Arc angle of circle Degrees

Direction ofrotation

in clockwise or counter-clockwise direction

R Radius of circle mm

I Position of arc center point in X direction (abs. or incr.) mm

J Position of arc center point in Y direction (abs. or incr.) mm

Transition tofollowingelement

Transition element to next contour is a chamfer (FS)Transition element to next contour is a radius (R)FS=0 or R=0 means no transition element.

mmmm

Additionalcommand

Any additional command in G code form




3.5.4 Programming examples for freely defined contours

Example 1 Starting point: X=0 abs., Y=5.7 abs.The contour is programmed in a CW direction using dialog selection.

5

22 °

R2R3.2

R2

60 °

R2

R9.5

11.5

Start pointX=0, Y=5.7 15

.214

.8

Y

X4.

654.

65Workshop drawing of contour

Element Input CommentCCW rotation, R=9.5, I=0 abs., make dialog selection,transition to following element: R=2

α1=−30 degrees Note the angle in the Helpdisplay!

CW rotation, tangent prev. elem.,R=2, J=4.65 abs.

CCW rotation, tangent prev. elem.R=3.2, I=11.5 abs., J=0 abs., make dialog selection,make dialog selection

CW rotation, tangent prev. elem.

R=2, J=−4.65 abs., make dialog selection

Tangent to prev. elem.

Y=−14.8 abs., α1=−158 degrees

Note the angle in the Helpdisplay!

All parameters, L=5, make dialog selection

Y=5.7 abs.

X=0 abs.




Example 2 Starting point: X=0 abs., Y=0 abs.The contour is programmed in a CW direction using dialog selection. It isadvisable to display all parameters for this contour by selecting the "Allparam." softkey.

R5

30 °

6

R7.5

R25

Y

X

Starting pointX=0, Y=0

Workshop drawing of contour

Element Input Comment

Y=−104 abs.

CW rotation, R=79, I=0 abs., make dialog selection,

all parameters, β2=30 degrees

CW rotation, tangent prev. elem.

R=7.5, all parameters, β2=180 degrees

CCW rotation, R=64, X=−6 abs., I=0 abs.,make dialog selection, make dialog selectionTransition to following element: R=5

All parameters, α1=90 degrees,Transition to following element: R=5

Note the angle in the Helpdisplay!

CW rotation, R=25, X=0 abs., Y=0 abs. I=0 abs.,make dialog selection, make dialog selection




Example 3 Starting point: X=5.67 abs., Y=0 abs.The contour is programmed in a counter-clockwise direction.

X= - 137.257 abs.

X=5.67 Y=0

43.972

R72

125 °

Starting point

X

Y

Workshop drawing of contour

Element Input Comment

All parameters, α1=180 degrees, Note the angle in the Help display!

X=−43.972 inc, all parameters

X=−137.257 abs, α1=−125 degrees

Coordinate X in "abs" and in "inc"Note the angle in the Help display!

X=43.972 inc

α1=−55 degrees

Coordinate X in "abs" and in "inc"Note the angle in the Help display!

X=5.67 abs

CW rotation, R=72, X=5.67 abs., Y=0 abs.,make dialog selection

3.5.5 Path milling of open and closed contours

Function

You can mill along any contour you have programmed with the "Pathmilling" function. The function operates with cutter radiuscompensation.The contour does not have to be closed. You can perform any of thefollowing operations:

• Inside or outside machining (on left or right of the contour).

• Machining along center-point path

Select with softkeys Contourmilling

Pathmilling >




Path milling on right or left

of the contour

A programmed contour can be machined with the cutter radius on theright or left. You can also select various modes and strategies ofapproach and retraction from the contour.

Approach/retraction mode The tool can approach or retract from the contour along a quadrant,semi-circle or straight line.

• With a quadrant or semi-circle approach path, you must enter thecurrent center point path.

• With a straight line, you must specify the distance between thecutter outer edge and the contour start or end point.

You can also program a mixture of modes, e.g. approach alongquadrant, retract along semi-circle.

L1/L2

R1/R2

R1/R2

Approach and retraction along straight line, quadrant and semi-circle;

(L1=approach length, L2=retract length, R1=approach radius, R2=retract radius)

Approach/retraction strategy You can choose between planar approach/retraction and spatialapproach/retraction:

• Planar approach: The tool first approaches in the Z direction (machining depth) and then in the XY plane.

• Spatial approach: The tool approaches in depthand plane simultaneously.

• Retraction takes place in the opposite order.You can program a mixture of strategies, e.g. planar approach,spatial retraction.

Path milling along the

center-point path

A programmed contour can also be machined along the center-pointpath if the operation has been activated under radius compensation

(no radius compensation). In this instance, the tool can approachand retract only along a straight line since the control cannotdetermine which side the contour must be approached from.




L1/L2

Approach and retraction in a straight line on center-point path (L1=approach length,

L2=retraction length)

Parameters Description Unit

T, F, S, V See Section "Program tool, offset value and spindle speed".

Radiuscompensation

Machining on left of contour

Machining on right of contour

Machining along center-point path

Machining type RoughingFinishing

Z0 Reference plane (abs. or incr.)

Z1 Final depth (abs. or incr.) mm

DZ Infeed depth mm

UZ Finishing allowance on base mm

UXY Finishing allowance on edge (not applicable to center-point path machiningoperations)

mm

Approachmode

along a quadrant (segment of a helix) *)along a semi-circle (segment of a helix) *)along a straight line (oblique line in space)

Approachstrategy

planar

spatial

R1 or L1 Approach radius *), approach length

Retractionmode

along a quadrant (segment of a helix) *)along a semi-circle (segment of a helix) *)along a straight line (oblique line in space)

Retractionstrategy

planar

spatial

R2 or L2 Retraction radius *), retraction length

Select lift-offmode

Z0 + safety clearanceBy safety clearanceTo return planeNo retraction

*) applies only to path milling on left and right of contour




3.5.6 Rough drilling in contour pockets

Function

When solid machining contour pockets with vertical plunging, roughdrilling is often performed first to avoid having to use end millingcutters that mill across the center.The number and positions of the required rough drill holes depends oncertain conditions, e.g. type of contour, tool, plane infeed, finishingallowances. To avoid unnecessary tool changes, it is best to rough drillall pockets first. It is important to ensure that the rough drillingoperation (centering and rough drilling) is programmed in the samemachining sequence as the contours and solid machining.

To do this, you must call a special rough drilling cycle, consisting of acentering cycle and the rough drilling cycle itself.The drilling positions in the contour pocket cycle are determined whenthe contour pocket is calculated. This calculation generates a specialdrilling program that is called in the rough drilling cycles (centering andrough drilling).

Contour pocket

Contour island

Rough drilling/centering contour pocket

Rough drilling/rough drilling contour pocket

Solid machining, roughing

Residual material

Solid machining, finishing plane

Solid machining, finishing depth

Example of a chain containing rough drilling (centering and rough drilling) and solid

machining

All para-meters

You can select softkey "All parameters" to extend each screenform forthe purpose of entering additional parameters. If you do not enter anyvalues, the parameter settings for Solid Machining (roughing) are usedinstead.




Centering

Select with softkey Contourmilling

Rough-drilling >

Centering

Select key to call Help display

Centering in contour pocket


T, F, S See Section "Program tool, offset value and spindle speed".

TR Reference tool for centering

Z0 Workpiece height (abs.) mm

Z1 Depth in relation to Z0 (incr.) mm

DXY Max. infeed planeAlternatively, you can specify the plane infeed as a %, as the ratio --> plane infeed(mm) to milling cutter diameter (mm).

mm

%

UXY Finishing allowance, plane mm

Select lift-offmode

Liftoff mode before new infeedIf a machining operation requires several insertion points, you can program theretraction height:

• To return plane

• Z0 + safety clearanceOn making the transition to the next insertion point, the tool returns to this height. Ifthere are no elements larger than Z0 in the pocket area, "Z0 + safety clearance" canbe selected as the lift-off mode.

mmmm

Rough-drilling

Select with softkey Contourmilling

Roughdrilling >

Rough-drilling


Rough-drilling a contour pocket





T, F, S See Section "Program tool, offset value and spindle speed".

TR Reference tool for rough-drilling


Z1 Depth in relation to Z0 (incr.) mm

DXY Max. infeed planeAlternatively, you can specify the plane infeed as a %, as the ratio --> plane infeed(mm) to milling cutter diameter (mm).

mm

%


UZ Finishing allowance, depth mm

Select lift-offmode,

Liftoff mode before new infeedIf a machining operation requires several insertion points, you can program theretraction height:

• To return plane

• Z0 + safety clearanceOn making the transition to the next insertion point, the tool returns to this height. Ifthere are no elements larger than Z0 in the pocket area, "Z0 + safety clearance" canbe selected as the lift-off mode.

mmmm




3.5.7 Machine (rough cut) pocket with islands

Function

Before you can machine a pocket with islands, you must enter thecontour of the pocket and islands (see Section "Free contourprogramming"). The first contour you specify is interpreted as thepocket contour and all the others as islands.

Using the programmed contours and the input screen form for solidmachining, ShopMill generates a program which removes the pocketswith islands from inside to outside in parallel to the contour.

The islands may lie partially outside the pocket or overlap one another.


Remove >

Select key

to call Help display

Help displays for solid machining


T, F, V See Section "Program tool, offset value and spindle speed".

Machining type Roughing mm


Z1 Depth in relation to Z0 (abs. or incr.) mm

DXY Max. infeed in X/Y plane.Alternatively, you can specify the plane infeed as a %, as a ratio � plane infeed(mm) to milling cutter diameter (mm).

mm

%

DZ Max. infeed depth (abs. or incr.) mm


ZU Finishing allowance, depth mm

Starting point The start point can be calculated automatically or entered manually.

XY

Start point X (abs.), manual input onlyStart point Y (abs.), manual input only

mmmm




Insertion Pe = oscillating: The tool is inserted in oscillating mode at the programmed angle (EW).

He = Helical: The tool is inserted along a helical path with the programmed radius (ER) and programmed pitch (EP).

Mi = Center: This insertion strategy requires a cutter which cuts acrosscenter. It is inserted at the programmed feedrate (FZ).

EW Insertion angle (for oscillation only) Degrees

FZ Feedrate FZ (for Center only) mm/min

EP Insertion pitch (for Helical only) mm/rev

ER Insertion radius (for Helical only) mm


If the machining operation requires several points of insertion, the retraction heightmust be programmed:

• To return plane

• Z0 + safety clearance (SC)

On making the transition to the next insertion point, the tool returns to this height.If the pocket area does not contain any elements larger than Z0, thenZ0 + safety clearance (SC) can be programmed as the lift-off mode.

mmmm

When input manually, the starting point can also be located outsidethe pocket. This can be useful, for example, when machining a pocketwhich is open on one side. The machining operation then beginswithout insertion with a linear movement into the open side of thepocket.

3.5.8 Remove residual material

Function

Residual material can be removed from a partially machined pocketwith islands. This function is optional.

Allparam.

Notes

It is normally assumed that "solid machining" has taken place beforeresidual material is removed. The residual material is calculated bycomparing the cutter used for solid machining and the current cuttingtool.You can program any other tool as the reference tool for thecalculation under softkey "All param.".

Example: If the same pocket needs to be milled in several different

places, it is best to machine all pockets first and then remove allresidual material to minimize the number of tool changes required.





Residualmaterial >

Select key


Help display for residual material



Machining type Roughing

TR Reference tool for residual material



DXY Max. infeed, planeAlternatively, you can specify the plane infeed as a %, as a ratio --> plane infeed(mm) to milling cutter diameter (mm).

mm%

DZ Max. infeed, depth mm




If the machining operation requires several points of insertion, the retraction heightcan be programmed:

• To return plane

• Z0 + safety clearance (SC)On making the transition to the next insertion point, the tool returns to this height.If the pocket area does not contain any elements larger than Z0, thenZ0 + safety clearance (SC) can be programmed as the lift-off mode.

mmmm




3.5.9 Finish pocket with islands

Function

After solid machining and removal of residual material (if necessary),you can finish cut the pocket and islands.In this case, the base can be finished in the depth or the edge in theplane in one machining operation.


Remove >

Select key


Help display for "Finish pocket with islands"

Parameters Description of finish cut along base: Unit


Machining type Finishing on base



DXY Max. infeed, planeAlternatively, you can specify the plane infeed as a %, as a ratio --> plane infeed(mm) to milling cutter diameter (mm).

mm%



Starting point The start point can be determined automatically or entered manually.When entered manually, the start point can be positioned outside the pocket. In thiscase, the tool first machines along a straight line into the pocket, e.g. for a pocketopen on the side without insertion.

XY

Coordinate of start point (abs.), manual input onlyCoordinate of start point (abs.), manual input only

mmmm

Insertion Pe = oscillating: The tool is inserted at the programmed angle (EW).He = Helical: The tool is inserted along a helical path with the

programmed radius (ER) and programmed pitch (EP).Mi = Center: This insertion strategy requires a cutter which cuts across

center. It is inserted at the programmed feedrate (FZ).


EP Insertion pitch (for Helical only) mm/rev

ER Insertion radius (for Helical only) mm




FZ Feedrate FZ (for Center only) mm/min



• To return plane

• Z0 + safety clearance (SC)On making the transition to the next insertion point, the tool returns to this height.If the pocket area does not contain any elements larger than Z0, thenZ0 + safety clearance (SC) can be programmed as the lift-off mode.

mmmm

Parameters Description of finish cut along edge: Unit


Machining type Finishing on edge



DZ Max. infeed, depth mm




• To return plane

• Z0 + safety clearance (SC)

On making the transition to the next insertion point, the tool returns to this height.If the pocket area does not contain any elements larger than Z0, thenZ0 + safety clearance (SC) can be programmed as the lift-off mode.

mmmm

Note: An alternative to the "Edge finish cut" option is the "Path milling" function

which offers greater optimization potential (approach and retract strategies andmodes).


3.6 Programing simple path motions 3


3.6 Programing simple path motions

This function is intended for the implementation of very simplemachining operations as path movements.More complex operations such as contours with chamfers, radii,approach strategies, tangential transitions, etc. should beimplemented using the "Mill contour" and "Path milling" functions.

You must program a tool before you program simple lines or circles. Atool with spindle speed is selected by means of softkeys "Straightcircle" and "Tool".You can only program rapid traverse for linear travel motions.

3.6.1 Line

Function

The tool moves at the programmed feedrate or in rapid traverse fromits current position to the programmed end position.

Radius compensation You can machine with radius compensation if you wish. The radiuscompensation has a modal action.

When executing the first path motion with radius compensation, thetool traverses without compensation at the starting point and withcompensation at the end point, i.e. when a vertical path isprogrammed, the tool traverses and oblique path. The compensationis not applied over the entire traversing path until the secondprogrammed path motion with radius compensation is executed. Theeffect is reversed when you deselect radius compensation.

programmed path

travel path

programmed path

travel path

First path motion with

radius compensation

First path motion with deselected radius

compensation

To avoid deviation between the programmed and actually traversedpath, you can program the first path motion with radius compensationor deselected radius compensation outside the workpiece. You cannotprogram a motion without specifying coordinates.




Select with softkeys StraightCircle

Straight

Select key


Help display for a line


XYZ

Coordinate of end point in X direction (abs. or incr.)Coordinate of end point in Y direction (abs. or incr.)Coordinate of end point in Z direction (abs. or incr.)

mmmmmm

Radiuscompensation

Input defining which side of the contour the cutter travels in the programmeddirection:

Radius compensation, leftof contourRadius compensation, rightof contour






3.6.2 Circle with known center point

Function

The tool travels along a circular path from its current position to theprogrammed circle end point. You must know the position of the circlecenter point. The control calculates the radius of the circle/arc on thebasis of your interpolation parameter settings.The circle can only be traversed at machining feedrate. You mustprogram a tool before the circle can be traversed.


CircleCenter point

Select key


Help display for circle with known center point



The tool travels in the programmed direction from the circle start point to its endpoint. You can program this direction as clockwise or counter-clockwise.

XY

X position circle end point (abs. or incr.)Y position circle end point (abs. or incr.)

mmmm

IJ

Distance between circle start and center point in X direction (incr.)Distance between circle start and center point in Y direction (incr.)

mmmm

Plane The circle is traversed in the set plane with the relevant interpolation parameters:XYIJ: XY plane with interpolation parameters I and JXZIK: XZ plane with interpolation parameters I and KYZJK: YZ plane with interpolation parameters J and K

mmmmmm




3.6.3 Circle with known radius

Function

The tool traverses a circular path with the programmed radius from itscurrent position to the programmed circle end point. The controlsystem works out the circle center point. You do not need to programinterpolation parameters.The circle can only be traversed at machining feedrate.


CircleRadius

Select key


Help display for circle with known radius




XY

X position circle end point (abs. or incr.)Y position circle end point (abs. or incr.)

mmmm

R Radius of arc;You can select the arc of your choice by entering a positive or a negative sign.

mm




3.6.4 Helix

Function

Helical interpolation is implemented by superimposing a linear motionin the tool axis on a circular motion in the plane.


Helix

Select key


Help display for a helix




I, J Incremental: Distance between helix start and center pointin X and Y directions

Absolute: Center point of helix in X and Y directions

mm

P Pitch of helix; The pitch is programmed in mm per revolution. mm/360 °Z Z position of helix end point (abs. or incr.) mm




3.6.5 Polar coordinates

Function

If a workpiece has been dimensioned from a central point (pole) withradius and angles, you will find it helpful to program these as polarcoordinates.You can program straight lines and circles as polar coordinates.

Define a pole You must define the pole before you can program a line or circle inpolar coordinates. This pole acts as the reference point of the polarcoordinate system.The angle for the first line or circle then needs to be programmed inabsolute coordinates. You can program the angles for any further linesand circles as either absolute or incremental coordinates.


Polar

Pole


X X position of pole (abs. or incr.) mm

Y Y position of pole (abs. or incr.) mm




3.6.6 Polar line

Function

A straight line in the polar coordinate system is defined by a radius (L)

and an angle (α). The angle refers to the X axis.

The tool moves from its current position on a straight line to theprogrammed end point at the machining feedrate or in rapid traverse.

The 1st line in polar coordinates entered after the pole must beprogrammed with an absolute angle. You can program any furtherlines or circles with incremental coordinates.


Polar

StraightPolar

Select key


Help display for polar line with absolute and incremental angle


L Radius from pole to end point of line mm

α Polar angle (abs. or incr., positive or negative) Degrees

Radiuscompensation

Input defining which side of the contour the cutter travels in the programmeddirection:

Radius compensation, leftof contourRadius compensation, rightof contour






3.6.7 Polar circle

Function

A circle in the polar coordinate system is defined by an angle (α). The

angle refers to the X axis.The tool moves from its current position on a circular path to theprogrammed end point (angle) at the machining feedrate.The radius corresponds to the distance from the current tool positionto the defined pole, i.e. the circle start and end point positions are atthe same distance from the defined pole.

The 1st circle in polar coordinates entered after the pole must beprogrammed with an absolute angle. You can program any furtherlines or circles with incremental coordinates.


Polar

CirclePolar

Select key


Help display for polar circle with absolute and incremental angle



The tool travels in the programmed direction from the circle start point to its endpoint. You can program this direction as clockwise (right) or counter-clockwise (left).

α Polar angle (abs. or incr., positive or negative) Degrees




3.6.8 Programming examples for polar coordinates

Program a pentagon You want to machine the outside contour of a pentagon.Make sure that you enter the correct workpiece dimensions!Approach start point in rapid traverse: X70, Y50, radius compensation off.Pole: X=50, Y=50

1. 1st polar line: L=20, α= −72 absolute, radius compensation right

2. 2nd to 5th polar line: L=20, α= −72 degrees incremental,Radius compensation right

Programming graphic and extract from machining plan

Program an arc of

225 degrees

You want to machine the outside contour of an arc.Make sure that you enter the correct workpiece dimensions!Approach start point in rapid traverse: X=80, Y=50, radius compensation rightPole: X=60, Y=50

CW rotation, α= 135 degrees absolute

Programming graphic and extract from machining plan


3.7 Drilling 3


3.7 Drilling

Program holes and threads In ShopMill you first need to program the machining operations in theexact order in which they need to be performed, e.g.

1. Centering, with tool and input of spindle speed and machining

feedrate

2. Deep-hole drilling, with tool and input of spindle speed and

machining feedrate

3. Tapping with tool and input of spindle speed and machining

feedrate

Once you have programmed the technologies, you need to enter the

position data. ShopMill provides various positioning patterns (see

Section "Positions").


3.7 Drilling 3


3.7.1 Centering

Function

The tool is moved in rapid traverse to the position to be centered,allowing for the return plane and safety clearance. The tool is insertedinto the workpiece at programmed feedrate (F) until it reaches Z1 oruntil the surface diameter is the correct size. When the dwell timeexpires, the tool is retracted in rapid traverse to either the return planeor the safety clearance depending on the setting in parameter"Retraction position pattern". You will find parameter "Retractionposition pattern" in the program header or under "Settings" in the"Miscellaneous" menu.

Select with softkeys Drilling

Centering

Select key


Help display for centering at depth Help display for centering on diameter


T, D, F, S, V See Section "Program tool, offset value and spindle speed".

Diameter

Tip

The tool is inserted into the workpiece until the diameter on the surface is the correctsize. The angle for the center drill entered in the tool list is applied in this case.The drill is inserted into the workpiece until the programmed insertion depth isreached.

∅Z1

It is inserted into the workpiece until the diameter is correct.It is inserted into the workpiece until it reaches Z1.

mmmm

Z0 Height of workpiece; Z0 is specified in the position pattern ("Positioning" softkey). mm

DT Dwell time for relief cut s


3.7 Drilling 3


3.7.2 Drilling and reaming

Function

The tool is moved in rapid traverse to the programmed position,allowing for the return plane and safety clearance. It is then insertedinto the workpiece at the feedrate programmed under F until it reachesdepth Z1.

Drilling: If Z1 has been reached and the dwell time expired, the drill is

retracted at rapid traverse either to the return plane or the safetyclearance depending on the setting in parameter "Retraction positionpattern". You will find parameter "Retraction position pattern" in theprogram header or under "Settings" in the "Miscellaneous" menu.

Reaming: If Z1 has been reached and the dwell time expired, the

reamer is retracted at the programmed retraction feedrate to thesafety clearance.


DrillingReaming

Select key


Help display for drilling Help display for reaming



Shank

Tip

The drill is inserted into the workpiece until the drill shank reaches the valueprogrammed for Z1. The insertion angle entered in the tool list is applied.The drill is inserted into the workpiece until the drill tip reaches the valueprogrammed for Z1 (does not apply in reaming).

Z1 Insertion depth for drill tip or drill shank. mm



FB Retraction feedrate (for reaming only)


3.7 Drilling 3


3.7.3 Deep-hole drilling

Function

The tool is moved in rapid traverse to the programmed position,allowing for the return plane and safety clearance. It is then insertedinto the workpiece at the programmed feedrate.


Deep holedrilling

Stockremoval

The tool drills at the programmed feedrate (F) until the 1st infeeddepth is reached. On reaching the 1st depth, the tool is retracted fromthe workpiece at rapid traverse for stock removal and is then re-inserted at the 1st infeed depth reduced by a clearance distancecalculated by the control system. The tool then drills to the next infeeddepth and is then retracted again, repeating this process until the finaldrill depth (Z1) is reached. On expiry of the dwell time, the tool isretracted at rapid traverse to the safety clearance.

Chip-breaking

The tool drills at the programmed feedrate (F) until the 1st infeeddepth is reached. Once this depth is reached, the tool is retracted by aspecific amount for chipbreaking and is then inserted again down tothe next drilling depth. It repeats this process until the final drillingdepth (Z1) is reached.

Select key


Help display for deep hole drilling with

chipbreaking

Help display for deep hole drilling with

stock removal


3.7 Drilling 3




TipShank

The final drilling depth (Z1) refers to the drill tipThe final drilling depth (Z1) refers to the drill shank

Z1 Final drilling depth (incr.) mm


D Max. infeed mm

DF Reduction factor for infeed. The new infeed is obtained by multiplying the previousinfeed by DF.DF=1: Infeed increment remains unchangedDF<1: Infeed increment is reduced in direction of final drilling depth

Example application: Last infeed was 4 mm; DF is 0.8

Next infeed = 4 x 0.8 = 3.2 mmNext infeed = 3.2 x 0.8 = 2.56 mm etc.

V1 Minimum infeedParameter V1 is provided only if DF< 1 has been programmed.If the infeed increment becomes minimal, a minimum infeed can be programmed inparameter "V1".V1 < infeed increment: The tool is inserted by the infeed increment.V1 > infeed increment: The tool is inserted by the infeed value programmed under V1.

mm



3.7 Drilling 3


3.7.4 Boring

Function

The tool is moved in rapid traverse to the programmed position,allowing for the return plane and safety clearance. It is then insertedinto the workpiece at the feedrate programmed under F until it reachesthe programmed depth (Z1). "Lift off contour" or "Do not lift offcontour" can be programmed on expiry of the dwell time.


Boring

Select key


Help display for boring



Lift off contour

Do not lift offcontour

The cutting edge is retracted from the bore edge and then moved back to the returnplane. The parameters for lift-off distance and tool orientation angle can be set via amachine data.The cutting edge is not retracted, but traverses back to the safety clearance in rapidtraverse.




D Lift-off distance (can be set in a machine data) *) mm

α Tool orientation angle (can be set in a machine data) *) Degrees

*) applies only when tool is lifted off


3.7 Drilling 3


3.7.5 Tapping

Function

The tool is moved in rapid traverse to the programmed position,allowing for the return plane and safety clearance. It is then inserteddown to the programmed depth (Z1) in the workpiece.

A compensating chuck is not required.

The spindle speed can be controlled by the spindle override duringtapping. The feed override is inoperative during this process.


Spindle

Tapping

Select key


Help display for tapping



P PitchThe pitch is determined by the tool used.When you enter the thread pitch in turns/’’, enter the whole number before thedecimal point in the first parameter field and the number after the decimal point as afraction in the second and third fields.

For example, enter 13.5 turns/’’ in the following way:

mm/revinch/revMODULETurns/"

Z1 Tapping depth (abs. or incr.) mm



3.7 Drilling 3


3.7.6 Thread cutting

Function

You can use a form cutter to machine any type of right-hand or left-hand thread.Threads can be machined as right-hand or left-hand threads and fromtop to bottom or vice versa.


Spindle

Cutthread

Inside thread Sequence of operations:

• Position on thread center point on return plane in rapid traverse

• Infeed at rapid traverse to reference plane shifted forward byamount corresponding to safety clearance

• Approach along an approach circle calculated in the control atprogrammed feedrate

• Approach motion to thread diameter on circular path

• Cut thread along a helical path in clockwise or counter-clockwisedirection (depending on whether it is left-hand or right-hand thread)

• Exit motion along a circular path in the same rotational direction atprogrammed feedrate

• Retract to thread center point and then to return plane in rapidtraverse

Outside thread Sequence of operations:

• Position on starting point in return plane at rapid traverse

• Infeed at rapid traverse to reference plane shifted forward byamount corresponding to safety clearance

• Approach along an approach circle calculated in the control atprogrammed feedrate

• Approach motion to thread diameter on circular path

• Cut thread along a helical path in clockwise or counter-clockwisedirection (depending on whether it is left-hand or right-hand thread)

• Exit motion along a circular path in opposite rotational direction atprogrammed feedrate

• Retract to return plane in rapid traverse


3.7 Drilling 3


Select key


Help displays for thread cutting


Machining type RoughingThread cutting up to programmed finishing allowance (U)

Finishing

Direction Depending on the rotational direction of the spindle, a change in direction alsochanges the machining direction (climb/conventional).Z0 to Z1: Machining begins on workpiece surface Z0.Z1 to Z0: The machining starts at thread depth, e.g. for blind hole tapping

Inside thr.Outside thr.

An inside thread is cut.An outside thread is cut.

Left thr.Right thr.

A left-hand thread is cut.A right-hand thread is cut.

NT Number of teeth in a milling insert.Single or multiple toothed milling inserts can be used. The cutting teeth are enteredin parameter NT. The necessary motions are executed internally by the cycle in sucha manner that the tip of the bottom tooth on the milling insert corresponds to theprogrammed end position when the thread end position is reached. Depending onthe cutting edge geometry of the milling insert, the retraction path must be taken intoaccount at the base of the workpiece.

Z1 Thread length mm


∅ Nominal thread diameter, example: Nominal diameter of M12 = 12 mm mm


3.7 Drilling 3


P PitchIf the milling insert has several teeth, the pitch will be dependent on the tool used.When you enter the thread pitch in turns/’’, enter the whole number before thedecimal point in the first parameter field and the number after the decimal point as afraction in the second and third fields.

For example, enter 13.5 turns/’’ in the following way:

mm/revinch/revMODULETurns/"

K Thread depth mm

DXY Infeed per cutAlternatively, you can specify the plane infeed as a %, as a ratio --> plane infeed(mm) to milling cutter diameter (mm).

mm%

U Finishing allowance mm

α0 Start angle Degrees

Programming example for

thread cutting

Cut circular pocket in a solid blank and cut a thread.The milling tool cannot cut across center. The circular pocket willtherefore have to be predrilled with a Ø22 mm drill. The milling toolcan then be inserted centrally.

Using position patterns, the positions of the above-mentioned cyclescan be programmed (see Section "Using position patterns in milling").

X

Y

60 40 Z

YA A - B

B

50

56

Workshop drawing of circular pocket with thread

Extract from machining plan; cut a circular pocket with thread


3.7 Drilling 3


3.7.7 Position on freely programmable positions and position patterns

Function

After you have programmed the machining technologies, you mustprogram the positions. ShopMill offers a variety of positioning patterns,i.e.

• Freely programmable positions

• Position on a line or matrix

• Position on a full or pitch circle

You can program any number of these position patterns one after theother. They are traversed in the order in which you program them.

The programmed technologies and subsequently programmedpositions are automatically chained by the control.

Machining sequence and

tool travel path

The first tool in the program traverses all programmed positions, e.g.center all positions. The second tool in the program then machines allprogrammed positions, etc. This process is repeated until everyprogrammed drilling operation has been performed at everyprogrammed position.

Inside a position pattern or on the approach from one position patternto the next, the tool is retracted to safety clearance in the case ofoptimized retraction, or otherwise to the return plane (see also Section"Create new program; define a blank"). The new position is thenapproached in rapid traverse.

If the position pattern consists of only one position, the tool is retractedto the return plane after machining.


Positions


3.7 Drilling 3


3.7.8 Freely programmable positions

Function

This pattern allows you to program positions freely, i.e. rectangular orpolar, in the X/Y plane. Individual positions are approached in theorder in which you program them. Press softkey "Delete all" to deleteall positions programmed in X/Y.


Positions

Select key


Help display for "Freely programmable

positions, rectangular"

Help display for "Freely programmable

positions, polar"


Rectangular/polar

Programming with rectangular or polar dimensions.

Z0 Height of workpiece (abs. or incr.) mm

X0Y0

1st Position of the hole in X (abs. or incr.)1st Position of the hole in Y (abs. or incr.)

mmmm

Rectangular:X1 ... X8Y1 ... Y8

Other positions in the X axis (abs. or incr.)Other positions in the Y axis (abs. or incr.)

If you want to program further positions, store the ones you have alreadyprogrammed and then open the parameter input form again by pressing softkey"Any positions".

mmmm

Polar:L1 ... L7

α1 ... α7

Position distance (abs.)Angle of rotation of line in relation to the X axis.Positive angle: Line is rotated in CCW direction.Negative angle: Line is rotated in CW direction.

If you want to program further positions, store the ones you have alreadyprogrammed and then open the parameter input form again by pressing softkey"Any positions".

mmDegrees


3.7 Drilling 3


3.7.9 Line position pattern

Function

You can use this function to program any number of positions spacedat the same distance along a line.


Positions

Position the cursor in the "Line/matrix" field. You can toggle betweenMatrix and Line by means of softkey "Alternat.".

Select key


Help display for "Line"


Z0 Height of workpiece (abs. or incr.)This position must be programmed absolutely in the first call.

mm

X0 Reference point (first position)This position must be programmed absolutely in the first call.

mm

Y0 Reference point (first position)This position must be programmed absolutely in the first call.

mm

α0 Angle of rotation of line in relation to the X axis.Positive angle: Line is rotated in CCW direction.Negative angle: Line is rotated in CW direction.

Degrees

L Position spacing. mm

N Number of positions.


3.7 Drilling 3


3.7.10 Matrix position pattern

Function

You can use this function to program any number of positions spacedat an equal distance along one or several parallel lines.


Positions

Position the cursor in the "Line/matrix" field. You can toggle betweenMatrix and Line by means of softkey "Alternat.".

Select key


Help display for "Matrix"


Z0 Height of workpiece (abs. or incr.)This position must be programmed absolutely in the first call.

mm

X0 Reference point (first position)This position must be programmed absolutely in the first call.

mm

Y0 Reference point (first position)This position must be programmed absolutely in the first call.

mm

α0 Angle of rotation of matrix in relation to X axis.Positive angle: Matrix is rotated in CCW direction.Negative angle: Matrix is rotated in CW direction.

Degrees

L1L2

Position spacing in X direction in relation to an angle of 0 degrees.Position spacing in Y direction in relation to an angle of 0 degrees.

mm

N1N2

Number of positions in X direction in relation to an angle of 0 degrees.Number of positions in Y direction in relation to an angle of 0 degrees.


3.7 Drilling 3


3.7.11 Full circle position pattern

Function

This function can be used to program drill holes on a circle with a

defined radius. The basic angle of rotation (α0) for the 1st position

refers to the X axis. The control calculates the angle of the next holeposition as a function of the total number of holes. The angle itcalculates is identical for all positions.

The tool can approach the next position along a linear or circular path.

The tool approaches the positions on a linear path. The result may be a contour violation in a circumferential groove.

The tool approaches the positionson the programmed circular path. No contour violation results in a circumferential groove.

Approach positions on a linear or circular path


Positions

If you position the cursor on the "Full/pitch circle" field, you can togglebetween the two options using softkey "Alternat.".

Select key


Help display for "Full circle of holes"


3.7 Drilling 3




X0 X position of full circle center point (abs. or incr.) mm

Y0 Y position of full circle center point (abs. or incr.) mm

α0 Basic angle of rotation; angle of 1st hole in relation to X axis.Positive angle: Full circle is rotated in CCW direction.Negative angle: Full circle is rotated in CW direction.

Degrees

R Radius of full circle mm

N Number of positions on full circle

FP Feed for positioning on a circular path. mm/min

Positioning Linear: Next position is approached linearly at rapid traverse.Circular: Next position is approached at the programmed feedrate

(FP) along a circular path.


3.7 Drilling 3


3.7.12 Pitch circle position pattern

Function

This function can be used to program holes on a pitch circle with adefined radius.The tool can approach the next position along a linear or circular path.(please see "Full circle" for detailed description).


Positions

If you position the cursor on the "Full/pitch circle" field, you can togglebetween the two options using softkey "Alternat.".

Select key


Help display for "Pitch circle"



X0 X position of pitch circle center point (abs. or incr.) mm

Y0 Y position of pitch circle center point (abs. or incr.) mm

α0 Basic angle of rotation; angle of 1st position in relation to X axis.Positive angle: Pitch circle is rotated in CCW direction.Negative angle: Pitch circle is rotated in CW direction.

Degrees

α1 Advance angle; after the first hole has been drilled, all further positions areapproached at this angle.Positive angle: Further positions are rotated in a CCW direction.Negative angle: Further positions are rotated in a CW direction.

Degrees

R Radius of pitch circle mm

N Number of positions (holes) on the pitch circle

FP Feed for positioning on a circular path. mm/min

Positioning Linear: Next position is approached linearly at rapid traverse.Circular: Next position is approached at the programmed feedrate (FP)

along a circular path.


3.7 Drilling 3


3.7.13 Obstacle

Function

If there is an obstacle between 2 position patterns, it can be crossed.The height of the obstacle can be programmed absolutely orincrementally.

If all positions in the 1st pattern have been machined, the tool axistravels in rapid traverse to a height corresponding to the obstacleheight + safety clearance. The new position is approached in rapidtraverse at this height. The tool axis then approaches a positioncorresponding to Z0 of the position pattern + safety clearance.


Positions

Obstacle

Note Obstacles are registered only if they lie between 2 position patterns.If the tool change point and the programmed return plane arepositioned below the obstacle, the tool travels to the return planeheight and on to the new position without taking the obstacle intoaccount. The obstacle must not be higher than the return plane.

Programming example Drilling 4 positions with an obstacle in-between.The holes are first centered and then drilled. When you have programmedthe first two positions at X=15, you need to program the obstacle. Theremaining positions are then programmed at X=100.

Z=-20

Z=20

30

15

100

46

X

Y

X

Z

Z=0

Safety clearance (SC)

Workshop drawing

Extract from machining plan for "Obstacle" programming example


3.7 Drilling 3


3.7.14 Repeat positions

Function

If you want the tool to re-approach positions that you have alreadyprogrammed, the "Repeat positions" function is a quick and easysolution.

You must specify the number of the position pattern. This is a numberassigned automatically by ShopMill. You will find it inserted after theblock number in the machining plan.

Extract from machining plan, position pattern number=001


Repeatpositions

After you have entered the position pattern number, e.g. 1, presssoftkey "Accept". The position pattern you have selected is thenapproached again.

Extract from machining plan; repeat positions in block no. 60


3.7 Drilling 3


3.7.15 Programming examples for drilling

Drilling at different heights Machining task: You have already cut a recess in a workpiece. You now

want to machine blind and through holes of Ø 12 mm on this workpiece withdifferent machining planes.

Programming:

Center the 4 holes

Deep drill the blind holes with stock removal

Deep drill the through holes with chipbreaking

X

Y

X

Z Z0

Z-36

Z-50

Z-14

1230

25

60

Safetyclearancefor Z=0

Tool

Return plane

Safetyclearancefor Z= -36

4 holesDiameter 12 mm

Rapid traverseMachining feedrate

Workshop drawing

Extract from machining plan


3.7 Drilling 3


Drilling with a counterbore You want to machine through holes with screw head recesses around a pitchcircle on a workpiece.

When you program the counterbore, you must select offset value D2(see Section "Create tool offset block for tool edge 1/2").

X

Y

X

Z

A

B

4580

40

50

100

Cut A-B

308.

5

159

60

Workshop drawing

Extract from machining plan


3.8 Milling 3


3.8 Milling

3.8.1 Face milling

Function

You can use this cycle to face mill any workpiece. Two types of cutcan be programmed in the cycle:Roughing:

• Several material removal operations on surface

• Tool turns above the workpiece edge

Finishing:

• First material removal operation on surface

• Tool turns at safety clearance height

• Retraction of mill

Depth infeed always takes place outside the workpiece.

A percentage cutting width for the milling tool can be stored in amachine data for face milling operations. This value determines howfar the tool overshoots the workpiece during face milling operations.Please read the machine manufacturer’s instruction manual!

Select with softkeys Milling

Facemilling

Then select the machining strategy using the vertical softkeys.

Select key


Help display for face milling, alternate

machining directions in parallel to X axis

Help display for face milling, alternate

machining directions in parallel to Y axis


3.8 Milling 3


Help display for face milling, one milling

direction in parallel to X axis

Help display for face milling, one

machining direction in parallel to Y axis


Machining type Roughing:Face milling up to programmed finishing allowance (UZ).

Finishing:The surface is milled once in the plane. The tool is retracted after every cut.

X0, Y0Z0

Corner point 1 of surface in X or Y direction (abs. or incr.)Height of blank (abs. or incr.)

mm

X1Y1Z1

Corner point 2 of surface in X direction (abs. or incr.)Corner point 2 of surface in Y direction (abs. or incr.)Height of finished part (abs. or incr.)

mm

DXY Max. infeed in the XY plane (dependent on mill diameter)Alternatively, you can specify the plane infeed as a %, as a ratio � plane infeed(mm) to milling cutter diameter (mm).

mm%

DZ Max. infeed in Z direction mm

UZ Finishing allowance mm

• Define corner point 1 of the surface where machining is to begin.

• The same finishing allowance must be entered for both roughingand finishing. The finishing allowance is used to position the tool forretraction.


3.8 Milling 3


Programming example

Face milling

You want to cut to a depth of 10 mm on a workpiece surface. 8 mm must beremoved in a rough cut and 2 mm in a finish cut. The cutter diameter is40 mm.Blank dimensions: X0=0, Y0=0, Z0=10, X1=100 abs., Y1=50 abs., Z1=0 abs

UZ=2Z1=0

100

X

Z

ZO=10

Z=-40

Roughing

Finishing

Face milling: Roughing and finishing

Face milling, roughing Face milling, finishing

Extract from machining plan; Roughing and finishing in face milling


3.8 Milling 3


3.8.2 Mill a rectangular pocket

Function

You can mill a rectangular pocket of any type with this cycle.

Approach: The tool axis first approaches the pocket centre point in

the return plane (RP) in rapid traverse. It then feeds in to the safetyclearance (SC) in rapid traverse. The pocket is then machinedaccording the selected insertion strategy allowing for the unfinishedpart dimensions.

Finishing: The pocket edge is always finished first, followed by the

pocket base. The tool traverses the pocket only once when finishingthe edge. The pocket edge is approached on the quadrant which joinsthe corner radius. If the tool executes a depth infeed when finishingthe pocket edge, it approaches the pocket centre in the plane,executes the new depth infeed in rapid traverse and approaches thestart point of the quadrant in rapid traverse.When finishing the pocket base, the tool rapidly approaches a positioncorresponding to pocket depth + finishing allowance + safetyclearance over the pocket centre point. It is then inserted vertically topocket depth at the programmed depth infeed rate. The pocket base ismachined in a single operation.


Pocket

Rectangularpocket

Select key


Help display for milling a rectangular pocket



Position ofreference point

5 different positions for the reference point can be selected:

• Pocket centre

• Lower left-hand corner

• Lower right-hand corner

• Upper left-hand corner

• Upper right-hand cornerThe reference point (highlighted in yellow) is displayed in the Help screen.


3.8 Milling 3


Machining type RoughingFinishingFinishing on edge

Single pos.Pos. pattern

A rectangular pocket is machined at the programmed position (X0, Y0, Z0).Several rectangular pockets are machined in a position pattern (e.g. full circle,pitch circle, matrix, etc.).

X0Y0Z0

The positions refer to the reference point:Position in X direction (single position only), abs. or incr.Position in Y direction (single position only), abs. or incr.Workpiece height (abs.) or incr.

mmmmmm

W Pocket width mm

L Pocket length mm

R Radius at pocket corners mm

α0 Angle of rotation of pocket in relation to X axis. Degrees

Z1 Depth of pocket in relation to Z0 (abs. or incr.) mm

DXY Max. infeed in plane (XY direction)Alternatively, you can specify the plane infeed as a %, as a ratio � plane infeed(mm) to milling cutter diameter (mm).

mm%

DZ Max. depth infeed (Z direction) mm

UXY Finishing allowance in plane (pocket edge) mm

UZ Finishing allowance in depth (pocket base) mm

Insertion You can select several insertion strategies:

Helical: Insertion along helical pathThe cutter centre point traverses along the helical path determined by the radius anddepth per revolution. If the depth for one infeed has been reached, a full circlemotion is executed to eliminate the inclined insertion path.

Oscillation: Insertion with oscillation along centre axis of pocketThe cutter center point oscillates along a linear path until it reaches the depth infeed.Once it has reached the required depth, it traverses the path again without depthinfeed in order to eliminate the inclined insertion path.

Center: Insert vertically in centre of pocketThe tool executes the calculated depth infeed vertically in the centre of the pocket.Note: This setting can be used only if the cutter can cut across centre or if thepocket has been predrilled.

EP Max. insertion pitch (for helical insertion only) mm/rev

ER Insertion radius (for helical insertion only) mm

EW Insertion angle (for insertion with oscillation only) Degrees

FZ Depth infeed rate (for insertion in centre only) mm/minmm/tooth

Solidmachining

Complete machining:The pocket must be milled from a solid workpiece (e.g. casting).

Remachining:A small pocket or hole has already been machined in the workpiece. This needs tobe enlarged in one or several axes. You must program parameters AZ, W1 and L1for this purpose.

AZ Depth of premachined pocket (for remachining only) mm

W1 Width of premachined pocket (for remachining only) mm

L1 Length of premachined pocket (for remachining only) mm


3.8 Milling 3


Programming example You wish to cut a rectangular pocket, starting with a rough cut operation andfollowed by a finish cut. Since the cutting tool you are using cannot cut acrosscentre, the workpiece needs to be predrilled first with a drill of Ø 20 mm.

Y

X

120

80

50 90

Finishing allowance 1 mm

PredrilledDiameter 20 mm

Reference point of rectangular pocket

Workpiece drawing of the rectangular pocket

Rough cut a rectangular pocket Finish cut a rectangular pocket

Extract from machining plan; predrilling and milling a rectangular pocket


3.8 Milling 3


3.8.3 Mill a circular pocket

Function

You can mill a circular pocket with this cycle.You can cut the circular pocket

• from a solid workpiece or

• predrill the centre of the pocket, for example, where you are usinga cutter that cannot cut across centre(for programming example, see rectangular pocket).

Approach:The tool axis first approaches the pocket centre point in the

return plane (RP) in rapid traverse. The tool axis then moves to safetyclearance (SC) in rapid traverse. The pocket is then machinedaccording the selected insertion strategy allowing for the unfinishedpart dimensions.

Finishing:The pocket edge is always finished first, followed by the

pocket base. The tool traverses the pocket only once when finishingthe edge. The pocket edge is approached on the quadrant which joinsthe corner radius. If the tool executes a depth infeed when finishingthe pocket edge, it approaches the pocket centre in the plane,executes the new depth infeed in rapid traverse and approaches thestart point of the quadrant in rapid traverse.When finishing the pocket base, the tool rapidly approaches a positioncorresponding to pocket depth + finishing allowance + safetyclearance over the pocket centre point. It is then inserted vertically topocket depth at the programmed depth infeed rate. The pocket base ismachined in a single operation.


Pocket

Circularpocket

Select key


Help display for milling a circular pocket


3.8 Milling 3




Machining type RoughingFinishingFinishing on edge


A circular pocket is machined at the programmed position (X0, Y0, Z0).Several circular pockets are machined in a position pattern (e.g. full circle, pitchcircle, matrix, etc.).

X0Y0Z0

The positions refer to the centre point of the circular pocket:Position in X direction (single position only), abs. or incr.Position in Y direction (single position only), abs. or incr.Workpiece height (abs.) or incr.

mmmmmm

∅ Diameter of pocket mm

Z1 Depth of pocket in relation to Z0 (abs. or incr.) mm


mm%


UXY Finishing allowance in plane (pocket edge) mm

UZ Finishing allowance in depth (pocket base) mm

Insertion: You can select several insertion strategies:Helical: Insertion along helical pathThe cutter centre point traverses along the helical path determined by the radius anddepth per revolution. If the depth for one infeed has been reached, a full circlemotion is executed to eliminate the inclined insertion path.Feedrate: Machining feedrateCenter: Insert vertically in centre of pocketThe tool executes the calculated depth infeed vertically in the centre of the pocket.Feedrate: Infeed rate as programmed under FZNote: The vertical insertion into pocket centre method can be used only if the toolcan cut across centre or if the workpiece has been predrilled.

EP Max. insertion pitch (for helical insertion only) mm/rev

ER Insertion radius (for helical insertion only) mm

FZ Depth infeed rate (for insertion in centre only) mm/minmm/tooth

Solidmachining

Complete machining:The pocket must be milled from a solid workpiece (e.g. casting).Remachining:A small pocket or hole has already been machined in the workpiece. This needs tobe enlarged. Parameters AZ and ∅ must be programmed.

AZ Depth of premachined pocket or hole (for remachining only) mm

∅1 Diameter of premachined pocket or hole (for remachining only) mm


3.8 Milling 3


3.8.4 Mill rectangular spigots

Function

This cycle can be used to mill rectangular spigots of any typewith/without a corner radius on condition that a premachined, largerrectangular spigot is available.

Shapes of a rectangular spigot


Spigot

Rectangularspigot

Contour

approach/retraction

The tool approaches the return plane (RP) in rapid traverse. It thenapproaches the start point on return plane level (RP) that ShopMill hascalculated. The start point is located on the positive X axis rotated

through α0. It then approaches safety clearance (SC) at rapid

traverse.The spigot contour is approached along a semi-circle at machiningfeedrate. The tool first executes infeed at machining depth and thenmoves in the plane. The spigot is machined as a function of theprogrammed machining direction (climb/conventional) in a CW orCCW direction. When the spigot has been circumnavigated once, thetool retracts from the contour along a semi-circle in the plane and theninfeeds to the next machining depth. The contour is then approachedagain in a semi-circle and the spigot traversed once. This process isrepeated until the programmed spigot depth is reached.The tool finally approaches the return plane (RP) in rapid traverse.

Y

X

Contour retraction

Contour approach

Contour approach/retraction along semi-circle with CW rotating spindle and

conventional milling operation


3.8 Milling 3


Select key


Help displays for milling rectangular spigots



Referencepoint

You can select 5 different reference points:• Spigot center• Bottom left• Bottom right• Top left• Top right



A rectangular spigot is machined at the programmed position (X0, Y0, Z0).Several rectangular spigots are machined in a position pattern (e.g. full circle,pitch circle, matrix, etc.).

X0Y0Z0


mmmmmm

W Width of spigot after machining mm

L Length of spigot after machining mm

R Radius at edges of spigot (corner radius) mm

α0 Angle of rotation Degrees

Z1 Depth of spigot (abs. or incr.) mm


UXY Finishing allowance in the plane in relation to length (L) and width (W) of the spigot;Smaller spigot dimensions are obtained by calling the cycle again and programmingit with a lower finishing allowance.

mm

UZ Finishing allowance in depth (tool axis) mm

W1 Width of premachined spigot (important for determining approach position!) mm

L1 Length of premachined spigot (important for determining approach position!) mm


3.8 Milling 3


3.8.5 Mill circular spigots

Function

You can use this cycle to mill a circular spigot on condition that apremachined, larger circular spigot is available.


Spigot

Circularspigot

Contour

approach/retraction

The tool approaches the return plane (RP) in rapid traverse. It thenapproaches the start point on return plane level (RP) that ShopMill hascalculated. The start point is located on the positive X axis. It thenapproaches safety clearance (SC) at rapid traverse.The spigot contour is approached along a semi-circle at machiningfeedrate. The tool first executes infeed at machining depth and thenmoves in the plane. The spigot is machined as a function of theprogrammed machining direction (climb/conventional) in a CW orCCW direction. When the spigot has been circumnavigated once, thetool retracts from the contour along a semi-circle in the plane and theninfeeds to the next machining depth. The contour is then approachedagain in a semi-circle and the spigot traversed once. This process isrepeated until the programmed spigot depth is reached.The tool finally approaches the return plane (RP) in rapid traverse.

Y

X

Contour retraction

Contour approach

Contour approach/retraction along semi-circle with CW rotating spindle and

conventional milling operation


3.8 Milling 3


Select key


Help display for milling a circular spigot





A circular spigot is machined at the programmed position (X0, Y0, Z0).Several circular spigots are machined in a position pattern(e.g. full circle, matrix, line).

X0Y0Z0


mmmmmm

∅ Diameter of spigot after machining mm

Z1 Depth of spigot (abs. or incr.) mm


UXY Finishing allowance in plane (spigot diameter) mm

UZ Finishing allowance in depth (spigot base) mm

∅1 Diameter of premachined spigot(important for determining approach position!)

mm


3.8 Milling 3


3.8.6 Mill longitudinal slots

Function

You can use this cycle to face mill any type of longitudinal slot.

Approach: The tool approaches the slot center point on return plane

(RP) level in rapid traverse. It then feeds in to the safety clearance(SC) in rapid traverse. The groove is then machined according theselected insertion strategy allowing for the unfinished part dimensions.

Finishing: The pocket edge is always finished first, followed by the

pocket base. The tool traverses the slot only once when finishing theedge. The slot edge is approached on the quadrant which joins thecorner radius. If the tool executes a depth infeed when finishing theslot edge, it approaches the slot center point in the plane, executes thenew depth infeed in rapid traverse and approaches the start point ofthe quadrant in rapid traverse.When finishing the slot base, the tool rapidly approaches a positioncorresponding to slot depth + finishing allowance + safety clearanceover the slot center point. It is then inserted vertically to slot depth atthe programmed depth infeed rate. The slot base is machined in asingle operation.


Slot

Longitu-dinal slot

Select key


Help display for a longitudinal slot


3.8 Milling 3




Referencepoint

The reference point position must be defined:• Center point of longitudinal slot:• Inside left• Inside right• Left-hand edge• Right-hand edge



A longitudinal slot is milled at the programmed position (X0, Y0, Z0).Several longitudinal slots are milled in a position pattern (e.g. full circle, pitch circle,matrix, etc.).

X0Y0Z0

The positions refer to the reference point:Position in X direction (single position only), abs. or incr.Position in Y direction (single position only), abs. or incr.Workpiece height, abs. or incr.

mmmmmm

W Slot width mm

L Slot length mm

α0 Angle of rotation Degrees

Z1 Slot depth mm


mm%


UXY Finishing allowance in plane (slot edge) mm

UZ Finishing allowance in depth (slot base) mm

Insertion The tool can be inserted vertically over slot center (Mi) or with oscillating motion(Pe):Center=Insert vertically in center of longitudinal slot:The tool is inserted to infeed depth in the pocket center.Note: This setting can be used only if the cutter can cut across center.Oscillation=Insert with oscillation along center axis of longitudinal slot:The cutter center point oscillates along a linear path until it reaches the depth infeed.Once it has reached the required depth, it traverses the path again without depthinfeed in order to eliminate the inclined insertion path.

mm

FZ Depth infeed rate (for insertion in center only) mm/minmm/tooth



3.8 Milling 3


3.8.7 Mill circumferential slots on a full or pitch circle

Function

This cycle can be programmed to mill one or several circumferentialslots of equal size.

Approach 1st circumferential slot: The tool travels in rapid traverse

to safety clearance (SC) over the center point of the slot. It thenexecutes depth infeed at machining feedrate, allowing for themaximum Z direction infeed and the finishing allowance. ShopMill alsoapplies the programmed machining direction (climb or conventional)and machines the circumferential slot in a CW or CCW direction.

Approach further slots within the position pattern: The tool travels

to safety clearance (SC) at machining feedrate. It then approaches thecenter point of the next slot at safety clearance level. It then executesa depth infeed at machining feedrate.

Retraction: The tool travels to safety clearance (SC) at machining

feedrate. It then approaches the return plane (RP) in rapid traverseand finally the tool change point.

Notes

You can also use the circumferential slot cycle to machine an annular

slot. In this case, the number (N) of slots must be 1 and the arc angle

α1 360°.


Slot

Circumfe-rential slot

You can toggle between the "Full circle" and "Pitch circle" positioningpatterns with softkey "Alternat.".

Select key


Help display for circumferential slot as full and pitch circle


3.8 Milling 3





Full circle

Pitch circle

The slots are positioned around a full circle. The slot spacing is uniform andcalculated by the control.The slots are positioned around a pitch circle. The slot spacing can be determined

on the basis of angle α2.

X0Y0Z0

The positions refer to the center point:Position in X direction, abs. or incr.Position in Y direction, abs. or incr.Workpiece height, abs. or incr.

mmmmmm

W Slot width mm

R Radius of circumferential slot mm

α0 Angle of rotation in relation to X axis Degrees

α1 Arc angle of a slot Degrees

α2 Advance angle (for pitch circle only) Degrees

N Number of slots

Z1 Depth of slot in relation to Z0 mm


UXY Finishing allowance in XY plane (edge of slot) mm


3.8 Milling 3


3.8.8 Use of position patterns for milling

Function

You can position any milling cycle, e.g. rectangular or circular pockets,etc. using a position pattern. When you call the milling cycle, usesoftkey "Alternat." to select "Pos. pattern" in the "Single position"parameter field. The parameters for single positions X0, Y0 and Z0then disappear from the display.

Extract from the parameter form of a rectangular pocket with "Pos. pattern" entry

After you have finished programming the cycle and stored it, you needto program the position pattern.

Select with softkeys Drill

Positions

ShopMill automatically chains the milling cycle and the subsequentlyprogrammed position pattern.


3.8 Milling 3


Programming example 1 You want to mill 12 mutually parallel rectangular pockets at an angle of 15degrees. Arrangement on matrix: 4 columns, 3 rows.Blank dimensions: X=115 mm, Y=80 mm, Z=30 mmRectangular pocket dimensions: Length 20 mm, width 10 mm, depth 8 mmCorner radius 1.5 mm.You have selected "Bottom left" as the pocket reference point.

Parameter input fields for rectangular pocket and position pattern

Programming graphic, rectangular pockets on matrix at angle of 15 degrees

Extract from machining plan; milling rectangular pockets on a matrix


3.8 Milling 3


Programming example 2 You want to rough cut 6 longitudinal slots on a full circle of Ø 32 mm.The slots are rotated through 30 degrees.Blank dimensions: X=100 mm, Y=100 mm, Z=20 mmSlot dimensions: Length 28 mm, width 16 mm, depth 5 mmYou have selected "center point" as the slot reference point.

Parameter input fields for longitudinal slot and position pattern

Programming graphic, longitudinal slots at angle of 30 degrees on full circle

Extract from machining plan; milling longitudinal slots on a full circle


3.9 Measurements 3


3.9 Measurements

3.9.1 Workpiece zero point

Function

This function can be used to measure the zero point of a workpieceand store it in the basic zero offset or in a settable zero offset(max. 100 possible).

Select an axis with softkeys "X", "Y" or "Z".

Select with softkeys Misc.

Workpiecezero point >

Select key


Measurement of workpiece in X+ and X–

Measurement of workpiece in Y+ and Y–

Measurement of workpiece in Z


3.9 Measurements 3



T You must use a 3D probe.

XYZ

Approach position in X direction (abs.)Approach position in Y direction (abs.)Approach position in Z direction (abs.)

mmmmmm

Zero off. You can set the following:

• Basic zero offset

• Settable zero offset

• GUD data: This option enables you to scan the measurement result inGUD E_MEAS, e.g. for other calculations (tolerance checks, etc.).

Approachdirection

Plus (+): The probe approaches the workpiece in the plus directionMinus (–): The probe approaches the workpiece in the minus directionNote: If you have selected the approach position in the Z direction, this parameterdoes not apply as the tool can only approach the workpiece in a negative direction!

X0, Y0, Z0 Workpiece edge mm

If several workpieces are to be machined, an offset may occur in oneor several directions when the workpiece is clamped. This offset canbe compensated by measuring the workpiece edge.

Workpiece

Y

X

Probe

Clampingon vise

Offset

X0 newX0 old

Workpiece clamping with offset in relation to previous clamping

If several workpieces are clamped on a machine table for machining inparallel, the sensing probe can be used to measure one or severalworkpiece edges so that the zero point for each workpiece can becalculated.

Y

X

Probe

Workpiece 1

Workpiece 2 Workpiece 4

Workpiece 3

4 clamped workpieces


3.9 Measurements 3


3.9.2 Measure tool

Function

This function can calculate and monitor the wear on a tool. Before themeasuring cycle is called, the tool must be positioned above the toolprobe.

If the wear exceeds the value set in ∆L or ∆R, the tool is replaced and

disabled against further use. If no replacement tool is available, themachining operation is interrupted.

ShopMill automatically executes the measurement with either arotating or stationary spindle depending on the tool type and selectedmeasurement method (measure radius/length).


Measureworkpiece >

Measureradius or

Measurelength

Select key


Measure the tool radius Measure the tool length


T Tool name

D Offset value for tool edge 1 or 2

V Lateral offset (incr) with length measurementLongitudinal offset (incr.) with radius measurement

mmmm

∆L Max. wear value (applies only to length measurement), see tool data sheet suppliedby tool manufacturer.

mm

∆R Max. wear value (applies only to radius measurement), see tool data sheet suppliedby tool manufacturer.

mm


3.10 Miscellaneous functions 3


3.10 Miscellaneous functions

3.10.1 Subroutines and program section repeats

Subprogram If you require a section of a program to machine several workpieces, itis advisable to write it as a separate routine. There is no differencebetween subroutines and main programs in ShopMill.If you have special requirements of a program section that you cannotimplement using a ShopMill cycle, you can write and test the section inG code. You can then call it in ShopMill routines.

Select with softkeys: Misc.

Sub-routine

MMC 100.2: Select the required program type

• ShopMill

• G code

For MMC 103: Enter the path or workpiece name if

the desired subroutine is not stored in the workpiece directory whereyou are writing the main program.

Enter the name of the subroutine that you want to insert under

Program Name. You can specify the file ending (*.mpf or *.spf) if

necessary. If you only enter the program name, the default ending isadded.

Note • You can program another subroutine call in the subroutine. Themaximum nesting depth is 8 subroutines.

• You should not insert subroutines among blocks chained by thecontrol.

Repeat program

blocks

You can use this function to execute program blocks repeatedlywithout having to program them again.Blocks to be repeated must be inserted between 2 so-called markers(start and end markers). You must assign a unique name to eachmarker. All programmed markers must have different names. Thename "Marker" appears as a default name in the marker field.


Setmarker

The marker is always inserted after the current block!




To execute marked program blocks again, you must program a"repeat" instruction.


Repeat

Enter the start and end markers.Start marker: Name of marker identifying beginning of repeat

section.End marker: Name of marker identifying end of repeat section.

Example

Machining plan with repeat of program section

N10 Start marker "begin"

N20 End marker "end"

N35 Repeat program section from "begin" to "end"

3.10.2 Alter the safety clearance or return plane

Function

This function allows you to program a new return plane or safetyclearance for the following program blocks. You can also use it tochange the machining direction. The function is modal and remainsvalid until it is redefined.


Settings >

Note: The tool axis programmed in the program header cannot be

altered.




3.10.3 Zero offsets

Function

After referencing, the actual value display is referred to the machinezero of the machine coordinate system (MCS). The part program forthe workpiece refers to the workpiece zero of the workpiececoordinate system (WCS).The machine zero and workpiece zero do not have to be identical.The distance between the machine zero and workpiece zero may varydepending on the workpiece type and clamping method. This zerooffset is taken into account when the part program is processed.

There are two types of zero offset, i.e.

• settable zero offsets and

• programmable zero offsets

Settable zero offset Settable zero offsets are offsets which can be called from anyprogram. The offset and rotation values are preset by the operator andstored in the control. They can be fetched from the zero offset list.

Programmable zero offset Programmable zero offsets are valid in the current program and referto settable zero offsets. A programmable zero offset can comprise

− an offset,

− a rotation,

− scaling and

− mirroring.

Further notes

The number of settable zero offsets (up to 100) is defined by amachine data.Please read the machine manufacturer’s instruction manual!




Operating sequence

Settable zero offset

In the program you have called, you can activate a settable zero offsetwith ZO1 (G54) to ZO4 (G57) and other zero offsets (100 in total). Youcan do this in the following way:

Select softkey "Alternat." to toggle between the basic offset and theactive zero offsets

orUse the Edit key to enter the desired offset directly in the input field

and terminate the input by pressing the "Input" key.


Transfor-mations >

Zerooffset >

Y

X

Y

X

Y

X

Y

X

ZO1

ZO2

ZO3

M

M

Zero offset in X and Y directions

Z0

Y0

X0

Z1

X1

Y1

Zero offset and rotation

3 08.00 Programming with ShopMill3.10 Miscellaneous functions 3


Programmable zero offsets

Translation You can program a zero offset for each axis in the direction of thespecified axis.


Transfor-mations >

Offset >

New offset

The last settable zero offset you entered (as absolute coordinate) actsas the reference.

Additive offset

The currently active offset (additive) acts as the reference.

Examples

new

additive

Offset

new

Scal

ing

Rotationadditive

addi

tive

New and additive offsets Offset, rotation and scaling




Rotation An angle of rotation can be set for each axis.


Transfor-mations >

Rotation >

New rotation

The last settable zero offset you entered (as absolute coordinate) acts as the

reference.

If a "new" rotation is active, an existing scaling is deactivated.

Additive rotation

The currently active rotation (additive) acts as a reference.

Example

X

Y

30

60°45°

7

2055

10

3540

r7

128

Offset and rotation of workpieces in the X/Y plane




Scaling You can set a scaling factor for the X/Y plane and the tool axis. Theprogrammed values are multiplied by this factor.The scaling always refers to the zero point of the workpiece.

If, for example, the size of a pocket is increased whose center pointdoes not coincide with the zero point, then the pocket center point isshifted in the scaling.


Transfor-mations >

Scaling >

New scaling


reference.

If a "new" scaling is active, an existing rotation is deactivated.

Additive scaling

The currently active scaling (additive) acts as the reference.

Examples

X

Z

Y

Offset

new

Sca

ling

Rotationadditive

addi

tive

Scaling of a contour pocket in the X/Y plane and offset, rotation and scaling of a

workpiece.




Mirroring Mirroring can be performed in relation to several axes simultaneously.


Transfor-mations >

Mirroring >

New mirroring


reference.

Additive mirroring

The currently active transformation (additive) acts as the reference.

Examples

X

Y

Mirrorin

g X

Mirrorin

g Y

Mirroring in relation to X and Y axes

X

Y

Mirroring on the X axis

The direction of travel of the cutting tool is also mirrored

(note machining direction (climb/conventional)).




3.10.4 Cylinder peripheral surface transformation

Function

The cylinder peripheral surface transformation is an option.Cylinder peripheral surface transformation is required to machine

• longitudinal slots on cylindrical solids,

• cross slots on cylindrical solids,

• any other slot shapes on cylindrical bodies.

The shape of the slots is programmed with reference to the developedlevel cylinder surface area. The slot can be programmed as aline/circle contour, via drilling or milling cycles or with the contourmilling function (free contour programming).

X

Z

Y

There are two types of cylinder peripheral surface transformation:

• Slot side compensation off

• Slot side compensation on (path milling only)

Slot side compensation

OFF

When slot side compensation isdeactivated, any type of slot withparallel sides can be machined ifthe tool diameter equals the slotwidth.

The slot sides are not parallel if theslot width is larger than the tooldiameter.

Longitudinal groove Cross groove

Groove side compensation off

The slot contour is programmed for machining purposes.




Slot side compensation ON When slot side compensation isactive, slots with parallel sides aremachined even if the slot width islarger than the tool diameter.

Longitudinal groove limited in parallel, groove side compensation on

The slot contour must not be programmed for machining purposes,but the imaginary center-point path of a bolt inserted in the slot; thebolt must be in contact with all sides of the slot. The slot width isdetermined by parameter D (see also Section "Example 5: Slot sidecompensation".)

Programming The basic programming procedure is as follows:

1. Select zero offset for cylinder surface transformation (e.g. offsetthe zero point on the center point of the cylinder end face)

2. Position the Y axis (Y axis must be positioned prior to cylindersurface transformation because it is defined differently aftertransformation)

3. Activate cylinder peripheral surface transformation4. Select zero offset for machining on developed cylinder surface

(e.g. shift zero point to the zero point on the workpiece drawing)5. Program machining operation (e.g. enter contour and path milling)6. Deactivate cylinder peripheral surface transformation

The programmed cylinder peripheral surface transformation issimulated only as a developed peripheral surface.

The zero offsets active prior to selection of cylinder surfacetransformation are no longer active after the function has beendeselected.


Transfor-mations >

Cylindersurface >





Transformation Activate/deactivate cylinder peripheral surface transformation (see also examplebelow)

∅ Cylinder diameter (only when transformation is active) mm

Slot side comp. Activate/deactivate slot side compensation (only when transformation is active)

D Offset to the programmed path (onlywhen slot side compensation is active)

mm

Options for free contour programming

General For contours (e.g. slots) on a cylinder, lengths in the circumferentialdirection of the cylinder peripheral surface (e.g. Y axis) are oftenspecified as angles.Several options are available under the "Mill contour" function in freecontour programming for this purpose.Depending on the selected axis (selection is made via a displaymachine data), you can enter the length as an angle.

Start point In the screen form for selecting the start point, you can also activate ordeactivate the cylinder peripheral surface transformation function viathe "Alternat." softkey. When the function is active, you are offered

diameter ∅ of the cylinder.

Contour elements Depending on the axis and the relevant element, angle parameters

Xα, Iα or Yα, Jα are added to screenforms

"Horizontal/vertical/diagonal line" and "Arc" when the cylinderperipheral surface transformation function is active.

Notes

• The dimensions of the developed surface are specified in mm inthe graphic!

• You must delete the Y value before you can enter an angular value

for Yα in the start screen form.




3.10.5 Swiveling

Function

If you wish to create or machine inclined planes, you can swivel themachining coordinate system. Swivel heads or tables are used for thispurpose.

The swiveling function can be used only if the zero offset has been setin the unswiveled state (rotary axis positions in MCS/WCS =0). Whenthe coordinate system is swiveled, the previously set zero offset isautomatically converted for the swiveled state.

The basic programming procedure is as follows:

1. Swivel the coordinate system into the plane to be machined.2. Program the machining operation for the unswiveled plane.3. Swivel coordinate system back to its original position.

Please note the following when traversing the tool axes:

• Retract the tool axis in such a manner that the tool and workpiececannot collide when it swivels.

• If a program has been interrupted in the swiveled state, it ispossible to remove the tool from an inclined hole by retracting it inthe Z+ direction during NC Stop in Jog mode. This is no longerpossible after an NC Reset.

The coordinate system can be swiveled either axially or via solid orprojection angles. A machine data determines which swiveling variantsare available.

• With the axial swiveling variant, the coordinate system is rotatedabout the individual axes sequentially, which each rotationcommencing directly from the previous rotation. The axis sequenceis freely selectable.

• With the swiveling variant based on solid angles, the coordinatesystem is rotated first about the Z axis and then about the Y axis.The second rotation commences directly from the first.

• The projection angle variant involves swiveling the coordinatesystem about the individual axes sequentially; the sequence ofaxes is freely selectable. The first two rotations refer in each caseto the initial state, the last rotation commences directly from theprevious two.

The positive direction of rotation for each of the different swivelvariants can be found in the Help displays.

3 08.00 Programming with ShopMill3.10 Miscellaneous functions 3


In swivel systems with 2 rotary axes, a particular position can bereached in two different ways, i.e. either via a CW or a CCW rotation.The geometry of the swivel head or table is such that the head or tableassumes two different positions depending on the selected direction.This may affect the working area. You can choose between these twodifferent positions in the "Direction" parameter. If one of the twopositions cannot be reached for mechanical reasons, the alternativeposition is automatically selected irrespective of the setting of the"Direction" parameter.

To avoid collisions, you can leave the position of the tool tipunchanged during swiveling. Please refer to information supplied bythe machine manufacturer to find out whether this function is available.

The "Measure workpiece" and "Measure tool" functions are notoperative in a swiveled plane.


Transfor-mations >

Swivelling


Reference point of rotation Axial swivel

Swivel solid angle Swivel projection angle




Zero point of rotated surface


TC Name of swivel data block0: Remove inclinable head–: No change to set swivel data block

T Tool name

Transformation Transformation (swiveling) additive or new

X0 Reference point for rotation mm

Y0 Reference point for rotation mm

Z0 Reference point for rotation mm

Swiveling Axial swiveling, or swiveling via solid or projection angle

X Axis angle (axial swivel) The sequence of axes Degrees

Y Axis angle (axial swivel) can be changed round Degrees

Z Axis angle (axial swivel) as required Degrees

α Angle of rotation in the XY plane about the Z axis (swiveling via solid angle) Degrees

β Angle of rotation in space about the Y axis (swiveling via solid angle) Degrees

Xα Axis angle (swiveling via projection angle) The sequence of axes Degrees

Yα Axis angle (swiveling via projection angle) can be changed round Degrees

Zβ Axis angle (swiveling via projection angle) as required Degrees

X1 New zero point of rotated surface mm

Y1 New zero point of rotated surface mm

Z1 New zero point of rotated surface mm

Direction Preferred direction of rotation with 2 alternatives+: Larger angle of 2nd axis on the scale of the swivel head/table–: Smaller angle of the 2nd axis on the scale of the swivel head/table

Fix tool tip Correct: The position of the tool tip is maintained during swiveling.Do not correct: The position of the tool tip is changes during swiveling.

Other additive transformations can be added to the offsets before

(X0, Y0, Z0) or after (X1, Y1, Z1) swiveling (see Section "Zerooffsets").




Programming example You want to bevel a corner on a cube.

The machining plane is to be the inclined surface, i.e. the machiningplane must be swiveled as follows:

• With axial swiveling and swiveling using solid angles, the systemof coordinates is rotated first in the XY plane in such a way thatthe upper edge of the inclined surface of the cube runs parallel

to the X axis (rotate 45° about Z axis or α=45°). The system of

coordinates is then tilted so that the inclined plane of the cube is

in the XY plane (rotate –54.736° about Y axis or β=54.736°).

• With the swiveling via projection angles options, the X and Y axesare rotated through 45° so that the inclined plane of the cube is inthe XY plane. The Z axis is then rotated through 30° so that theX axis runs through the center point of the inclined surface (zeropoint of rotated surface).

Workpiecezero

Zero pointof rotatedarea

Referencepoint forrotation

54.736°

View A

50

50

25

APlan view

50

25 2545°

Z

X

Y

45°

30°

45°

View of left-hand side

Workpiece machined by an inclinable head




Swivel (axial) Swivel (solid angle) Swivel (projection angle)




3.10.6 Define a new blank

Function

A new blank can be defined within ShopMill programs to allow thevisible section to be modified during simulation. This is useful for thezero offset, cylinder peripheral surface transformation and swivelingfunctions.

Program the functions listed above before you define a new blank.

Operating sequence

Misc.

Settings >

Select softkeys "Miscellaneous" and "Settings". Enter the desiredvalues under corner point 1 and corner point 2 or dimensions (seealso Section "Create a new program; define a blank").

The new blank definitions are stored in the ShopMill program.

If you are machining exclusively in a swiveled plane, for example, therequired blank dimensions can also be entered directly in the programheader.


3.11 Insert G code in a ShopMill program 3


3.11 Insert G code in a ShopMill program

Function

You have the option of inserting G code blocks/comments in aShopMill program in the ShopMill operator interface.

A G code block can be programmed according to DIN 66025.Please refer to the following Programming Guide for an exactdescription of G code blocks to DIN 66025:"SINUMERIK 810D/840D/FM-NC Fundamentals".

Operating sequence

Precondition A program has been created under "Programs/New/ShopMillProgram".

Insert a G code block

Select with softkey G codeblock

This softkey inserts a G code block in the program. You can now editthe selected G code block. Press the "Input" key to terminate oneG code block and create a new one.

Insert comment Comments are used to document the program. Individual blocks withina program can be explained by comments.A semi-colon (;) is inserted in front of the comment text to mark thecomment beginning. A comment block is terminated with the "Input"key.

Example

Example of a program with G code and comment




Cursor control in the

G code block

You can position the cursor in a line or move from G code block toG code block using the cursor keys.

DelPress the "Delete" key to delete the character selected with the cursor.

Further notes

• You cannot insert a G code block before the program header orafter the program end.

• You cannot program a G code block within a chain of programblocks.

• G code blocks are not displayed in the programming graphic.

�




Notes

4 08.00 Programming with G Code 4


Programming with G Code

4.1 Create a G code program ....................................................................................... 4-204

4.2 R parameters (arithmetic parameters).................................................................... 4-207

4.3 User data ................................................................................................................ 4-208

4.4 ISO dialects............................................................................................................. 4-211

4 Programming with G Code 08.00

4.1 Create a G code program 4


4.1 Create a G code program

Function

You have the option of creating your own G code program in the Gcode editor on the ShopMill operator interface.

A G code block can be programmed according to DIN 66025.For an exact description of G code blocks to DIN 66025, please referto/PG/, Programming Guide Fundamentals/PGZ/, Programming Guide Cycles.

The G code program is stored in the "Program Manager" directory.

Select with softkeys ProgramManager

New >

G codeprogram

Enter a program name Enter a program name.

Program names may be a maximum of 24 characters in length.You can use any letters, digits or the underscore symbol (_).Lower case is automatically changed to upper case.

Confirm the program name by pressing

or

The G code editor is then opened.

The editor offers the following functions:

• Transfer a tool from the tool list

• Mark

• Copy/Delete/Insert

• Seach/Replace

• Number NC block

• Simulate a part program

• Execute a part program

Part programs or sections of part programs can be edited in theG code editor only if the relevant blocks have not yet been executed.Editable blocks are specially highlighted.A part program can be edited completely when selected or in the"Reset" state.

4 08.00 Programming with G Code



Operating sequence

Insert a tool

Tools

Toprogram

Select softkey "Tools" to go to the tool list.Position the cursor on the tool you want to transfer.Transfer the tool to the G code editor by selecting softkey"To program".Text such as the example below is displayed at the current cursorposition: T=MILL10

> When you select the "ETC" key, all the following functions aredisplayed in the vertical softkey menu:

Edit part program

Mark This softkey marks the beginning of a block.Position the cursor at the block end. The block is automaticallyselected.

Copy This softkey copies the selected block into a clipboard. The blockremains stored in the clipboard, even when you change to another partprogram.

Insert This softkey inserts the cut or copied block from the clipboard in thetext after the cursor.

Delete Deletes the selected block.

Search

Search/Replace >

This softkey displays a new vertical softkey menu. You can choosebetween "Search" and "Search/Replace".

Search

Find next

Select softkey "Search". Enter the string you wish to find and confirmyour input with "OK". The part program is searched in a forwardsdirection until the string is found. The search result is marked by thecursor in the editor. You can continue the search by selecting softkey"Find next".

Search/Replace >

Find next

Replace

Replaceall

Select softkey "Search/Replace". Enter the string you wish to find andthe replacement string and confirm your input with "OK". The partprogram is searched in a forwards direction until the string is found.The search result is marked by the cursor in the editor.You can select whether you wish the search to continue, replace thestring or do a global search and replace on the entire part program.




Positioning

Re-number >

The following functions are defined in the "Renumber" input window:

• Block number incrementation (e.g. 1’s, 5’s, 10’s)

• Number of the first blockYou can cancel the numbering again by entering 0 as theincrementation or first block number.

This softkey deselects the vertical softkey menu.

Simulate a part program

Simula-tion

This simulates the part program. The functions "Zoom Origin","Zoom +", Zoom –" and "Zoom Auto" are available (see Section"Zoom a finished part viewport").

Execute a part program

Machinefrom here

The part program is called in "Machine Auto" (Automatic) mode. Youcan start the part program with NC Start.


4.2 R parameters (arithmetic parameters) 4


4.2 R parameters (arithmetic parameters)

Function

R parameters are read and written by the G code programs. They canbe manually altered.

Operating sequence

ToolOffset

The R parameter list is displayed via the "Tool Offset" key

ToolsZO

or via softkey "Tools ZO".

R para-meters

This opens the R parameter list.

You can page up and down with the "Paging" keys.

Find an R parameter

Find This softkey opens the "Find an R parameter" input window.

Enter the parameter number you want to find.

Press the "Accept" softkey to display the R parameter found by thesearch function.

Closes the "Find" window.

Edit an R parameter

Position the cursor bar on the relevant input field and enter the values.

Delete an R parameter

DelPosition the cursor bar on the relevant input field and delete the valueswith the "Delete" key.

Further notes

Input and deletion of R parameters can be disabled via the keyswitch.


4.3 User data 4


4.3 User data

Function

User data can be defined by several different variable types:

• Global variables (GUD) which are applicable in all programs.

• Local variables (LUD) which are valid only in the program orsubroutine in which they were defined.

• Program-global variables (PUD) are generated from the localvariables (LUD) defined in the main program as a function of amachine data setting.Program-global variables are thus valid on all subroutine levels onwhich they can also be read and written.

SW 4.3 and earlierGlobal user data (GUD) should be defined as part of the start-upprocess as they require re-initialization of the control system.

SW4.4 and later:User data (GUD) can be defined for the MMC103 without re-initialization.The following applies:

• Definition files that are on the hard disk are not active.

• Definition files that are on the NC are always active.

The user memory size must be configured large enough to hold theGUD definition file before it is loaded to the control.All relevant machine data contain the letters GUD in their name.

Further notes

The display of global user data (GUD) can be disabled by means ofkeyswitch or password.


4.3 User data 4


Find/edit user data/variables

Operating sequence

User dataPress softkey "User data".The "Program-specific user data" window is opened.The vertical softkey menu changes.

Globaluser data

You have the option of switching between windows

• "Global user data" (GUD)

Chan. spec.user data

• "Channel-specific user data" (CHUD) and

Localuser data

• "Local user data" (LUD).

The name and value of the current user data are displayed in eachcase.

Programuser data

• "Program user data"This softkey displays program-global (PUD) and local variable (LUD)user data.

You can page up and down in the list using the "Paging keys".

Edit user data

Position the cursor on the user data that you wish to edit and enter anew value or

select a new value via the "Toggle" key.The new values are transferred directly.

Find user data

GUD +

GUD –

CHUD +

CHUD –

You can scroll through the user data GUD 1 to GUD 9 using softkeys"GUD +" to "GUD –".

The same applies to softkeys "CHUD +" to "CHUD –" .

GUD:

CHUD:

This opens the "Select global user data" window. You can make thefollowing settings:

• 1 = SGUD (Siemens)

• 2 = MGUD (Machine Manufacturer)

• 3 = UGUD (Machine User)

• 4 ... 9 = GUD4 ... GUD9

The same applies to "CHUD".

The selected user data are displayed in the "Global user data" window.

Find Press softkey "Find".Dialog box "Find user data" is displayed.


4.3 User data 4


You can look for the name or character strings contained in the name.The cursor is positioned on the user data found by the search.

Continuesearch

The next user data with the specified initial identifier is displayed.

Only the local user data still stored in the processing sequence on thecontrol are displayed.

The list of displayed local user data are updated with every "NC Stop",but the display values are refreshed continually.Before global user data definitions can become effective in the control,it might be necessary to set the corresponding machine data.


4.4 ISO dialects 4


4.4 ISO dialects

Function

ISO dialect0 M programs (Fanuc0 milling) can also be executed underShopMill. These are read in and out via the V.24 interface.

Operating sequence

Read in An ISO dialect0 M program is read in by the same method as aShopMill program.ISO dialect0 M programs which you read in are stored as mainprograms in the ShopMill directory.

Execute Before you can execute an ISO dialect0 M program, you must makethe following settings:1. A tool offset data set (geometry and wear data) must be assigned

to every H number in the ISO dialect0 M program.Add the tool geometry data in column "H" of the tool list with theappropriate H number. Each data set must have a unique Hnumber; only replacement tools may have the same H number asanother set.

2. Each ISO dialect0 M program must be preceded by command"G291". Command "G290" marks a return to the Siemens program.

You can display specific ISO dialect G functions by selecting softkey"G functions".

Read out An ISO dialect0 M program is read out by the same method as aShopMill program.Select punched tape/ISO format as the output format.

You can view the assignments between Siemens zero offsets andISO dialect0 M zero offsets in a table.Please read the machine manufacturer’s instruction manual!

�


4.4 ISO dialects 4


Notes

5 08.00 Simulation 5


Simulation

5.1 General ................................................................................................................... 5-214

5.2 Start/abort program................................................................................................. 5-214

5.3 Representation as a plan view................................................................................ 5-215

5.4 Representation as a 3-plane view........................................................................... 5-216

5.5 Zoom a finished part viewport................................................................................. 5-217

5.6 Three-dimensional representation of finished part ................................................. 5-2185.6.1 Change position of finished part ............................................................................. 5-2185.6.2 Cut open finished part............................................................................................. 5-2195.6.3 Update finished part display.................................................................................... 5-219

5 Simulation 08.00

5.1 General 5


5.1 General

Function

To simulate the machining process, the control system completelycalculates the currently selected program and displays the result ingraphic form.

You can select the following modes of representation for simulation:

• Plan view

• 3-plane view

• Volume model

The simulation function displays tools and workpiece contours in theircorrect proportions.

5.2 Start/abort program

Function

Start program

Precondition You have selected the program you want to simulate, i.e.

• a ShopMill program or a

• G code programand called it in the Program Editor.

Simula-tion

Press softkey "Simulation".

In the case of ShopMill programs, the dimensions of the blank forsimulation are taken from the program header. With G codeprograms, you must specify the dimensions of the blank or theselected viewport yourself.

Settings With a G code program, select softkey "Settings" and enter thedimensions of your choice (see also Section "Create a new program;define a blank").These dimensions are stored for simulation of the next G codeprogram. If you set the "Blank" parameter to "off", the dimensions willbe deleted.

Starts the program.

Processing time The processing time (in hours/minutes/seconds) indicates theapproximate time that would actually be required to execute themachining program on the machine (incl. tool change).The timer is stopped if the program is interrupted.

5 08.00 Simulation

5.3 Representation as a plan view 5


Abort program

Interrupt the simulation with the "back" softkey.

Simula-tion

The program is restarted when you press softkey "Simulation".

5.3 Representation as a plan view

Function

You can display the contour as a plan view by pressing this softkey.A depth display indicates the current depth at which machining iscurrently taking place.The following applies with respect to depth display in this graphic:"The deeper, the darker".

Select with softkey Plan view

Example of a plan view display of a finished part:

5 Simulation 08.00

5.4 Representation as a 3-plane view 5


5.4 Representation as a 3-plane view

Function

The process is represented as a plan view with 2 sections, similar to atechnical drawing.Functions for zooming viewports are provided in the 3-plane view.

Select with softkey

Example of a 3-plane view of a finished part:

Shift cutting planes The cross-hair can be positioned in the plan view to display the cuttingplane in the respective side view. Example of a volume model(finished part):

To reveal concealed contours, you can shift the cutting planes to anyposition you want in the 3-plane display.

Shiftin the ...

with keys ...

y plane

x plane

z plane

5 08.00 Simulation

5.5 Zoom a finished part viewport 5


5.5 Zoom a finished part viewport

Function

Functions for displaying a more detailed representation of a finishedpart are available

• in the plane view and

• in the 3-plane display.

Select with softkey Details

Zoom a viewport Softkeys/keys Meaning

Toorigin

You return to the initial display

Zoom+

Zoom–

You can use softkey "Zoom +" or "Zoom –" todisplay the current screen contents in a higher orlower resolution. Use the cursor or "Paging" keysto position the cross-hair in the centre of theselected viewport.

Note:The same functions are provided by the "Plus" and"Minus" keys on the operator panel.

AutoZoom

Press this softkey to display a window-proportionate representation of all travel paths inthe graphic display area.

5 Simulation 08.00

5.6 Three-dimensional representation of finished part 5


5.6 Three-dimensional representation of finished part

Function

The finished part is displayed as a volume model. The simulationwindow displays the current machining status.You can display concealed contours and views on the volume modelby

• changing the position about the vertical axis or

• cutting open the volume model at the desired point.

Select with softkey

Example of a volume model (finished part):

5.6.1 Change position of finished part

Select with softkey Details

Select views You can select one of the following views:

Left-hand side of part from front

Right-hand side of part from front

Right-hand side of part from rear

Left-hand side of part from rear

5 08.00 Simulation



5.6.2 Cut open finished part

Precondition You have selected one side of the finished part.

Select with softkey

Shift cutting planes To make concealed contours visible, shift the cutting planes using thecursor and "Paging" keys (see also Section "Representation in 3-planeview") to any position.

Update The new setting is updated when you select this softkey.

Example of a cut volume model (finished part):

5.6.3 Update finished part display

Precondition You are in "Volume model" representation mode and have started theprogram.

Update While you are testing the program, the 3D representation of thefinished part is refreshed to correspond to the latest machining statusevery time you press softkey "Update".

�

5 Simulation 08.00



Notes

6 08.00 File Management 6


File Management

6.1 Function .................................................................................................................. 6-222

6.2 Directory structure................................................................................................... 6-222

6.3 "Directory" operating area (MMC 100.2)................................................................. 6-2246.3.1 Select a file ............................................................................................................. 6-2246.3.2 Create a file............................................................................................................. 6-2246.3.3 Execute a program ................................................................................................. 6-2256.3.4 Copy/rename files ................................................................................................... 6-2256.3.5 Delete files .............................................................................................................. 6-2256.3.6 Set up the V.24 interface ........................................................................................ 6-2266.3.7 Execute a program via the V.24 ............................................................................. 6-2276.3.8 Multiple clamping .................................................................................................... 6-2286.3.9 Back up tool/zero point data ................................................................................... 6-2306.3.10 Read in tool/zero point data .................................................................................... 6-2316.3.11 Read out files .......................................................................................................... 6-2326.3.12 Read in files ............................................................................................................ 6-2336.3.13 Error log .................................................................................................................. 6-233

6.4 "Directory" operating area (MMC 103).................................................................... 6-2346.4.1 Basic display ........................................................................................................... 6-2346.4.2 Create files/directories ............................................................................................ 6-2366.4.3 Open files/directories .............................................................................................. 6-2376.4.4 Load and unload programs..................................................................................... 6-2376.4.5 Select several programs ......................................................................................... 6-2396.4.6 Copy/rename/insert files/directories ....................................................................... 6-2396.4.7 Delete/move files/directories................................................................................... 6-2406.4.8 Execute from hard disk ........................................................................................... 6-2406.4.9 Set up the V.24 interface ........................................................................................ 6-2416.4.10 Multiple clamping .................................................................................................... 6-2426.4.11 Back up tool/zero point data ................................................................................... 6-2446.4.12 Read in tool/zero point data .................................................................................... 6-2456.4.13 Read out files .......................................................................................................... 6-2466.4.14 Read in files ............................................................................................................ 6-2466.4.15 Error log .................................................................................................................. 6-247

6 File Management 08.00

6.1 Function 6


6.1 Function

The "Directory" operating area offers the following functions:

• Read in/out of programs

• Management of programs in the NC user memory and datamanagement directory on the hard disk, on a floppy disk drive andon network drives

6.2 Directory structure

All files are stored in a directory structure.

MMC 100.2

ShopMill operator interfaceMMC100.2

NCuser memory

ShopMill programs

ShopMill subroutines

G code programs

Channel 1

Edit EditDisplay

data

Axes

V.24

Programs are always stored in the NC where they can be editeddirectly.

6 08.00 File Management

6.2 Directory structure 6


MMC 103ShopMill operator interfaceMMC103

NC user memory

Chan. 1ShopMill prog.ShopMill subroutineG code prog.

Edit

Axes

V.24

Data management

directory

on hard disk

ShopMill prog.ShopMill subroutineG code prog.Edit

Displaydata

Edit

Load

Unload

Store

Floppy disk drive

Edit

Network drive

ShopMill prog.ShopMill subroutineG code prog.

• ShopMill with an MMC 103 operator interface has its own hard diskin addition to the NC main memory. As a result, any program that isnot needed in the NC can be stored on hard disk. Programs aresorted in file-tree form in directories.

• On the MMC 103 operator interface with ShopMill, it is alsopossible to set up a floppy disk drive and other network drives inthe directory management. Please read the machinemanufacturer’s instruction manual!


6.3 "Directory" operating area (MMC 100.2) 6


6.3 "Directory" operating area (MMC 100.2)

6.3.1 Select a file

Operating sequence

ProgramManager or

ProgramManager

Select with softkey or the "Program Manager" key.

File information The following information is displayed:

Name:

Files which are stored in the directory

Size:

Size of file in bytes

Date:Date on which the file was created or last modified.

Select and call a file

Select the file you want using the cursor keys.

or

Press the "Input" or "Cursor right" key.

The selected file is displayed in the "Program" operating area.

6.3.2 Create a file

Function

This subsection describes how new programs can be created.

Operating sequence

ProgramManager

"Directory" operating area is selected.The current program overview is displayed.

New Once you have pressed the "New" softkey, you can

• create a ShopMill program (see Section"Create a ShopMill program")

• or a G code program (see Section "Programming G code").Enter a name for the new program and confirm your input.




6.3.3 Execute a program

Function

This subsection describes how to execute a program.

Operating sequence

Precondition You have selected a file.

Execute Press softkey "Execute".You then change over to the "Machine Auto" operating area.

6.3.4 Copy/rename files

Operating sequence

Precondition You have selected a file.

Copy Press softkey "Copy"or

Rename select the "Rename" softkey.

Enter a new file name in the "To:" field and confirm with the "Input"key.

You can rename a file if it is not currently selected and beingprocessed in "Auto" mode or if the new name has not yet been used.

6.3.5 Delete files

Operating sequence

Precondition The file to be deleted is selected.

Delete Press softkey "Delete".

Confirm the delete operation.

Abort delete operation.




6.3.6 Set up the V.24 interface

Function

You can send files to an external data backup device (e.g. PG/PC,printer), or read them in (e.g. PG/PC) via the V.24 interface. You mustset the appropriate parameters for the V.24 interface and your databackup device. The control offers you a suitable input screen form inwhich you can define the specific data for your device.

Operating sequence

Precondition "Program Manager" operating area is selected.

Continue >>

Read out

Read in

Select one of the softkeys for the V.24 interface. The softkey remainshighlighted for check purposes:

V.24settings

Press softkey "V.24 settings" to display the "Parameterization V.24user" screen form. Assign the parameters in this screen form.

Position the cursor bar on the input fields and enter the necessaryvalues.

or

The values for parameters "Interface", "Protocol", "Baud rate","Data bits", "Parity" and "Stop bits" can be selected with the toggle keyor "Alternat." softkey.

You can also activate or deactivate special functions with the"toggle key" or the "Alternat." softkey.

Notes

Make sure that you set the correct file format (binary/PC, punchedtape or punched tape/ISO format).

This softkey closes the "Parameterization V.24 user" screen form.

The modified data are stored.




6.3.7 Execute a program via the V.24

Function

Programs stored externally can be executed via the V.24 interface.If a program needs more memory space for execution than isavailable in the NC main memory, for example, then you can load theprogram contents continuously via the V.24 interface.

Operating sequence

Precondition "Program Manager" operating mode is selected.

Select the program you want to execute.

Continue >>

ExecuteV.24

Select softkeys "Continue" and "Execute V.24".

The program contents are loaded continuously to the NC mainmemory while the program is being processed.


The program remains in the external storage medium when"Execute from V.24" is active.




6.3.8 Multiple clamping

Function

You can machine several workpieces at the same time by using the"Multiple clamping" function. You can either execute the sameprogram several times or select several different machining programs.The "Multiple clamping" function is an option.

The multiple clamping function creates one single program fromseveral different programs. This includes optimization of tool changesin order to reduce machining times. The tool sequence within aprogram remains unchanged. Cycles are not opened, position patternsare processed as closed units.

The individual programs must meet the following requirements:

• ShopMill programs only

• Program must have been tested

• No markers/repetitions, i.e. no branches in the program

• No inch/metric switchover

• No transformations

• Contours must have unique names, i.e. the same contour namemust not be called in several different programs

• Max. of 50 contours per clamping

• Max. (99 start ZO) clampings

Operating sequence

ProgramManager or

ProgramManager

Select the "Program Manager" key or softkey.

Multipleclamping

Select softkey "Multiple clamping" in the extended softkey menu.

Enter the number of clampings and the number of the first zero offsetto be used. The clampings are processed in ascending sequence fromthe start zero offset. The zero offsets are defined in the "Tools/ZeroOffsets" menu (see Section "Zero offsets").Enter a name for the new, global program (XYZ.MPF) and confirmwith "OK".A list is displayed in which the different programs must be assigned tothe zero offsets.




Programselection

Go to the program overview by selecting softkey "Program selection".Select the program you want and select softkey "OK".Repeat this process until a program is assigned to every zero offset.

On allclampings

If you wish to execute the same program on all clampings, selectsoftkey "On all clampings" after you have selected the program.You can assign different programs to individual zero offsets first, andthen assign one program to the remaining zero offsets by selectingsoftkey "On all clampings".

Deleteselection

Delete all You can clear individual or all programs from the assignment list againby means of softkeys "Delete selection" and "Delete all".

Calculateprogram

When you have completed the assignment list, select softkey"Calculate program". This optimizes the tool changes.The global program is then renumbered. The number of the currentclamping is specified every time the program switches from oneclamping to another.

• Apart from the global program (XYZ.MPF), the file XYZ_MCD.INIis also set up in which the assignment between zero offsets andprograms is stored.

• If you switch from the assignment list (without "Abort" or "Createprogram") to another function and then call the "Multiple clamping"function later on, the same assignment list is displayed again.




6.3.9 Back up tool/zero point data

Function

You can use the "Back up data" function to save the tool offset andzero point data which are associated with a program or stored in thetool management system.

Operating sequence

Position the cursor on the relevant program in the directory.

Continue >>

Back updata

Select softkey "Back up data" in the extended softkey menu.

Select whether and which tool offset data and zero offsets you wish tosave. With "All used in program", all the tools or zero offsets used in aparticular program will be backed up; "Complete tool list" or "All" willback up all the data from the tool management system. You can alsoread out the associated magazine assignments and basic zero offsetat the same time.

You cannot read out the magazine assignments with the"Tool management without loading/unloading" option.

Change the default file name ("Name_TMZ") if necessary.If a file with the selected program name already exists, you canoverwrite or rename the file.

When you select "OK", the data are stored in the same directory asthe selected program.




6.3.10 Read in tool/zero point data

Function

You can use the "Read in data" function to read in the tool offset andzero point data stored for a program.

Operating sequence

Position the cursor on the file containing the tool/zero point data("Name_TMZ") in the directory.

Execute

Select the "Execute" softkey, the "Input" key or the "Cursor right" key.

Select which data (tool offset data, magazine assignments, zero pointdata, basic zero offset) you wish to read in.Confirm your selection with "OK".

With respect to reading in data, please note the following:

• If all tool offset data need to be read in, the tool management isdeleted first and the backup data then read in.

• If all the tool data used in the program are read in and a particulartool already exists in the tool management, then you can choosebetween the following options:

Replaceall

All tool data used in the program are read in, i.e. existing tools areoverwritten without further warning.

Replacenone

The data read-in operation is aborted.

The old tool is retained.

The old tool is overwritten.With the tool management option without loading/unloading, theold tool is deleted; in the case of the "with loading/unloading"variant, the old tool is unloaded beforehand.If you change the tool name with "Yes" before the data aretransferred, the tool is also entered in the tool list.

• Existing zero offsets are always overwritten when data are read in.

• If the magazine assignments are not read in with the other data,the tools are entered without location number in the tool list.




6.3.11 Read out files

Function

You can read out one or more files via the V.24 interface.

• When you select one single file, the ShopMill subroutines includedin the program are transferred at the same time.

• When you select more than one file, only the selected files aretransferred.

When reading out files to an external storage medium, please note theoutput formats and device settings of the V.24 interface.

Operating sequence

Position the cursor on the file you wish to read out in the directory.

Continue >>

Read out Press softkey "Read out".

Start the data storage device.

Start Press softkey "Start".

The selected file and all its ShopMill subroutines are read out.

The "Readout" window displays the name of the file and the number oftransferred bytes.

Stop You can abort the data output by pressing softkey "Stop".

Allfiles

You can select all files stored in the directory by pressing softkey"All files".




6.3.12 Read in files

Operating sequence

Precondition The interface for your data storage device is correctly selected.

Continue >>

Read in Press softkey "Read in".

Start When you press softkey "Start", the data are read in and stored in thespecified path.The system automatically detects whether the file to be read in is inbinary/PC, punched tape or punched tape/ISO format.The names of the imported files and the number of transferred bytesare displayed on the screen.


Stop You can abort the data import by pressing softkey "Stop".

Start To restart the data import process, press softkey "Start" again. Youmust also start the data storage device again at the same time.

6.3.13 Error log

Function

Select the error log

Error log By pressing softkey "Error log", you can display information about thedata transfer operation.

• For data to be exported, the information includes

− the file name including path name and

− a status acknowledgement.

• For data to be imported, the information includes

− the file name and



6.4 "Directory" operating area (MMC 103) 6


6.4 "Directory" operating area (MMC 103)

6.4.1 Basic display

Function

The "Directory" basic screen displays all the directories/programsstored in the data management directory of the hard disk, in theNC main memory or accessible via network drives/floppy disk drive(if installed) (see example below).

Example of a directory management screen on the MMC103

Explanation of the basic

display

Display of the current file tree

The following file properties (depending on default setting) can bedisplayed for each file:

Name Directory name/file nameFiles with a name of maximum 24 characters in length can beadministered on the MMC.If files are transferred to external systems (V.24, floppy disk), thename is truncated to 8 characters. The full name is not however lost.When files of this type are read back in, they must be renamedafterwards.

Type Specifies the file type

• WPD for directories

• MPF for programs

Loaded To execute a program in the NC (via NC Start), it must be loaded inthe NC main memory beforehand.




To prevent the main memory from becoming overloaded, however,interrelated progr. and data can be loaded (from the hard disk to theNC main memory) and unloaded (from NC main memory to hard disk)explicitly. The current status of a file is identified by an "X": File loaded.

Size Size of file in bytes (the source MMC or NCK directory is listed here fordirectories).

Date/time Date of creation or date of last modification with time.

Horizontal softkeys

NC Programs/files in the NC main memory and data managementdirectory on the hard disk.

Softkey 2

...Softkey 5 Softkeys 2 and 5 display directories and files which are stored on

• network drives (network card required!),

• the floppy disk drive and

• on the hard disk as an archive directory.

Example

Example of a directory overview with programs from a network drive

The softkeys in the above example ("Archive", "DISK A:" and L:) canbe configured via display machine data.Please read the machine tool manufacturer’s instruction manual!

Vertical softkeys

Execute Program is selected when required and loaded to the NC mainmemory. The system switches over to the "Machine Auto" operatingarea simultaneously.

New

...Cut Files/directories can be set up, renamed, copied, deleted and moved.




Continue >>

Press this softkey to switch to a new vertical softkey menu in whichyou can

• load or unload files,

• execute programs from the hard disk,

• program multiple clamping,

• back up tool and zero point data or

• read data out or in.

6.4.2 Create files/directories

Function

This subsection describes how new programs or a new directory canbe set up.

Operating sequence

ProgramManager

"Directory" operating area is selected.The current overview of directories stored in the NC is displayed.

Create programs

Position the cursor on a directory of your choice and open it. Anoverview of the programs already existing in the directory is displayed.If it contains no programs, an empty program overview appears.

New Once you have pressed the "New" softkey, you can

• create a ShopMill program (see Chapter "Programming withShopMill")

• or a G code program (see Chapter "Programming with G code").

Create a directory

ProgramManager

"Directory" operating area is selected.The current overview of directories stored in the NC is displayed.

New

Directory The input window "New directory" is opened.

Enter a new directory name.

Confirm the directory name by pressing

or with

The new directory is created in the directory overview.




No further subdirectories can be set up in the NC main memory.

6.4.3 Open files/directories

Operating sequence

Select and call a

file/directoryProgramManager

"Directory" operating area is selected.The current overview of directories stored in the NC main memory andthe data management directory on the hard disk is displayed.Position the cursor on the file/directory you want to open.

or

• The selected file is called in the Program Editor.

• The selected directory branches into the next directory level(subdirectory) or file level.

Return to the next higher directory levelThe return line is displayed if there is a higher directory level in thedirectory overview.

Position the cursor on the return line and press the "Input" key.

OR

position the cursor on any line and press the "Cursor left" key.

The higher directory level is displayed.

6.4.4 Load and unload programs

Function

Load Programs can be saved from the data management directory on thehard disk to the NC main memory by the following methods:

• By executing the program with softkeys "Execute" and "Executefrom here" (see Section "Select a program for execution")

• By manually loading one or several programs.When you manually load one single program, the

− ShopMill subroutines

− and all other subroutines starting with "CALL" are loaded at thesame time.




If you select several programs in the program directory, then only theselected programs are loaded and not the associated subroutines.

Unload Programs you have loaded are not automatically unloaded. With amanual unload operation, you can save programs from the NC mainmemory back to the data management directory on the hard disk. Youcan relieve the load on the NC by removing any programs which areno longer needed.

Operating sequence

Manual load/unload

ProgramManager

Press the "Program Manager" key.

Position the cursor on the program you want to unload.

Continue >>

Loadmanual

The file you select is deleted from the data management directory onthe hard disk and loaded to the NC main memory. The file is thenmarked with an "X" (for loaded) in the "Loaded" column of the directoryoverview.

Continue >>

Unloadmanual

The selected file is deleted from the NC main memory and loaded tothe data management directory on the hard disk. No "X" appears inthe "Loaded" column of the directory overview.

Load (execute)

Execute Position the cursor on the program in the directory you want toexecute. When you select the "Execute" softkey, the selected programis loaded to the NC main memory.

Machinefrom here

You can use this softkey to load a program from the "Program"operating area to the NC main memory.

The program is executed when you press "NC Start".

When you select "Execute" or "Machine from here", the necessarysubroutines are automatically loaded if they are not already loaded.Programs you have loaded are not automatically unloaded.




6.4.5 Select several programs

Operating sequence

Position the cursor on the first file to be selected in the directoryoverview.

Mark Using softkey "Mark", you can select and mark blocks of files with thecursor.

Using the toggle key, you can select and mark several filesindividually.

6.4.6 Copy/rename/insert files/directories

Function

You can copy

• a single file,

• more than one file or

• a complete directory.

Operating sequence

Position the cursor on the file/directory you wish to copy.

Copy The selected file/directory is copied.

Select the copy destination.

Insert The copied source file/source directory is inserted at the selecteddestination.

Rename a file/directory

File/directory is selected.

Rename

Enter a new file/directory name in the "To:" field and confirm with the"Input" key.




6.4.7 Delete/move files/directories

Function

File You can delete one or several files at a time.

Directory You can delete one directory with all its contents.

Operating sequence

Position the cursor on the file/directory you wish to copy.

Delete

Cut The selected file/directory is deleted.

Move

Cut

Insert The source file/source directory is pasted at the selected destination.

6.4.8 Execute from hard disk

Function

If a program needs more memory space for execution than isavailable in the NC main memory, then you can load the programcontents continuously from the hard disk.

Operating sequence

Precondition You have selected the directory via the "Program Manager" key.

Select the program you want to execute with the cursor.

Continue >>

Execute frm.hard disk

The program contents are loaded continuously to the NC mainmemory while the program is being processed.


The program remains stored on the hard disk when it is loaded for"Execute from hard disk".




6.4.9 Set up the V.24 interface

Function

You can send files to an external data backup device (e.g. PG/PC,printer), or read them in (e.g. PG/PC) via the V.24 interface. You mustset the appropriate parameters for the V.24 interface and your databackup device. The control offers you a suitable input screen form inwhich you can define the specific data for your device.

Operating sequence

Precondition • You have selected the directory in the "Program Manager" and the"NC" data area (NC main memory and data management directoryon the hard disk)

Continue >>

• and pressed softkey "Continue".

Read out

Read in Select the mode of transmission for the V.24 interface.

V.24settings

Press softkey "V.24 settings" to display the "Parameterization V.24user" screen form. Assign the parameters in this screen form.

Position the cursor bar on the input fields and enter the necessaryvalues.

or

The values for parameters "Interface", "Protocol", "Baud rate","Data bits", "Parity" and "Stop bits" can be selected with the toggle keyor "Alternat." softkey.

You can also activate or deactivate special functions with the"toggle key" or the "Alternat." softkey.

Notes

Make sure that you set the correct file format (binary/PC, punchedtape or punched tape/ISO format).

This softkey closes the "Parameterization V.24 user" screen form.

The modified data are stored.




6.4.10 Multiple clamping

Function

You can machine several workpieces at the same time by using the"Multiple clamping" function. You can either execute the sameprogram several times or select several different machining programs.The "Multiple clamping" function is an option.

The multiple clamping function creates one single program fromseveral different programs. This includes optimization of tool changesin order to reduce machining times. The tool sequence within aprogram remains unchanged. Cycles and subroutines are not opened,position patterns are processed as closed units.

The individual programs must meet the following requirements:

• ShopMill programs only

• Program must have been tested

• Program for the 1st clamping must have been trial run

• No markers/repetitions, i.e. no branches in the program

• No inch/metric switchover

• No transformations

• Contours must have unique names, i.e. the same contour namemust not be called in several different programs

• Max. of 50 contours per clamping

• Max. (99 start ZO) number of clampings

You can substitute subroutines for the markers or repetitions whichmay not be included in programs for multiple clampings.

Operating sequence

ProgramManager or

ProgramManager

Select the "Program Manager" key or softkey.

Multipleclamping

Select softkey "Multiple clamping" in the extended softkey menu.

Enter the number of clampings and the number of the first zero offsetto be used. The clampings are processed in ascending sequence fromthe start zero offset. The zero offsets are defined in the "Tools/ZeroOffsets" menu (see Section "Zero offsets").




Enter a name for the new, global program (XYZ.MPF) and confirmwith "OK". The program is stored in the directory that was previouslyselected in the program manager.A list is displayed in which the different programs must be assigned tothe zero offsets.

Programselection

Go to the program overview by selecting softkey "Program selection".Select the appropriate directory and mark the relevant program. Presssoftkey "OK".Repeat this process until a program is assigned to every zero offset.

On allclampings

If you wish to execute the same program on all clampings, selectsoftkey "On all clampings" after you have selected the program.You can assign different programs to individual zero offsets first, andthen assign one program to the remaining zero offsets by selectingsoftkey "On all clampings".

Deleteselection

Delete all You can clear individual or all programs from the assignment list againby means of softkeys "Delete selection" and "Delete all".

Createprogram

When you have completed the assignment list, select softkey "Createprogram". This optimizes the tool changes.The global program is then renumbered. The number of the currentclamping is specified every time the program switches from oneclamping to another.

• Apart from the global program (XYZ.MPF), the file XYZ_MCD.INIis also set up in which the assignment between zero offsets andprograms is stored.

• If you switch from the assignment list (without "Abort" or "Createprogram") to another function and then call the "Multiple clamping"function later on, the same assignment list is displayed again.




6.4.11 Back up tool/zero point data

Function

You can use the "Back up data" function to save the tool offset andzero point data which are associated with a program or stored in thetool management system.

Operating sequence

Position the cursor on the relevant program in the directory.

Continue >>

Back updata

Select softkey "Back up data" in the extended softkey menu.

Select whether and which tool offset data and zero offsets you wish tosave. With "All used in program", all the tools or zero offsets used in aparticular program will be backed up; "Complete tool list" or "All" willback up all the data from the tool management system. You can alsoread out the associated magazine assignments and basic zero offsetat the same time.

You cannot read out the magazine assignments with the "Toolmanagement without loading/unloading" option.

Change the default file name ("Name_TMZ") if necessary.If a file with the selected program name already exists, you canoverwrite or rename the file.

When you select "OK", the data are stored in the same directory asthe selected program.




6.4.12 Read in tool/zero point data

Function

You can use the "Read in data" function to read in the tool offset andzero point data stored for a program.

Operating sequence

Position the cursor on the file containing the tool/zero point data("Name_TMZ") in the directory.

Execute

Select the "Execute" softkey, the "Input" key or the "Cursor right" key.

Select which data (tool offset data, magazine assignments, zero pointdata, basic zero offset) you wish to read in.Confirm your selection with "OK".

With respect to reading in data, please note the following:

• If all tool offset data need to be read in, the tool management isdeleted first and the backup data then read in.

• If all the tool data used in the program are read in and a particulartool already exists in the tool management, then you can choosebetween the following options:

Replace all All tool data used in the program are read in, i.e. existing tools areoverwritten without further warning.

Replacenone

The data read-in operation is aborted.

The old tool is retained.

The old tool is overwritten.With the tool management option without loading/unloading, theold tool is deleted; in the case of the "with loading/unloading"variant, the old tool is unloaded beforehand.If you change the tool name with "Yes" before the data aretransferred, the tool is also entered in the tool list.

• Existing zero offsets are always overwritten when data are read in.

• If the magazine assignments are not read in with the other data,the tools are entered without location number in the tool list.




6.4.13 Read out files

Function

You can read out one or more files via the V.24 interface.

• When you select one single file, the ShopMill subroutines includedin the program are transferred at the same time.

• When you select more than one file, only the selected files aretransferred.

When reading out files to an external storage medium, please note theoutput formats and device settings of the V.24 interface.

Operating sequence

Position the cursor on the file you wish to read out in the directory.

Continue >>

Read out Select softkeys "Continue" and "Read out".


Start Press softkey "Start".

The selected file and all its ShopMill subroutines are read out.

The "Readout" window displays the name of the file and the number oftransferred bytes.

Stop You can abort the data output by pressing softkey "Stop".

Allfiles

You can select all files stored in the directory by pressing softkey"All files".

6.4.14 Read in files

Operating sequence

Precondition The interface for your data storage device is correctly selected.

Continue >>

Read in Select softkeys "Continue" and "Read in".

Start When you press softkey "Start", the data are read in and stored in thespecified path.The system automatically detects whether the file to be read in is inbinary/PC, punched tape or punched tape/ISO format.




The names of the imported files and the number of transferred bytesare displayed on the screen.


Stop You can abort the data import by pressing softkey "Stop".

Start To restart the data import process, press softkey "Start" again. Youmust also start the data storage device again at the same time.

6.4.15 Error log

Function

Select the error log

Error log By pressing softkey "Error log", you can display information about thedata transfer operation.

• For data to be exported, the information includes

− the file name including path name and


• For data to be imported, the information includes

− the file name and


�




Notes

7 08.00 Alarms and Messages 7


Alarms and Messages

7.1 Cycle alarms and messages................................................................................... 7-2507.1.1 Error treatment in cycles ......................................................................................... 7-2507.1.2 Cycle alarm overview.............................................................................................. 7-2507.1.3 Messages in cycles................................................................................................. 7-254

7.2 Alarms for ShopMill................................................................................................. 7-2557.2.1 Alarm overview ....................................................................................................... 7-2557.2.2 Select the alarm/message overview ....................................................................... 7-2567.2.3 Description of alarms .............................................................................................. 7-257

7 Alarms and Messages 08.00

7.1 Cycle alarms and messages 7


7.1 Cycle alarms and messages

7.1.1 Error treatment in cycles

If the system detects an error status while processing a cycle, itgenerates an alarm and aborts cycle execution.Alarms with numbers ranging from 61000 to 62999 are generated incycles.The reset criteria for these number ranges are

• NC-RESET for 61000 ... 61999 and

• CANCEL for 62000 ... 62999The error text that is simultaneously displayed with the alarm numberindicates the possible error cause.

7.1.2 Cycle alarm overview

The following table provides an overview of cycles that might be generated inmachining cycles and tips for remedying the underlying errors.

Alarm number Alarm text Explanation, remedy

61000 "No tool offset active" D offset must be programmed before cycle iscalled

61001 "Thread pitch incorrectly defined" Check parameters for thread size and pitchsettings (for contradiction)

61002 "Machining type incorrectlydefined"

The machining type parameter has been set tothe wrong value and needs to be altered.

61003 "No feedrate programmed in cycle" The feedrate parameter has been set to thewrong value and needs to be altered.

61006 "Tool radius too large"

61007 "Tool radius too small"

61009 "Active tool number = 0" Load the required tool

61010 "Finishing allowance too large" Reduce the finishing allowance setting

61011 "Invalid scaling" The active scaling factor is not permissible forthis cycle.

61012 "Different scales in one plane"

61013 "Basic settings have been altered,program cannot be executed"

Check basic settings and alter them ifnecessary

61101 "Reference plane incorrectlydefined"

If you choose to program relative depthsettings, you must select different values for thereference and return planes. Alternatively, setan absolute depth value

7 08.00 Alarms and Messages



61102 "No spindle direction programmed" A spindle direction must be programmed

61103 "Number of holes is zero" You have not programmed a value for thenumber of holes

61104 "Contour violation of slots" Errors in parameterization of milling pattern inthose parameters which define the position ofslots on a circle and their shape

61105 "Cutter radius too large" The diameter of the selected cutting tool is toolarge for the profile to be machined. You musteither use a tool with a smaller radius or modifythe contour

61106 "Number or spacing of circleelements"

Parameterization error, programmed circleelements cannot be arranged around a fullcircle

61107 "First drilling depth incorrectlydefined"

First drilling depth is inverted in relation to totaldrilling depth

61108 "No valid settings for parameters_RAD1 and _DP1"

Parameters "Radius" and "Infeed depth perrevolution" must be taken into account forinsertion along helical path

61109 "Parameter _CDIR incorrectlydefined"

Parameter defining milling direction isincorrectly defined

61110 "Finishing allowance on base >infeed depth"

Alter setting for depth infeed if necessary

61111 "Infeed width > tool diameter" The programmed infeed width is greater thanthe diameter of the active tool. The infeed widthmust be reduced.

61112 "Tool radius negative" The radius of the active tool is negative. This isillegal.

61113 "Parameter _CRAD for cornerradius too large"

Reduce the parameter for corner radius

61114 "Direction of machining G41/G42incorrectly defined"

Check the machining direction of tool radiuscompensation left/right and alter

61115 "Approach or retract mode(line/circle/plane/space) incorrectly defined"

The contour approach and retract mode hasbeen incorrectly defined. Check parameters"Approach/retract mode" and "Approach/retractstrategy".

61116 "Approach or retract path = 0" The approach or retract path is set to zero, itmust be increased.

61117 "Active tool radius <= 0" The radius of the active tool is negative or set tozero. This is illegal.

61118 "Length or width = 0" The length or width of the milling surface is notlegal.

61119 "Nominal or core diameterincorrectly programmed"

61120 "Thread type internal, external notdefined"

You must enter the internal, external threadtype




61121 "Number of teeth/cutting edgemissing"

Enter the number of teeth/cutting edge for theactive tool in the tool list

61122 "Safety clearance in the planeincorrectly defined"

The safety clearance is negative or zero. This isillegal.

61124 "Infeed width is not programmed" In active simulation without a tool, a value forthe infeed width must always be programmed.

61200 "Too many elements in machiningblock"

Edit machining block, delete elements ifnecessary

61201 "Incorrect sequence in machiningblock"

Sort the machining block sequence

61202 "Not a technology cycle"

61203 "Not a position cycle"

61204 "Unknown technology cycle"

61205 "Unknown position cycle"

61210 "Block search element not found"

61211 "Absolute reference missing"

61212 "Incorrect tool type" Select a new tool type

61213 "Circle radius too small" Enter a larger value for the circle radius

61214 "No pitch programmed" The pitch must be programmed

61215 "Blank dimension incorrectlyprogrammed"

61216 "Feed/tooth possible only formilling tools"

Alternatively, you can set another feed type

61217 "Cutting rate programmed for toolradius 0 "

Enter a cutting rate setting

61218 "Feed/tooth programmed, butnumber of teeth is zero"

Enter the number of teeth of the cutting tool inthe "Tool list" menu

61222 "Plane infeed greater than tooldiameter "

61223 "Approach path too small" Enter a larger value for the approach path

61224 "Retract path too small" Enter a larger value for the retract path

61225 "Swiveling data block unknown" An attempt has been made to access anundefined swiveling data block.

61226 "Swivel head cannot be replaced" The parameter "Swivel data block change" isset to "no". An attempt has still been made tochange the swivel head.

61230 "Tool probe diameter too small" The tool probe is not correctly calibrated.

61231 "ShopMill program cannot beexecuted; not yet tested byShopMill"

The program must be simulated in ShopMill firstor transferred to the "Machine Auto" area.

61232 "Magazine tool cannot be loaded" An attempt has been made to automaticallyload a tool into a swivel head which can holdonly manual tools.




61234 "ShopMill subroutine cannot beexecuted; not yet tested byShopMill"

The subroutine must be simulated in ShopMillfirst or transferred to the "Machine Auto" area.

61301 "Probe is not responding" • Check probe connections

• Set a longer measuring distance via MD9752, 9753, 9754, 9755

• For edge measurements: Position probecloser to edge

• Position approximately over center ofspigots/holes

• Check setting for spigot/hole diameter

61302 "Probe collision" The probe has collided with an obstacle on itspositioning path.

• Check spigot diameter (it may be too small)

• Check measuring path (it may be too long)

61303 "Safe area exceeded" Result of spigot/hole diameter measurementdeviates significantly from specified value.Check radius or diameter.Check measuring location (e.g. for inaccuraciescaused by swarf)

61308 Check measuring path 2a Enter measuring path = 0Check MD 9752, 9753, 9754, 9755

61309 Check probe type Probe type: 3D probe not active

61310 Scaling factor is active Scaling factor = scaling is active

61311 No D number is active No tool offset has been selected for the probe(for workpiece measurements) or for the activetool (for tool measurements).

61316 Center point and radius cannot becalculated

The system cannot calculate a circle from themeasured points.

61332 Alter the tool tip position Tool tip is positioned below the probe surface(e.g. with a setting ring gauge or cube)

61338 Positioning speed is zero Set corresponding feedrate (plane/infeed rate)via MD 9757 or 9758

61605 "Contour incorrectly programmed"

61610 "No infeed depth programmed" The infeed depth must be programmed

62100 "No drilling cycle active" No modal drilling cycle has been called beforethe drilling pattern cycle

62101 "Milling direction not correct - G3will be generated"

Climb or conventional milling programmed, butthe spindle was not rotating when the cycle wascalled.

62103 "No finishing allowanceprogrammed"




7.1.3 Messages in cycles

Cycles display messages in the dialog line of the control system.Messages of this type do not interrupt the machining process.Messages describe certain operational characteristics of the relevantcycle and indicate the current processing status. They are generallydisplayed for one processing section or until the cycle end.


7.2 Alarms for ShopMill 7


7.2 Alarms for ShopMill

7.2.1 Alarm overview

If errors are detected in ShopMill, the system generates an alarm andaborts program execution if necessary.The error text that is simultaneously displayed with the alarm numberindicates the possible error cause.

Overview of alarms 100000-100999 Basic system MMC

101000-101999 Diagnostics

102000-102999 Services

103000-103999 Machine

104000-104999 Parameters

105000-105999 Programming

106000-106999 Spare

107000-107999 OEM

110000-110999 Reserved

111000-112999 ShopMill

120000-120999 Reserved

Danger

Please check the plant situation as indicated in the description of thealarm/s that has/have been generated. Eliminate the cause of thealarm/s and acknowledge it/them as instructed. If you fail to observethis alarm response procedure, you will endanger the machine,workpiece, stored settings and possibly your own safety.

If you are working in CNC mode, please refer to alarm descriptions inthe following document:/DA/, Diagnostics Guide




7.2.2 Select the alarm/message overview

Function

You can view alarms and messages and then acknowledge them.

Operating sequence

AlarmsMessages or

AlarmThe alarm/message overview displays all active alarms and messageswith numbers, date, cancel criterion and explanation.Cancel the alarm with the key displayed in symbol form:

Switch machine/control off and on again (main switch)or NCK POWER ONPress the "Reset key"

Press the "Acknowledge alarm" key

The alarm is cancelled by an "NC Start"

The alarm is cancelled by the "Recall" key




7.2.3 Description of alarms

111 311 NC Start is not possible: Deselect SBL mode

Explanation You have activated a program with block search even though SBLmode was active at the same time.

Reaction NC-Start disableAlarm displayInterface signals are set

Remedy Deselect SBL mode

112 045 More insertion points required

Explanation The system requires more insertion points to machine the contourpocket.The machining process is divided into several individual operations.Residual material will be left on the workpiece.

Reaction Alarm displayThis alarm is a warning only.The program can be started.

Remedy If you use a smaller cutter, you may be able to perform the operationwith a single insertion point.

112 046 Main contour cannot be traversed

Explanation The pocket contour cannot be traversed with the programmed cuttingtool.Residual material will be left on the workpiece.


Remedy You may be able to traverse the whole pocket contour if you use asmaller cutter.

112 052 No residual material generated

Explanation No residual material has been generated.You may not need to remove any residual material.


Remedy No remedial action necessary.




112 057 Programmed helix violates contour

Explanation You have selected the starting point for helical insertion such that theprogrammed contour is violated by the helix.


Remedy Select another starting point.Use a smaller helix radius.

112 099 System error contour pocket

Explanation An error has occurred during calculation of the contour pocket.Reaction Alarm display

The system cannot calculate the contour pocket.The program cannot be started.

Remedy Please note the error text and contact the Siemens A&D MC Hotline.

112 100 Renumbering error.

Initial state restored.Explanation You have selected softkey "Renumber" in the program editor. An error

has occurred during renumbering which has damaged the program inthe memory. The original program must now be reloaded to thememory.

Reaction Alarm displayProgram has not been renumbered.

Remedy Create space in the memory, e.g. by deleting an old program.Select "Renumber" softkey again.

112 200 Contour is Step in current program sequence. Processing not

enabledExplanation The selected contour is an element of the program loaded under

"Program".Reaction Alarm display

The contour is an element from a loaded program and cannot bedeleted or renamed.

Remedy Remove contour from the loaded program.




112 201 Contour is step in current Automatic sequence. Processing not

enabledExplanation The selected contour is an element of the program loaded under

"Machine Auto".Reaction Alarm display

The contour is an element of a program loaded under "MachineAutomatic" and cannot be deleted or renamed. After program start,contours included in the current program cannot be altered under"Program" while the program is running.

Remedy Stop program run and load program under "Program". Delete contourfrom program.

112 210 Tool axis cannot be reselected. Insufficient NC memory.

Explanation If you select another tool axis, you must generate a new NC program.You must save the old NC program first and then generate the newone. There is not sufficient NC memory available at this point to storethe new program.

Reaction Alarm displayThe new tool axis is not selected.

Remedy You must create free space in the NC memory corresponding to atleast the space required by the new program (e.g. by deletingprograms you no longer need).

112 211 System unable to process tool preselection. Insufficient NC

memory.Explanation Before a tool preselection can be processed, you must generate a

new NC program. You must save the old NC program first and thengenerate the new one. There is not sufficient NC memory available atthis point to store the new program.

Reaction Alarm displayThe system does not process the tool preselection.

Remedy You must create free space in the NC memory corresponding to atleast the space required by the new program (e.g. by deletingprograms you no longer need).

112 300 Tool management strategy 2 impossible.

Magazine is not fully loadedExplanation The magazine is not fully loaded with tools. The number of tools

defined in machine data MM_NUM_TOOL must be set up in themagazine for tool management strategy 2.

Reaction POWER-ON alarmRemedy Start-up: Set up the correct number of tools




112 301 Tool management strategy 2 impossible.

Magazine is not sorted according to tool listExplanation The magazine list is not sorted in the same way as the tool list.

The tool order in the magazine for tool management strategy 2 mustbe defined according to their T numbers.

Reaction POWER-ON alarmRemedy Start-up: Define tools according to their T numbers in magazine

locations

112 323 Remove inclinable head

Explanation You are requested to remove the specified inclinable head from thespindle.

Reaction Alarm displayPlease read the machine manufacturer’s instruction manual!

Remedy Remove inclinable head.Please read the machine manufacturer’s instruction manual!

112 324 Attach inclinable head

Explanation You are requested to mount the specified inclinable head in thespindle.


Remedy Mount inclinable head.Please read the machine manufacturer’s instruction manual!

112 325 Replace inclinable head

Explanation You are requested to replace the specified inclinable head in thespindle with a new inclinable head.


Remedy Replace inclinable headPlease read the machine manufacturer’s instruction manual!

112 326 Set inclinable head

Explanation You are requested to set the inclinable head according to the specifieddata.


Remedy Set inclinable head.Please read the machine manufacturer’s instruction manual!




112 327 Angle outside the permissible range

Explanation The programmed machining operation cannot be performed with theinclinable head.

Reaction Alarm displayRemedy Press NC Start.

Clamp the workpiece differently if appropriate.

112 328 Angle adjusted to angular grid

Explanation Owing to the angular grid, the inclinable head cannot be set to exactlythe specified angle.

Reaction Alarm displayRemedy The machining operation can continue with the set values, but will not

match the programmed machining values exactly.

112 329 Set swivel head/table

Explanation You are requested to set the swivel head/table according to thespecified data.


Remedy Set swivel head/tablePlease read the machine manufacturer’s instruction manual!

112 330 Set swivel table

Explanation You are requested to set the swivel table according to the specifieddata.


Remedy Set swivel tablePlease read the machine manufacturer’s instruction manual!

112 350 No swiveling data available

Explanation No swiveling data sets are available.Reaction Alarm displayRemedy Set up the necessary swiveling data sets

(see /FBSP/, ShopMill Description of Functions)

112 400 Not available in the tool management

Explanation The tool stipulated in the program does not exist.Reaction Alarm displayRemedy You must create the tool before saving the data.

112 401 Tool setup has failed

Explanation The system was unable to set up a tool as the tool data were beingread in.

Reaction Alarm displayRemedy Check tool management.




112 420 Error in inch/metric system switchover! Check all data!

Explanation Not all data have been converted for the inch/metric switchover.Reaction Alarm display

NC-Start disableRemedy Check the following data:

• Display machine data:MD9655: $MM_CMM_CYC_PECKING_DIST

MD9656: $MM_CMM_CYC_DRILL_RELEASE_DIST MD9658: $MM_CMM_CYC_MIN_COUNT_PO_TO_RAD

MD9664: $MM_CMM_MAX_INP_FEED_P_MINMD9665: $MM_CMM_MAX_INP_FEED_P_ROTMD9666: $MM_CMM_MAX_INP_FEED_P_TOOTHMD9670: $MM_CMM_START_RAD_CONTOUR_POCKETMD9752: $MM_CMM_MEASURING_DISTANCEMD9753: $MM_CMM_MEAS_DIST_MANMD9754: $MM_CMM_MEAS_DIST_TOOL_LENGTHMD9755: $MM_CMM_MEAS_DIST_TOOL_RADIUSMD9756: $MM_CMM_MEASURING_FEEDMD9757: $MM_CMM_FEED_WITH_COLL_CTRLMD9758: $MM_CMM_POS_FEED_WITH_COLL_CTRLMD9759: $MM_CMM_MAX_CIRC_SPEED_ROT_SPMD9761: $MM_CMM_MIN_FEED_ROT_SP

MD9762: $MM_CMM_MEAS_TOL_ROT_SP MD9765: $MM_CMM_T_PROBE_DIAM_LENGTH_MEAS MD9766: $MM_CMM_T_PROBE_DIAM_RAD_MEAS MD9767: $MM_CMM_T_PROBE_DIST_RAD_MEAS

MD10240: $MN_SCALING_SYSTEM_IS_METRICMD20150 [12]: $MC_GCODE_RESET_VALUES

• Tool data for tool edges D1 and D2:Length Z, radius R,wear lengths Z and R

• Zero offsets:Basic offsetPosition in X, Y, Z and A, C (if configured)Settable zero offset

• Settings in the MANUAL operating area:Return planeSafety clearance

Note This alarm can occur only in connection with hardware defects.

112 502 Insufficient memory

Abort in line %1Explanation %1 = line number

Program contains too many program blocksReaction Alarm display

Program is not loadedRemedy Modify program in PROGRAMS operating area of SINUMERIK 840D

or 810D (CNC mode).




112 504 File does not exist or is faulty: %1

Explanation %1 = Name of file/contourProgram cannot interpret a program block containing contourprogramming. Contour does not exist in directory.

Reaction Alarm displayNC-Start disable

Remedy Load contour to directory.

112 505 Error in interpreting contour %1

Explanation %1 = Name of contourContour is faulty


Remedy Check contour machining sequence

112 506 Maximum number of contour elements exceeded %1

Explanation %1 = Name of contourThe maximum permissible number of contour elements (50) has beenexceeded during interpretation of the contour machining sequence.

Reaction Alarm displayRemedy Check contour machining sequence, revise if necessary.

112 541 Program cannot be interpreted

Explanation The program cannot be interpreted as a ShopMill program duringloading as the program header is missing.


Remedy -

112 604 Link to PLC interrupted

Explanation Checkback message to the PLC user program that the link to theShopMill MMC is interrupted.

Reaction Alarm displayShopMill PLC is shut down

Remedy Check the PLC user program.

112 605 Asynchronous subroutine has not been executed

Note The NC has not been able to process the input values correctly.Reaction Alarm displayRemedy Press NC Start.

112 650 Unknown PLC error

Explanation The PLC has signaled an error which cannot be recognized by theoperator interface.





Remedy Press POWER ON, contact Siemens.

�

8 08.00 Examples 8


Examples

8.1 Example 1: Machine with rectang./circ. pocket and circumf. slot ........................... 8-266

8.2 Example 2: Shift and mirror a contour .................................................................... 8-274

8.3 Example 3: Chamfer on circular spigot................................................................... 8-277

8.4 Example 4: Cylinder surface transformation........................................................... 8-280

8.5 Example 5: Slot side compensation........................................................................ 8-283

8.6 Example 6: Swiveling.............................................................................................. 8-287

8 Examples 08.00

8.1 Ex. 1: Machine with rectang./circ. pocket and circumf. slot 8


8.1 Ex. 1: Machine with rectang./circ. pocket and circumf. slot

Workpiece drawing

R10

R10

R5

20

3570

40

15o

Start point

30

R10

15

20o

R28

30 o

R40

R25

15

R20

Depth -3

R15

10

420

16

10

0

95

180

0+X

+Y

15

25

60

115

135

155

850

- 4-10

0-6

015 25 90 155 165

180

Program part_4

1. Program header • Define a blank:

X0 0 abs Y0 0 abs Z0 0 abs

X1 180abs Y1 180abs Z1-20abs

• Select softkey

2. Face milling• Select via softkeys

Milling

Facemilling > and choose a machining

strategy

• Example of technological data:

T FACING TOOL F 0.1 mm/tooth V 1200 m/min

Machining Roughing

X0 0 abs

Y0 0 abs

Z0 1 abs

X1 180 abs

Y1 180 abs

8 08.00 Examples



Z1 0 abs

DXY 80 %

DZ 0.5

UZ 0

• Select softkey

3. Outside contour ofworkpiece

The outside contour can be defined as a rectangular spigot as shown

here. It is of course also possible to use the contour milling function.

• Select via softkeys Milling

Spigot >

Rectangularspigot

• Assign technological parameters T, F and S accordingly and enterthe following parameters:

Position of

reference point

Bottom left

Position type Single position

X0 0 abs

Y0 0 abs

Z0 0 abs

W 180 abs

L 180 abs

R 10 abs

α0 0 degrees

Z1 20 inc

DZ 20

UXY 0

UZ 0

W1 185 (fictitious blank dimension)

L1 185 (fictitious blank dimension)

4. Outside contour of island In order to machine the entire surface outside the island, define acontour pocket around the blank and then program the island. Thisensures that the entire surface area is machined and no residualmaterial is left behind.

a) Outside contour of pocket• Select via softkeys

Contourmilling

Newcontour >

• Enter a contour name (in this case: Part_4_Pocket) and confirm

• Fill in start screenform for contour

Tool axis Z

X0 –20 abs Y0 0 abs

and confirm .

• Enter the following contour elements and confirm each with softkey

:

1. X 200 abs

8 Examples 08.00



2. Y 200 abs

3. X -20 abs

4. Closecontour

• Select softkey a) Outside contour of island

• Select via softkeys Contourmilling

Newcontour >

• Enter a contour name (in this case: Part_4_Island) and confirm


Tool axis Z

X0 90 abs Y0 25 abs

and confirm .


:

1. X 25 abs FS 15

2. Y 115 abs R 20

3. X 15 abs Y 135 abs

4. Y 155 abs R 10

5. X 60 abs R 15

6. Y 135 abs R 20

7. Tangentto prec. Direction of rotation

R 25abs X 110abs Y 135absDialogselection

Acceptdialog

8. Tangentto prec.

Y 155abs R 15

9. R 0 abs

10. X 165 abs Y 95 abs α1 290 degrees R 0

11. X 155 abs α1 240 degrees R 28

12. FS 0

13. X 140 abs Y 25 abs α1 225 degrees R 0

14. Closecontour

8 08.00 Examples



c) Mill/solid machine a contour• Select via softkeys

Contourmilling

Remove >

• Assign technological parameters T, F and S accordingly (e.g. cutterdiameter 10) and enter the following parameters:

Z0 0 abs

Z1 10 inc

DXY 4.5 mm

DZ 10

UXY 0 mm

UZ 0

Starting point auto

Insertion Center

FZ 0.1 mm/tooth

Select lift-off mode, e.g. to retraction plane

•

Notes:

• When selecting the milling tool, please make sure that the tooldiameter is large enough to cut the intended pocket. A messagewill be output if you make a mistake.

• If you want to finish cut the pocket, you must assign parametersUXY and UZ accordingly and add a second solid machining cyclefor finishing.

5. Mill a rectangular pocket(large) • Select via softkeys

Milling

Pocket >

Rectangularpocket


T MILLTOOL10 F 0.1mm/tooth V 200m/min

Position ofreference point

Center


X0 90 abs

Y0 60 abs

Z0 0 abs

W 40

L 70

R 10

α0 15

Z1 4 inc

DXY 4.5 mm

DZ 4

UXY 0

UZ 0

Insertion Helical

EP 2

ER 2

8 Examples 08.00



Stock removal Complete machining

•

6. Mill a rectangular pocket(small) • Select via softkeys

Milling

Pocket >

Rectangularpocket

• Enter parameters:

X0 90 abs

Y0 60 abs

Z0 -4 abs

W 20

L 35

R 5

α0 15

Z1 4 inc

DXY 4.5 mm

DZ 2

UXY 0

UZ 0

Insertion Oscillation

EW 10 degrees


•

7. Mill a circumferential slot• Select via softkeys

Millling

Groove >

Circumf.groove


T MILLTOOL8 F 0.5mm/tooth FZ 0.02mm/tooth

V 150m/min

Full/pitch circle Pitch circle

X0 85 abs

Y0 135 abs

Z0 0 abs

W 10

R 40

α0 180 degrees

α1 180 degrees

α2 0 degrees

N 1

Z1 3 inc

DZ 3

UXY 0 mm

•

8. Drill/Center• Select via softkeys

Drilling

Center-ing >

8 08.00 Examples



• Assign technological parameters T, F and S accordingly and enterthe following parameters:

Diameter/tip Diameter

∅ 16

•

9. Drilling/reaming• Select via softkeys

Drilling

DrillingReaming >

Drilling

• Assign technological parameters T, F and S accordingly (e.g.DRILL10) and enter the following parameters:

Diameter/tip Tip

Z1 -25 abs

DT 0

•

10. Positions• Select via softkeys

Drilling

Positions >


rectangular

Z0 -10 abs

X0 15 abs

Y0 15 abs

X1 165 abs

Y1 15 abs

•

11. Obstacle• Select via softkeys

Drilling

Positions >

Obstacle


Z 2 abs

•

Note:If this obstacle cycle is not inserted, the drill will violate the right-handcorner of the island contour. Alternatively, you could increase thesafety clearance.

12. Positions• Select via softkeys

Drilling

Positions >


rectangular

Z0 -10 abs

X2 165 abs

Y2 165 abs

X3 15 abs

8 Examples 08.00



Y3 165 abs

•

13. Mill a circular pocket• Select via softkeys

Milling

Pocket >

Circularpocket


T MILLTOOL8 F 0.15mm/tooth V 300m/min



X0 85 abs

Y0 135 abs

Z0 –6 abs

Diameter 30

Z1 15 inc

DXY 4

DZ 5

UXY 0 mm

UZ 0

Insertion Center

FZ 0.1 mm/tooth


•

Result • Programming graphic

8 08.00 Examples



• ShopMill program representation

8 Examples 08.00

8.2 Example 2: Shift and mirror a contour 8


8.2 Example 2: Shift and mirror a contour

Workshop drawing

X+

Y+

Z+

Y+

12030

5010

6040

10

R3

10

In this example, the displayed shapes occur several times in the sameprogram. Mirroring is to be carried out in addition to the shiftingoperation. The shapes are to be machined with a stock removal cycle.

Program Part_1


Corner point: X0 0 abs Y0 0 abs Z0 2 abs

Dimensions: L 120 W 60 H –30

• Select softkey

2. Set start marking forrepetition of the contour • Select via softkeys

Misc.

Setmarker >

• Set start marking with "Marker1"

•

3. Define the contour• Select via softkeys

Contourmilling

Newcontour >

• Enter a contour name (in this case: PART_1_3COR) and confirm


Tool axis Z

X0 10 abs Y0 10 abs

and confirm .


:

1. X 60 abs R 3

2. X 10 abs Y 40 abs R 3

3. X 10 abs Y 10 abs R 3

8 08.00 Examples



• Select softkey

4. Solid machining• Select via softkeys

Contourmilling

Stockremoval >

• Assign technological parameters T, F and S accordingly (e.g. cutterdiameter 3) and enter the following parameters:

Z0 0 abs

Z1 10 inc

DXY 1.5 mm

DZ 2

UXY 0.5

UZ 0.5

Starting point auto

Insertion Center

FZ 0.1 mm/tooth

Select lift-off mode, e.g. to retraction plane

•

5. Set end marker for contourrepetition • Select via softkeys

Misc.

Setmarker >

• Set end marking with "Marker2"

•

6. Offset• Select via softkeys

Misc.

Transfor-mations >

Offset >

• Set the following parameters:

New/additive New

X 120

Y 60

Z 0

•

7. Mirroring• Select via softkeys

Misc.

Transfor-mations >

Mirror-ing >


New/additive add

X On

Y On

Z Off

•

8 Examples 08.00



8. Repetition of contour• Select via softkeys

Misc.

Repetition >

• Set the following markers:

Start marker Marker 1

End marker Marker 2

Number of

repetitions

1

•



8 08.00 Examples

8.3 Example 3: Chamfer on circular spigot 8


8.3 Example 3: Chamfer on circular spigot

Workshop drawing

X+

Y+

Z-

100

50

100

90o

2x45o

80

25

Tool,e.g. centering tool

In this example, a circular spigot with chamfer (2mmx45°) is machined

on a blank with a pre-machined circular spigot using a centering tool.

The general tool requirements for machining a chamfer are as follows:

• Tool diameter = 0 (e.g. centering tool)

• Tool cutting edge angle = 90°

Determining UXY and Z1:

Z1 (inc) = UXY + chamfer

8 Examples 08.00



2x45o90o

UXY=1mm allowancefor

Plane Z0=0of the spigot

Tool,e.g. centering tool

2mm chamfer

3mm = Z1

Program Part_3



X1 100abs Y1 100abs Z1 –50abs

• Select softkey

2. Circular spigot• Select via softkeys

Milling

Spigot >

Circularspigot


TMILLTOOL40 F2000mm/min V200m/min




X0 50 abs

Y0 50 abs

Z0 0 abs

∅ 80

Z1 25 inc

DZ 5

UXY 0 mm

UZ 0.5

∅1 100

•

8 08.00 Examples



3. Circular spigot• Select via softkeys

Milling

Spigot >

Circularspigot


T CENTERER F 2000mm/min S 200rev/min


Machining type Finishing


X0 50 abs

Y0 50 abs

Z0 0 abs

∅ 80

Z1 3 inc

DZ 10

UXY 1 mm

UZ 0

∅1 100

•



8 Examples 08.00

8.4 Example 4: Cylinder surface transformation 8


8.4 Example 4: Cylinder surface transformation

Z

Y

X

90°

10°

30°o80mm

360o

90o

30o

10o

0o

0-45-60-100

Y

X

Preconditions • There is a rotary axis, e.g. axis A, and the transformation isconfigured via machine data.

• The reference points on the cylinder are predefined.Program the reference points X0, Y0, Z0 and the required zerooffset, for example, in "Machine Manual", "Workpiece zero" and"Edge". The zero offset calculated from these is entered in the zerooffset list.

Program

1. Program header • The blank dimensions correspond to the developed cylinder

peripheral surface (L= ∅ x π).

Define a blank:

X0 0abs Y0 0abs Z0 40abs

X1 –100abs Y1 251.327abs Z1 20abs RP 50

Note: Y1 is calculated from diameter 80 multiplied by π (3,14...)

• Select softkey

2. Activate the zero offset inthe program

Select zero offset for cylinder surface transformation (e.g. offset thezero point on the center point of the cylinder end face).

• Select via softkeys Misc.

Trans-formations>

Move zeropoint >

• Select the required zero offset and then select softkey .

3. Position the Y axis Position the tool in the Y axis over the center of the cylinder since theY axis is not traversed after cylinder transformation is selected.

• Select via softkeys Straight l.Circle

Straightline


X 10 abs Y 0 abs Z 50 abs A 0 abs

F *rapid traverse* mm/min radius compensation Off

8 08.00 Examples



4. Activate cylinder peripheralsurface transformation • Select via softkeys

Misc.

Transfor-mations >

Cylindersurface >


Transformation On

∅ 80

Slot side comp. OFF


Define the zero offset for the machining operation on the developedcylinder surface.


Transfor-mations >

Move zeropoint >

• Select the required zero offset and then select softkey .6. Enter contour with contour

calculator • Select via softkeys Contourmilling

Newcontour >

• Enter contour name and confirm

• Fill in the contour start screen form

Tool axis Z

Cylinder surface yes

∅ 80

X 0 Yα 10abs

Note: Delete Y value, then enter Yα value (in this case, 10°).


:

1. X –60abs

2. Yα 90abs

3. X –45abs

4. Yα 30abs

5. X 0abs

7. Path milling• Select via softkeys

Contourmilling

Pathmilling

• Enter parameters

T CUTTER8 F 0.2mm/tooth S 5000U/min

Radius compensation Machining

Z0 40abs Z1 10inc DZ 10

UZ0

UXY 0

Approach Linear

Depth infeed

L1 2

FZ 0,1 mm/tooth

Retract Linear

8 Examples 08.00



Retract strategy

L2 2

Liftoff mode to return plane

8. Deactivate cylinderperipheral surfacetransformation


Transfor-mations >

Cylindersurface >


Transformation OFF

9. Result • Programming graphic


8 08.00 Examples

8.5 Example 5: Slot side compensation 8


8.5 Example 5: Slot side compensation

A slot with parallel slot sides is milled in a pipe. In this instance, it isnot the slot contour which is programmed, but the imaginary center-point path of a bolt inserted in the slot.

50

35o

3

12

50

y

x

100

25 15

15

45 o

35o

Preconditions • There is a rotary axis, e.g. axis A, and the transformation isconfigured via machine data.

• The reference points on the cylinder are predefined. Program thereference points X0, Y0, Z0 and the required zero offset, forexample, in "Machine Manual", "Workpiece zero" and "Edge".

8 Examples 08.00



The zero offset calculated from these is entered in the zero offsetlist.

Program

1. Program header • The blank dimensions correspond to the developed cylinderperipheral surface.


X1 –130 abs Y1 157.08 abs Z1 22 abs

RP 50 SC 1

Note: Y1 is calculated according to equation: Y1 = ∅ • πIn this case: Diameter 50 multiplied by 3.14...

• Select softkey


Select zero offset for cylinder surface transformation (e.g. offset thezero point on the center point of the cylinder end face).


Transfor-mations >

Move zeropoint >


3. Position the Y axis Position the tool in the Y axis over the center of the cylinder since theY axis is not traversed after cylinder transformation is selected.

• Select via softkeys Straight l.Circle

Straight


X 10abs Y 0abs Z 40abs

F *rapid traverse*mm/min radius compensation OFF

4. Activate cylinder peripheralsurface transformation • Select via softkeys

Misc.

Transfor-mations >

Cylindersurface >


Transformation On

∅ 50

Slot side comp. On

D 6

Note: D is the distance from the imaginary center-point path to the

slot wall.


Define the zero offset for the machining operation on the developedcylinder surface (shift zero point to the zero point on the workpiecedrawing).


Transfor-mations >

Move zeropoint >


8 08.00 Examples



6. Enter contour with contourcalculator • Select via softkeys

Contourmilling

Newcontour >

• Enter a contour name (in this case: cylinder) and confirm

• Fill in the contour start screen form

Tool axis Z

Cylinder surface yes

∅ 50 X –25 abs Yα 0 abs

Note:Delete Y value, then enter Yα value (in this case 0°).


:

1. X –44 abs

2. X –25 abs

3. Allparameters Yα –35 abs I 0 incSelectdialog (α2 tang.)

Acceptdialog β2 180°

4. X –94 abs

5.

6. X –6 abs Yα 0 abs α1 45°

7. X –25 abs

• Accept contour by selecting softkey .

7. Path milling• Select via softkeys

Contourmilling

Pathmilling

• Enter parameters

T CUTTER_8 F 0.2 mm/tooth S 5000 rev/min

Radius compensation Machining

Z0 25 abs Z1 3 inc DZ 2

UZ 0 UXY 0

Approach Quadrant

R1 1

FZ 0.1 mm/tooth

Retract Quadrant

R2 1

Liftoff mode to return plane

8 Examples 08.00



8. Deactivate cylinderperipheral surfacetransformation


Transfor-mations >

Cylindersurface >


Transformation OFF

9. Result • Programming graphic


8 08.00 Examples

8.6 Example 6: Swiveling 8


8.6 Example 6: Swiveling

54.736°

View A

14.434

Front view50

25

25

2010

45°

10 in depth

View of left-hand side

10 indepth

25

25

10 20

45°

Z

XY

17.678

20.4

1310

.206

R5

10 indepth

90°

A

Plan view

10 indepth

25

25

10 20

45°

5050

R2

R2

R2

8 Examples 08.00



In this example, the machining plane is swiveled several times.

Program example 4



X1 –50abs Y1 –50abs Z1 –50abs

• Select softkey

2. Rectangular pocket• Select via softkeys

Milling

Pocket >

Rectang.pocket


T CUTTER_4 D 1 F 0.1 mm/tooth V 200 m/min


Position of

reference point

Center



X0 –25 abs

Y0 –25 abs

Z0 0 abs

W 10

L 20

R 2

α0 –45°

Z1 5 inc

DXY 3 mm

DZ 2.5

UXY 0 mm

UZ 0

Insertion Center

FZ 0.05mm/tooth

Stock removal Complete mach.

•

8 08.00 Examples



3. Swiveling• Select via softkeys

Misc.

Transfor-mations >

Swiveling >


T CUTTER_4 D 1


Transformation NewX0 0

Y0 –50

Z0 0

Swiveling Axial

X 90°

Y 0

Z 0

X1 0

Y1 0

Z1 0

Direction –

•


Milling

Pocket >

Rectang.pocket




Position of

reference point

Center



X0 –25 abs

Y0 –25 abs

Z0 0 abs

W 10

L 20

R 2

α0 45°

Z1 5 inc

DXY 3 mm

DZ 2.5

UXY 0 mm

UZ 0

Insertion Center

FZ 0.05mm/tooth


•

8 Examples 08.00




Misc.

Transfor-mations >

Swiveling


T CUTTER_4 D 1


Transformation New

X0 –50

Y0 –50

Z0 0

Swiveling Axial

Z –90°

X 90°

Y 0

X1 0

Y1 0

Z1 0

Direction –

•


Milling

Pocket >

Rectang.pocket




Position of

reference point

Center



X0 –25 abs

Y0 –25 abs

Z0 0 abs

W 10

L 20

R 2

α0 –45°

Z1 5 inc

DXY 3 mm

DZ 2.5

UXY 0 mm

UZ 0

Insertion Center

FZ 0.05mm/tooth


•

8 08.00 Examples



7. Setting• Select via softkeys

Misc.

Settings

• Define a blank:

X0 –17.678 abs Y0 10.206 abs Z0 0 abs

X1 17.678 abs Y1 –20.413 abs Z1 –10 abs

• Select softkey

•


Misc.

Transfor-mations >

Swiveling


T FACING TOOL D 1


Transformation New

X0 –50

Y0 –50

Z0 –25

Swiveling Axial

Z –45°

X 54.736°

Y 0

X1 0

Y1 20.413

Z1 0

Direction –

•

9. Face milling• Select via softkeys

Milling

Facemilling > and choose a machining

strategy


T FACING TOOL D 1 F 0.1 mm/tooth V 200 m/min



X0 –17.678 abs

Y0 –20.413 abs

Z0 14.434 abs

X1 17.678 abs

Y1 10.206 abs

Z1 0 abs

DXY 80 %

DZ 2.5

UZ 0

•

8 Examples 08.00



10. Drilling• Select via softkeys

Drilling

DrillingReaming

Drilling


T DRILL_3 D 1 F 0.1 mm/rev V 2000 rev/min


Shank/tip Shank

Z1 5 inc

DT 0 s

•

11. Position pattern• Select via softkeys

Drilling

Positions >


Full/pitch circle Full circle

Z0 0 abs

X0 0 abs

Y0 0 abs

α0 –90°

R 5

N 3

Positioning Linear

•


Misc.

Transfor-mations >

Swiveling >


T 0 D 1


Transformation New

X0 0

Y0 0

Z0 0

Swiveling Axial

X 0

Y 0

Z 0

X1 0

Y1 0

Z1 0

Direction –

•

8 08.00 Examples



Result • ShopMill program representation

�

8 Examples 08.00



Notes

A 08.00 Appendix A

Siemens AG 2000. All rights reservedSINUMERIK 840D/810D, ShopMill Operation/Programming (BAS) – 08.00 Edition A-295

Appendix

A Abbreviations .......................................................................................................... A-296

B Terms...................................................................................................................... A-299

C References ............................................................................................................. A-307

D Index ....................................................................................................................... A-319

A Appendix 08.00

Abbreviations A

Siemens AG 2000. All rights reservedA-296 SINUMERIK 840D/810D, ShopMill Operation/Programming (BAS) – 08.00 Edition

A Abbreviations

ASCII American Standard Code for Information Interchange

CNC Computerized Numerical Control

CRC Cutter Radius Compensation

DIN Deutsche Industrie Norm (German Industry Standard)

DIO Data Input/Output: Data transfer display

DOS Disk Operating System

DRF Differential Resolver Function

FDD Feed Drive

FST Feed Stop

HW Hardware

INC Increment

INI Initializing Data

IPO Interpolator

K1 .. K4 Channels 1 to 4

LF Line Feed

MCP Machine Control Panel

MCS Machine Coordinate System

MD Machine Data

MMC Man Machine Communication: User interface on numerical controlsystems for operator control, programming and simulation

NC Numerical Control

NCK Numerical Control Kernel (with block preparation, traversing range,etc.)

A 08.00 Appendix

Abbreviations A


OI Operator Interface

PC Personal Computer

PLC Programmable Logic Controller

POS Positioning function

REF Reference point approach function

REPOS Reposition function

SBL Single Block

SK Softkey

SKP Skip block

SM Stepper Motor

SW Software

TC Tool Change

TLC Tool Length Compensation

TNRC Tool Nose Radius Compensation

TO Tool Offset

TRC Tool Radius Compensation

UP Subroutine

V.24 Serial Interface (Definition of interchange lines between DTE andDCE)

WCS Workpiece Coordinate System

ZO Zero offset

A Appendix 08.00

Abbreviations A


A 08.00 Appendix

Terms A


B Terms

Important terms are listed below in alphabetical order, accompaniedby explanations. Cross-references to other entries in this glossary areindicated by the symbol ->.

A

Absolute dimension A destination for an axis movement is defined by a dimension thatrefers to the origin of the currently active coordinate system. See also-> incremental dimension.

Access rights CNC program modules and data are protected by a 7-level system ofaccess restrictions:

• Three password levels for system manufacturer, machine-toolmanufacturer and user, and

• four keyswitch settings which can be evaluated via the PLC.

Alarms All -> messages and alarms are displayed on the control panel inplain-text form and accompanied by date and time and the symbol forthe appropriate deletion criterion. Alarms and messages are displayedseparately.

Archiving Exporting files and/or directories to an external storage device.

Auto Operating mode of ShopMill in which a program is selected and thenprocessed without interruption.

Auxiliary functions Auxiliary functions can be used to pass -> parameters to the -> PLC in-> programs, triggering reactions there which are defined by themachine manufacturer.

Axes CNC axes are categorized by their functional scope as follows:

• Axes: Interpolative path axes

• Auxiliary axes: Non-interpolative infeed and positioning axes withaxis-specific feedrates. Auxiliary axes do not participate inworkpiece machining as such and include tool feeders, toolmagazines, etc.

B

Blank The unmachined workpiece.

Block Part of a -> program.

A Appendix 08.00

Terms A


C

Channel A channel can execute a -> program independently of other channels.A channel has exclusive control over the axes and spindles assignedto it. Part program sequences on different channels can becoordinated by -> synchronization.

CNC -> NC

Contour Outline of a -> workpiece

Contour monitoring The following error is monitored within a definable tolerance bandwidthas a measure of contour precision. The following error might violatepermissible limits, for example, on account of drive overload. In thiscase, an alarm is output and the axes are stopped.

Coordinate system See -> machine coordinate system, -> workpiece coordinate system.

Cycle Protected subroutine for execution of a recurring machining processon the -> workpiece.

D

Dimensions in metric

and inch systems

In the machining program, position and lead/pitch values can beentered in inches. The control is set to a base system irrespective ofthe programmable unit of measure (G70/G71).

DRF Differential Resolver Function An NC function which generates anincremental zero offset in AUTOMATIC mode in conjunction with anelectronic handwheel.

E

Editor The editor allows programs/texts/program blocks to be created,modified, extended, chained and inserted.

Electronic handwheel Electronic handwheels are used to traverse selected axessimultaneously under manual control. The handwheel clicks areanalyzed by the increment analyzer.

A 08.00 Appendix

Terms A


F

Feedrate override The current feedrate setting entered via the control panel or by thePLC is overlaid on the programmed feedrate (0-200 %). The feedratecan also be corrected by a programmable percentage factor (1-200 %)in the machining program.

Finished-part contour Contour of the finished workpiece. See also -> Blank.

Fixed-point approach Machine tools can execute defined approaches to fixed points such astool-change points, loading points, pallet-change points, etc. Thecoordinates of these points are stored in the control. The controltraverses the axes in question in -> rapid traverse if possible.

G

Geometry Description of a -> workpiece in the -> workpiece coordinate system.

Geometry axis Geometry axes are used to describe a 2- or 3-dimensional area in theworkpiece coordinate system.

I

I/O module I/O modules establish the link between the CPU and the process.I/O modules are:

• -> Digital input/output modules

• -> Analog input/output modules

• -> Simulator modules

Inch system of

measurement

System of measurement in which distances are measured in inchesand fractions of inches.

Incremental dimensions A destination for axis traverse is defined by a distance to be coveredand a direction referenced to a point already reached. See also-> absolute dimension. Length of the traversing path given by thenumber of increments. The number of increments can be stored as ->setting data or selected using the corresponding keys 10, 100, 10 000.

A Appendix 08.00

Terms A


M

Machine axes Axes which physically exist in the machine tool.

Machine Control Panel An operator panel on a machine tool with operating elements such askeys, rotary switches, etc. and simple indicators such as LEDs. It isused for direct control of the machine tool via the PLC.

Machine coordinate

system

Coordinate system that refers to the axes of the machine tool.

Machine fixed point A point uniquely defined by the machine tool, for example, thereference point.

Machine zero A fixed point on the machine tool which can be referenced by allderived measuring systems.

Machining channel A channel structure provides a means of reducing non-productivetimes by paralleling operations. For example, a loader can execute itsmovements during a machining operation. In this respect, a channelranks as an autonomous CNC complete with decoding, blockpreparation and interpolation.

Manual Operating mode of the ShopMill application (setup mode):The machine can be set up in Manual mode. Individual axes andspindles can be traversed in JOG via the Direction keys. Otherfunctions in the Manual operating mode are -> reference pointapproach, -> Repos and -> basic offset.

Messages All messages programmed in the program and -> alarms detected bythe system are displayed on the control panel in plain-text form withdate and time and the appropriate symbol for the deletion criterion.Alarms and messages are displayed separately.

Mirroring Mirroring exchanges the leading signs of the coordinate values of acontour in relation to an axis. Mirroring can be performedsimultaneously in relation to several axes.

N

NC Numerical Control NC control incorporates all the components of themachine tool control system: -> NCK, -> PLC, -> MMC, -> COM.

NCK Numeric Control Kernel: Component of the NC control which executes-> programs and essentially coordinates the movements on themachine.

A 08.00 Appendix

Terms A


O

Offset memory Data area in the control used to store the tool offset data.

Operator Interface The operator interface (OI) is the display medium of a CNC in the formof a screen. It has eight horizontal and eight vertical softkeys.

Override Manual or programmable control feature which enables the operator tooverlay programmed feedrates or speeds to adapt them to a specificworkpiece or material.

P

PLC Programmable Logic Controller. A component of the -> NC control:A control which can be programmed to control the logic on a machinetool.

Polar coordinates A coordinate system which defines the position of a point on a plane interms of its distance from the origin and the angle formed by theradius vector with a defined axis.

Power On Disconnection and reconnection of control system power supply.

Program A sequence of instructions to the NC control which combine toproduce a specific -> workpiece by performing machining operationson a -> blank.

R

Rapid traverse Highest speed of an axis, used, for example, to bring the tool from anidle position to the -> workpiece contour or retract it from theworkpiece contour.

Reference point A point on the machine tool to which the measurement system ofthe -> machine axes refers.

Reference point

approach

If the system of position measuring employed is not based onabsolute-value encoders, the control must perform a reference pointapproach in order to ensure that the measured values supplied by themeasuring system coincide with the machine coordinate values.

A Appendix 08.00

Terms A


REPOS 1. Reapproach to contour, triggered by operatorThe Repos function provides a means of returning the tool to theinterrupt position with the aid of the direction keys.

2. Program-driven return to contourA number of repositioning strategies driven by program commandsare available: Reposition at interrupt point, reposition at start ofblock, reposition at end of block, reposition at a point on the pathbetween beginning of block and interruption.

Rotation Component of a programmable offset which defines a rotation of thecoordinate system through a specific angle.

S

Scale Component of a -> frame which causes axis-specific alterations in thescale.

Softkey A key whose name appears on an area of the screen. The choice ofsoftkeys displayed is adapted dynamically to the operating situation.Freely assignable function keys (softkeys) are assigned to functionsdefined in the software.

Subroutine Sequence of statements in a -> program that can be called repeatedlywith differing initial parameters. Subroutines are called from the mainprogram. Every subroutine can be protected against unauthorizedreadout and display. -> Cycles are a type of subroutine.

T

Tool Component used to machine workpieces, e.g. milling tool, drill,...

Tool radius

compensation

Direct programming of a -> workpiece contour requires the control tobe able to travel a path equidistant to the programmed contour, takingthe radius of the tool used into account.

W

Working space Three-dimensional zone into which the tool tip can be moved onaccount of the physical design of the machine tool.See also -> protection zone.

Workpiece Part to be produced/machined by the machine tool.

A 08.00 Appendix

Terms A


Workpiece coordinate

system

The datum of the workpiece coordinate system is the -> workpiecezero. If the workpiece coordinate system is used for programming,dimensions and directions are referenced to this system.

Workpiece zero The workpiece zero is the datum for the -> workpiece coordinatesystem. It is defined by distances from the machine zero.

Z

Zero offset Specification of a new reference point for a coordinate system bymeans of a reference to an existing zero and a programmable offset.1. Settable

Four independent zero offsets can be selected per CNC axis.2. External

All offsets which define the position of the workpiece zero can beoverlaid with an external zero offset- defined by handwheel (DRF offset) or- defined by the PLC.

3. ProgrammableZero offsets can be programmed for all path and positioning axesby means of programmable zero offsets NPV1...4.

A Appendix 08.00

Terms A


A 08.00 Appendix

References A


C References

General Documentation

/BU/ SINUMERIK 840D/810D/FM-NCOrdering InformationCatalog NC 60.1Order No.: E86060-K4460-A101-A8-7600

/ST7/ SIMATICSIMATIC S7 Programmable Logic ControllersCatalog ST 70Order No.: E86 060-K4670-A111-A3

/W/ SINUMERIK 840D/810D/FM-NCBrochure

/Z/ SINUMERIK, SIROTEC, SIMODRIVEAccessories and Equipment for Special-Purpose MachinesCatalog NC ZOrder No.: E86060-K4490-A001-A7-7600

Electronic Documentation

/CD6/ The SINUMERIK System (10.00 Edition)DOC ON CD(with all SINUMERIK 840D/810D/FM-NC and SIMODRIVE 611D publications)Order No.: 6FC5 298-6CA00-0BG2

A Appendix 08.00

References A


User Documentation

/AUE/ SINUMERIK 840D/810D/FM-NC

AutoTurn Graphic Programming System (07.99 Edition)

Part 2: SetupOrder No.: 6FC5 298-4AA50-0BP1

/AUK/ SINUMERIK 840D/810D/FM-NC

Short Guide AutoTurn Operation (07.99 Edition)

Order No.: 6FC5 298-4AA30-0BP1

/AUP/ SINUMERIK 840D/810D/FM-NC

AutoTurn Graphic Programming System (07.99 Edition)

Part 1: ProgrammingOrder No.: 6FC5 298-4AA40-0BP1

/BA/ SINUMERIK 840D/810Di/FM-NC

Operator’s Guide (10.00 Edition)


• Operator’s Guide

• Operator’s Guide with HMI Advanced

/BAE/ SINUMERIK 840D/810D/FM-NC

Operator’s Guide Unit Operator Panel (04.96 Edition)


/BAH/ SINUMERIK 840D/810 D

Operator’s Guide HAT 6 (HPU new) (06.00 Edition)

Order No.: 6FC5 298-0AD60-0BPO

/BAK/ SINUMERIK 840D/810Di/FM-NC

Short Operating Guide (10.00 Edition)


/BAM/ SINUMERIK 840D/810D

Operator’s Guide ManualTurn (02.00 Edition)

Order No.: 6FC5 298-5AD00-0BP0

/KAM/ SINUMERIK 840D/810D

Short Guide ManualTurn (12.99 Edition)


A 08.00 Appendix

References A


/BAS/ SINUMERIK 840D/810D

Operator’s Guide ShopMill (08.00 Edition)


/KAS/ SINUMERIK 840D/810D

Short Guide ShopMill (01.98 Edition)


/BAP/ SINUMERIK 840D/840Di/810D

Operator’s Guide Handheld Programming Unit (04.00 Edition)


/BNM/ SINUMERIK 840D/840Di/810D/FM-NC

User’s Guide Measuring Cycles (06.00 Edition)


/DA/ SINUMERIK 840D/840Di/810D/FM-NC

Diagnostics Guide (10.00 Edition)


/PG/ SINUMERIK 840D/840Di/810D/FM-NC

Programming Guide Fundamentals (10.00 Edition)

Order No.: 6FC5 298-6AB00-0BP2

/PGA/ SINUMERIK 840D/840Di/810D/FM-NC

Programming Guide Advanced (10.00 Edition)


/PGK/ SINUMERIK 840D/840Di/810D/FM-NC

Short Guide Programming (10.00 Edition)


/PGZ/ SINUMERIK 840D/840Di/810D/FM-NC

Programming Guide Cycles (10.00 Edition)


/PI/ PCIN 4.4Software for Data Transfer to/from MMC ModuleOrder No.: 6FX2 060-4AA00-4XB0 (German, English, French)Order from: WK Fürth

A Appendix 08.00

References A


a) Lists

Manufacturer/Service Documentation

/LIS/ SINUMERIK 840D/840Di/810D/FM-NCSIMODRIVE 611D

Lists (10.00 Edition)


b) Hardware

/BH/ SINUMERIK 840D/840Di/810D/FM-NC

Operator Components Manual (HW) (10.00 Edition)


/BHA/ SIMODRIVE Sensor

Absolute Encoder with Profibus DP (02.99 Edition)

User’s Guide (HW)Order No.: 6SN1 197-0AB10-0YP1

/EMV/ SINUMERIK, SIROTEC, SIMODRIVE

EMC Installation Guide (06.99 Edition)

Planning Guide (HW)Order No.: 6FC5 297-0AD30-0BP1

/PHC/ SINUMERIK 810D

Manual Configuring (HW) (10.00 Edition)


/PHD/ SINUMERIK 840D

NCU 571.2-573.2 Manual (HW) (10.00 Edition)

Order No.: 6FC5 297-6AC10-0BP2

/PHF/ SINUMERIK FM-NC

NCU 570 Manual (HW) (04.96 Edition)


/PMH/ SIMODRIVE Sensor

Measuring System for Main Spindle DrivesPlanning/Installation Guide, SIMAG-H (HW) (05.99 Edition)

Order No.: 6SN1197-0AB30-0BP0

A 08.00 Appendix

References A


c) Software

/FB/ SINUMERIK 840D/840Di/810D/FM-NC

Description of Functions Basic Machine (Part 1) (10.00 Edition)

(the various sections are listed below)Order No.: 6FC5 297-6AC20-0BP2

A2 Various Interface SignalsA3 Axis Monitoring, Protection ZonesB1 Continuous Path Mode, Exact Stop and Look AheadB2 AccelerationD1 Diagnostic ToolsD2 Interactive ProgrammingF1 Travel to Fixed StopG2 Velocities, Setpoint/Actual Value Systems, Closed-Loop

ControlH2 Output of Auxiliary Functions to PLCK1 Mode Group, Channels, Program Operation ModeK2 Coordinate Systems, Axis Types, Axis Configurations,

Actual-Value System for Workpiece, External Zero OffsetK4 CommunicationN2 EMERGENCY STOPP1 Transverse AxesP3 Basic PLC ProgramR1 Reference Point ApproachS1 SpindlesV1 FeedsW1 Tool Compensation

/FB/ SINUMERIK 840D/840Di/810D (CCU2)/FM-NC (10.00 Edition)

Description of Functions, Extended Functions (Part 2)

including FM-NC: Turning, Stepping Motor(the various sections are listed below)Order No.: 6FC5 297-6AC30-0BP2

A4 Digital and Analog NCK I/OsB3 Several Operator Panels and NCUsB4 Operation via PC/PGF3 Remote DiagnosticsH1 Jog with/without HandwheelK3 CompensationsK5 Mode Groups, Channels, Axis ReplacementL1 FM-NC Local BusM1 Kinematic TransformationM5 MeasurementsN3 Software Cams, Position Switching SignalsN4 Punching and NibblingP2 Positioning AxesP5 Oscillation

A Appendix 08.00

References A


R2 Rotary AxesS3 Synchronous SpindlesS5 Synchronized Actions (up to and including SW 3)S6 Stepper Motor ControlS7 Memory ConfigurationT1 Indexing AxesW3 Tool ChangeW4 Grinding

/FB/ SINUMERIK 840D/840Di/810D (CCU2)/FM-NC

Description of Functions, Special Functions (Part 3)(10.00 Edition)


F2 3-Axis to 5-Axis TransformationG1 Gantry AxesG3 Cycle TimesK6 Contour Tunnel MonitoringM3 Coupled Motion and Leading Value CouplingS8 Constant Workpiece Speed for Centerless GrindingT3 Tangential ControlV2 PreprocessingW5 3D Tool Radius CompensationTE1 Clearance ControlTE2 Analog AxisTE3 Master-Slave for DrivesTE4 Transformation Package HandlingTE5 Setpoint Value ChangearerTE6 MCS Link

/FBA/ SIMODRIVE 611D/SINUMERIK 840D/810D

Description of Functions, Drive Functions (10.00 Edition)

(the various sections are listed below)Order No.: 6SN1 197-0AA80-0BP6

DB1 Operational Messages/Alarm ReactionsDD1 Diagnostic FunctionsDD2 Speed Control LoopDE1 Extended Drive FunctionsDF1 Enable CommandsDG1 Encoder ParameterizationDM1 Calculation of Motor/Power Section Parameters and

Controller DataDS1 Current Control LoopDÜ1 Monitors/Limitations

A 08.00 Appendix

References A


/FBAN/ SINUMERIK 840D/SIMODRIVE 611 DIGITALDescription of Functions

ANA-MODULE (02.00 Edition)

Order No.: 6SN1 197-0AB80-0BP0

/FBD/ SINUMERIK 840D

Description of Functions Digitizing (07.99 Edition)

Order No.: 6FC5 297-4AC50-0AP0

DI1 StartupDI2 Scanning with Tactile Sensors (scancad scan)DI3 Scanning with Lasers (scancad laser)DI4 Milling Program Generation (scancad mill)

/FBDN/ CAM-Integration DNC NT-2000Description of Fonctions

System for NC Data Management and Data

Distribution (05.00 Edition)

Order No.: 6FC5 297-6AE50-0BP0

/FBFA/ SINUMERIK 840D/810DDescription of Functions

ISO Dialects for SINUMERIK (10.00 Edition)


/FBHLA/ SINUMERIK 840D/SIMODRIVE 611D digitalDescription of Functions

HLA Module (08.99 Edition)

Order No.: 6SN1 197-0AB60-0BP1

/FBMA/ SINUMERIK 840D/810D

Description of Functions ManualTurn (02.00 Edition)


/FBO/ SINUMERIK 840D/810D/FM-NCDescription of Functions

Configuring of Operator Interface OP 030 (03.96 Edition)


BA Operator’s GuideEU Development Environment (Configuring Package)PS Online only: Configuring Syntax (Configuring Package)PSE Introduction to Configuring of Operator InterfaceIK Screen Kit: Software Update and Configuration

A Appendix 08.00

References A


/FBP/ SINUMERIK 840D

Description of Functions C-PLC Programming (03.96 Edition)


/FBR/ SINUMERIK 840D/810DDescription of Functions

SINCOM Computer Link (02.00 Edition)


NFL Host Computer InterfaceNPL PLC/NCK Interface

/FBSI/ SINUMERIK 840D/SIMODRIVEDescription of Functions

SINUMERIK Safety Integrated (05.00 Edition)


/FBSP/ SINUMERIK 840D/810D

Description of Functions ShopMill (08.00 Edition)


/FBST/ SIMATIC (11.98 Edition)

FM STEPDRIVE/SIMOSTEPDescription of FunctionsOrder No.: 6SN1 197-0AA70-0YP3

/FBSY/ SINUMERIK 840D/840Di/810D(CCU2)

Description of Functions Synchronized Actions (10.00 Edition)

for Wood, Glass, Ceramics and PressesOrder No.: 6FC5 297-6AD40-0BP0

/FBTD/ SINUMERIK 840D/810DDescription of Functions

Tool Information SINTDI with Online Help (04.99 Edition)


/FBU/ SIMODRIVE 611 universalDescription of Functions (05.00 Edition)Closed-Loop Control Component for Speed Controland PositioningOrder No.: 6SN1 197-0AB20-0BP3

/FBW/ SINUMERIK 840D/810D

Description of Functions Tool Management (07.00 Edition)


A 08.00 Appendix

References A


/HBI/ SINUMERIK 840Di

Manual (06.00 Edition)


/IK/ SINUMERIK 840D/810D/FM-NC

Screen Kit MMC 100/Unit Operator Panel (06.96 Edition)

Description of Functions: Software Update and ConfigurationOrder No.: 6FC5 297-3EA10-0BP1

/KBU/ SIMODRIVE 611 universalShort Description (05.00 Edition)Closed-Loop Control Component for Speed ControlOrder No.: 6SN1 197-0AB40-0BP3

/PLJM/ SIMODRIVE

Planning Guide Linear Motors (05.00 Edition)

(on request)ALL General Information about Linear Motors1FN1 1FN3 Three-Phase AC Linear MotorCON ConnectionsOrder No.: 6SN1 197-0AB70-0AP1

/PJM/ SIMODRIVE

Planning Guide MotorsAC Motors for Feed and (01.98 Edition)Main Spindle DrivesOrder No.: 6SN1 197-0AA20-0BP3

/PJMS/ SIMODRIVE

Planning Guide Synchronous Integrated Motor 1FE1AC Motors for Main Spindle Drives (03.00 Edition)Order No.: (on request)

/PJU/ SIMODRIVE 611-A/611-D

Planning Guide Inverters (08.98 Edition)

Transistor PWM Inverters for AC Feed Drives andAC Main Spindle DrivesOrder No.: 6SN1 197-0AA00-0BP4

/POS1/ SIMODRIVE POSMO A (02.00 Edition)

User GuideDecentralized Positioning Motor on PROFIBUS DPOrder No.: 6SN2 197-0AA00-0BP1

A Appendix 08.00

References A


/POS2/ SIMODRIVE POSMO A (12.98 Edition)

Installation Instructions (enclosed with POSMO A)Order No.: 462 008 0815 00

/POS3/ SIMODRIVE POSMO SI/CD/CA (09.00 Edition)

Decentralized Servodrive Technology, Operator ManualOrder No.: 6SN2 197-0AA20-0BP0(available soon)

/S7H/ SIMATIC S7-300Manual: Assembly, CPU Data (HW) (10.98 Edition)Reference Manual: Module DataOrder No.: 6ES7 398-8AA03-8AA0

/S7HT/ SIMATIC S7-300Manual: STEP 7, Basic Information, V. 3.1 (03.97 Edition)Order No.: 6ES7 810-4CA02-8AA0

/S7HR/ SIMATIC S7-300Manual: STEP 7, Reference Manuals, V. 3.1 (03.97 Edition)Order No.: 6ES7 810-4CA02-8AR0

/S7S/ SIMATIC S7-300

FM 353 Step Drive Positioning Module (04.97 Edition)

Order in conjunction with Configuring Package

/S7L/ SIMATIC S7-300

FM 354 Servo Drive Positioning Module (04.97 Edition)

Order in conjunction with Configuring Package

/S7M/ SIMATIC S7-300

FM 357 Multi-Axis Module for Servo and (10.99 Edition)

Stepper DrivesOrder in conjunction with Configuring Package

/SHM/ SIMODRIVE 611Manual (01.98 Edition)

Single-Axis Positioning for MCU 172AOrder No.: 6SN 1197-4MA00-0BP0

/SP/ SIMODRIVE 611-A/611-D

SimoPro 3.1Program for Configuring Machine-Tool Drives

Order No.: 6SC6 111-6PC00-0AA❏

Order from: WK Fürth

A 08.00 Appendix

References A


d) Installation and start-up

/IAA/ SIMODRIVE 611A

Installation and Start-Up Guide (04.00 Edition)

Order No.: 6SN 1197-0AA60-0BP5

/IAC/ SINUMERIK 810D


(incl. description of SIMODRIVE 611Dstart-up software)Order No.: 6FC5 297-4AD20-0BP0

/IAD/ SINUMERIK 840D/SIMODRIVE 611D


(incl. description of SIMODRIVE 611Dstart-up software)Order No.: 6FC5 297-6AB10-0BP0

/IAF/ SINUMERIK FM-NC



/IAM/ SINUMERIK 840D/840Di/810D

MMC Installation and Start-up Guide (10.00 Edition)


IM1 Start-up functions for the MMCIM3 Start-up functions for the MMC 103IM4 Start-up HMI Advanced (PCU 50)HE1 Editor helpBE1 Supplement operator interface

A Appendix 08.00

References A


Notes

A 08.00 Appendix

Index A


D Index

33D probe 2-503D representation 5-2183D tools 2-773-plane view 5-216

AAbsolute dimension 1-30Absolute dimensioning 3-97Access authorization 1-24Additional commands 3-113Alarms

Cycles 7-250ShopMill 7-257ShopMill 7-255

Allowance 3-110Alphanumeric keypad 1-17Alternat. 1-31, 3-106Angle for tapered milling tools 2-77Annular slot 3-175Approach a cycle 3-107Approach mode 3-121Approach strategy 3-121Area switchover key 1-17ASCII editor 4-204Automatic mode 2-62Auxiliary functions 2-63Axes 3-97Axis

Position 2-59

BBase offset 2-90Basic angle of rotation 3-154Basic offset 2-47Blank 3-104Blank dimensions 5-214Block search 2-66Boring 3-145

CCalibrate the workpiece probe 2-54Center 8-270Centering 3-124Centering 3-141Center-point path 3-121

Chaining 3-100Chamfer 3-113Change the tool type 2-87Change view 5-218Change viewport 5-218Chip breaking 3-143Circle 3-117

Polar 3-138With known center point 3-133With known radius 3-134

Circular pocket 3-167, 8-272Circular spigot 8-278Circular spigots 3-171Circumferential slot 8-270Circumferential slot 3-175CNC operation 2-94Comment 3-200Complete machining 3-106Conditional stop 2-68Contour

Close 3-116New 3-112

Contour element 3-116Contour milling 3-111Coolant 2-83Coordinate system

Rectangular 1-29Corner point 3-104Correction/cursor keypad 1-17Create tool wear data 2-84Cutter radius compensation 3-98Cutting plane 5-219Cutting rate 3-98, 3-110Cylinder peripheral surface transformation

3-115, 3-191

DD1 3-110D2 3-110Deep-hole drilling 3-143Define a blank 3-199Define search target 2-66Define the starting point 3-112Dialog selection 3-115

A Appendix 08.00

Index A


Disable magazine location 2-86DR 3-110DRF offset 2-91Drilling 3-140, 3-142Dry run 2-68Dry run feedrate 2-69Duplo number 2-75

EEdge probe 2-48, 2-49Emergency Stop 1-20Equidistant path 2-82Example

Cylinder peripheral surface transformation8-280

Drilling 3-159Face milling 3-163Free contour programming 3-118Polar coordinates 3-139Position pattern for milling 3-178Rectangular pocket 3-166Slot side compensation 8-283Thread cutting 3-149

Examples 8-266, 8-274, 8-277Execute 2-62

FFace milling 2-60, 3-161Feed control 1-22Feed Start 1-22Feed Stop 1-22Feedrate 3-99, 3-106Feedrate override 1-22Finish 3-129Finish cutting 2-60Finishing 3-106Fixed location 2-85Free contour programming 3-111, 3-112Function keys 1-19

GG code 3-113G code 3-200G code program 4-204G functions 2-63Gear stage 2-45Graphics interface 1-28Graphics monitor 1-17GUD 4-208

HH functions 2-63H number 2-75, 4-211

Helix 3-135Help display 3-101

IInc 1-21Inch/metric 3-97Inch/metric switchover 1-33Inch/mm 2-46Increment 2-40Increment size 1-21Increment value 1-21Incremental dimension 1-31Incremental dimensioning 3-97Information key 3-102Insertion 3-165Inside contour 3-113Inside thread 3-147ISO dialect 2-75ISO dialects 4-211

KKeyswitch 1-24

LLength allowance 2-84Line 3-131

Polar 3-137Location assignment 2-76Location number 2-75Longitudinal slot 3-173LUD 4-208

MM functions 2-63Machine control panel 1-20Machine coordinate system 1-34Machine functions 1-21Machine zero 2-90Machining direction 3-105Machining feedrate 3-99Machining plan 3-101Machining plane 2-45Magazine 2-86Magazine list 2-86Manual mode 2-40, 2-59Manual mode 2-40Manual tools 2-79Marker 3-183Marking 8-274MCS 1-22MCS/WCS 1-34MDA mode 2-61Measurements 3-180

A 08.00 Appendix

Index A


MessagesCycles 7-254

Metric/inch 3-97Metric/inch switchover 1-33Milling 3-161Mini handheld unit 1-26Mirroring 8-275Mirroring 3-190mm/inch 2-46

NNC Start 1-25NC Stop 1-25No. of loadings 2-85Number of teeth 2-83

OObstacle 3-157, 8-271Offset 8-275

Programmable 2-90Offset value 3-110Offset values 2-82OP 031 1-17OP 032S 1-18OP031 slimline operator panel 1-17OP032S slimline operator panel 1-18Operating modes 1-21Operator components 1-17Outside contour 3-113Outside thread 3-147

PParameters 3-115Password 1-24Path milling 3-111, 3-120Plan view 5-215Plane designations 1-29Pocket calculator 1-32Pocket with islands 3-111, 3-126, 3-129Polar coordinates 1-30, 3-136Pole 3-136Position

Freely programmable 3-151Position

Repeat 3-158Position pattern

Full circle 3-154Line 3-152Matrix 3-153Milling 3-177Pitch circle 3-156

Position value 2-47

Positioning 3-150Positioning motions 3-131Positions 8-271Power OFF 2-37Power ON 2-37Program

Abort 2-64Correct 2-73Execute a trial run 2-72Interrupt 2-65Select for execution 2-63Start 2-64Stop 2-64

Program block 3-100Change 3-108Copy 3-108Delete 3-108Find 3-109Move 3-108New 3-106Paste 3-108Paste 3-108Repeat 3-183

Program blocksMark 3-108

Program control 1-25, 2-68Program header 3-100, 3-103Program name 3-103Program structure 3-100Programming graphic 3-101, 3-114PUD 4-208Punched tape/ISO format 4-211

RR parameters 4-207Radii allowance 2-84Radius 3-113Rapid traverse 2-59Rapid traverse override 1-22Reaming 3-142Recall 1-17Rectangular pocket 3-164, 8-269Rectangular spigots 3-169Ref 1-21Reference point approach 2-38Remote diagnosis 2-94Remove residual material 3-111Repeat 3-183Repetition 8-276Replacement tool 2-79

A Appendix 08.00

Index A


Repos 1-21, 2-65Reposition tool on contour 2-65Reset 1-25Residual material 3-127Retract tool from contour 2-65Retraction mode 3-121Retraction strategy 3-121Retraction withposition patterns 3-105Return plane 2-59, 3-104, 3-184Right-hand rule 1-29Rotation 3-188Rough cut 3-126Rough cutting 2-60Rough drilling 3-123Rough-drill 3-111Roughing 3-106Rounding radius 2-77

SS 3-110Safety clearance 2-59, 3-104, 3-184Scale 2-92Scaling 3-189Scratching 2-56Select the alarm overview 7-256Select the message overview 7-256Sensor probe 2-48Setup feedrate 2-40Setup, manual 2-50Setup, manual 2-49ShopMill 1-16, 2-94ShopMill program 3-97Simulation 4-206, 5-214

Abort 5-215Start 5-214

Simultaneous recordingBefore machining 2-70During machining 2-71

Single block 1-25, 2-72Deselect 2-72

Skip block 2-69Slot side compensation 3-191Solid machine 3-126Sort block numbers 3-109Special function

Tool 2-83Special functions 2-45Spindle

Position 2-44Start/stop 2-44

Spindle control 1-23Spindle direction of rotation 2-83Spindle override 1-23Spindle speed 2-44, 3-110Spindle speed 3-98Spindle Start 1-23Spindle Stop 1-23Status display 2-70Stock removal 3-143Straight line 3-117Subroutine 3-183Swiveling 3-194, 8-289

TT, F, S 2-63Tangent 3-115Tapping 3-146Thread cutting 3-147Three-dimensional representation 5-218Tool

Accept from tool list 2-56Change 2-41create new 2-77Delete 2-87Disable 2-85Load 2-87Load in magazine 2-43load new 2-42Measure 2-56, 2-57Measure 3-182Oversized 2-85Program 3-110Program 3-97Sort 2-89Unload 2-88

Tool axis 2-45Tool length compensation 2-81, 3-97Tool life 2-85Tool list

Select 2-76Tool list 2-74Tool magazine 2-76Tool monitoring 2-85Tool name 2-79Tool offset 2-80Tool offset block for edge 2-78Tool offsets 2-74Tool probe 2-57

Calibrate 2-58Tool radius compensation 2-81, 3-98

A 08.00 Appendix

Index A


Tool status 2-86Tool type 2-75Tool wear list 2-76Tool zero 2-90Tools 2-74Total offset 2-91Transition element 3-113Traverse at rapid rate 3-99Traverse axes 2-40

UUnit of measurement 3-104Update view 5-219User data 4-208

Define 4-208

VV 3-110Variable

Global 4-208Local 4-208Program-global 4-208

WWCS 1-22

WCS/MCS 1-34Workpiece

Measure 3-180Zero point 3-180

WorkpieceSet up 2-48

Workpiece coordinate system 1-34

ZZero offset 2-48

Deselect 2-93Display 2-91Programmable 3-187Select 2-93Settable 2-90, 3-186Settable 2-93

Zero offset list 2-48Zero offsets 3-185Zero offsets 2-90Zoom 5-217

A Appendix 08.00

Index A


Notes

ToSIEMENS AG

Suggestions

Corrections

A&D MC BMSP.O. Box 3180D-91050 ErlangenFederal Republic of Germany(Tel. 0180 / 525 - 8008 [Hotline]Fax ++49-9131/98-1145email: [email protected])

for Publication/Manual:

SINUMERIK 840D/810D

ShopMill

User Documentation

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