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Multitasking with SINUMERIK For complex and demanding turn-milling and mill-turning applications

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Contents

SINUMERIK 840D sl 4

Operation and programming with SINUMERIK Operate 5

Innovative cycles for multitasking 6

Innovative cycles for 5-axis machining 8

Workpiece simulation for turn-milling and mill-turning 10

Process chain 12

Technological competence 14

Technical information — an overview 15

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Leading-edge multitasking with SINUMERIKSeamlessly integrated in SINUMERIK OperateBased on SINUMERIK Operate, multitasking machining is seamlessly supported across all technologies. Irrespective of whether series production or shopfloor operation: tool management supports the various tool types when milling and turning, the NC is programmed with DIN/ISO and cy-cles in programGUIDE or graphically in ShopMill/ShopTurn;

in SINUMERIK Operate workpieces can be simulated, both for turn-milling as well as for mill-turning. This means that Siemens offers an attractive package for complete machining and the preconditions for efficient and highly productive CNC machining.

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SINUMERIK 840D sl – ultimate performance in the premium class

SINUMERIK 840D sl is considered to be the standard in

premium class CNC, which is certainly justified.

Maximum CNC performance, along with a degree of

flexibility and openness that has not been able to

be achieved until now, are the basis for almost any

CNC machine.

Maximum performanceThe SINUMERIK 840D sl offers an almost inexhaustible performance potential – thanks to its drive-based, high-performance NCUs (Numerical Control Units) with state-of-the-art multicore processor technology. This means that up to 93 axes in 30 machining channels can be controlled in the NCU link. Machine tools with fewer axes benefit from the performance of the SINUMERIK 840D sl as a result of the highest degree of machining precision with the shortest machining times.

Demanding turning and milling applications …High-speed milling and turning are two of the strengths of the SINUMERIK 840D sl. The milling spectrum extends from highly productive machining centers for powertrain manufacturing in the automotive industry, up to high-speed 5-axis machining centers for moldmaking in the aerospace industry. The turning spectrum extends from multi-channel 5-axis turning centers with B-axis up to highly productive multi-spindle applications.

… are part of the wide technology spectrumBeyond turning and milling applications, the SINUMERIK 840D sl can address an almost inexhaustible range of technologies ranging from grinding and laser machining, through gearwheel, up to multi-tasking machining. The SINUMERIK 840D sl is even the first choice for new engineering and manufacturing applications including tapelaying and composites for the aerospace industry.

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SINUMERIK Operate – the state-of-the-art operating concept for the 21st century

Interactive input with Animated ElementsWith Animated Elements, SINUMERIK Operate makes it very easy to enter parameters. Animated Elements completely redefine what graphic pro-gramming and operation really mean – using a unique display with moving image sequences.

Program manager for an enhanced overviewSimple data handling – just the same as when using a PC: SINUMERIK makes it possible with its program manager. Content in the DXF, BMP, PDF, JPG and HTML formats of various storage media are transparently displayed. CNC programs can be transferred from the data server to the CNC memory by simply copying and pasting. And now it has been made even simpler: Large moldmaking workpieces can be selected in the program manager, and directly executed via the company network, USB stick or CF card.

SinuTrain for SINUMERIK OperateThe SinuTrain NC programming station, which is identical to the control system, brings SINUMERIK Operate – including animated machine operator panel – to the PC. This facilitates convenient job preparation in a familiar work environment. NC programs can be directly generated here, and as a result of the original SINUMERIK CNC kernel, can be verified before they are transferred to the real machine. Users profit from a higher machine availability and reliability. Further, SinuTrain can be ideally used for train-ing machine operators on how to operate and program SINUMERIK – as well as for presenting and testing new SINUMERIK functions.

www.siemens.com/sinutrain

SINUMERIK Operate provides the highest degree of operator convenience at the machine tool –

therefore setting the standard for efficient machine tool operation. www.siemens.com/sinumerik-operate

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Turning cycleIn order that complex multitasking machines can be simply operated, the turning cycles were extended in programGUIDE and in ShopMill/ShopTurn. A graphic con-tour computer supports users when entering data, while parameterization is realized quite simply per dialog. This function is especially intuitive, as turning tools are dis-played in the form of symbols.

For the turning cycles function with ShopTurn and B-axis, aligned turning tools can be graphically and interactively programmed – in all of the available turning cycles. The approach angle of the B-axis and the positioning angle of the tool spindle are directly specified in the technology area of the cycle.

SINUMERIK cycles support users so that workpieces

can be even more simply and quickly programmed.

Also for complex machining tasks, extensive machining

steps can be handled faster and more simply by using

innovative cycles.

CYCLE800 swivel cycleUsing the CYCLE800 swivel cycle, machining operations can be simply programmed in the swivel plane (swivel table, swivel head). Also when using turning tools, this function – known from the milling domain – can be used on a milling machine to approach turning tools or aligning them, for example. CYCLE800 in an easily understandable version is available for multitasking applications. It per-fectly combines turning and milling on one user interface. Using swivel heads or swivel tables, inclined planes can be machined and set up – both manually as well as automati-cally. Transparent graphic displays provide support when parameterizing and/or programming.

Innovative cycles for multitasking

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Milling cycleMilling cycles with programGUIDE and B-axes are used to program on swiveled planes. After selecting the “Swivel plane” function in CYCLE800, a new machining plane is generated on which all milling functions can be gener-ated, also using cycles.

Milling cycles with ShopTurn and B-axis, allow workpieces to be milled on swiveled planes on a turning machine. Milling at the face or cylindrical surface is defined by selecting the plane in the cycle.

All milling cycles at a turning machine are identical with those in ShopMill.

Multi-channel cutting cycleContours can be machined in many ways using the intelli-gent CYCLE952 SINUMERIK cutting cycle. Powerful func-tions simplify machining. Automatic residual material detection ensures optimum cut distribution. The auto-matic feed interruption uniformly breaks the chip and removes it in a controlled fashion. 4-axis cutting with CYCLE952 is now also available on multi-channel turning machines. Further, the interpolation turning cycle can be optionally added, which allows corners at outer and inner contours to be cut, either longitudinally or transversely.

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Innovative cycles for 5-axis machining

5-axis milling is used for milling with aligned tools,

relief cuts or geometries arbitrarily located in space.

The three linear axes X, Y and Z – and two rotary axes

A, B or C are required.

The axes must be simultaneously controlled.

SINUMERIK – supports all kinematicsSINUMERIK has powerful functions that significantly simplify multi-axis programming and operation. For instance, the center point programming tool TRAORI, orientation smoothing ORISON and tool radius compen-sation CUT3DC – CUT3DF.

TRAORIUsing the dynamic 5-axis transformation TRAORI, SINUMERIK 840D sl transforms lathes into high-quality milling centers. On one hand, this allows universal multi-side machining in just one clamping operation. On the other hand, TRAORI ensures a dynamic but at the same time homogeneous orientation of the tool on the work-piece surface, therefore facilitating the machining of demanding moldmaking workpieces – also on lathes.

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3-D tool radius compensation CUT3DC – CUT3DFSINUMERIK supports handling and machining complex workpieces, for example, peripheral milling and face mill-ing with tool radius compensation in the 5-axis area.

Orientation smoothing for 5-axis milling with ORISON Using the “Smoothing of the orientation characteristic (ORISON)” function, orientation fluctuations are smoothed across several blocks. As a consequence, a smooth orien-tation and contour are achieved and in turn axes are smoothly and harmoniously traversed.

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Perfect simulation – so that it really is preciseSimulation in SINUMERIK Operate guarantees maximum process reliability and safety as the real geometries of the tools are always used. It goes without saying that the simulation shows the precise image of the required machining operation. Whether face or peripheral surfaces, swiveled workpiece planes or even machining in several channels. With the moldmaking quick view, even very large part programs can be displayed on the screen within seconds.

Turn-milling simulationIn turn-milling machines, milling and turning as well as workpiece measurement can be simultaneously simu-lated. 3-D stock removal simulation is also possible for workpieces with inclined surfaces (3+2-axis machining) or free-form surfaces (3 to 5-axis machining). Machining operations using counterspindles can also be simulated – as well as simulation across several channels. Simulta-neous recording of the machining operation is also possible in addition to simulation.

As the application becomes more complex and the

workpiece to be machined more expensive, then it

becomes that much more important to have a meaning-

ful and informative simulation: The virtual check of the

production process before machining avoids mistakes,

and helps to calculate the machining time before cutting

commences. Important to achieve an optimum result:

The simulation can be started and stopped at any time,

and relief cuts and hidden contours can be made visible.

Workpiece simulation for turn-milling and mill-turning

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Mill-turning simulationMill-turning machines have the same identical simulation and simultaneous recording options as turn-milling machines. Further, for milling machines with several rotary axes, which can be used as spindle for turning, the clamping parameters ensure the correct alignment of the unmachined part and the alignment with the simulation.

Quick moldmaking viewFor mill-turning machines, the Quick View for moldmak-ing allows programs with free-form surfaces to be quickly simulated. G0, G1, G2, G3, BSPLINE, POLY blocks and the display of vectors for 5-axis machining are supported. This applies when programming rotary axes as well as vectors.

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Always a reliable overview of the entire process chain

Machining complex workpieces always represents special

challenges when it comes to precise machining, perfect

surfaces and high process reliability. With SINUMERIK,

Siemens offers the complete range of innovative, seamless

solutions across the complete process – from job preparation

with CAD/CAM systems through control-specific

simulation up to CNC machining.

Efficient processes with SINUMERIKIn CNC production landscapes, the focus is especially on the process between the original product idea and the machined part. This process encompasses:

• Computer-supported product development at the CAD/CAM level

• NC program generation with optimum postprocessors• Simulation to check and optimize the manufacturing

process at the PC• Optimized efficient workpiece machining at the

machine tool

Computer-supported NC programming is based on NX CAM from Siemens PLM, for example. This offers extended programming functions to support the already powerful SINUMERIK functions. Already at the CAM level, the functions, cycles and options available with SINUMERIK are parameterized for the particular machining step. In addition to the portfolio of flexible NC program-ming methods, NX CAM also provides the possibility of managing data and establishing a data coupling to the shopfloor.

Manage MyPrograms and Manage MyTools, modules of the software suite SINUMERIK Integrate for production, facilitate efficient program and tool management across the complete production environment. This increases prod uction efficiency:

• Operators can load changes to NC programs or tool lists to the server

• The changes are compared and released at the job preparation

Central production data management:This saves time and increases the reliability of the inter-action between operators and job planners.

This process chain can even be implemented up to higher- level IT systems: This means that tools, their asso ciated components, holders and cutting edges can be intelli- gently managed and organized with an additional avail- ability analysis.

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Higher production efficiency• The optimized process chain – from designing a work-

piece in the CAD system up to CNC production – increases flexibility and productivity

• 100% offline verification/evaluation of NC programs is possible as a result of the original CNC kernel

• Production resources can be networked with SINUMERIK Integrate

• Production processes can be optimized through central-ized production data management

VNCK simulation for an optimum final result Even before the actual production at the machine, the production sequences can be simulated – based on the integrated SINUMERIK virtual NC kernel – and finally also optimized. With Run MyVNCK, Siemens makes it possible to set up a virtual machine: The new workpiece can already be run in at the virtual machine on the PC, while the real machine produces another part.

The machine operator can increase the cycle times and does not have to wait for machines to become available in order to test the new workpieces. As a consequence, he can optimize the production planning and utilization of his machines. The workpiece costs can be reliably cal-culated using the machining times calculated within the VNCK.

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SINUMERIK MDynamics – synonymous for outstanding milling results

Cutting-edge operation, unique technology cycles,

ultimate shopfloor programming and high-quality CNC

simulation – together with premium motion control –

combined in one package: This is the outstanding

SINUMERIK MDynamics milling package.

Advanced Surface and Top Surface to achieve maximum machine performanceAdvanced Surface and Top Surface are synonymous for milling at physical machine limits – with the highest velocity and precision, the best surface quality – and not only for moldmaking.

5-axis machining at the highest levelSINUMERIK CNCs offer the optimum kinematic transfor-mations for modern milling machines – from peripheral surface transformation with slot wall correction for cylin-drical workpieces, through statically-swiveled planes for multi-side machining, up to dynamic 5-axis transforma-tions (TRAORI) for demanding toolmaking, moldmaking and aerospace applications.

High-speed settingsThe user-friendly high-speed settings cycle simplifies parameterizing moldmaking applications. With just a few parameters, SINUMERIK is set to the machining task – roughing, finishing or pre-finishing – as well as the required machining tolerance.

The sum makes the differenceAdvanced Surface and Top Surface, high-speed settings, kinematic transformations, SINUMERIK Operate for efficient operating and programming as well as a com- prehensive portfolio of technology and measuring cycles create a unique set of highlights for demanding and sophisticated milling machines. And top-class milling has a name: SINUMERIK MDynamics.

www.siemens.com/sinumerik-mdynamics

Machining time: 281 sec Machining time: 231 sec

Velo

city

5-axis machining with TRAORI Surface quality

Precision Velocity

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SINUMERIK 840D sl

CNC operation

SINUMERIK Operate ●

Animated Elements ●

startGUIDE: graphical interactive commissioning, onboard tutorials

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User interface on NCU/PPU (Linux)/ PCU50 (Windows®)

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Training and offline programming tools ● (SinuTrain)

CNC programming

SINUMERIK CNC programming language with high-level language elements

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Online ISO dialect interpreter ●

programGUIDE ●

Technology cycles for turning, drilling, milling

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Cycles for process measurements (with cycle support)

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ShopMill/ShopTurn machining step programming

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Cycles for multitasking

CYCLE800 swivel cycle ●

Turning cycles ●

Milling cycles ●

CYCLE952 multi-channel cutting cycle ●

Cycles for 5-axis machining

TRAORI 5-axis transformation ●

ORISON orientation smoothing ●

3-D tool radius compensation CUT3DC – CUT3DF

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Simulation

3-D stock removal simulation 3+2-axis machining

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3-D stock removal simulation 3 to 5-axis machining

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3-D stock removal simulation counterspindle machining

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Simultaneous recording ●

Quick moldmaking view (Quick View) ●

Safety functions

SINUMERIK Safety Integrated ●

Technical data

SINUMERIK 840D sl

Configuration

Mechanical design Drive-based

CNC performance versions NCU710 NCU720 NCU730

Display size (TFT color display) 7.5" / 10" / 12" / 15" / 19"

Maximum number of axes/spindles 93

PLC adaptation control SIMATIC S7-300

Maximum number of machining channels/ mode groups

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CNC user memory, up to 22 Mbyte

Extended CNC user memory 100 Mbyte

Additional CNC user memory on hard disk 12 Gbyte

Axis functions

Acceleration with jerk limitation ●

Dynamic feed forward control ●

Dynamic Servo Control in the drive ●

Interpolation

Interpolating axes, up to 20

Linear, circle, helix ●

Splines ●

Advanced Surface ●

Top Surface ●

Look Ahead ●

Compressor ●

Tools/tool management

Number of tools/cutting edges, up to 1500 / 3000

Unit quantity/tool lifetime monitoring with management of replacement tools

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Compensations

Compensation of measuring systems and spindle pitch

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Temperature compensation ●

Other compensations (sag, volumetrics) ●

SINUMERIK synchronous architecture

Synchronized actions ●

Asynchronous subprograms ●

⦁ available (certain functions are available as CNC option, please ask your machine tool manufacturer)

Subject to change without prior notice Article No.: E20001-A1860-P610-X-7600 Dispo 06311 D&M/74396 V1.MKTECH.WES WS 09153.0 Printed in Germany © Siemens AG 2015

The information provided in this brochure contains me re ly general descriptions or characteristics of per-for m ance which in case of ac tual use do not always ap ply as described or which may change as a result of fur ther de ve lopment of the products. An obli-gation to provide the respective characteristics shall only exist if ex pressly agreed in the terms of contract.

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