How can workpieces be machined quickly and even more cost-effectively?

Transcription

1 How can workpieces be machined quickly and even more cost-effectively? SINUMERIK the turning and milling solution for the shopfloor Answers for industry.

2 Contents CNC solutions for the shopfloor using SINUMERIK 03 SINUMERIK from simple up versatile, the perfect CNC platform SINUMERIK 828D compact, powerful, simply brilliant SINUMERIK 840D sl open, flexible, powerful packed with innovations SINUMERIK Operate the new user interface Operation, programming and setup same look and feel, whether turning or milling Milling with SINUMERIK 10 Turning with SINUMERIK 12 Data and facts milling functions, SINUMERIK Operate Data and facts turning functions, SINUMERIK Operate Tips and tricks when using SINUMERIK Operate

3 CNC solutions for the shopfloor using SINUMERIK Do you want everything to run smoothly on your shopfloor? Do you want to schedule and process your orders while meeting and exceeding quality standards? Do you want to manufacture small batch sizes economically? Then SINUMERIK is the right choice for you. Special expertise for the shopfloor Behind SINUMERIK, there are machine tool control systems, drives and motors, as well as complete solutions for machine tool automation. Used in many industries, this is the expertise that we have specifically implemented for the shopfloor and in turn, for your applications. Two control systems for turning and milling With SINUMERIK 828D and SINUMERIK 840D sl, Siemens offers you two numerical controls from the SINUMERIK family of control CNCs. They combine the flexibility and benefits of conventional machining with the productivity and cost-effectiveness of a CNC machine. Designed for the typical shopfloor, these solutions will decisively improve operations with CNC turning and milling machines. SINUMERIK Operate The new SINUMERIK Operate user interface is now even more transparent and intuitive. It combines the well-known HMI Advanced, ShopMill and ShopTurn under one standard, innovative operating and programming interface. SINUMERIK Operate is equipped with a multitude of new and powerful functions and sets new standards when it comes to operation to achieve perfect usability. Programming and operation have never been so simple, tailored to the requirements of trained operators in the field and easy-to-use, even for beginners. 3

4 SINUMERIK from simple to versatile, the perfect CNC platform SINUMERIK 828D compact, powerful, simple, and simply brilliant This panel-based numerical control has been tailored to address sophisticated turning and milling machines that are typically used on the shopfloor. The range of applications extends from vertical and basic horizontal machining centers, up to slant bed lathes with machining slides, equipped with Y-axis and counter-spindle. Both the operator panel and CNC are combined in a rugged and maintenancefree unit. With extremely small dimensions, the SINUMERIK 828D offers powerful CNC functionality, which sets new standards in the compact CNC class. Equipped with a comprehensive CNC programming package, the SINUMERIK 828D is optimally prepared for every global machine tool market. Additionally, technology-specific, pre-configured system software and intelligent service functions allow the costs for commissioning and maintenance of the machines to be drastically reduced. SINUMERIK 828D at a glance: Compact CNC operator panel with horizontal and vertical operator panel layout options Up to 6 axes/spindles (milling) and 8 axes/spindles (turning) in one machining channel 80 bit NANOFP precision Operator panel with 10.4 TFT color display Programming support, programguide Machining step programming ShopMill/ShopTurn Operation and programming support using animated help graphics with moving images Setup with innovative measuring cycles SINUMERIK MDynamics for 3-axes (milling version) Customized system software versions for turning and milling with parameter pre-assignment Process monitoring using text messages (SMS) 4

5 SINUMERIK 840D sl open, flexible, powerful, and packed with innovation SINUMERIK 840D sl offers modularity, openness and flexibility, as well as standard structures for operator control and programming. It provides a system platform with leading-edge functions for almost every technology. Integrated into the SINAMICS S120 drive, and supplemented by the SIMATIC S7-300 automation system, the SINUMERIK 840D sl is a complete, digital CNC system. SINUMERIK 840D sl sets itself apart as a result of the high degree of flexibility, highest dynamic performance and precision, as well as optimum integration into networks. SINUMERIK 840D sl at a glance: Drive-based CNC for sophisticated and demanding solutions Ideal for up to 31 axes/spindles in 10 machining channels 80 bit NANO FP precision 7.5 /10 /12 /15 TFT operator panel fronts Programming support using programguide Machining step programming ShopMill/ShopTurn Operator control and programming using animated graphics Setup using innovative measuring and setting-up cycles SINUMERIK MDynamics 3-axis/5-axis technology packages Several operator panels can be connected to a CNC Tool management functions SINUMERIK Safety Integrated safety functions Multi-channel programming double editor programsync for time synchronization 5

6 SINUMERIK Operate for efficient machine operation SINUMERIK Operate advantages at a glance: Standard user interface for all new SINUMERIK CNC systems Perfect operating and programming usability Transparent, can be intuitively used Optimum display using a modern Windows style With new powerful functions for setup, programming, tool and program management Programming solutions to address each and every requirement and the highest productivity New functions for complete machining Highest degree of operator-friendliness The new SINUMERIK Operate user interface is equipped with a multitude of new and powerful functions. This allows machining step and high-level language programming to be combined under one system interface; therefore, facilitating a very logical and intuitive NC programming and production planning. Faster from the drawing to the finished workpiece Whether you are setting up, programming or machining parts with SINUMERIK Operate, you are supported by a visual, userfriendly display showing the various tasks as well as graphical help displays and animation when operating your machine. 6 With Animated Elements for milling and turning applications

7 Programming the way you like it SINUMERIK Operate offers unique programming methods for every application. This includes the ShopMill/ShopTurn machining step programming, as well as the SINUMERIK high-level language with programguide. ISO-code programming is also supported. SINUMERIK high-level language with programguide CNC programming for the highest degree of productivity The SINUMERIK high-level language with programguide has been developed to provide the maximum degree of flexibility and short machining times. It is well-suited for medium- to large-batch sizes. programguide guarantees a maximum of productivity and flexibility when it comes to programming, combined with innovative technology and machining cycles CNC language with high-level programming commands programguide with graphic cycle support screens including tooltip (brief, context-related information) Online ISO dialect interpreter is available Machining step programming with ShopMill and ShopTurn ShopMill and ShopTurn machining step programming is the tailored programming solution for the production of individual parts and small-batch quantities. In addition to programguide, the unique machining step programming allows the shortest programming times to be achieved. Machining steps are clearly displayed without requiring any knowledge about G-code Technology functions are simply linked using geometrical elements The workpiece is dynamically displayed during programming 7

8 Intuitive programming, operation and setup whether milling or turning Parameters, which are entered into a CNC on a daily basis, control machine motion. Using static help graphics, this motion can only be displayed with some restrictions. This is the reason that SINUMERIK with Animated Elements offers a completely new level of user-friendliness when it involves data input. It completely redefines the term graphical programming and operation, thanks to a unique type of display using moving image sequences. Transparent tool and program management also provide useful support. Turning and milling with the same look and feel Intelligent HMI functions support you with the highest efficiency in your daily work. The optimum display in the modern Windows style is also user-oriented. In addition, the user interface sets new standards when it comes to graphic support. In this case, Animated Elements provide a helpful function they predict each machining step in the form of a graphically animated simulation. But the best is yet to come: whether milling or turning, the user interface is almost identical and allows you to change between a turning and milling machine with extremely short training time, facilitating fast, productive entry into the system. 8

9 Tool and program management made easy SINUMERIK offers you a modern and transparent tool and program management functionality. The tool list has a configurable display and uses context-dependent functions with self-explanatory symbols that can be intuitively used and displayed for efficient tool data management. Using innovative program management, you can create subfolders for workpieces in local drives and directly access external data storage media. Users benefit from fast program preview, user-friendly data transfer, as well as simple program handling. 9

10 Milling with SINUMERIK Our SINUMERIK controls, in conjunction with the new user interface are precisely the right choice if you are looking for a solution with comprehensive functions for milling. As a result of their outstanding performance and flexibility, the controls are also admirably suited for the tool- and mold-making industries, and with the SINUMERIK 840D sl, also five-axis simultaneous machining, too. The SINUMERIK Operate user interface, ShopMill and programguide are designed so that machines can be simply operated and workpieces easily programmed. You benefit from standard and integrated CNC solutions with the same look and feel, no matter if you are milling or turning. Extended setup functions With the right tools, machine tool setup is a simple procedure. The functions in manual operation mode allow the machine to be quickly set up for machining exactly what is required. For example, this includes determining the workpiece position in the machine, as well as measuring the tools used. Manual and automatic measuring functions are available to measure both workpiece and tool. Automatic measuring cycle in programguide and ShopMill Input screen forms with graphic support and automatic logging of the measurement results Measuring in JOG on a five-axis milling machine Aligning the rotary axis over two holes Swiveling during setup Complex workpieces can be machined in one clamping operation through simple and fast handling. Different kinematics can be very easily set up. Swiveling can be realized axis-by-axis and directly including the optional coordination rotation. 10

11 SINUMERIK Operate milling at a glance User-friendly feature with a graphical machining step editor Perfect input support using animated elements Dynamic broken-line graphics for complete workpiece and cycle screen forms Wide selection of standard drilling, milling and turning cycles Contour computer makes it easy to input geometrical workpiece contours Cycles for contour milling with residual material detection Process measuring for workpiece and tool High-speed cutting (HSC) functions and complete machining with swivel and transformation Powerful 2-D and 3-D CNC simulation Technology cycles for standard machining operations Whether drilling, position pattern or milling using the standard technology cycles, you can simply address a high percentage of the shopfloor programming requirements by parameterizing practical cycles. You can also effectively use special cycles from the CAM area such as trochoidal milling and plunge milling. Using the new multi-edge cycle, by entering the number of edges or width over flats, you can generate a multi-edge with any number of edges. Centering, drilling, reaming, tapping, thread-cutting Position pattern line, grid and circle Milling cycles for pockets, holes, grooves, spigots and multi-edge SINUMERIK MDynamics milling expertise as a package SINUMERIK MDynamics combines all of our expertise around milling, the powerful SINUMERIK CNC hardware, intelligent CNC functions and our unique CAD/CAM/CNC process-chain in technology packages for three-axis and five-axis milling. With Advanced Surface, SINUMERIK MDynamics guarantees perfect surfaces through innovative motion control and an optimized NC data compressor, fast adaptation to the workpiece, tool and program handling, and optimum machining using the flexible programguide programming technique and ShopMill. This allows you to achieve the shortest programming times possible. 11

12 Turning with SINUMERIK With the combination of modern CNC hardware and SINUMERIK Operate, even sophisticated turning operations can be easily and reliably mastered. Even for complex machines with B-axis and counter-spindle, you always have operation and programming under control. With the SINUMERIK Operate user interface, you have various programming types available that you can use, such as the ShopTurn machining step programming or the SINUMERIK high-level language with programguide. Our programguide is the perfect combination of SINUMERIK CNC programming language and the parameterization of technology cycles. Even multi-channel machining operations are now easy-to-program and synchronize thanks to programsync. Optimal support at your fingertips Whether you are setting up, programming or machining, SINUMERIK Operate, and especially ShopTurn, optimally reflect the way the machine operator views the work sequence. Visual, user-orientated presentation of job tasks in line with user requirements support you when operating the system using graphical help displays and animation. The machining plan displays every step such as roughing, finishing, drilling, milling, tapping or grooving. Would you like additional support for operation and programming? Not a problem complete documentation can be called up at the control in a context-sensitive fashion so that you are always on top of the situation. Setup is easy With SINUMERIK Operate, tool and workpiece setup are straightforward thanks to the functions in manual mode. These include determining the workpiece zero points in the machine, as well as measuring the tools used. Manual measuring and automatic measuring are available as functions. After setup, all of the tools are clearly listed in a tabular form in the tool manager. You even have various views for the work offsets, e.g. all active offsets are displayed in one window. 12

13 SINUMERIK Operate turning at a glance User-friendly feature using a graphical machining step editor Perfect input help using animated elements Dynamic broken-line graphics for complete workpiece and cycle screen forms Wide selection of standard drilling, milling, turning and plunge turning cycles A geometry computer makes it simpler to input workpiece contours Contour turning and milling with residual material detection Process measuring for workpiece and tool Complete machining with counter-spindle and transformation at the face and peripheral surfaces, as well as machining inclined surfaces (B-axis) Powerful 2-D and 3-D CNC simulation programsync for multi-channel programming Contour computer in combination with turning/milling cycles Special technology cycles are available for standard elements such as grooves. When things get a little bit more difficult, using the contour calculator, you can generate any geometrical contours directly at the machine and then link these with the contour turning or contour milling cycles. Programming is completed in just two work steps. Painting by numbers even for difficult contours Converting contours and position patterns into the DXF format using the CAD reader with further processing in the contour calculator Linking contours with stock removal cycles Automatic residual material detection From the real environment fast and effective plunge turning Generally, difficult contours involving elements with negative gradients require a large number of tools, for example to machine from the left or right. This involves time and resources when making the appropriate measurements, and normally the number of tools is limited by the turret. With plunge and plunge turning cycles, you can machine the complete contour using just one tool and this is even more productive as setup and tool change are eliminated. When programming, just as usual, you generate the contour and then link this with the plunge turning cycle. No additional programming is required and you move quickly from the drawing to the workpiece. 13

14 Milling functions SINUMERIK Operate data and facts Graphical programming, ShopMill Transparent, clearly structured programming in machining steps Programming without DIN/ISO know-how Easily understandable symbols to display the machining steps Linking of contours with solid machining cycles Linking of drilling and milling operations with position patterns Automatic measuring cycles for workpiece, tool Simple modification, insertion and deletion of machining steps Significant reduction of the programming time when compared to DIN/ISO programming Dynamic broken-line graphics for displaying workpieces true-to-scale Dynamic help graphics as input support for cycle parameters Contour programming Powerful contour calculator for creating contours in the milling plane Automatic calculation of partially defined geometrical elements True-to-scale representation of contours with up to 255 contour elements Importing DXF files via an optional CAD reader is possible Machining cycles Milling cycles for free contours Solid machining of contour pockets with up to 12 isolated contours Machining of contour spigots with up to 12 isolated contours Automatic detection and follow-up machining of residual material Automatic or manual specification of machining start point with possibility for pre-drilling Plunge strategy: linear, diagonal, helical Combined countersinking/thread milling Engraving of any texts Open groove for trochoidal milling and plunge milling Drilling cycles Centering, reaming, boring Boring with chip break and stock removal function Tapping with chip break and stock removal function High-speed settings Moldmaking cycle for the selection of the machining type and contour tolerance Position pattern Any position pattern in the milling plane Position patterns such as line, circle or grid Complete machining Swivel cycle Any drilling and milling machining in swiveled machining planes on 5-axis milling machines Flexible input of swivel angle in the workpiece coordinate system (axis, solid or projection angle) or direct axis input Multi-channel programming 840D sl Double editor DIN/ISO programming and programguide Full program editor to flexibly generate DIN/ISO programs programguide for standard machining cycles Input support for automatic measuring cycles Simulation/simultaneous recording 5-axis simulation Powerful simulation of machining steps and DIN/ISO programs Presentation in plan view, 2-side view and 3-D view Simultaneous recording in the automatic mode Program management Direct access to external data storage media including network drives Part programs with plain text, max. 24 characters Subdirectories for workpieces in local drives Program preview Work offsets All active adjustable and programmable WO in one overview Rotation, scaling, mirroring also as screen Display of the offsets of the active swivel data set Setup functions Menu-prompted probing function to determine work offset, also in swiveled machining planes Tool measurement using scratching or tool probe Face milling cycle for workpiece preparation Swivel cycle for setup and measurement tasks Automatic functions Block search also for defined machining operations in position patterns Traversing path display of machining steps in G-code (basic block display) Feed reduction using program control for rapid traverse motion Accessories PC training and programming software CAD reader for the PC CNC systems SINUMERIK Operate is available on the following CNC systems: SINUMERIK 840D sl SINUMERIK 828D Milling cycles for standard contours Multiple-edge spigots Face milling cycle with lateral limitation Rectangular and circular pockets with different plunge strategies Rectangular and circular spigots Longitudinal and circular grooves Thread milling 14 Tools Tool types shown as symbols Tool and magazine data on one screen including details Tool name as plain text or number with max. 24 characters Efficient management of the tool data including all the details and replacement tool handling

15 Turning functions SINUMERIK Operate data and facts Graphical programming Transparent, clearly structured programming in machining steps Programming without DIN/ISO know-how Easily understandable symbols for displaying the machining steps Linking of contours with stock removal cycles Linking of drilling and milling operations with position patterns Automatic measuring cycles for workpiece, tool Simple modification, insertion and deletion of machining steps Significant reduction of the programming time when compared to DIN/ISO programming Dynamic broken-line graphics for displaying workpieces to scale Dynamic help graphics as input support for cycle parameters Contour programming Powerful contour calculator for creating turning and milling contours Automatic calculation of partially defined geometrical elements Automatic calculation of grinding allowances, also with negative values Importing DXF files via an optional CAD reader is possible Machining cycles Stock removal cycle Stock removal for freely definable contours Axis- and contour-parallel roughing and finishing Automatic detection of residual material Stock removal cycle for plunge cutting and plunge turning of freely definable contours Freely definable blank contour Grooving/undercut cycles Grooving cycle for any trapezoidal grooves Undercut cycle for any threads and DIN threads Undercut shape E, shape F Thread-cutting cycle Face, longitudinal and tapered threads Constant and variable pitch Linear and degressive infeed Multiple-thread machining Drilling cycles Centering, deep-hole drilling and tapping with stationary tools Any drilled holes on face and peripheral surfaces with driven tools Milling cycles Any milling operations on face and peripheral surfaces Standard geometry such as circular and rectangular pockets Multi-edge Solid machining cycle for free geometries with residual material detection Engraving any texts Open groove for trochoidal milling and plunge milling Position patterns Any position patterns on face and peripheral surfaces Position patterns such as line, circle or grid Counter-spindle machining Counter-spindle cycle with graphic input Automatic workpiece transfer Swiveling B-axis Milling and drilling on swiveled planes Turning with swiveled tools Multi-channel programming, 840D sl Double editor and programsync DIN/ISO programming and programguide Full program editor for flexible creation of DIN/ISO programs programguide with standard machining cycles Input support for automatic measuring cycles (optional) Program management Direct access to external data storage media including network drives Part programs with plain text, max. 24 characters Subdirectories for workpieces in local drives Program preview Work offsets All active adjustable and programmable WO in one overview Rotation, scaling, mirroring also as screen Tools Tool types shown as symbols Tool and magazine data on one screen including details Tool name as plain text or number with max. 24 characters Efficient management of the tool data including all the details and replacement tool handling Setup functions Menu-prompted scratching function to determine work offset Tool measurement by scratching or with probe Universal turning cycle for applications such as hollowing out soft end pieces Automatic functions Block search also for defined machining operations in position patterns Display of traversing paths of machining steps in G-code (basic block display) Accessories PC training and programming software CAD reader for the PC CNC systems SINUMERIK Operate is available on the following CNC systems: SINUMERIK 840D sl SINUMERIK 828D Simulation Powerful simulation of machining steps and DIN/ISO programs Presentation in turning plane, face and 3-D view 15

16 Tips and tricks for SINUMERIK Operate See exactly how the helpful functions of SINUMERIK Operate can make your production environment even more efficient. The best tips and tricks for the new SINUMERIK user interface are explained. Language-independent help can be called up in every screen using the Help key. Using short film sequences, animated elements offer a high degree of user-friendliness when it comes to operation and programming. Vertical softkeys on the right-hand side can all be used as switch-on/switch-off element. Grayed-out softkeys indicate that the function cannot be presently used. Undo function with Insert as long as an input key has not been pressed or data have not been accepted in the fields. insert Tips as simple help in every screen are displayed in red when incorrect entries are made on screen. Select option with the insert key and/or using any other key. 16

17 Calculator function can be called using the = function. Zero offsets can be written from the ShopTurn program header. All cycles can be recompiled using the right arrow key. ShopTurn and ShopMill cycles can also be defined using parameters. Cycles can be edited without recompiling using: shift insert 17

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19 Functions softkeys shortcut keys Your overview of the most important shortcut keys Control key CTRL P Create screenshot CTRL L Toggle between languages CTRL C Copy CTRL X Cut Insert key CTRL V Insert insert insert Edit mode of input fields or selection mode of combo boxes and toggle fields. These can be exited without any change by pressing Insert again. Undo function, as long as an input key has not been pressed or data have not been accepted in the fields. CTRL Y Repeat input (editor functionality) CTRL Z Undo function max. 5 lines in the editor (editor functionality) CTRL A Select all (editor functionality) Toggle key CTRL Go to the start of program. select You can also directly change over toggle fields using the toggle key (Select) without opening them. You can scroll through them backwards using Shift-Toggle. CTRL END Go to the end of program. CTRL ALT D Backup log files on USB or Compact Flash (CF) card Cursor keys Simulation/simultaneous recording Open/close folder, open/close program, open/close cycle Various Shift: Shift cursor up/down and rotate in the 3-D screen shift insert Commenting out cycles and directly editing programguide cycles Calculator function CTRL or Shift cutout Override +/ (simulation) Help function CTRL S Single block on/off (simulation) 19

20 Want more information? Everything you want to know about SINUMERIK CNC: Everything about shopfloor manufacturing: Information about CNC training: Siemens AG Industry Sector Motion Control Systems P.O. Box ERLANGEN GERMANY Subject to change without prior notice Order No.: E20001-A850-P610-V Dispo WÜ/29070 GD.MC.MT.STAN WS Printed in Germany Siemens AG 2011 The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteris tics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.