Traceability NC-functions in 840 D G-Code (DRAFT) Julio Garrido Campos (jgarri@uvigo.

es) Vigo University

get_time()
Siemens840D Could translate directly into a write operation dumping (WRITE code o Procedure) into a LOG file the appropriate text, and any of the following 840D Variables (CNC internal variables) according with the standard definition of the function: $A_YEAR $A_MONTH $A_DAY $A_HOUR $A_MINUTE $A_SECOND $A_MSECOND. Validated and tested example code :

WRITE(ERROR,"LOGFILE", "WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND )
(Using the write function or any external-defined file writing procedure)

(Sinutrain 840 Screenshot)

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start_getting_max_deviaton_along_tool path()
Siemens840D Could be translated with the aid of a Siemens Synchronous Motion Action code, using several user variables (R parameters) to store user-defined values. In the examples, R[1], R[2],R[3] have been used to store X,Y,Z positions of the measured value as given by the encoders variables: $VA_IM[X], $VA_IM[Y] & $VA_IM[Z] R[5], used to store the actual max deviation path (following error), calculated as:
SQRT( POT($VA_LAG_ERROR[X])+POT($VA_LAG_ERROR[Y])^2+POT($VA_LAG_ERROR[Z])))

For each tool path segments, during its interpolation cycles, the previously stored R[5] value is compared with the new calculated deviation value, and if it is greater, R[5] and X,Y,Z positions are updated and recorded. This is done with the following sample code:

ID=1 WHENEVER ($R[5]<SQRT(POT($VA_LAG_ERROR[X]) +POT($VA_LAG_ERROR[Y])+POT($VA_LAG_ERROR[Z]))) DO TCICLO

1. ID=1, identifies the synchronous action as number 1, to be cancelled with the corresponding stop function. WHENEVER is the vocabulary word to indicate that that the action alter DO word should be performed each time the condition (in green is fulfilled) 2. TCICLO is a procedure/subroutine, programmed to store the current variables in the corresponding R-Parameters. 3. After each G-code block corresponding to a tool path segment and before the next motion G-code, recorded values are DUMPED to the log File (1 value per segment), via a WRITE command and the used variables (R-parameters) are reset to 0 to prepare the measure of the next tool path segment deviation value Validated and Tested example code (software tested, so no ability to obtain non cero $VA_LAG_ERROR[]):

G2X-27.299979Y-90.799979Z-84.74075CR=38.608 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE :" << R[5] << "POSITION: X" << R[1] << Y << R[2] << Z << R[3]) R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 MSG("SEGMENT-1 DEVIATION VALUE RECORDED")
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G1X-90.799979Y-27.299979 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION VALUE : ...") R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0

4. It would be necessary to add AP-238 information in the log to macth these values with the corresponding Ap-238 toolpath geometry.

stop_getting_max_deviaton_along_tool path()
Siemens840D Could translate directly into cancelling the previously started synchronous action

CANCEL (ID NUMBER)

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Sample Code executed in Sinutrain Sinumerik 840d.

;Sample Program (with M00 inserted to pause simulation at several points ) ;AP-238 STEP-NC MAIN PROGRAM ;N01 EXTERN WSSPINDL( INT, REAL ) ;N02 EXTERN WSTOOL( INT ) N03 DEF INT ERROR ; VARIABLE INITIALIZATION N04 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N10 T="PF25" N10 G17 G40 G53 G90 N11 MSG("TOOLCHANGEBEGINNING ") N12 MSG("TOOLCHANGEEND ") N13 MSG("FACE TOP OF PART") N14 MSG("BLANK STATEMENT for NC_COMPENSATION ") N15 MSG("") N16 M00 ; Workingstep 1: line 33 WS 1 ;N15 WSMODEON ;N17 WSTOOL( 1 ) N17 G70 ;N19 WSSPINDL( 3, 2000.00 ) ;N20 WS_FLOOD N18 G0X0Y0Z-2.54 N19 X-184.15Y143.51Z-55.88 N20 Z-80.772 N21 G1X-152.4F1016 N22 X152.4 N23 Y124.46 N24 X-152.4 N25 Y105.41 N26 X152.4 N27 Y86.36 N28 X-152.4 N29 Y67.31 N30 X152.4Y67.31 N31 Y48.26 N32 X-152.4Y48.26 N33 Y29.21 N34 X152.4Y29.21 N35 Y10.16 N36 X-152.4 N37 Y-8.89 N38 X152.4Y-8.89 N39 Y-27.94 N40 X-152.4Y-27.94 N41 Y-46.99 N42 X152.4 N43 Y-66.04 N44 X-152.4Y-66.04 N45 Y-85.09 N46 X152.4 N47 Y-104.14 N48 X-152.4 N49 Y-123.19

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N50 N51 N52 N53 N54 N55 N56

X152.4 Y-142.24 X-152.4 Y-161.29 X152.4 X177.8 G0Z-55.88

; Workingstep: line 123 WS 2 ; WRITE IN LOG FILE WS3 START TIME ; WRITE COMMAND (N59) N57 WRITE(ERROR,"LOGFILE", "WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ) ; Display The log message N58 MSG("WS2 START TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ) ; STOP AFTER TO PAUSE SIMULATION N59 M00 N61 MSG("EXECUTING TOOLPATH 1 - TP4") ; WS2 TOOLPATH 1 POLYLINE (TP4) N62 X175.980235Y-18.319722 N63 Z-82.20075 N64 MSG("EXECUTING TOOLPATH 2 - TP5") ; WS2 TOOLPATH 2 POLYLYNE (TP5) N65 G1Z-84.74075F1016 N66 X99.780235 N67 X90.799979Y-27.299979 N68 X27.299979Y-90.799979 ; WS3 TOOLPATH 3 COMPOSITE CURVE (TP6) ; START MONITORING MAX DEVIATION POSITION ALONG TOOLPATH N69 MSG("ACTIVATING MONITORING OF MAX DEVIATION ALONG TOOLPATH for TP6") ; COMO LLAMADA A CICLO N69 ID=1 WHENEVER ($R[5]<SQRT(POT($VA_LAG_ERROR[X])+POT($VA_LAG_ERROR[Y]) +POT($VA_LAG_ERROR[Z]))) DO TCICLO N70 G2X-27.299979Y-90.799979Z-84.74075CR=38.608 ; EJEMPLO PARA EL LOG N71 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION "POSITION" << $VA_IM[X] << $VA_IM[Y] << $VA_IM[Z]) ; EJEMPLO DE SALIDA POR PANTALLA N72 MSG("SEGMENT-1 DEVIATION VALUE RECORDED") N73 G1X-90.799979Y-27.299979 N74 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N75 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N76 MSG("SEGMENT-2 DEVIATION VALUE RECORDED") N77 G2X-90.799979Y27.299979Z-84.74075CR=38.608 N78 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N79 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N80 MSG("SEGMENT-3 DEVIATION VALUE RECORDED") N81 G1X-27.299979Y90.799979 N82 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N83 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N84 MSG("SEGMENT-4 DEVIATION VALUE RECORDED") N85 G2X27.299979Y90.799979Z-84.74075CR=38.608 N86 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N87 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N88 MSG("SEGMENT-5 DEVIATION VALUE RECORDED") N89 G1X90.799979Y27.299979 N90 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N91 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N92 MSG("SEGMENT-6 DEVIATION VALUE RECORDED") N93 X99.780235Y18.319722 N94 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION N95 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N96 MSG("SEGMENT-7 DEVIATION VALUE RECORDED") N97 X175.980235 N98 WRITE (ERROR,"LOGFILE","SEGMENT MAX DEVIATION

VALUE :" << R[5] <<

VALUE : ...")

VALUE : ...")

VALUE : ...")

VALUE : ...")

VALUE : ...")

VALUE : ...")

VALUE : ...")

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N99 R[1]=0 R[2]=0 R[3]=0 R[4]=0 R[5]=0 N100 MSG("SEGMENT-8 DEVIATION VALUE RECORDED") ; STOP MONITORING MAX DEVIATION POSITION ALONG TOOLPATH N101 MSG ("TP6 END AND STOP TOOLPATH MONITRING") N102 CANCEL(1) N103 M00 N105 MSG("COMPLETING THE REST OF WORKINGSTEP 2") N106 G0X166.999979Y-9.339466 N107 G1X90.799979F1016 N108 X81.819722Y-18.319722 N109 X18.319722Y-81.819722 N110 G2X-18.319722Y-81.819722Z-84.74075CR=25.908 N111 G1X-81.819722Y-18.319722 N112 G2X-81.819722Y18.319722Z-84.74075CR=25.908 N113 G1X-18.319722Y81.819722 N114 G2X18.319722Y81.819722Z-84.74075CR=25.908 N115 G1X81.819722Y18.319722 N116 X90.799979Y9.339466 N117 X166.999979 N118 G0X158.019722Y-0.35921 N119 G1X81.819722F1016 N120 X72.839466Y-9.339466 N121 X9.339466Y-72.839466 N122 G2X-9.339466Y-72.839466Z-84.74075CR=13.208 N123 G1X-72.839466Y-9.339466 N124 G2X-72.839466Y9.339466Z-84.74075CR=13.208 N125 G1X-9.339466Y72.839466 N126 G2X9.339466Y72.839466Z-84.74075CR=13.208 N127 G1X72.839466Y9.339466 N128 X81.819722Y0.35921 N129 X158.019722 N130 G0X175.980235Y-18.319722 N131 Z-88.9635 N132 G1X99.780235F1016 N133 X90.799979Y-27.299979 N134 X27.299979Y-90.799979 N135 G2X-27.299979Y-90.799979Z-88.9635CR=38.608 N136 G1X-90.799979Y-27.299979 N137 G2X-90.799979Y27.299979Z-88.9635CR=38.608 N138 G1X-27.299979Y90.799979 N139 G2X27.299979Y90.799979Z-88.9635CR=38.608 N140 G1X90.799979Y27.299979 N141 X99.780235Y18.319722 N142 X175.980235 N143 G0X166.999979Y-9.339466 N144 G1X90.799979F1016 N145 X81.819722Y-18.319722 N146 X18.319722Y-81.819722 N147 G2X-18.319722Y-81.819722Z-88.9635CR=25.908 N148 G1X-81.819722Y-18.319722 N149 G2X-81.819722Y18.319722Z-88.9635CR=25.908 N150 G1X-18.319722Y81.819722 N151 G2X18.319722Y81.819722Z-88.9635CR=25.908 N152 G1X81.819722Y18.319722 N153 X90.799979Y9.339466 N154 X166.999979 N155 G0X158.019722Y-0.35921 N156 G1X81.819722F1016 N157 X72.839466Y-9.339466 N158 X9.339466Y-72.839466 N159 G2X-9.339466Y-72.839466Z-88.9635CR=13.208 N160 G1X-72.839466Y-9.339466 N161 G2X-72.839466Y9.339466Z-88.9635CR=13.208 N162 G1X-9.339466Y72.839466 N163 G2X9.339466Y72.839466Z-88.9635CR=13.208 N164 G1X72.839466Y9.339466 N165 X81.819722Y0.35921 N166 X158.019722

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N167 Z-86.4235 N168 G0Z-55.88 ; WRITE IN LOG FILE WS3 END TIME N169 WRITE(ERROR,"LOGFILE", "WS2 END TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ) ; If we want to display a log message N170 MSG("WS2 END TIME :" << $A_HOUR << ":" << $A_MINUTE << ":" << $A_SECOND << ":" << $A_MSECOND ) N171 M00 N172 MSG("CONTINUE WITH THE REST of WSTEPs") ; Workingstep: line 337 WS 3 N173 X171.958Y0 N174 Z-90.51925 N175 G1Z-93.05925F1016 ; PROGRAM STOP FOR THE SIMULATION PART

...
;Sample Technological Cycle ; CALCULATE DEVIATION VALUE N000 $R[5] = SQRT(POT($VA_LAG_ERROR[X]) + POT($VA_LAG_ERROR[Y]) + POT($VA_LAG_ERROR[Z])) N030 $R[1]=$AA_IM[X] N040 $R[2]=$AA_IM[Y] N050 $R[3]=$AA_IM[Z] N020 M17

Operation and Programming 10/2002 Edition Turning SINUMERIK 802D Valid for Control SystemSoftware Version SINUMERIK 802D2 10.02 Edition SINUMERIK 802D Operation and Programming Turning Introduction 1 Turning On an Reference-Point Approach 2 Setting Up3 Manually Controlled Mode4 Automatic Mode5 Part Programming6 System 7 Programming 8 Cycles 9 SINUMERIK Documentation

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ANew documentation BUnrevised reprint with new Order No CRevised edition with new status Printing history Brief details of this edition and previous editions are listed below. IThe status of each edition is shown by the code in the Remarks column. Status code in the Remarks column: If actual changes have been made on the page since the last edition, this is indicated by a new edition coding in the header on the page. 10.02 6FC56982AA000BP2 C Edition OrderNo. Remark 1.0 6FC56982AA00BP0 A 07.01 6FC56982AA00 0BP1 C This Manual is included on the documentation on CDROM (DOCONCD) Edition OrderNo. Remark 1.02 6FC52986CA000BG3 C Trademarks SIMATIC , SIMATIC HMI , SIMATIC NET , SIMOTION , SINUMERIK and SIMODRIVE are registered trademarks of Siemens. Third parties using for their own purposes any other names in this document which refer to trademarks might infringe upon the rights of trademark owners. Further information is available on the Internet under: http://w.ad.siemens.de/sinumerik This publication was produced with Interleaf V 7 The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for demages. All rights, including rights created by patent grant or registration of utility model or design, are reserved. Siemens AG 2002. All rights reserved. Other functions not described in this documentation might be executable in the control. This does not, however, represent an obligation to supply such functions with a new control or when servicing. We have checked that the contents of this document correspond to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this document is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement. Subject to change without prior notice. SiemensAktiengesellschaftBestellNr. 6FC5 6982AA000BP2 Printed in the Federal Republic of Germany

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Safety notices

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This Manual contains notices intended to ensure your personal safety and to avoid material damage. The notices are highlighted by a warning triangle and, depending on the degree of hazard, represented as shown below: ! Danger indicates that loss of life, severe personal injury or substantial material damage will result if the appropriate pre- cautions are not taken. indicates that loss of life, severe personal injury or substantial material damage may result if the appropriate precautions are not taken. ! Caution indicates that minor personal injury or material damage may result if the appropriate precautions are not taken. Caution eithout a warning triangle means that material damage can occur if the appropriate precautions are not taken. Attention means that an undesired event or status can occur if the appropriate note is not observed. Note is used to draw your special attention to an important information on the product, the handling of the product or the corresponding part of the documentation. Qualified personnel Start-up and operation of a device may only be carried out by qualified personnel. Qualified personnel as referred to in the safety notices provided in this Manual are persons who are authorized to start up, ground and tag devices, systems and circuits according to the relevant safety standards. Usage as per intended purpose Please observe the following: The device may only be used for the cases of application, as intended by the Catalog, and only in conjunction with third-party devices and components recommended or approved by Siemens. The proper and safe operation of the product requires transport, storage and installation according to the relevant instructions and qualified operation and maintenance at the prescribed intervals. Contents viSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 1Introduction1-13 1.1Screen Layout1-13 1.2Operating Areas1-16 1.3Accessibility Options1-17 1.3.1Calculator1-17 1.3.2Editing Chinese Characters1-2 1.3.3Hotkeys1-2 1.4The Help System1-23 1.5Coordinate Systems1-24 2Turning on and Reference Point Approach2-27 3Setting Up3-29 3.1Entering Tools and Tool Offsets3-29 3.1.1Creating a New Tool3-31 3.1.2Determining Tool Offsets (manually)3-32 -9-

3.1.3Determining the Tool Compensations Using a Probe3-35 3.1.4Determining the tool compensations values using an optical measuring system336 3.1.5Probe Settings3-36 3.2Tool monitoring3-39 3.3Entering/Modifying Zero Offset3-40 3.3.1Determining Zero Offset3-41 3.4Programming Setting Data - Operating Area Parameters3-42 3.5R Parameters - Operating Area Offset/Parameters3-45 4Manually Controlled Operation4-47 4.1Jog Mode - Operating Area Position4-48 4.1.1Assigning Handwheels4-51 4.2Operating Mode MDA (Manual Input)4-52 4.2.1Face Turning4-5 5Automatic Mode5-59 5.1Selecting and Starting a Part Program5-63 5.2Block Search - Operating Area Machine5-64 5.3Stopping/Aborting a Part Program5-65 5.4Re-approach after abortion 5-6 5.5Re-approach after Interruption - Operating Area Machine5-6 5.6Program Execution from External (RS232 Interface)5-67 6Part Programming6-69 6.1Entering a New Program - Operating Area Program6-72 6.2Editing a Part Program - Operating Mode Program6-73 6.3Blueprint programming6-75 6.4Simulation6-93 Contents 6.5Data Transfer via the RS232 Interface6-94. . . . . . . . . . . . . . . . . . . . . . . . . . . ................. Contents viiSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 7System7-97 7.1PLC diagnosis using the ladder diagram representation7-118 7.1.1Screen layout7-118 7.1.2Operating options7-119 8Programming8-129 8.1Fundamentals of NC Programming8-129 8.1.1Program Names8-129 8.1.2Program Structure8-129 8.1.3Word Structure and Address8-130 8.1.4Block Structure8-131 8.1.5Character Set8-132 8.1.6List of Statements8-134 8.2Positional Data8-149 - 10 -

8.2.1Absolute / Incremental Data Input: G90, G91, AC, IC8-149 8.2.2Metric and Inch Dimensions: G71, G70, G710, G7008-150 8.2.3Radius / Diameter Programming: DIAMOF, DIAMON8151 8.2.4Programmable Zero Offset: TRANS, ATRANS8-152 8.2.5Programmable Scaling Factor: SCALE, ASCALE8-153 G54 to G59, G500, G53, G1538-154 G25, G26, WALIMON, WALIMOF8-155 8.3Axis Movements8-157 8.3.1Linear Interpolation at Rapid Traverse: G08-157 8.3.2Linear Interpolation with Feed: G18-158 8.3.3Circular Interpolation: G2, G38-159 8.3.4Circular Interpolation via Intermediate Point: CIP8-162 8.3.5Circle with Tangential Transition: CT8-162 8.3.6Thread Cutting with Constant Lead: G338-163 8.3.7Thread cutting with variable lead: G34, G358-166 8.3.8Thread interpolation: G331, G3328-167 8.3.9Fixed-Point Approach: G758-168 8.3.10Reference Point Approach: G748-168 8.3.11Measuring with Switching Tracer: MEAS, MEAW8-169 8.3.12Feed F8-170 8.3.13Exact Stop / Continuous-Path Control Mode: G9, G60, G648171 8.3.14Acceleration Behavior: BRISK, SOFT8-173 8.3.15Percentage Acceleration Compensation: ACC8-174 8.3.16Traversing with Feedforward Control: FFWON, FFWOF8-175 8.3.173rd and 4th Axes8-175 8.3.18Dwell Time: G48-176 8.3.19Travel to fixed stop8-177 8.4Spindle Motions8-180 8.4.1Spindle Speed S; Directions of Rotation8-180 8.4.2Spindle Speed Limiting: G25, G268-180 8.4.3Positioning the Spindle: SPOS8-181 8.4.4Gear stages8-182 8.4.52nd spindle8-182 8.5Special Turning Functions8-184 8.5.1Constant Cutting Speed: G96, G978-184 8.5.2Rounding, Chamfer8-186 8.5.3Contour Definition Programming8-187 8.6Tool and Tool Compensation8-190 8.6.1General Notes8-190 8.6.2Tool T8-190

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8.2.6Workpiece Clamping - Settable Zero Offset: 8.2.7Programmable Working Area Limitation: 8.6.3Tool Offset Number D8191. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Contents viiiSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 8.6.4Selection of Tool Radius Compensation: G41, G428-194 8.6.5Corner Behavior: G450, G4518-196 8.6.6Tool Radius Compensation OFF: G408-197 8.6.7Special Cases of Tool Radius Compensation8-198 8.6.8Example of Tool Radius Compensation8-199 8.6.9Using milling tools8-200 8.6.10Tool compensation special cases8-202 8.7Miscellaneous Function M8-203 8.8H function8-204 8.9Arithmetic parameters R, LUD and PLC variables8-205 8.9.1Arithmetic parameters R8-205 8.9.2Local user data (LUD)8-207 8.9.3Reading and writing PLC variables8-208 8.10Program Jumps8-209 8.10.1Jump Destination for Program Jumps8-209 8.10.2Unconditional Program Jumps8-209 8.10.3Conditional Program Jumps8-210 8.10.4Programming Example of Jumps8-212 8.11Subroutine Technique8-213 8.1.1General8-213 8.1.2Calling Machining Cycles8-215 8.12Timer and Workpiece Counter8-216 8.12.1Runtime Timer8-216 8.12.2Workpiece Counter8-217 8.13Language commands for tool monitoring8-219 8.13.1Overview: Tool monitoring8-219 8.13.2Tool life monitoring8-220 8.13.3Count monitoring8-221 8.14Milling on turning machines8-224 8.14.1Milling face ends - TRANSMIT8-224 8.14.2Milling of peripheral surfaces - TRACYL8-226 8.15Equivalent G Functions with SINUMERIK 802S - Turning8231 9Cycles9-233 9.1Overview of cycles9-233 9.2Programming cycles9-234 9.3Graphical cycle support in the program editor9-236 9.4Drilling cycles9-238 - 12 -

9.4.1General9-238 9.4.2Preconditions9-239 9.4.3Drilling, centering CYCLE819-240 9.4.4Center drilling CYCLE829-243 9.4.5Deep hole drilling CYCLE839-245 9.4.6Rigid tapping CYCLE849-249 9.4.7Tapping with compensation chuck CYCLE8409-252 9.4.8Reaming 1 (boring 1) CYCLE859-256 9.4.9Boring (boring 2) CYCLE869-259 9.4.10Reaming 2 (boring 3) CYCLE879-262 9.4.11Drilling with stop 1 (boring 4) CYCLE889-265 9.4.12Drilling with stop 2 (boring 5) CYCLE899-267 9.4.13Row of holes HOLES19-269 9.4.14Circle of holes HOLES29-273 Contents ixSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 9.5.1Preconditions9-276 9.5.2Grooving CYCLE939-278 9.5.3Undercut form E F CYCLE949-286. . . . . . . . . . . . . . . . . . . . . . . . . . ......................

9.5.4Stock removal CYCLE959-290 9.5.5Thread undercut CYCLE969-303 9.5.6Thread cutting CYCLE979-307 9.5.7Chaining of threads CYCLE989-313 9.6Error Messages and Error Handling9-320 9.6.1General notes9-320 9.6.2Error handling in the cycles9-320 9.6.3Overview of cycle alarms9320 9.6.4Messages in the cycles9-322. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ............ xSINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) SINUMERIK 802D Key Definition & Recall key ETC key Acknowledge Alarm key Not assigned Info key Shift key Control key Alt key SPACE (INSERT) Deletion key (Backspace) Deletion key Insertion key Tabulator

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ENTER / Input key Position operating area key Program operating area key Parameters operating area key Program Manager operating area key Alarm/System operating area key Not assigned Paging keys Cursor keys Selection key/toggle key Alphanumeric keys Double assignment on the Shift level Numerical keys Double assignment on the Shift level SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) External machine control panel Reset NC STOP NC START emergency stop %Spindle override User-defined key with LED User-defined key with LED INCREMENT JOG REFERENCE POINT AUTOMATIC SINGLE BLOCK SPINDLE START CCW rotation SPINDLE START CW rotation RAPID TRAVERSE OVERRIDE Rapid traverse override X axis Z axis %Feed override xii SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) notice

1-13SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Introduction 1.1Screen Layout Status area Application area Tip and softkey area G function Fig. 1-1 Screenlayout The screen is divided into the following main areas: Status area Application area Tip and softkey area Introduction 1.1Screen Layout SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Status area Fig. 1-2Status area Table 1-1Explanation of the display elements in the status area DisplayElement Display Meaning Active operating area, active mode Position

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JOG; 1 INC, 10 INC, 100 INC, 1000 INC, VAR INC (incremental evaluation in JOG mode) MDA1 MDA AUTOMATIC Offset ProgramProgram Program Manager SystemSystem Alarm Marked as an external language using G291 Alarm and message line Thflliidild(ith/)2The following is displayed (either/or): 1. Alarm number with alarm text1. Alarm number with alarm text 2. Message text Program status RESETProgram aborted / basic status 3RUNProgram running STOPProgram stopped 4Program controls in Automatic mode 5 Reserved 6NC messages 7Selected part program (main program)

Introduction 1.1Screen Layout

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Tip and softkey area Fig. 1-3Tip and softkey area Table 1-2Explanation of the display elements in the tip and softkey area DisplayElement Display Meaning 1 Recall symbol Pressing the Recall key lets you return to the next higher level. Displays tips for the operator MMC status information ETC is possible (If you press this key, the horizontal softkey bar will display further functions.) Mixed notation active Data transfer running Link with the PLC programming tool active

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4Softkey bar vertical and horizontal Standard softkeys Use this softkey to quit the screen form. Use this softkey to cancel input; the window will be quitted. Pressing this softkey will complete your input and start the calculation. Introduction 1.2Operating Areas SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Pressing this softkey will complete your input and accept the entered values. This function is used to switch over the screen form from diameter programming to radius programming. 1.2Operating Areas The functions of the control system can be carried out in the following operating areas: Position Machine operation Offset/ParametersInput of compensation values and setting data ProgramCreation of part programs Program ManagerPart program directory System Diagnosis, start-up AlarmAlarm and message lists To switch to a different operating area, press the appropriate key (hardkey). Protection levels The input or modification of data in the control system is password-protected in sensible places. In the menus listed below the input or modification of data depends on the protection level set. Tool offsets Zero offsets Setting data RS232 settings Program creation / program correction Introduction 1.3 Accessibility Options

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 1.3 Accessibility Options 1.3.1 Calculator To calculate terms, the four basic arithmetic operations can be used, as well as the functions sine, cosine, squaring and square root. A bracket function is provided to calculate nested terms. The bracketing depth is unlimited. - 16 -

If the input field is already occupied by a value, the function will accept this value into the input line of the calculator. When you press the Input key, the result is calculated and displayed in the calculator. Pressing the Accept softkey enters the result in the input field at the current cursor position of the part program editor and closes the calculator automatically. Fig. 1-4Calculator Characters permitted for input SSine function The X value (in degrees) before the input cursor is replaced by the value sin(X). CCosine function The X value (in degrees) before the input cursor is replaced by the value cos(X). QSquare function RSquare root function The X value before the input cursor is replaced by the value X. ( )Bracket function (X+Y)*Z Introduction 1.3 Accessibility Options

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Calculation examples TaskInput -> Result 100 + (67*3)100+67*3-> 301 sin(45)45 S -> 0.707107 cos(45)45 C -> 0.707107 424 Q -> 16 4 R -> 2 (34+3*2)*10 (34+3*2)*10 -> 400 To calculate auxiliary points on a contour, the calculator provides the following functions: Calculating the tangential transition between a circle sector and a straight line Moving a point in the plane Converting polar coordinates to Cartesian coordinates Adding the second end point of a straight line/straight line contour section given from an angular relation Softkeys This function is used to calculate a point on a circle. The point results from the angle of the tangent created, the radius and the direction of rotation of the circle. Fig. 1-5 Enter the circle center, the angle of the tangent and the circle radius. Use the softkey G2 / G3 to define the direction of rotation of the circle. When you press this softkey, the abscissa and ordinate values are calculated. The abscissa is the first axis, and the ordinate is the second axis of the plane. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane. G2/G3

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Introduction 1.3 Accessibility Options

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

in plane G18. Example: Calculate the intersection point between circle sector and straight line Given:Radius: 10 Circle center: Z 147 X103 Connection angle of the straight line: -45 Result:Z = 154.071 X = 110.071 This function calculates the Cartesian coordinates of a point in the plane, which is to be linked with a point (P) on a straight line. For calculation, the distance between the points and the slope angle (A2) of the new straight line to be created with reference to the slope (A1) of the given straight line must be known. Fig. 1-6 Enter the following coordinates or angles: the coordinates of the given point (P) the rise angle of the straight line (A1) the distance of the new point with reference to P the rise angle of the connecting straight line (A2) with reference to A1 When you press this softkey, the Cartesian coordinates are calculated, which are then copied into two input fields following another to one. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane.

Introduction 1.3 Accessibility Options

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SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) This function converts the given polar coordinates into Cartesian coordinates. Fig. 1-7 Enter reference point, vector length and slope angle. When you press this softkey, the Cartesian coordinates are calculated, which are then copied into two input fields following another to one. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part program editor, the coordinates are saved with the axis names of the selected basic plane. This function is used to calculate the missing end point of the straight line/straight line contour section whereby the second straight line stands vertically on the first straight line. The following values of the straight line are known: Straight line 1: Straight line 2: Fig. 1-8 Start point and slope angle Length and one end point in the Cartesian coordinate system

This function is used to select the given coordinate of the end point. The ordinate value or the abscissa value is given. Introduction 1.3 Accessibility Options

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) The second straight line is rotated in CW direction or in counter-clockwise direction by 90 degrees relative to the first straight line. The missing end point is calculated. The value of the abscissa is copied into the input box from which the calculator function has been called, and the value of the ordinate is copied into the next following input box. If the function has been called from the part - 19 -

program editor, the coordinates are saved with the axis names of the selected basic plane. Example Fig. 1-9 Add the drawing above by the value of the center circle in order to be able to calculate then the intersection point between the circle sector of the straight line. The missing coordinate of the center point is calculated using the calculator function , since the radius in the tangential transition stands vertically on the straight line. Fig. 1-10 Calculating M1 in section 1: Der Radius steht 90 im Uhrzeigersinn gedreht auf der durch den Winkel festgelegten Gerade. to select the appropriate direction of rotation. Use the softkey to define the given end point. Use the softkey Enter the coordinates of the pole, the slope angle of the straight line, the ordinate angle of the end point and the circle radius as the length. Accept

Introduction 1.3 Accessibility Options

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Fig. 1-1 Result:X = 60 Z = -4.601 1.3.2Editing Chinese Characters This function is only available in the Chinese language version. The control system provides a function for editing Chinese characters in the program editor and in the PLC alarm text editor. After activation, type the phonetic alphabet of the searched character in the input box. The editor will then offer various characters for this sound, from which you can choose the desired one by entering either of the digits 1 to 9. Fig. 1-12Chinese editor AltSis used to turn on/turn off the editor 1.3.3 Hotkeys - 20 -

This operator control can be used to select, copy, cut and delete texts using special key commands. This functions are available both for the part program editor and for input fields. CTRL C Copy CTRL B Select CTRL X Cut CTRL V Paste AltLis used to switch to mixed notation AltHHelp system or Info key Introduction 1.4The Help System SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 1.4The Help System To activate the help system, use the Info key. It offers a brief description for all essential operating functions. Further, the help feature contains the following topics: Overview of the NC commands with a brief description Cycle programming Explanation of the drive alarms Fig. 1-13Table of contents of the help system This function opens the topic selected. Fig. 1-14Description with regard to a help topic <<. This softkey is only unhidden if a cross reference is displayed in the application area. Use this function to select cross references. A cross reference is marked by the characters >> If you select a cross reference, in addition, the Back to topic softkey is displayed. This function lets you return to the previous screen form. Show Go to topic Back to topic Introduction 1.5 Coordinate Systems SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Use this function to search for a term in the table of contents. Type the term you are looking for and start the search process. Help in the Program Editor area The system offers an explanation for each NC instruction. To display the help text directly, position the cursor behind the instruction and press the Info key. 1.5 Coordinate Systems For machine tools, right-handed, right-angled coordinate systems are used. The movements on the machine are described as a relative movement between tool and workpiece. Fig. 1-15Determination of the axis directions another to one; coordinate system for programming on turning Find

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Introduction 1.5 Coordinate Systems SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Machine coordinate system (MCS) How the coordinate system is located with reference to the machine, depends on the machine type concerned. It can be rotated in different positions. Fig. 1-16Machine coordinates/machine axes using the example of a turning machine The origin of this coordinate system is the machine zero. In this point, all axes have the position zero. This point represents only a reference point defined by the machine manufacturer. It need not be approachable. The traversing range of the machine axes can be in the negative range. Workpiece coordinate system (WCS) The coordinate system described above (see Fig. 1-15) is also used to describe the geometry of a workpiece in the workpiece program. The workpiece zero can be freely selected by the programmer in the Z axis. In the X axis, it is in the turning center. X Workpiece Z Workpiece W Workpiece W - workpiece zero Fig. 1-17Workpiece coordinate system Introduction 1.5 Coordinate Systems SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Relative coordinate system Apart from the machine and workpiece coordinate systems, the control system provides a relative coordinate system. This coordinate system is used for setting reference points that can be freely selected and have no influence on the active workpiece coordinate system. All axis movements are displayed relative to these reference points. Clamping the workpiece For machining, the workpiece is clamped in the machine. The workpiece must be aligned such that the axes of the workpiece coordinate system run in parallel with those of the machine. Any resulting offset of the machine zero with reference to the workpiece zero is determined along the Z axis and entered in a data area intended for the settable zero offset. In the NC program this offset is activated, e.g. using a programmed G54. XMachine X Workpiece Z Workpiece e.g.Z G54 Workpiece Machine Fig. 1-18Workpiece on the machine Current workpiece coordinate system The programmed zero offset TRANS can be used to generate an offset with reference to the workpiece coordinate system resulting in the current workpiece coordinate system (see Section Programmable Zero Offset: TRANS). - 22 -

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Turning on and Reference Point Approach Note When you turn on the SINUMERIK 802D and the machine, please also observe the Machine Documentation, since turning on and reference point approach are machinedependent functions. This documentation assumes an 802D standard machine control panel (MCP). Should you use a different MCP, the operation may be other than described herein. Operating sequence First turn on the power supply of CNC and machine. After the control system has booted, you are in the Position operating area, Jog mode. The window Reference-point approach is active. Fig. 2-1The Jog-Ref start screen Use the Ref key on the machine control panel to activate reference-point approach. The Reference-Point Approach window (Fig. 2-1) will display whether the axes have a reference point or not. Axis has to be referenced Axis has reached its reference point Turning on and Reference Point Approach SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Select a direction key. If you select the wrong approach direction, no movement will be carried out. Approach the reference point one after the other for each axis. Quit the function by selecting a different mode (MDA, Automatic or Jog). Note Reference-point approach is only possible in Jog mode.

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T)

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Setting Up Preliminary remarks Before you can work with the CNC, set up the machine, the tools, etc. on the CNC as follows: Enter the tools and the tool offsets. Enter/modify zero offset. Enter setting data. 3.1Entering Tools and Tool Offsets Functionality The tool offsets consist of several data describing the geometry, the wear and the tool type. Depending on the tool type, each tool is assigned a defined number of parameters. Tools are identified by a number (T number). See also Section 8.6 Tool and Tool Offset Operating sequence Use this softkey to open the Tool Offset Data window that contains a list of the tools created. Use the cursor keys and the Page Up/PageDown keys to navigate in this list. Fig. 3-1Tool list Offset Param Tool List Setting Up 3.1Entering Tools and Tool Offsets

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Use the following operating sequence to enter the compensation values: Position the cursor bar on the input box you want to modify, enter the desired value(s) and confirm your input by pressing Input or by a cursor movement. For special tools, the softkey function Extend is provided, which offers a complete parameter list, which can be filled in. Softkeys Use this softkey to determine the tool offset data. Use this softkey to determine the tool offset data manually (see section 3.1.2). Use this softkey to determine the tool offset data semi-automatically (see Section 3.1.3). Use this softkey to calibrate the probe. Use this softkey to delete the tool offset data of all cutting edges of the tool. Use this softkey to display all parameters of a tool. - 24 -

Fig. 3-2Screen form for entering special tools Use this softkey to open a lower-level menu bar offering all functions required to create and display further cutting edges. Use this softkey to select the next higher cutting edge number. Tool measure Measure manual Measure auto Calibrate probe Delete tool Extend Activate change Edges

Setting Up 3.1Entering Tools and Tool Offsets

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Use this softkey to select the next lower cutting edge number. Use this softkey to create a new edge. Use this softkey to reset all offset values of the cutting edge to zero. Use this function to change the tool type. Use the relevant softkey to select the appropriate tool type.

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Type the number of the tool you are looking for and start the search using the OK softkey. If the tool you are looking for exists, the cursor is positioned on the corresponding line. Use this softkey to create tool offset data for a new tool. Note: Max. 32 tools can be created. 3.1.1Creating a New Tool Operating sequence This function provides another two softkey functions required to select the tool type. After selection, type the desired tool number in the input box. Fig. 3-3The New Tool windowInput of tool number For milling and drilling tools, the operator must select the machining direction. Fig. 3-4Selection of the machining direction for a milling tool New tool edge Reset edge Change type Find New tool New tool Setting Up 3.1Entering Tools and Tool Offsets SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Use OK to confirm your input. A data record loaded with zero by default will be accepted into the tool list. 3.1.2Determining Tool Offsets (manually) Functionality This function can be used to determine the unknown geometry of a tool T. Prerequisite The respective tool is changed. In JOG mode, use the cutting edge of the tool to approach a point on the machine with known machine coordinate values. This can be a workpiece with a known position. Procedure Enter the reference point in the appropriate field or Z0. Please observe: The assignment of length 1 or 2 to the axis depends on the tool type (turning tool, drill). With a turning tool, the reference point for the X axis is a diameter dimension! Using the actual position of the point F (machine coordinate) and the reference point, the control system can calculate the compensation value assigned to length 1 or length 2 for the axis preselected. Note: You can also use a zero offset already determined (e.g. value of G54) as the known machine coordinate. In this case, use the edge of the tool to approach the workpiece zero point. If the edge is positioned directly at workpiece zero, the reference point is zero. XMachine Z - 26 -

Workpiece Machine Length 2=? Actual position Z F - tool carrier reference point Length 1 =? Actual position X OffsetM M - machine zero The offset value in the X axis is a diameter value. W - workpiece zero Gxx Fig. 3-5Determination of length compensation values using the example of a cutting tool Setting Up 3.1Entering Tools and Tool Offsets SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) XMachine Workpiece Machine Length 1=? Actual position Z F - tool carrier reference point M - machine zero FW Gxx W - workpiece zero Fig. 3-6Determining the length compensation using the example of a drill: Length 1 / Z axis Note The diagram 3-6 is only applicable if the variables 42950 TOOL_LENGTH_TYPE and TOOL_LENGHT_CONST!=0; otherwise, length tool will apply for the milling and drilling tools. Operating sequence Use this softkey to open the selection window for manual or semiautomatic measurement. Fig. 3-7Selection of manual or semi-automatic measurement Use this softkey to open the Measure tool window. Measure tool Measure manual Setting Up 3.1Entering Tools and Tool Offsets

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SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Fig. 3-8The Measure tool window In the field Z0, type the workpiece diameter or in the Z0 field, type a value you wish to have for the tool at the current position. This can be either the current machine coordinate or a value from the zero offsets. If any other values are used, the compensation value will refer to the specified position. After the softkeys Set length 1 or Set length 2 have been pressed, the control system will determine the searched geometry length 1 or length 2 according to the preselected axis. The compensation value determined will be stored. Pressing this softkey wiull save the position of the X axis. The X axis can be moved from the workpiece away.It is thus possible, e.g. to determine the workpiece diameter. The saved value of the axis position will then be used for calculating the length compensation. The behavior of the softkey is determined by the display machine data 373 MEAS_SAVE_POS_LENGTH2 (see also Manufacturer Documentation SINUMERIK 802D Start-Up) Save position Setting Up 3.1Entering Tools and Tool Offsets

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 3.1.3Determining the Tool Compensations Using a Probe Operating sequence - 28 -

Select this softkey and then: the Measure Tool window appears. Fig. 3-9The Measure Tool window This intercative screen form can be used to enter tool and edge number. In addition, the tool point direction is displayed after the symbol. After the screen form has been opened, the boxes of the interactive screen form are filled with the tool currently being in mesh. The tool can be either the active tool of the NC (loaded via a part program) or a tool loaded via the PLC. If the tool has been loaded by the PLC, the tool number in the interactive screen form can differ from the tool number in the window T,F,S. If you change the tool number, no automatic tool change is carried out. The measurement results, however, are assigned to the entered tool. Measuring process Approach the probe using either the traversing keys or the handwheel. After the symbol Probe has appeared, release the traversing key and triggered wait until the end of the measuring process. During the automatic measurement, a gauge is displayed, symbolizing that the measuring process is in progress. Measure tool Measure auto Setting Up 3.1Entering Tools and Tool Offsets

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Note If several axes are moved simultaneously, no calculation of the compensation data is carried out. 3.1.4Determining the tool compensations values using an optical measuring system Fig. 3-10Measuring using an optical measuring system (input fields T and D, see measuring using a sensing probe) Measuring process For measuring, position the tool tip of a chisel or of a drilling tool into the crosshair. With a milling tool, use the highest point of the cutting edge to determine the tool length. Then, press the Set length softkey to calculate the compensation values. 3.1.5Probe Settings This screen form is used to store the probe coordinates and to set the axis feedrate for the automatic measuring process. All position values refer to the machine coordinate system. Settings Data probe - 29 -

Setting Up 3.1Entering Tools and Tool Offsets SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Fig. 3-11The Probe Data screen form Table 3-1 Parameter Meaning Absolute position P1Absolute position of the probe in the Z direction Absolute position P2Absolute position of the probe in the X+ direction Absolute position P3Absolute position of the probe in the Z+ direction Absolute position P4Absolute position of the prober in the X- direction FeedrateFeedrate at which the tool is moved towards the probe Calibrating the probe The calibration of the probe can be carried out either in the Settings menu or in the Measure tool menu. To do so, approach four points of the probe. For calibration, use a tool of the type 500 with tool tip position 3 or 4. The appropriate parameters to determine the four probe positions can be written to the data records of two cutting edges. Calibrate probe

Setting Up 3.1Entering Tools and Tool Offsets

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Fig. 3-12Calibrating the probe

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After the screen form has opened, an animation signaling the current step to be carried out appears next to the current positions of the probe. This position must be approached with the appropriate axis. After the symbol Probe triggered has appeared, release the traversing key and wait until the end of the measuring process. During the automatic measuring process, a gauge is displayed, symbolizing the progress of the measuring process. The position provided by the measuring program serves to calculate the real probe position. It is possible to quit the measuring function without all positions having approached. The points already captured remain stored. Note If several axes are moved simultaneously, no calculation of the compensation data is carried out. To skip a point not needed for measuring, use the Next Step function. Setting Up 3.2Tool monitoring

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Each monitoring type is displayed in 4 columns. Setpoint Prewarning limit Residual value active Use the checkbox in the 4th column to activate/deactivate the monitoring type. life Work Fig. 3-13Tool monitoring Use this softkey to reset the monitoring values of the selected tool. Fig. 3-14 Use this softkey to change the enable status of the selected tool. Toollife Reset monitor After enable Setting Up 3.3Entering/Modifying Zero Offset

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SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 3.3Entering/Modifying Zero Offset Functionality After reference-point approach, the actual-value memory and thus also the actual-value display are referred to the machine zero. A machining program, however, is always referred to the workpiece zero. This offset must be entered as the zero offset. Operating sequence Select Zero Offset via Parameters and Zero Offset. A list of settable zero offsets will appear on the screen. The screen form also displays the values of the programmed zero offset, the active scaling factors, the status display Mirroring active, and the total of all active zero offsets. Fig. 3-15The Zero Offset window Position the cursor bar on the input box you wish to modify, enter value(s). The values are accepted into the zero offsets either by a cursor movement or using the Input key. The offset values of the cutting edge come into effect immediately. Zero Offset Change activated Setting Up 3.3Entering/Modifying Zero Offset

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 3.3.1Determining Zero Offset

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Prerequisite You have selected the window with the corresponding zero offset (e.g. G54) and the axis for which you wish to determine the offset. XMachine Workpiece Machine Zero offset Z=? Length 2 Actual position Z F-tool carrier reference point M-machine zero W W-workpiece zero Fig. 3-16Determining the zero offset - Z axis Procedure Press the softkey Zero Offs Measur. The control system will switch to the operating area Position and open the dialog box for measuring the zero offsets. The axis selected will appear as a softkey with a black shadow. Then scratch the workpiece using the tool tip. In the box Set position to:, type the position you wish to have for the workpiece edge in the workpiece coordinate system. Fig. 3-17Screen form Determine zero offset in XScreen form Determine zero offset in Z The softkey will calculate the offset and will display the result in the Offset box. Press Abort to quit the window. Measure workpiece Set zero offset Abort Setting Up 3.4Programming Setting Data - Operating Area Parameters SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) 3.4Programming Setting Data - Operating Area Parameters Functionality The setting data are used to make the settings for the operating states. These can be modified if necessary. Operating sequence Use the Offset Parameters and Setting Data softkeys to open the Setting Data window. The Setting Data softkey will branch into another menu level where various control options can be set. Fig. 3-18Main screen Setting data Jog feed Feed value in Jog mode If the feed value is zero, the control system will use the value stored in the machine data. Spindle - 33 -

Spindle speed Min. / max. A limitation of the spindle speed in the max. (G26)/min. (G25) fields can therefore only be carried out within the limit values specified in the machine data. Programmed (LIMS) Programmable upper speed limiting (LIMS) at constant cutting speed (G96). Dry run feed (DRY) The feed that can be entered here will be used instead of the programmed feed in automatic mode if the function Dry run feed is selected. Start angle for thread cutting (SF) For thread cutting, a start position for the spindle is displayed as the start angle. If the thread cutting operation is repeated, a multiple thread can be cut by modifying the angle. Setting data

Setting Up 3.4Programming Setting Data - Operating Area Parameters SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Position the cursor bar on the input box you wish to modify, enter value(s). Use the Input key or carry out a cursor movement to confirm your input. Softkeys The work area limiting is active for the geometry and for additional axes. Enter the values for the work area limiting. The softkey Set Active enables/disables the values for the axis selected using the cursor. User data Fig. 3-19 Fig. 3-20 Work area limit. Time counter Setting Up 3.4Programming Setting Data - Operating Area Parameters SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Meaning: Parts required: Number of workpieces required ( required workpieces ) Parts total: Number of workpieces manufactured in total ( actual total )

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Part count: This counter logs the number of all workpieces produced beginning from the starting time. Run time: Total runtime of NC programs in the AUTOMATIC mode ( in seconds ) The AUTOMATIC mode counts the runtimes of all programs executed between NC START and end of program / RESET. The timer is reset to zero with every power-up of the control system; runtime of the selected NC program ( in seconds ) Cycle time: Tool action time ( in seconds ) In the NC program selected, the runtime between NC START and end of program / RESET is measured. Starting a new NC program will clear the timer. Cutting time The runtime of the path axes is measured in all NC programs between NC START and end of program, without rapid traverse active and the tool active. With the dwell time active, the measurement is additionally interrupted. If the control system is booted with the default values, the timer is reset to zero automatically. Use this softkey to display a complete list of all setting data of the control system. The data are divided into general, axis-specific and channel setting data. Channel specific spec. Fig. 3-21 Misc Setting Up 3.5R Parameters - Operating Area Offset/Parameters SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Functionality The main screen R Parameters displays a complete list of all R parameters of the control system (see also Section 8.9 Arithmetic Parameters R). These can be modified if necessary. Find User data Fig. 3-22The R Parameters window Operating sequence Select the softkeys Parameters and R Parameters, position the cursor bar on the input box you wish to modify, and enter value(s). Use the Input key or carry out a cursor movement to confirm your input. Use this softkey to search for R parameters. R Para. meter Find Setting Up 3.5R Parameters - Operating Area Offset/Parameters SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) For your notes

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SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Manually Controlled Operation Preliminary remark Manually controlled operation is possible in Jog and MDA modes. SettingsSetbase Measureworkpiece Measure tool Back << Switch m>inch. Back << Set rel x=0 z=0 x=z=0 Delete base W0 Measuremanual Data probe Measure auto Calibrate probe Back << Set work offset Work offset Back << Fig. 4-1Jog menu tree Face Settings Abort OK Set basis Back << Set rel x=0 z=0 x=z=0 Delete base W0 Back << Switch m>inch. Dataprobe Peripher. surface Fig. 4-2MDA menu tree Manually Controlled Operation 4.1Jog Mode - Operating Area Position

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SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Operating sequence Use the Jog key on the machine control panel to select Jog mode. To traverse the axes, press the appropriate key of the X or Z axis. As long as this key is hold down, the axes will traverse continuously at the rate defined in the setting data. If the value in the setting data is zero, the value stored in the machine data will be used. Set the speed using the override switch. If you also press the Rapid Traverse Override key, the selected axis will be traversed at rapid traverse velocity as long as the keys are hold down. In Incremental Dimension mode, you can use the same operating sequence to traverse settable increments. The set increment is displayed in the display area. To cancel, simply press Jog once more. The Jog main screen displays position, feed and spindle values, as well as the current tool. Fig. 4-3The Jog main screen Manually Controlled Operation 4.1Jog Mode - Operating Area Position SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) Parameters Table 4-1 Description of the parameters displayed in the Jog main screen Parameters Explanation Display of addresses of existing axes in the machine coordinate system (MCS). +X- ZIf you traverse an axis in the positive (+) or negative (-) direction, a plus or minus sign is displayed in the corresponding field. If the axis is already in the desired position, no sign will be displayed. Position m These fields display the current position of the axes in the MCS or WCS. Repos offsetIf the axes are traversed in the state Program interrupted in Jog mode, this column displays the distance traversed by each axis with reference to the break point. G functionDisplay of important G functions Spindle Srpm Display of actual and set values of spindle speed Feed Fmm/min Display of feedrate actual and set values ToolDisplay of the currently engaged tool and of the current edge number

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Note If a second spindle is integrated into the system, the workspindle is displayed using a lower font size. The window will always display only the data of one spindle. The control system displays the spindle data, taking into account the following aspects: The master spindle is displayed: -in the idle condition, -at spindle start, -if both spindles are active. The workspindle is displayed: -at spindle start of the workspindle. In all cases, the power bar applies to the spindle currently active. Softkeys This softkey is used to set the basic zero offset or a temporary reference point in the relative coordi- nate system. After opening, this function can be used to set the basic zero offset.Set base Manually Controlled Operation 4.1Jog Mode - Operating Area Position

SINUMERIK 802D 6FC5 698-2AA00-0BP2 (10.02) (OP-T) The following subfunctions are offered: Direct input of the axis position desired In the position window, position the input cursor on the desired axis and enter the new position. Complete your input either by pressing the Input key or by a cursor movement. Setting all axes to zero The softkey function X=Y=Z=0 will overwrite the current position of the corresponding axis with zero. Setting individual axes to zero If you select either of the softkeys X=0, Y=0 or Z=0, the current position will be overwritten with zero. Pressing the Set Rel softkey switches the display to the relative coordinate system. The following inputs will modify the reference point in this coordinate system. Note A modified basic zero offset will act regardless of any other zero offsets. Determining the zero offset (see Chapter 3) Use this softkey to determine the tool compensation values (see Chapter 3) In MDA mode, this screen form is used to set the retraction level, the safety distance and the direction of rotation for part programs generated automatically. In addition, this screen form can be used to set the values for JOG feed and for the variable incremental dimension. - 38 -

Fig. 4-4 Retraction plane: The Face function will retract the tool to the specified position (Z position) after execution. Safety distance: Clearance to the workpiece surface. defines the minimum distance between workpiece surface and workpiece. It is used by the functions Face and Automatic tool gauging.

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Overview
Acceleration with jerk limitation To achieve optimum acceleration with reduced wear on the machine's mechanical parts, you can select SOFT in the part program to ensure continuous, jerk-free acceleration. When you select "acceleration with jerk limitation", the velocity characteristic over the path is generated as a sinusoidal curve. Access protection Protection level 0 1 Type Password Password Users Siemens Access to (examples) All functions, programs, data

Machine manufacturers: Defined functions, Development programs and data (options) Machine manufacturers: Defined functions, Start-up engineers programs and data (machine data) End user: Servicing Assigned functions, programs and data

Password

3 4

Password

Key red End user: < Protection level 0 to 3 Switch position Programmers, machine- Machine 3 setters manufacturer/end user Key green End user: Switch position Qualified users who do 2 not program < Protection level 0 to 3 End user

Key black End user: Program selection only, Switch position Trained users who do not tool wear entries, and 1 program work offset entries Switch position End user: 0 Semi-skilled users No input and program selection possible, only the machine control panel can be operated

Access to programs, data and functions is protected in a user-oriented hierarchical system of eight access levels. - 40 -

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