Shop Mill Programming

A.
Grzinger: Demo Workpiece
SHOPMILL
SINUMERIK 810D / 840D
Demo Workpiece ShopMill

ABOUT THE CONTENT ................................................................................................................................... 2
PURPOSE OF THIS DOCUMENTATION .................................................................................................................. 2
PLEASE NOTICE ............................................................................................................................................... 2
LEGEND ........................................................................................................................................................... 3
DESCRIPTION OF KEYS ..................................................................................................................................... 3
DRAWING ......................................................................................................................................................... 4
SETTING UP THE TOOLS ............................................................................................................................... 4
SETTING UP THE TOOLS ............................................................................................................................... 5
PROGRAMMING .............................................................................................................................................. 7
CREATING THE WORKPIECE .............................................................................................................................. 7
DEFINING THE PROGRAM HEADER ..................................................................................................................... 8
ZERO-OFFSET ................................................................................................................................................. 9
DRILLING OPERATIONS ................................................................................................................................... 10
Centering.................................................................................................................................................. 10
Deep-hole drilling ..................................................................................................................................... 11
Tapping .................................................................................................................................................... 12
Assigning a position pattern ..................................................................................................................... 13
MILLING OPERATIONS ..................................................................................................................................... 15
Generating a pocket contour.................................................................................................................... 15
Generating an island contour................................................................................................................... 17
Solid machining of a pocket (roughing).................................................................................................... 18
Residual material detection...................................................................................................................... 19
Solid machining of a pocket (finishing bottom) ........................................................................................ 20
Solid machining of a pocket (finishing wall) ............................................................................................. 21
INSERTING G CODE / ISO BLOCK .................................................................................................................... 22
PROGRAM DISPLAY......................................................................................................................................... 22
SIMULATION ................................................................................................................................................... 23
MACHINE SET-UP ......................................................................................................................................... 24
CHANGING TOOLS ONTO THE SPINDLE ............................................................................................................. 24
TOOL GAUGING .............................................................................................................................................. 25
Activating the settable ZO, loading the edge probe................................................................................. 25
Probing a workpiece................................................................................................................................. 26
Gauging tool length manually .................................................................................................................. 27
Workpiece face milling ............................................................................................................................. 28
WORKPIECE MACHINING ............................................................................................................................ 29
EXECUTING A PART PROGRAM......................................................................................................................... 29
SIMULTANEOUS RECORDING (MONITORING) ..................................................................................................... 30
BLOCK SEARCH .............................................................................................................................................. 31
WRITING G-CODE / ISO-CODE PROGRAM................................................................................................. 32
CREATING A G-CODE PROGRAM ...................................................................................................................... 32
SIMULATION G-CODE PROGRAM ...................................................................................................................... 33
EXECUTING A G-CODE PROGRAM .................................................................................................................... 33
BLOCK SEARCH .............................................................................................................................................. 33
A. Grzinger
Siemens AG 2002, All rights reserved, November 2002 Edition
Page 1

About the content
Purpose of this documentation
This documentation describes the creation of a sample workpiece with ShopMill:
Programming
Machine set-up
Program editing
Please notice
This documentation is not a complete user manual for the operation of a machine tool.
Machine specific functions are not described.
The machine should be operated by authorized persons only.
Page 2
A. Grzinger

Legend
Prompt for input
Note
Description of keys
Enter key (equivalent to the enter key on an MF2 keyboard)

Toggle key on the machine control panel
(equivalent to the numeral 5 on the numeric keypad of the MF2 keyboard)
Area key on the operator panel (equivalent to F10 on the MF2 keyboard)
Key for machine background on the operator panel
Info key on the operator panel (equivalent to F12 on the MF2 keyboard)
OK
Tools
Zero
Softkey on the operator panel

(when horizontal, equivalent to F1 to F9, when vertical, to Shift+F1 to F8)
Hotkey on the machine control panel
NC key on the machine control panel
A. Grzinger
Page 3

Drawing
Page 4
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Setting up the tools
Tools
zerooffs..
Tool
list
Or alternatively
Machine control panel:
Tools
Zero
sort
Acc. To
magazine
Position the cursor on the first free magazine location
New
tool
Milling
tool
Enter the name: ROUGH_25MM
Enter the length: 100mm
Enter the diameter (): 25mm
Enter number of milling cutter teeth (N): 3
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Page 5

Repeat tool input for the following tools:
sort
Acc. to
type
Cursor on 3D_PROBE
Unload
The unloaded tool is now in the tool list (behind the magazine locations). In the tool list you
can manage the tools that have not been set up along with their tool data. The number of
tools in the tool list is set individually by the machine manufacturer (up to 900 tools).
If you call up a tool from the tool list in the program, a manual change is started
automatically.
Cursor on 3D_PROBE
Load
Confirm the location

The tool is now set up again in the magazine.
Page 6
A. Grzinger

Programming
Creating the workpiece
Programmanager.
Or
Machine control panel
Program
Manager
New
Enter the name for the workpiece directory: DEMO_WKS

Cursor on:
DEMO_WKS
New
Shopmill
program
Enter the name: DEMO_PROGRAM
A. Grzinger
OK
Page 7

Defining the program header
Enter the following values:
The blank dimensions are only relevant for simulation.

If the blank dimensions are preset to 0, it is possible to simulate the tool paths.
The machining direction preset in the program header is effective for standard geometries
(milling) and solid machining (contour milling). For path milling (contour milling), the
defined direction of the contour and the position of the tool with respect to the contour
determine the machining direction !
Accept
Page 8
A. Grzinger

Zero-Offset
Misc.
Transformations
Work
offset >
Select work offset 1 (G54)
or
()
Alternat.
The work offset 1 can be selected through direct input of digit 1.
A. Grzinger
Page 9

Drilling operations
Centering
Drill
Center
Tools
Cursor on tool:
CENTER
To
Program
Switch over technology parameters F and V
or
()
Alternat.
Accept
Pay attention to the yellow help text in the header
Switch over dynamic broken-line graphics to dynamic auxiliary displays
Page 10
A. Grzinger

Deep-hole drilling
Drill
Deep hole
drilling
Accept
With absolute depth data (e.g.: Z1 40.000 abs), the dynamic broken-line graphics does
not draw the contour.
Enter depth data incrementally if possible (inc).
Where parameters are contradictory (e.g.: D>Z1), a message appears in the message line
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Page 11

Tapping
Drill
Thread
Tapping
Cursor on P (thread pitch)

()
Alternat.
The thread can be entered in mm/rev, inch/rev, turns/inch, or modulus.
The input value is converted to the alternatives.
Switch over dynamic auxiliary displays to dynamic broken-line graphics
The chained machining operations are displayed to scale one on top of the other with the
associated tool sizes.
Avoidance of incorrect input due to scale display
Accept
Page 12
A. Grzinger

Assigning a position pattern
Drill
Position

Switch over dynamic broken-line graphics to dynamic auxiliary displays
Positioning in a circle is intended for drill holes in annular grooves. This requires input of a
feed value because rapid traverse movements can only be executed linearly.
Accept
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Page 13

Position
During machining, first center drilling on both drilling patterns is performed, then deep-hole
drilling, then thread tapping.
It is possible to chain several position patterns.
Accept
Page 14
A. Grzinger

Milling operations
Generating a pocket contour
Contour
milling
New
contour
Enter the name of the contour: DEMO_PROGRAM_POCKET
Enter the following geometry elements:
Starting point
A. Grzinger
Reference axis
X
Y
Direction of rotation
R
X
Y
I
J
2
R
X
Y
1
2
R
R
X
Y
I
J
2
R
X
Y
1
2
R
Drehrichtung
R
X
Y
I
J
2
R
Z
60.0 abs
0.0 abs
15.0
45.0 abs
0.0
Tangente
an Vorg.
0.0
20.0
Tangente
an Vorg.
0.0 abs
20.0 abs
0.0
Tangente
an Vorg.
0.0
15.0
Tangente
an Vorg.
-45.0 abs
0.0 abs
0.0
Page 15

X
Y
1
2
R
R
X
Y
I
J
2
R
X
Y
1
2
R
R
X
Y
I
J
2
R
Tangente
an Vorg.
0.0
20.0
Tangente
an Vorg.
0.0 abs
-20.0 abs
0.0
Tangente
an Vorg.
0.0
15.0
60.0 abs
Tangente
an Vorg.
45.0 abs
0.0 abs
0.0
Undefined elements are automatically calculated by the control.

Contours are stored in the program (as from software version 5.3)
Accept
Page 16
A. Grzinger

Generating an island contour
Contour
milling
Accept
New
contour
Accept
Accept
Enter the name of the contour: DEMO_PROGRAM_ISLAND
Accept
Enter the following geometry elements:
Starting point
Reference axis
X
Y
X
2
R
Y
2
R
X
2
R
Y
2
R
X
2
R
Z
0.0 abs
10.0 abs
20.0 abs
3.0
-10.0 abs
3.0
-20.0 abs
3.0
10.0 abs
3.0
0.0 abs
3.0
Accept
A pocket can contain up to 12 islands
A. Grzinger
Page 17

Solid machining of a pocket (roughing)
Contour
milling
Solid
machining
Accept
As of 50% milling path overlap, the pocket might not be removed completely. This is
detected and indicated during simulation ! The milling path overlap must be set to less
than 50%.
Machining with a 25mm milling cutter is effected by multiple insertions because the
distance between the pocket and the island is too small at some positions. In that way, the
island is not destroyed. The residual material is removed in the next step "residual
material detection".
The milling paths are only calculated once before stock removal and stored in a temporary
subroutine. Only when one of the contours or a parameter in the solid machining cycle has
changed, are the paths recalculated.
Page 18
A. Grzinger

Residual material detection
Contour
milling
Residual
material
Accept
Machining is now only performed at positions where residual material still has to be
removed after the preceding solid machining operation.
The function detection of residual material is an option.
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Page 19

Solid machining of a pocket (finishing bottom)
Contour
milling
Solid
machining
Accept
The finishing allowances must also be entered for finishing because the tool must retract
at least by the allowance of the roughing step when positioning !
Page 20
Few inputs due to modal parameter masks
A. Grzinger

Solid machining of a pocket (finishing wall)
Contour
milling
Solid
machining
Accept
Finishing on the edge of the pocket/island contour is also possible with the path milling
function. Path milling allows more freedom in the approach and retract strategy and the
position of the tool with respect to the contour.
The machining direction preset in the program header is effective for standard geometries
(milling) and solid machining (contour milling). For path milling (contour milling), the
defined direction of the contour and the position of the tool with respect to the contour
determine the machining direction !
A. Grzinger
Page 21

Inserting G code / ISO block
Enter NC text: N55
MSG(HELLO)
Enter NC text: N60
G4 F2
You can enter an NC block as the G code block. The syntax is not checked !
During simulation, the tool paths of the G code block are displayed graphically.
Program display
Switch over the program step display to dynamic broken-line graphics
The program display is either in plain text with all technological information or in dynamic
broken-line graphics.
Page 22
A. Grzinger

Simulation
Simulation
Simulation is running
Details
The cutting planes are defined using the cursor keys and the PgUp/PgDn keys.
The 3D view is not refreshed until you switch to another view.

Simulation is based on block search with calculation to end of program. Simulation cannot
therefore be performed simultaneously with machining on the machine !
Simulation makes use of the tool operating data
Simulation can also be performed with the function "program test" with dry run feedrate.
You can control the velocity of the simulation with the override switch.
If the dimensions of the blank are set to 0, simulation is executed as a broken-line graphic
in the top view.
A. Grzinger
Page 23

Machine set-up
Changing tools onto the spindle
M
T,S,M....
Tools
Cursor on tool:
ROUGH_10MM
In
manual
<<
Back
Page 24
A. Grzinger

Tool gauging
Activating the settable ZO, loading the edge probe
M
T,S,M....
Tools
Cursor on tool:
EDGEFINDER
In
manual
Setting the zero offset: with
or
()
Alternat.
If the zero offset is greater than 1, the value is entered directly.
<<
Back
If the first zero offset was not yet active, the axis positions in the workpiece coordination
system (WCS) will now change. No compensatory movement of the machine axes is
made !
It is possible to manage up to 99 zero offsets.
All zero offsets with workpiece offset angles
A. Grzinger
Page 25

Probing a workpiece
M
Set zero
offset
Edge
X
Use the direction keys to traverse axes toward the required edge up to the edge probe.
Instead of the edge probe you can use a milling cutter with known tool data. The tool is
then moved until the first chip falls.
Set zero
offset
The axis position of the X axis in the workpiece coordinate system (WCS) now shows the
value -82.5mm. That corresponds exactly to the position of the edge probe center (diam.
5mm) with reference to the zero offset calculated (G54).
If a touch trigger 3D probe is used for gauging, "Set zero offset" is not required. The probe
is prepositioned roughly using the direction keys of the axes. Gauging is started with "NC
start". The necessary measuring cycles are included in ShopMill.
Repeat the measurement for the Y and Z axes. For the Z axis, a value of ZO 3mm abs is
entered.
Page 26
A. Grzinger

Gauging tool length manually
M
Measure
tool
Length
manual
Tools
Cursor on tool:
DRILL_M12
In
manual
Use the direction keys to move the axes toward the dial gauge until it shows the value 0
The value for Z0 is ascertained by positioning the spindle nose directly on the dial gauge.
Set
length
The calculated length is now displayed in the value tool length.
The functions "Lnge Auto" and "Durchm. Auto" assume that you have a touch trigger
probing socket on the machine. The tool is prepositioned roughly. Gauging is started with
"NC start". The necessary measuring cycles are included in ShopMill.
A. Grzinger
Page 27

Workpiece face milling
M
Face
milling
Tools
Cursor on tool:
MESSERKOPF_63MM
In
manual
OK
It is also possible to call up "face milling" in the part program as a machining step.
Page 28
A. Grzinger

Workpiece machining
Executing a part program
ProgrammManager.
Or
Program
Manager
The part program last programmed is opened.

Cursor on the first program step
P N0 DEMO_PROGRAM
Machine
from here
The control automatically switches to "AUTOMATIC" mode.
If the cursor is not on the first program step, a block search is started automatically !
If you want to start a program that you are not editing, use the program manager.
A. Grzinger
Page 29

Simultaneous recording (monitoring)
M
Record
"Simultaneous recording" is now active
Program
view
In practice it is better to start the program in the program view.
Top view
The 3D view is not refreshed until you switch to another view.

Simulation can also be performed with the function "program test" with dry run feedrate.
You can control the velocity of the simulation with the override switch.
The function monitoring is an option.
Page 30
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Block search
M
Cursor on program step
N30 001 Hole full cir. .....
Block
search
Start
search
Cursor on
N25 Tapping
Accept
No. of start drill op.
Accept
Block search is running
Wait for message
Block search finished - Initiate NC start
Control prepares the machine for machining (tool change, if necessary)
It is possible to start a block search directly from the program editor. Simply place the
cursor on the program step you require. Click on "Machine from here" to start the block
search.
A. Grzinger
Page 31

Writing G-code / ISO-code program
Creating a G-code program
Programmanager.
Or
Cursor on:
Program
Manager
DEMO_WKS
New
G-Code
Program
Enter the name: G_CODE_PROGRAM
Enter the following program:
N0 G54
N10 T=ROUGH_10MM
N20 L6
N30 D1 S1000 M3
N40 G0 X-30 Y-30 Z5
N50 Z-5
N60 G41 G1 F2000
N70 X0 Y0
N80 X100
N90 Y100
N100 X0
N110 Y0
N120 G40 G0 Z5
N130 M30
Page 32
A. Grzinger

Simulation G-code program
Simulation
Top View
Simulation is running
<<
back
Executing a G-code program

Cursor on the first NC block
N10 G54
Machine
from here.
Block search
Cursor NC block
N80 X100 .....
Block
search
Start
search
Block search is running
Wait for message
Block search finished - Initiate NC start
Control prepares the machine for machining (tool change, if necessary)
A. Grzinger
Page 33
Published by Siemens AG
MotionControl System Business Devision
PO Box 3180, D-91050 Erlangen

http://www.ad.siemens.de/jobshop
Page 34
A. Grzinger

Shop Mill Programming

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A.

Grzinger: Demo Workpiece

SINUMERIK 810D / 840D

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter key (equivalent to the enter key on an MF2 keyboard)

Key for machine background on the operator panel

Softkey on the operator panel

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Confirm the location

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter the name for the workpiece directory: DEMO_WKS

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

The blank dimensions are only relevant for simulation.

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

The work offset 1 can be selected through direct input of digit 1.

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Switch over technology parameters F and V

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Cursor on P (thread pitch)

Avoidance of incorrect input due to scale display

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter the following values:

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter the following values:

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Undefined elements are automatically calculated by the control.

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter the name of the contour: DEMO_PROGRAM_ISLAND

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Few inputs due to modal parameter masks

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Siemens AG 2002, All rights reserved, November 2002 Edition

Demo Workpiece ShopMill

Enter NC text: N55

Enter NC text: N60

Siemens AG 2002, All rights reserved, November 2002 Edition