SINUMERIK 828D

- Short guide on Turning

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 INDEX
1 Fundamental geometrical principles. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .3
1.1 Coordinate systems . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

2 User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2.1 Screen layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.2 CNC-full keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2.3 Keys in the hotkey-block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .7
2.4 Keys in the Cursor-Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

3 Operating mode "JOG". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3.1 Selecting the function "Measure tool". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4 Operating area “Parameter” or Tool management . . . . . . . . . . . . . . . . . . . . . . . . . 11

4.1 Selecting the function “Tool list” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.2 Creating a new tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14
4.3 Zero offset basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
4.4 Selecting the function “Work offset“. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.5 Settable zero offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 Operating area “Program” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6 Program structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

7 List of G functions/Preparatory functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

8 List of M functions/Miscellaneous functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

9 Standard turning cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

10 Simple programming example with cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

11 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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 ƒ Fundamental geometrical principles
Three-finger rule
The orientation of the coordinate system relative to the machine depends on the machine type.
The axis directions follow the so-called "three-finger rule" of the right hand (according to DIN
66217).Seen from in front of the machine, the middle finger of the right hand points in the
opposite direction to the infeed of the main spindle. Therefore:
● The thumb points in the +X direction
● The index finger points in the +Y direction
● The middle finger points in the +Z direction

Position of the coordinate system in turning machines

The position of the coordinate system resulting from the "three-finger rule" can have a
Different orientation for different machine types. As mentioned below

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1.1 Coordinate systems:
For the determination of all points within the work space, the control unit requires a zero point of
the coordinate system. This has been determined by the machine manufacturer. All other points
have either fixed distances from the machine zero point or else the distance must be defined.

The machine zero point (M) is determined by the machine manufacturer and
cannot be altered. On milling machines it usually lies on the work table, while on
turning machines it is on the spindle flange.

The work piece zero point (W) is the origin of the work piece coordinate system.
This can be specified by the programmer and should always be chosen in a way
that the least calculation work is required to determine points on the contour given
the dimen-sioning of the drawing. For turning work it lies mostly on the
turning axis and the right hand planar face.

The reference point (R) is approached for initializ-ing the path measuring system,
which means that at this point all axes are set to zero. This is necessary since
generally speaking the machine zero point cannot be
approached.

The tool carrier reference point (F) is of prime im-portance for the adjustment of
preset tools. The lengths L (XPF) and offset O (ZPF) shown in the im-age below are
used as tool calculation values for instance for the tool radius correction and must be
entered into the tool memory of the control unit.

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 ƒ 2.0 User interface
2.1 Screen layout
The screen is laid out as follows:

1 Operation sector
2 Program path and name Status
3 Program influence and program name
4 Alarm and message line
5 Canal operation messages
6 Position readout for the axes
7 Display of the active zero point and rotation
8 Display of:
ƒ T = Active tool
ƒ F = Present feedrate
ƒ S = Actual spindle revolution
ƒ Spindle load factor in percent
9 Vertical soft key bar
10 (VSK) Working window
11 Horizontal soft key bar (HSK)
12 Date and Time

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The horizontal soft key bar consists furthermore of: 4 screen keys (see pictures below)

“MACHINE”-key:
Calls-up the operating area “MACHINE” (in operating mode “JOG”, “MDA” or “AUTO”).

“Recall”-key:
Jumps to the next highest menu level.

“Extend”-key:
Extends the horizontal softkey bar.

“MENU SELECT”-key:
Calls the main menu for operating area selection.

2.2 CNC-full keyboard

A full CNC-keyboard for operation and programming can be integrated on an operating panel of
the machine, depending on the type of Operator panel used.

CNC-full keyboard “KB 483”:

Alpha block: The alpha-block features the letters A, …Z, the space key and the special
character for the input of text.

Hotkey block: The hotkey-block serves the direct selection of operation sectors.

Cursor block: The cursor-block is used for navigation around the screen display.

Number Block: The Number-Block features the numbers 0 ... 9, the decimal point and special
characters for the input of numerical characters and operators.

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 2.3 Keys in the hotkey-block
MACHINE
Opens up the operating area "Machine" (in operating mode “JOG”, “MDA”, “Auto”).
Corresponds to the yellow Horizontal soft key 1 (HSK) “Machine”

PROGRAM
Opens up the operating area "Program".
The key corresponds to the yellow HSK 3 “Program”.

OFFSET
Opens up the operating area "Parameter” (Tool list, Tool wear, Magazine, Work offset,
User variable, Setting data). The key corresponds to the yellow HSK 3 "Parameter".

PROGRAM MANAGER
Opens up the operating area "Program manager“.
The key corresponds to the yellow HSK 4 "Program Manager".

ALARM
Opens up the actual Alarm list-window.
The key corresponds to the VSK 1 (vertical soft key)"Alarm list" in the operating area
“Diagnostics”.

CUSTOM
This key is customized by the machine manufacturer.
See the machine manufacturer’s documentation

2.4 Keys in the Cursor-Block

ALARM CANCEL
Clears an active alarm shown in the alarm and mes-sage line that is identified
with this symbol.

CHANNEL
Selects a channel from 1 - n.

HELP
Opens the context-sensitive help window in a split-screen view. In case of the
G-Code editor the help documentation with intelligent support for program-ming
instructions is called up.

NEXT WINDOW
Activates the next subwindow in the actual working window. By pressing “CTRL
+ NEXT WINDOW“ in the G-Code editor window you can jump to the first line
of the program code.

PAGE UP or PAGE DOWN

Paging up or down in a directory or the work plan.

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 ƒ 3.0 Operating mode "JOG"
“JOG” mode is used for the following preparatory actions:
• Reference point approach, i.e. calibration of the position measuring system
• Preparing a machine for executing a program in automatic mode, i.e. measuring tools,
measuring the workpiece and, if necessary, defining the work offsets used in the program
• Traversing axes, e.g. during a program interruption
• Positioning axes

Selecting the operating mode “JOG”

The operating mode "JOG" can be selected as follows:

Press the “JOG” button on the machine control panel (MCP). The operating
mode “JOG” opens directly.

OR

Press the button “MENU SELECT“on the machine control panel.

Press the VSK 1 “JOG” in the yellow vertical softtkey bar on the right hand side
of the screen to switch directly to the operating mode “JOG”

Next, switch to the operating area “Machine” by pressing the “MACHINE” key on
the operator panel or on the keyboard or press the “MENU SELECT“-key on the
operator panel and the yellow HSK 1 “Machine“.

ƒ 3.1 Selecting the function "Measure tool"

Measuring tool manually – Diameter (X axis) measurement.
When measuring manually, traverse the tool manually to a known reference point in order to
determine the tool length, the diameter. The Sinumerik Operate then calculates the tool„s offset
data from the position of the tool carrier reference point and the reference point.

By pressing the HSK 4 "Meas. tool" the measure tool VSK-bar

opens on the left side of the screen.

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 By pressing the VSK 1 "Manual" the following input mask opens.

By pressing the VSK 2 "Tool" the tool list opens. Select the required tool
from the list.

By pressing the VSK 3 "X" the input mask for the manual length
measurement of the X-axis is called up.

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 By pressing the VSK 7 "Z" the input mask for the manual length
measurement of the X-axis is called up.

By pressing the VSK 8 “Back” you switch back to the main screen of the
sinumerik Operate.

Measuring tool manually – Length (Z axis) measurement.

By pressing the VSK 2 "Tool" the tool list opens. Select the required tool
from the list.

By pressing the VSK 4 "Z" the input mask for the manual length
measurement of the Z-axis is called up.

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 By pressing the VSK 7 "Z" the input mask for the manual length
measurement of the Z-axis is called up.

By pressing the VSK 8 “Back” you switch back to the main screen of the
Sinumerik Operate.

ƒ 4.0 Operating area “Parameter” or Tool

management
All tools and also all magazine locations that have been created or configured in the NC
are displayed in the lists in the Tool area. All lists display the same tools in the same
order. When switching between the lists, the cursor remains on the same tool in the
same screen segment.

The lists have different parameters and soft key assignments. Switching between lists is
a specific change from one topic to the next.
● Tool list
All parameters and functions required to create and set up tools are displayed.
● Tool wear
All parameters and functions those are required during operation, e.g. wear and
monitoring functions, are listed here.
● Magazine
You will find the magazine and magazine location-related parameters and functions for
the tools/ magazine locations here.
● Work offset
You will find the zero/work offset & base offset are displayed.

The operating area “Parameter“ can be opened from every operating modes (“JOG”, “MDA”,
“AUTO”).

Press the “OFFSET”-key on the keyboard.

The operating area “Parameter“respectively the “Tool list” opens directly.

OR

Press the “MENU SELECT“-key on the operator panel.

Then switch to the operating area “Parameter” by pressing the HSK 2

“Parameter on the operator panel.

By pressing the HSK 1 “Tool list” the tool list win-dow opens.

By pressing the HSK 2 “Tool wear“ the tool wear list opens

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 By pressing the HSK 4 “Magazine“ the “Magazine” window opens.

By pressing the HSK 5 Work offset“ the “Work off-set” window opens.

By pressing the HSK 6 “User variable“ a list with all “R variables” opens.

By pressing the HSK 8 “Setting data” the “Working area limitation” window
opens.

By pressing the VSK 1.1 “Tool measure” the “Measuring tool” window
opens.

By Pressing VSK 1.2 “ New tool” the vertical soft key bar for creating new
tools as per requirement.

By pressing the VSK 1.3 “Edges” the vertical soft-key bar for assigning new
cutting edges. If a tool has several cutting edges each edge gets its own set
of correction data.

By pressing the VSK 1.4 “Further data” more information about a tool will be
displayed. This function is only available for tools which have additional
information.

By pressing the VSKs 1.5 ”Unload” or “Load” the actual selected tool will be
unloaded from or loaded to the magazine.

By pressing the VSK 1.6 “Delete tool” the selected tool will be deleted from the
tool list.

By pressing the VSK 1.7 “Magazine selection” with each press of the softkey
you switch from the “NC memory” window to the “Magazine” window and from
the “Magazine” window back to the “NC memory” window.

By pressing the VSK 1.8 “Extend” on the operator panel the extended vertical
soft key bar 2 opens on the right hand side of the screen.

ƒ 4.1 Selecting the function “Tool list”

By pressing the HSK 1 “Tool list” the tool list window opens.

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In the tool list all parameters and functions that are required to create and set up the tools are
displayed. Each tool is uniquely identified by the location number. The most common tools and
probes for turning, drilling and milling are reachable over the tool list.

Column header Meaning

Loc Magazine location number
Tool name Name of the tool to identify a tool you can enter a tool name as text or/and
number.
ST Replacement tool number (for replacement tool strategy)
• ST1 original tool
• ST2 first replacement tool
D Cutting edge number
In the case of tools with more than one cutting edge, a separate set of
offset data is assigned to each cut-ting edge. The number of possible
cutting edges depends on the control configuration (maximum 9).
Length X/Z Tool length compensation in the X and Z direction
Radius/ Diameter Tool radius/diameter
Radius of the cutting edge in case of turning tools Type 500 - 560
Radius or diameter in case of rotating tools
Radius or diameter of the ball in case of probes type 580 and 711
Reference direction
Holder angle for roughing and finishing tools
The reference direction for the holder angle specifies the cut direction.
N Number of teeth: for all milling tools
Holder angle Holder angle of turning tools for
• Roughing tool type
• Finishing tool type 510

Loc width Width of the cutting edge of Groove/parting insert type 520
Cutting tool type 530

Tip angle Tip angle for

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 • Twist drill type 200
• Center drill type 220
• Countersink type 230

Pitch Pitch for tap type 240

Drill rad. Drill radius for Rotary drill type 560

Cutting edge angle Cutting edge angle for turning tools

• Roughing tools type 500
• Finishing tools type 510 (refer to holder angle)
Loc. len Insert length for
• Roughing tools type 500
• Finishing tools type 510
• Plunge cutter type 520

Direction of spindle rotation

Turning tools and non-driven tools: direction of the main spindle
Powered tools for milling and boring: direction of the tool spindle

Coolant 1 and 2 can be switched off and switched on.

ƒ 4.2 Creating a new tool

Follow the below steps:

Note: Standing on the empty row select the “new tool” option

By pressing the VSK 1.2 “New tool “ the “New tool - favorites“ window opens.

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Select from the list as per tool technology.

Next select OK soft key.

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 ƒ 4.3 Zero offset basics
The machine zero and workpiece zero are not necessarily identical. The distance
between the machine zero and workpiece vary in accordance with the type of tool and
the way it is clamped. This zero offset is taken into account during execution of the
program and can be a combination of different offsets.

Base offset: The base offset is a zero offset that is always active. If you have not
defined a base offset, its value will be zero. You determine the base offset via "Measure
workpiece zero”

Zero/work offset: Every zero offset (G54 to G57, G505 to G599) consists of a coarse
offset and a fine offset. You can call the work offsets from any sequence program
(coarse and fine offsets are added together). You can save the workpiece zero, for
example, in the coarse offset, and then store the offset that occurs when a new
workpiece is clamped between the old and the new workpiece zero in the fine offset.

ƒ 4.4 Selecting the function “Work offset“

By pressing the HSK 5 “Work offset“.“ the “Work offset - active” window opens.

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Above screen you will find the active system offset.

Display area Description

By pressing the VSK 2 “Active” for all installed axis
all current active offsets will be displayed, as well as as all active system
offsets. Fields in the work offset list with a light blue back-ground can not be
altered.
By pressing the VSK 3 “Overview” the active offsets and system offsets are
displayed for all set-up axes.

By pressing the VSK 3 “Base“ for all installed axis the channel specific basic
work offsets are displayed in coarse offset and fine offset. The values can be
changed directly in the “Work offset - basic” window,

ƒ 4.5 Settable zero offset

All settable offsets, divided into coarse and fine offsets, are displayed in the "Work offset -
G54...G57" window. Rotation, scaling and mirroring are displayed.

Selecting the function “Work offset - G54...G57”

By pressing VSK 4 G54...G57“the following window opens.

Displaying and editing settable zero offset

Press the “MENU SELECT“-key on the operator panel, then the HSK 2 “Parameter” to open the
operating area “Parameter”. Alternatively press the “OFFSET”-key on the keyboard. .
Press the HSK 5 “Work offset“.

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 ƒ 5.0 Operating area “Program”
In the program manager all parameters and functions that are required to create workpiece
directory, part program & sub-program & set up program, are displayed.

Press the “MENU SELECT“-key on the operator panel.

The following screen of the Sinumerik Operate will be displayed.

Press the HSK 3 “Program“

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The NC main memory
The memory structure shown in the picture below, with the 3 main directo-ries:
• Part programs
• Subprograms
• Workpiece
is always available on the NC, and does not have to be created

Directories:
Directories are displayed with a folder icon in the program manager window and have the
extension *.DIR (Directory) or *.WPD (work piece directory).

Program/Data:
Programs and data are displayed with a document icon.
Used file extensions:
*.WPD = Workpiece
*.MPF = Main program file
*.SPF = Sub program file

Navigation and program selection

Shown below is a directory tree of the opened NC-memory:

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 With the blue “cursor up” and the “cursor down” keys
You can navigate through the directory tree in the program manager window.

With the blue “cursor to the right” key you can open a folder or subfolder and
select and open file.

Alternatively you can use the yellow “INPUT” key for the same operations.

The VSK 1.1 “Select” loads a selected program into the main memory of the
NC, ready for machining.

The VSK 1.3 “Open” loads a selected program directly into the program editor
Window, ready for editing.

With the “cursor to the left” key on the keyboard you can close the selected
folders or subfolders and step back one level higher in the directory hierarchy.

Creating a new G code program

A new G code program can be created from the operating modes “JOG”, “MDA” and “AUTO” as
follows:
Press the “Program Manager“-key on the keyboard.
The program manager for creating and administering programs
opens directly

Press the “MENU SELECT“ key on the operator panel.

Press the yellow HSK 1.4 “Program Manager“.

The program manager for creating and administering programs opens.
Then Select a storage drive by pressing the horizontal softkey “NC”.

Press the VSK 2 “New”.

The vertical softkey bar with functions for creating new programs opens.

Press the VSK 3 „programGUIDE G code“, to open the input mask for
creating a new G code program.

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 Here you can create a new main program,

or a new sub program

Enter a name for the program and confirm your input by pressing the VSK 8 “OK”, or abort with
pressing the VSK 7 “Cancel”.

After creating a new program GUIDE program, the program will be loaded into the G code editor
in the operating area “Program”, where all the functions for entering and editing G code
commands and cycles are available (see picture below).

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 ƒ 6.0 Program structure
The NC-programming rules as per DIN 66025, maintaining these rules are of prime importance
for the running capability of the program and also improves the readability. A program consists of
no. of blocks (programming lines) arranged in a sequence which in turn contains no. of words or
commands to be performed by the machine in a single step.

Block structure
G Preparatory or slide or tool motion address

F Feed rates

S Spindle speeds

D Tool compensation

T Tool number

N Line number

M Miscellaneous Functions

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 ƒ 7.0 List of G functions/Preparatory functions.
G00 Rapid traverse – G00 X…Z…
G01 Linear interpolation - G01 X… Z… F….
G02 Circular interpolation clockwise G02 X…Z… CR=…
G03 Circular interpolation ccw G03 X… Z… CR=…
G04 Predefined dwell time S…spindle rotation or F…seconds
G09 Non-modal exact stop
G17 X/Y plane selection – for drilling application
G18 Z/X plane selection – turning
G25 X...Z… Minimum working area limitation – WALIMON/OF
G26 X...Z… Maximum working area limitation - WALIMON/OF
G33 Thread cutting with constant pitch.
G40 Tool nose radius compensation off
G41 Tool nose radius compensation active – left side of the geometry
G42 Tool nose radius compensation active – right side of the geometry
G53 Suppression of current frames – zero offset deactivate – non modal
G54 to G57 Settable zero offset on
G60 Exact stop in whole program – model
G64 Continuous-path mode – model
G70 Inch dimension input
G71 Metric dimensions input
G74 Reference point approach
G75 Fixed reference point
G90 Absolute dimensions
G91 Incremental dimensions
G94 Feedrate in mm/min
G95 Feedrate in mm/rev
G96 Constant cutting speed for turning ON
G97 Constant cutting speed for turning OFF
G450 Transition circle
G451 Point of intersection
G500 Deactivate all settable zero offsets

ƒ 8.0 List of M functions/Miscellaneous

functions
M Miscellaneous function, Max 5 M-codes in single block
M00 Program stop
M01 Optional stop
M02 End of program
M03 Spindle rotation clock wise
M04 Spindle rotation counter clock wise
M05 Spindle stop
M06 Tool change
M17 Sub program end
M30 End of main program

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 ƒ 9.0 Standard turning cycles
Cycles are sub-programs (technology-orientated functions) for the execution of a repeatedly
occurring operation on a work piece. Cycles can be selected comfortably via Soft keys and can
simply be parameterized by means of input masks.

Programmed cycles are inserted in G-Code or step-chain-programs as a program step and can
be reselected and newly set by parameter at any time.
The following functionality is available both in Program guide and Shop turn
¾ Technology turning cycles
¾ Technology drilling cycles.

¾ Turning cycles are classified as follows

1. Cycle930 - Grooving 8. Cycle951 – Stock removal
2. Cycle940 - Undercut form E & F
3. Cycle952 – Contour Stock Removal
4. Cycle940 - Undercut form A,B,C,D,
5. Cycle99 - Threading
6. Cycle99 - Thread chaining
7. Cycle62 - Contour call

¾ Drilling cycles are classified as follows

1. Cycle 81- Centering
2. Cycle82 – Drilling
3. Cycle85 – Reaming
4. Cycle83 – Deep hole drilling
5. Cycle84 - Tapping

ƒ 10.0 Simple programming example with cycles

Objective: A simple turning machining is to be programmed as a G code program, using the
program GUIDE with technology cycles.
ƒ Part drawing:

ƒ Tool layout

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The following tool- and technology data are needed for the programming:
Tool- and technology data
1. ROUGHING_TOOL_80 ( F 0.300 mm/rev)
2. FINISHING_TOOL_35 (F 0.150 mm/rev)
3. PLUNGECUTTER_3 ( F 0.150 mm/rev)
4. THREADING_TOOL_2 ( F 2.000 mm/rev)
5. PLUNGECUTTER_F_3 ( F 0.100 mm/rev)

ƒ Steps
ƒ Follows the below steps to perform above operations
1. First create a new G code program GUIDE-program

Press the “Program Manager“-key on the keyboard

The vertical soft key bar with functions for creating new programs.

Press the VSK 3 „program GUIDE G code“, to open the input mask for
creating a new G code program.

Here you can create a new main program & give name as
“THREAD_SPIGOT”.MPF

Select the OK soft key from Vertical soft key bar

2. Program the first G code lines in the program:

N1 G90 G40 G71 G95 G18
N2 G0 X200 Z300

3. Now insert a blank for the simulation.

For this, press the HSK 1.6 “Various” to open the operating area “Various”.

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 Press the VSK 1 “Blank” to open the parameter mask for the blank.

Insert the values into the parameter mask like displayed below:

Confirm the above inputs by pressing the VSK 8 “Accept”.

The following program line is inserted into the program. Refer below snap

4. Insert now a tool (ROUGHING_TOOL_80) into the program.

Press the VSK 1.1 “Select tool”. The tool list window opens.

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 Press the VSK1.1 “Tool list” from the tool management

Select the VSK1.2 “New tool” to create the new tool in tool management.

Select the “500-ROUGHING TOOL” from the favorites & then OK from VSK1.8

Modify the tool name as”Roughing_tool_80” & its tool data like displayed below:

Later on select the “To program” key from VSK1.1

N4 T="ROUGHING_TOOL_80"

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Above line is inserted into the program by “To program” option.

5. Add the following lines into the program.

N5 M6 D1
N6 G96 S250 LIMS=2000 M3
N7 G0 X102 Z5

6. Program the first stock removal cycle for facing operation

Press the HSK 1.3 “Turning”.

Press the VSK 1 “Stock removal”

The work area for the technology “Stock removal” opens.

Press the VSK 3 “Stock removal 1”, to open the pa-rameter mask for the “Stock
removal 1” cycle
.
7. Fill out the parameter mask like displayed below:

Confirm the above inputs by pressing the VSK 8 “Accept”.

The following program line is inserted into the program:

N8 CYCLE951(100,1,-1,0,-1,0,1,1,0,0.1,12,0,0,0,1,0.3,0,2,1110000)

8. Insert a “contour call” cycle into the program for rough profile operation.

Press the HSK 1.4 “Cont turn”

Press the VSK 1.1 “Contour”

Press the “contour call” VSK1.2 &

.

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Give labels name as LAB1 as “PROFILE” and LAB2 as “PROFILE_1 & acknowledge the screen
with “Accept”

Confirm the above inputs by pressing “Accept” Soft key

The following program line is inserted into the program:

N9 CYCLE62 ("PROFILE",1,,)

Above cycle is used to define rough profile details or sub-program.

9. Insert a “Stock removal” cycle into the program for rough profile operation

Press the “Cont turn” from HSK1.4

Press the “Stock removal” from VSK1.2

Fill out the parameter mask like displayed below:

Reference manual only*  Page 29 
Acknowledge the above cycle with “Accept” soft key.

Stock removal cycles is inserted in the program

N10CYCLE952("OUTPUT",,"",1101311,0.3,0.15,0,2,0.1,0.1,0.25,0.1,0.1,0,1,1,0.1,,,,,2,2,,,0,1,,0,1
2,1100110)

Add the below program line for tool change

N11 G0 X200 Z300

Add the following program lines in the program after M30

N13 PROFILE:
N14 G1 X36 Z0.
N15 X42 ANG=135
N16 Z-25
N17 X60 CHR=3
N18 Z-55
N19 G2 X70 Z-60 CR=5
N20 G1 X90
N21 G3 X100 Z-65 CR=5
N22 G1 Z-90
N23 PROFILE_1:

You will find the cycles & profile in editor screen like displayed below

; ****Finish facing with “FINISHING_TOOL_35”****

10 . Insert a new tool (FINISHING_TOOL_35) into the program.

Press the VSK 1.1 “Select tool”. The tool list window opens.

Press the VSK1.1 “Tool list” from the tool management

Reference manual only*  Page 30 
 Select the VSK1.2 “New tool” to create the new tool in tool management.

Select the “510-FINISHING TOOL” from the favorites & then OK from VSK1.8

Modify the tool name as”Finishing_tool_35” & its tool data like displayed below:

Later on select the “To program” key from VSK1.1

N11 T="FINISHING_TOOL_35"
Above line is inserted into the program by “To program” option.

Reference manual only*  Page 31 
 11. Add the following lines into the program.
N12 M6 D1
N13 G96 S300 LIMS=2000 M3
N14 G0 X44 Z5

12. Program the stock removal cycle for finish facing operation

Press the HSK 1.3 “Turning”.

Press the VSK 1 “Stock removal”

The work area for the technology “Stock removal” opens.

Press the VSK 3 “Stock removal 1”, to open the pa-rameter mask for the “Stock
removal 1” cycle
.
13. Fill out the parameter mask like displayed below:

Confirm the above inputs by pressing “Accept” Soft key

Stock removal cycles is inserted in the program

N16 CYCLE951(100,0.1,-1,0,-1,0,1,1,0,0.1,22,0,0,0,1,0.15,0,2,1110000)

14 Insert a “contour call” cycle into the program for finish profile operation.

Press the HSK 1.4 “Cont turn”

Press the VSK 1.1 “Contour”

Press the “contour call” VSK1.2 &

Give labels name as LAB1 as “PROFILE” and LAB2 as “PROFILE_1 & acknowledge the screen
With “Accept”

Reference manual only*  Page 32 
Confirm the above inputs by pressing “Accept” Soft key

The following program line is inserted into the program:

N17 CYCLE62 (, 2,"PROFILE","PROFILE_1")

Above cycle is used to define finish profile details or sub-program

15. Program the stock removal cycle for finish profile operation

Press the “Cont turn” from HSK1.4

Press the “Stock removal” from VSK1.2

16. Fill out the parameter mask like displayed below:

Reference manual only*  Page 33 
Confirm the above inputs by pressing “Accept” Soft key

Stock removal cycle is inserted in the program

N18
CYCLE952("OUTPUT2",,"",1101321,0.15,0.15,0,2,0.1,0.1,0.25,0.1,0.1,0,1,1,0.1,,,,,2,2,,,0,1,,0,12
,1100110)

Add the below program line for tool change

N19 G0 X200 Z300

17. Insert a new tool (FINISHING_TOOL_35) into the program.

Press the VSK 1.1 “Select tool”. The tool list window opens.

Press the VSK1.1 “Tool list” from the tool management

Select the VSK1.2 “New tool” to create the new tool in tool management.

Select the “520-“PLUNGER CUTTER” from the favorites & then OK from VSK1.8

Modify the tool name as “Plunger cutter_3” & its tool data like displayed below:

Reference manual only*  Page 34 
 Later on select the “To program” key from VSK1.1

N20 T="PLUNGE CUTTER_3"

Above line is inserted into the program by “To program” option.

18. Add the following lines into the program.

N21 M6 D1
N22 G96 S120 LIMS=1500 M3
N23 G0 X64 Z5

19. Program the Grooving cycle.

Press the HSK 1.3 “Turning”.

Press the VSK 1.2 “Groove”.

Reference manual only*  Page 35 
Select the “Groove1” VSK1.4 which is highlighted with red color.

Confirm the above inputs by pressing “Accept” Soft key

Groove cycle is inserted in the program

N24 CYCLE930(60,-45,6.23673,8,5,,0,10,10,1,1,1,1,0.2,2,1,10130,,1,30,0.15,1,0.1,0.1,2,10)

Add the below program line for tool change

N25 G0 X200 Z300

20. Insert a new tool (FINISHING_TOOL_35) into the program.

Press the VSK 1.1 “Select tool”. The tool list window opens.

Reference manual only*  Page 36 
 Later on select the “To program” key from VSK1.1

N26 T="FINISHING_TOOL_35"
Above line is inserted into the program by “To program” option.

21. Add the following lines into the program.

N27 M6 D1
N28 G96 S180 LIMS=2000 M3
N29 G0 X44 Z5
;****UNDERCUT OPERATION, WITH VNMG120404****

22. Program the undercut cycle.

Press the HSK 1.3 “Turning”.

Press the VSK1.3 “Undercut”

Press the VSK1.5 “ Undercut thrd DIN”

23. Fill out the parameter mask like displayed below:

Reference manual only*  Page 37 
Confirm the above inputs by pressing “Accept” key

Programmed cycle inserted in the program.

N30 CYCLE940(42,-25,"B",1,1,0.1,13,,,,,30,60,2,0.1,0.1,0.1,15,,,2,1000)

Add the below program line for tool change

N32 G0 X200 Z300

20. Insert a new tool (THREADING_TOOL_2) into the program.

Press the VSK 1.1 “Select tool”. The tool list window opens.

Press the VSK1.1 “Tool list” from the tool management

Select the VSK1.2 “New tool” to create the new tool in tool management.

Reference manual only*  Page 38 
Select the “540-“THREADING TOOL” from the favorites & then OK from VSK1.8

Modify the tool name as “Threading tool_2” & its tool data like displayed below:

Later on select the “To program” key from VSK1.1

N32 T="THREADING_TOOL_2"

Above line is inserted into the program by “To program” option.

Reference manual only*  Page 39 
 21. Add the following lines into the program.
N33 M6 D1
N34 G95 S800 M4
N35 G0 X44 Z5

22. Program the Threading cycle.

Press the HSK 1.3 “Turning”.

Press the VSK 1.4 “Thread”.

23. Fill out the parameter mask like displayed below:

Confirm the above inputs with “Accept” soft key

Programmed cycle is inserted in the program:

N36
CYCLE99(0,42,22,,1,1,1.22688,0.05,30,0,5,2,2,1310103,4,2,0.3,0.5,0,0,1,0,0.508068,1,,
,,102,0)

24. Add the final blocks into the program to end the program
N33 M6
N37 G0 X200 Z300
N38 M5 M01
N39 M30

Lastly, start the simulation of the program.

Press the HSK 1.7 “Simulation” to open the simulation window.
The control calculates the simulation and shows the simulation in a side view.

Reference manual only*  Page 40 
3D Simulation snap.

Reference manual only*  Page 41 
Cut section

*-This manual Developed for Easy reference to user. Refer Docon CD for detailed Learning

Reference manual only*  Page 42 
SINUMERIK 828D BASIC T

The all-round talent for

standard turning machines

SINUMERIK 828D BASIC T represents Highlights

the perfect getting-started solution • Compact, rugged and maintenance-free operator
in the 828D class. Together with panel CNC
SINAMICS drives and motors, it is • Comfortable program and parameter input via
accurately tailored to the requirements QWERTY keyboard
of modern standard turning machines. • Maximum machining precision with
Powerful CNC functions combined 80-bit NANOFP accuracy
with a unique 80-bit NANOFP accuracy • SINUMERIK® Operate graphical user interface
facilitate maximum workpiece • Intelligent kinematic transformations for
precision with minimum machining milling and drilling machining on face and
times. Thanks to a flexible CNC pro- peripheral workpiece surfaces
gramming language and the unique • ShopTurn: Minimum programming time for the
ShopTurn workstep programming, both production of individual parts and small-scale series
largescale production parts as well as • programGUIDE: Minimum machining time and
individual workpieces can be pro- maximum flexibility for the production of
grammed and machined with large-scale series
maximum efficiency. • Unique range of technology cycles – from the
Featuring powerful kinematic transfor- machining of arbitrary turning and milling contours
mations and a comprehensive set of with residual material detection to process measuring
technology cycles, SINUMERIK 828D • Animated Elements: Unique operator and program-
BASIC T is also perfectly equipped for ming support with animated graphic sequences
demanding machining applications • State-of-the-art data transmission via USB stick,
with driven tools. SINUMERIK 828D CF card and factory network (Ethernet)
BASIC T thus sets new standards in • Easy Message: Maximum machine availability thanks
the class of compact CNC controls for to process monitoring based on text messages (SMS)
workshops.

siemens.com/sinumerik
 CNC hardware • Large selection of position patterns for drilling
• Panel-based high-performance CNC control and milling operations
• Rugged operator panel front made of die-cast • Geometry calculator for free contour entries
magnesium • Automatic detection and machining
• Fully fledged integrated QWERTY keyboard of residual material*
• 8.4” TFT color display • Automatic measuring cycles with
• Maintenance-free design logging function*
(without fan and buffer battery)
Graphic functions
CNC performance data and functions • Animated Elements: Input help system for machining
• 80-bit NANOFP accuracy parameters with animated graphic sequences
• Multi-edge machining* • Context-sensitive graphical online help system
• Acceleration with jerk limitation • Graphical CNC simulation with plane representation
• Dynamic feedforward control • Graphical CNC simulation with 3D representation*
• 4-axis simultaneous interpolation (X, Y, Z, rotary axis)
• Linear, circular and helical interpolation CNC operation in setup mode (JOG)
• A-, B-, C-spline interpolation* • TSM input mask for easy machine
• Rigid tapping function enabling
• Oriented spindle stop • Turning cycle for the pre-machining
• Inch/metric selection of blanks and clamping jaws
• FRAME concept for individual coordinate • Manual and automatic tool measuring
transformation, rotation, scaling and mirroring • Manual workpiece measuring
• 50 setable work offsets
• Synchronized actions and rapid auxiliary function output CNC operation in automatic mode
• TRANSMIT for face machining with driven tools* • Block search function for CNC programs with automatic
• Cylinder transformation* provision of position, tool, spindle, feed and auxiliary
• Cylinder transformation with tool radius correction for function information
parallel-walled grooves (machine with Y axis required)* • Program control with single block machining, dry run
feed, program test and skip levels
CNC programming • Simultaneous graphical recording of current
• SINUMERIK G-code programming with high-level lan- CNC machining*
guage commands for the programming of medium- and
large-scale production parts CNC tool management
• programGUIDE: Technology cycle support for SINUMERIK • Display of tool and magazine data on one screen
G-code programming • Tool management with readable tool names
• ShopTurn workstep programming for the efficient • Loading/unloading function for easy turret allocation
programming of individual parts and small-scale series* • Number of tool cutting edges: 160
• Integrated ISO code interpreter • Tool management with service life monitoring
• Program manager with readable program names • Tool management with replacement tools*
• Program manager with unrestricted access to all
memory media CNC memory and communication
• Buffered CNC memory: 1 MB
CNC technology cycles • CNC memory expansion via user CF card on the
• Technology cycles available for programGUIDE and operator panel front (>16 GB)
ShopTurn workstep programming • Serial data transmission via RS232C interface
• Standard technology cycles (alternatively to Easy M
­ essage)
‒ Turning, drilling and milling cycles for standard • Data transmission via USB interface on the operator
geometries panel front
• Data transmission via CF card interface on the operator
‒ Simple contour stock removal cycle
panel front
• Advanced technology cycles*
• RCS Commander: Data exchange via the front-side
‒ Asymmetric grooves Ethernet interface with a notebook PC
‒ Combined drilling and thread milling • 100 Mbit/sec TCP/IP Ethernet interface for connection
‒ Thread milling to a company network*
‒ Multi-edge milling • Easy Message: Process monitoring via cell phone (SMS)
‒ Engraving on the basis of the GSM mobile communications
‒ Extended contour stock removal cycle with blank standard (optional SINAUT GSM quad-band modem
segmentation required)
‒ Contour plunge cutting and plunge turning • Remote diagnostics* (optional modem required)
‒ Milling of contour pockets and spigots
(with up to 12 islands) *CNC option

The information contained in this brochure merely comprises general descriptions

Siemens AG Subject to changes without prior notice or performance characteristics, which may not always be applicable in the described
Industry Sector Order No.: E20001-A1210-P610-X-7600 form to the specific application case or may change due to product advancement.
Motion Control Systems Dispo 06311 The desired performance characteristics shall only be binding if they are expressly
P.O. Box 31 80 SCHÖ/30854 GD.MC.MT.STAN.52.1.15 specified upon contract conclusion.
91050 ERLANGEN SB 04113.0
All product designations may be brands or product names of Siemens AG or other
GERMANY Printed in Germany sub-suppliers, whose utilization by third parties for their rights may violate the rights
© Siemens AG 2011 of the owner.