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SINUMERIK 802D solution line

Machine Controller Milling Handbook

Training Manual Edition 2006.7

Training Material

SINUMERIK 802D sl

Operating, Programming

and Service

Milling

Valid for

Control Software

SINUMERIK 802D sl 1.2

Edition 07.2006

Module content for end users.

Operating and Programming

CNC Basic Principles Milling C102

Basic Program Structure C98

Modality (preparatory functions) C89

Commonly used G functions - M C92

Basic Miscellaneous Codes C97

Additional G functions - M C94

Create part program - Milling C77

Cycles - M C99

File Management - CF card C59

Power On and Referencing C69

Axis Control - Jog C82

Control Structure / Navigation C70

MDA - Milling C76

Tools Turning—Milling functions C83

Tools Milling - work planes C72

Work offsets - Milling C74

Automatic C81

RCS 802 Data transfer tool C1

ISO Dialect programming - M C95

Service

Pushbutton test (MCP) C8

LED Diagnosis Drive C9

LED Diagnosis HMI C10

MCPA signal test C11

Save Data Backup C17

Restore Data Backup C18

External data backup and restore C19

Diagnose PLC program C28

Diagnose PLC alarm C31

PLC periphery (HW diagnosis) C32

Alarm structure C37

Editing of NC Machine data C41

Drive Diagnostic parameters C53

SINUMERIK 802D sl Operating and Service Training Manual Page 1 C102

C102

CNC Basic Principles Milling

C102

1 Brief description

Module Objective:

Upon completion of this module you can understand the basic functionality and requirements of a

CNC controller

Module description:

CNC machines replicate the functions of a manual machine through the use of a sequential program,

this program replicates the movements of a manual machine through the so called “CNC program” .

Geometric relationships of the component to the machine are achieved with (Tool and component)

numeric compensations. These compensations mathematically compensate the difference between

component, Tool and machine.

• Fundamentals of CNC Machines

Module Content:

Fundamentals of CNC

Machines Section 2

Notes

SINUMERIK 802D sl Operating and Service Training Manual Page 2 C102

C102

Fundamentals of CNC Machines

Section 2

The difference between a Manual machine and a CNC machine is a logical

difference based upon numerical values. This overview module and the

following CNC modules should help explain the myth of CNC.

ITS ONLY NUMBERS. No magic !!

Reference position Z

Reference position X

Zero Offset

Tool Offset

Zero Offset

SINUMERIK 802D sl Operating and Service Training Manual Page 1 C98

C98

Basic program structure

C98

1 Brief description

• Basic structure

• Basic structure for turning

• Basic structure for milling

Basic structure for

turning

Basic structure for

milling

Section 3

Section 4

Basic structure

Section 2

Module objective:

Upon completion of this module you will understand the basic structure of an NC program

Module description:

We use a basic structure when writing a program to give some kind of order to the program, this will

also help when performing a “Block search”.

Module content:

Notes

SINUMERIK 802D sl Operating and Service Training Manual Page 2 C98

C98

Section 2 Basic structure

2.1 Basic structure of NC program

There are five basic parts to an NC program.

1. Basic startup G functions.

2. Call tool and set spindle speed, feed, coolant.

3. Set geometry to cut component.

4. Tool to safe position

5. End of program

G00 G90 G94 G40 G17 G71 Basic G functions for program

6 Call tool etc

G95 S1500 F0.15 M08

G00 G54 X0.0 Y0.0 Z50.0

….

…

. Geometry for component

….

G00 G40 Z50.0

X0.0 Y200.0 Z200.0 Safe position for tool change

M30 End of program

You will note that for each tool there is always :

• Call tool etc

• Geometry for component

• Safe position for tool change

This will be the same for ever tool that is written in the NC program

If you keep to a good basic structure, this will make the program safer to

run and easier to perform a block search.

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