Die and Mold

Manual Edition 04/2004
sinumerik
Tool and Mold Making
SINUMERIK 810D/840D
s
s First for the
theory 1
Machine operators –
at the machine 2
References
SINUMERIK 810D/840D Information for
Tool and Mold Making programmers 3
Contents Page
4.1 Overview References

of higher-order
Manual functions 4.2 4
4.2 Index 4.10
Valid for
Control software version
SINUMERIK 840D 6
SINUMERIK 840DE (Export version) 6
SINUMERIK 840D powerline 6
SINUMERIK 840DE powerline 6
SINUMERIK 840Di 2
SINUMERIK 840DiE (Export version) 2
SINUMERIK 810D 3
SINUMERIK 810DE (Export version) 3
04.04 Edition
0 Introduction
Printing history, Trademarks
SINUMERIK® Documentation
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© Siemens AG 1995 - 2004. All rights reserved. Subject to change without prior notice
Order No. 6FC5095-0AB10-0BP0 Siemens Aktiengesellschaft

Printed in the Federal Republic of Germany
0.2
© Siemens AG 2004 All rights reserved. SINUMERIK 840D Manual, Tool and Mold Making 04.2004
Introduction
Contents 0
Contents
First for the theory
1.1 Introduction.......................................................................................... 1.2
1.2 What are the needs of tool and mold making? .................................... 1.3
1.3 Milling with 3 axes, 3 + 2 or 5 axes?.................................................... 1.6
1.4 What moves and how? ........................................................................ 1.8
1.5 Machine-independent CNC programs ............................................... 1.12
1.6 Theory of tool radius compensation .................................................. 1.14
1.7 What are frames? .............................................................................. 1.17
1.8 Precision, speed, surface quality....................................................... 1.19
1.9 Structure of CNC mold making programs.......................................... 1.22
1.10 Orientation in 5-axis applications....................................................... 1.23
Machine operators – at the machine
2.1 Workpiece – determining the zero point .............................................. 2.2
2.2 Gauging tools .................................................................................... 2.13
2.3 Program data transfer........................................................................ 2.16
2.4 Testing a program.............................................................................. 2.17
2.5 Calling and executing a program....................................................... 2.18
2.6 Interrupting a program ....................................................................... 2.20
2.7 High-speed settings – CYCLE832..................................................... 2.25
2.8 ShopMill ............................................................................................ 2.28
Information for programmers
3.1 Introduction.......................................................................................... 3.2
3.2 Kinematic-independent CNC programs............................................... 3.3
3.3 Five-axis transformation – TRAORI..................................................... 3.5
3.4 Tool orientation – A3= B3= C3=, ... ..................................................... 3.6
0.3
0 Introduction
Contents
3.5 High-speed settings – CYCLE832....................................................... 3.9
3.6 Feedrate proÞle – FNORM, FLIN, ... ................................................. 3.18
3.7 Orientation interpolation – ORI... ....................................................... 3.19
3.8 Tool offsets – CUT3DFS, ... ............................................................... 3.21
3.9 Programming at the machine ............................................................ 3.22
3.10 Example – bending device for pipes.................................................. 3.25
3.11 Example – motor cycle headlight....................................................... 3.36
References
4.1 Overview of higher-order functions...................................................... 4.2
4.2 Index.................................................................................................. 4.10
0.4
Contents Page
1.1 Introduction 1.2
1.2 What are the needs of tool and mold making? 1.3
1.3 Milling with 3 axes, 3 + 2 or 5 axes? 1.6
1.4 What moves and how? 1.8
1.5 Machine-independent CNC programs 1.12
1-6 Theory of tool radius compensation 1.14
1.7 What are frames? 1.17
1.8 Precision, speed, surface quality 1.19
1.9 Structure of CNC mold making programs 1.22
1.10 Orientation in 5-axis applications 1.23
1
1.1 First for the theory
Introduction
1.1 Introduction
5-axis machining of complex parts, in tool and mold making in particular, is based on the CAD - CAM
- CNC process chain.
The aim of this brochure is to help both CNC programmers at the CAM workstation and operators at
the machine to do their job, and to simplify communication between the CAM station and the machi-
ne.
Automotive
trim
Sinumerik 840D features powerful, sophisticated functions, the intelligent use of which greatly simpli-
Þes the entire 5-axis programming and machining process and improves production results.
1.2
© Siemens AG 0000-2004 All rights reserved. SINUMERIK 840D Brochure, Tool and Mold Making 04.2004
What are the needs of tool and mold making?
1.2
1.2 What are the needs of tool and mold making?
Prototype Object design standards in all areas of applicati-

construction on are becoming ever more demanding.
Increasingly, ergonomics, air drag coefÞcient
or simply aesthetics call for rounded forms. In
addition, processes have to be faster and even
more accurate.
The design comes primarily from CAD systems,
the machining programs for freeform surfaces
from CAM stations.
Nevertheless, the skilled machine tool operator

still bears the technological responsibility for the
quality of the mold and of the entire tool.
Impeller Sinumerik 840D from Siemens is a control sys-

tem that is precisely tailored to the requirements
of tool and mold making
– in the traditional 2 ½ D range, in
3-axis machining as well as in the 5-axis and
high-speed range:
! good operability
! user-friendly programming at the
machine
! optimum performance in the
CAD – CAM – CNC process chain
! maximum quality control at
the machine
Valve
1.3
What are the needs of tool and mold making?
Freeform
5-axis machining in
1
surface modern milling centers
The demands placed on molds, surface quality

and machining speed for stock removal, in tool
and mold making in particular,
are rising dramatically:
To obtain optimum cutting conditions when

machining surfaces with a three-dimensional
curve "
...
Inclined surface 2
with hole ... to machine geometries anywhere in the area
# (the setting angle of the tool axis must be
able to be varied) ...
3 + 2 axes
Deep cavity 3
... or to mill deep cavities $ ...
Dynamic 5-axis machining
In addition to the 3 linear axes X, Y and Z, 2

rotary axes A, B or C are also
required.
1.4
What are the needs of tool and mold making? 1.2
Machine movement
The linear axes X, Y and Z are used to

approach a tool position in the work area.
2 rotary axes, e.g. B and C, are used to

change the tool setting, the tool orientation.
Theoretically, with 3 linear axes and 2 rotary

axes, any point in the area can be approached
with the desired tool orientation.
CNC programming
Direction
vector for tool orientation
A set position in the CNC program is described
with the coordinate axes X, Y and Z. To describe
the tool orientation we recommend using the
direction vector A3, B3, C3, so that the orientati-
on can be programmed independently from the
kinematics.
C3
A3 B3
For certain tasks a Þxed orientation is perfectly adequate, e.g. on inclined planes. In many cases, ho-
wever, it is desirable for the tool orientation to change during the traversing movement. This is known
as 5-axis simultaneous machining. The control system has to interpolate 2 rotary axes in addition to
the 3 linear axes. With modern 5-axis control systems like Sinumerik 840D you can program elements
such as inclined holes and pockets with a Þxed tool orientation directly on the machine and adjust the
key machining parameters in CAM programs.
1.5
Milling with 3 axes, 3 +2 or 5 axes?
1.3 Milling with 3 axes, 3 + 2 or 5 axes?

Freeform surfaces with uniform convex curves in particular are conventionally produced with 3
controlled axes. For deep cavities or frequent curvature changes, however, 5 controlled axes are
required.
Sinumerik 840D naturally supports all machining strategies.
" 3 axes
Controlled path axes X, Y, Z
1
The orientation of the cutter remains unchanged along the entire cutter path. The cutting conditions at
the cutter tip are never perfect.
# 3 + 2 axes
Fixed rotary axes, e.g. A, C (table)
In these machine tools the orientation of the tool or the position of the table can be altered, e.g. by
resetting.
In the picture on the left the cutter is working with optimum cutting conditions. The cutting conditions
deteriorate as the cutter moves up towards the top or to the side of the workpiece. In order to obtain
optimum cutting conditions here too, the table is swiveled. To machine a freeform surface completely,
the table often has to be swiveled several times in various directions.
1.6
Milling with 3 axes, 3 +2 or 5 axes?
1.3
$ 5 axes:
Controlled rotary axes, e.g. A, B
Advantage: The orientation of the tool can be optimized along the entire path, synchronously to the
linear movement of the tool. In this way optimum cutting conditions are maintained throughout the
path.
1.7
What moves and how?
1.4 What moves and how?

The design of 5-axis milling machines
1 2
1.8
What moves and how?
1.4
4 5
A 5-axis machine can control tool movements in 5 axes: the 3 familiar

linear axes plus an additional 2 rotary axes. The two rotary axes have different
kinematic solutions. The most common ones are shown here diagrammatically. Machine tool manuf-
acturers are constantly developing new kinematic solutions for different requirements. With Sinumerik
840D, thanks to the integral kinematic transformation, we can also control special kinematics. Howe-
ver, we don‘t want to go into detail about hexapods, etc. here.
2 rotary axes in the head " Fork # nutated *
2 rotary axes in the table $ Rotate/swivel ' nutated *
1 rotary axis in the head, &

1 rotary axis in the table
* Term: If the rotary axis is not perpendicular to a linear axis,

it is referred to as a “nutated” axis.
1.9
What moves and how?
Kinematic-independent programming
Depending on the machine kinematics, completely different machine movements may be required
to machine the same surface. The machine kinematics in example 2 are much more suitable for the
production of this workpiece.
Example
Machining a cylinder jacket surface
1 " Sequence of movements for head/head

kinematics
To describe a simple circumference, descri-
be a semicircle in X/Y with radius = cylinder
radius. During the movement the tool must
rotate around the Z axis so that the cutter is
always perpendicular to the surface.
Sequence of movements for table/table

• Swivel 90° around A
2 # • C axis turns to position +90°,
then 90°
• Y axis moves in a linear direction
USION When programming on a machine with Sinumerik 840D there is generally no need to worry
CONCL about machine kinematics and tool length. All you need to think about is the relative move-
ment between the tool and the workpiece. The control system does the rest.
See below for details of how operation varies according to the machine kinematics.
1.10
What moves and how?
1.4
Inßuence of tool length on machine axis movement
The machine movements required for 5-axis

machining depend on the tool length.
Example
The longer the tool in the example, the
larger the traversing movements of the axis
slides.
Each tool change would require the CNC
program to be recalculated on the CAM system.
When programming on a machine with Sinume-
rik 840D, there is no need to worry about
tool length if tool offset is enabled. The control
system takes care of it automatically.
Note: Depending on the tool length, it can happen that the traversing range of an axis is overrun and
the axis runs on to the limit switch, even though all values in the CNC program are within the work
area. A distinction is made here between the “gross” and “net” work area.
Inßuence of a change in orientation on the movement of the

linear axes
Simple movements can be transformed into a

complex curve by simultaneously changing the
tool orientation.
To mill a straight line with no change of orienta-

tion, the tool holder describes a straight line. If
the orientation changes at the same time, the
tool tip describes a curve. This curve must be
compensated so that the tool tip describes the
desired straight line as the orientation changes.
Machine-independent CNC programs
The examples show that with 5-axis machining it is vital that the CNC programs are not speciÞc to the
machine or tool. This is why Sinumerik 840D features integral 5-axis transformation.
1.11
1.5 Machine-independent CNC programs
TRAORI – Calling 5-axis transformation
Of course we want CNC programs that can be run on various machine kinematics with a range of
tools. For this to be possible, the control system has to compensate the inßuences illustrated below.
Effects of the TRAORI command on Sinumerik 840D:

! The correct traversing movements are generated from the position and orientation data in the
CNC program according to the machine kinematics.
! The current tool length is taken into consideration when calculating the traversing movements.
Example
In the CNC program an orientation change is programmed with no other traversing
movement. The orientation change can be programmed with A3, B3, C3, irrespective of
the machine kinematics.
Without TRAORI
The control system disregards the tool length. It
rotates around the center of rotation
of the axis. The tool tip moves out of position
and does not remain Þxed.
With TRAORI
The control system only changes the orientation,
the position of the tool tip remains Þxed. The ne-
cessary compensating movements in X, Y and Z
are calculated automatically.
TRAORI is usually already called in the CNC

program obtained from the CAM system. The
CNC program then simply contains the points
X, Y and Z which are to be approached, and the
direction vector A3, B3, C3, which describes the
tool orientation.
In other words, the CNC program contains only

geometrical and orientation data.
1.12
1.5
Sample CNC program
Swivel.MPF ; Program name

N01 TRAORI ; Call 5-axis transformation
N02 T1 F1000 S10000 M3 ; Technology data, tool, speed, etc.
N03 G54 ; Zero offset
N04 G0 X0 Y0 Z5 ; Start point,
A3=0 B3=0 C3=1 Tool parallel to Z axis
N05 G1 Z-1 ; Travel command, infeed
N06 X10 Y0 A3=1 C3=1 ; Linear movement with orientation change to 45° in
the X/Z plane
N07 TRAFOOF ; 5-axis transformation “off”
N07 M30 ; End of program
In this example a straight line is milled from X0 to X10. The tool orientation changes from 90°
to 45°.
With TRAORI there is no need to worry about the actual machine movement when program-
NOTE ming a straight line. The end point is approached exactly, and the tool tip describes a straight
line.
1.13
Theory of tool radius compensation
1.6 Theory of tool radius compensation

Tool compensation makes a CNC program independent of the tool radius. Tool radius compensation
in the 2 ½ D range is a familiar concept. In the 3D range, however, especially with 5-axis milling, it
can be very different.
Inßuence of tool radius in face milling with CUT3DF
For radius compensation in face milling with CUT3DF, it is not enough simply to specify the cutter
geometry. The compensation direction is also required. The compensation direction is calculated
from the surface normal, the tool direction and the tool geometry. This perpendicular is known as
the surface normal or surface normal vector. It is calculated from the current tool orientation and the
perpendicular to the workpiece surface.
In the special case of a spherical cutter, for

example:
For a path in the work area the compensation
must be made perpendicularly to the surface
on which the path is running. This means that
the compensation direction is described by the
normal vector ", #of the surface at the inserti-
on point.
1
The compensation options in Sinumerik 840D
2
allow the tool offset to be calculated using the
surface normal vector. Previously, very few CAM
systems were capable of providing the surface
normal with every CNC block.
Generally speaking, only small radius changes relative to the standard tool (radius used for
NOTE calculations by the CAM program) can be corrected. A smaller cutter radius is easy to calcula-
te but results in a different peak-to-valley height. With a larger radius there is a risk of collision
between the tool and the workpiece contour.
1 2 3 If the surface normal, tool radius and also the

geometry of the cutter tip are known, Sinumerik
840D can calculate the new tool insertion point
PE if tool radius compensation (CUT3DF) is
enabled.
The illustration shows all the dimensions used

by the control system and the relevant geometri-
cal data for the cutter tip.
" End mill

# End mill with corner radius
$ Cylindrical die mill
FN Surface normal
TCP Tool center point
PE Tool insertion point
TB Path tangent
VK Compensation vector
1.14
1.6
Inßuence of tool radius compensation in 5-axis circumferential mil-
ling, taking account of the limitation surface (CUT3DCC)
Example
Milling a pocket with a smaller cutter
" Standard tool (the tool

speciÞed for the program)
1
5
2 # Tool with smaller radius
$ Machining surface, inner surface

6
' Limitation surface, base of pocket
3
& Correction to machining surface
( Correction to limitation surface
TCP PE
Compensation for 5-axis circumferential the aviation industry.

milling
After radius compensation in the machining
If a cutter with a smaller radius than speciÞed surface direction $ the tool tips TCP of the
is chosen, Sinumerik 840D can calculate the cutter with the smaller radius and the standard
new path. tool are at the same level if both tools, as in this
illustration, are the same length.
Here the control system has to take into ac-
count not only that a compensation is required At the same time the cutter engages axially (
in the direction of the machining surface & so that the tool insertion point PE just touches
but also that an infeed is required in the tool the limitation surface. This compensation in the
direction (. direction of the pocket base also requires an
adjustment of the tool in the milling direction.
A typical application for this function can be This is illustrated here by the visible underside
found in particular in structural components in of the tool.
1.15
Overview of available tool compensations

You are already familiar with the standard tool radius compensations in Sinumerik 840D:
G40 Disable tool radius compensation, G41 Tool radius compensation, compensation direction left of
path in circumferential milling, G42 Tool radius compensation, compensation direction right of path in
circumferential milling. G450/G451 deÞnes the behavior at external corners.
Sinumerik 840D also offers other compensation functions, however, a few applications of which we
have already seen on the previous pages. All variants of Sinumerik 840D tool radius compensation
are enabled with G41/42 and disabled with G40.
See the documentation for Sinumerik 840D:
2 1/2D circumferential milling
CUT2D 2 1/2D compensation with compensation plane determined with G17 - G19
CUT2DF 2 1/2D compensation with compensation plane determined by frame
3D circumferential milling
CUT3DC Compensation perpendicular to path tangent and to tool orientation
ORID No orientation changes in inserted circle blocks at external

corners. Orientation movement is executed in the linear blocks.
ORIC Travel path extended with circles. The orientation change

is executed proportionately in the circle as well.
Face milling
CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the

coordinate system deÞned with G17 - G19. Frames have no
inßuence.
CUT3DFF Constant orientation (3-axis). Tool in Z direction of the

coordinate system currently deÞned with frame.
CUT3DF 5-axis with variable tool orientation
3D circumferential milling with limitation surface

(combined circumferential/face milling)
CUT3DCC NC program refers to the contour on the machining surface.
CUT3DCCD NC program refers to the tool center path.
The compensations are activated by appending the appropriate

command G41/G42, e.g.: CUT3DC G41
1.16
What are frames?
1.7
1.7 What are frames?
Coordinate systems
Machine coordinate system " with reference

point, zero offset (G54, G55, ...) are familiar
terms.
1
2 Frames can be used to offset, rotate, mirror and

scale coordinate systems.
Frames are used to describe the position of a

destination coordinate system by specifying
coordinates and angles starting from the current
workpiece coordinate system #. Possible fra-
mes include
! Basic frame (basic offset)

! Settable frames (G54...G599)
! Programmable frames
Coordinate systems and traversing movements
A 5-axis machine can also be used to work on

surfaces that can be offset and rotated anywhe-
re in the area.
The workpiece coordinate system can only be

offset using frames and set in an inclined plane
by rotation.
That is precisely why we need FRAMES. All the

following traversing commands now relate to the
workpiece coordinate system.
1.17
What are frames?
Using frames
When settable zero offset is activated (G54,

G55), the workpiece coordinate system is at
workpiece zero.
With the exception of special machine kine-

matics, the axes are now aligned parallel to the
machine axes.
Using a FRAME this coordinate system can now

be offset and rotated anywhere in the area.
Example
Machining on an inclined plane
When the coordinate system " is rotated into

the inclined plane, a hole for example can
be programmed simply by calling the drilling
cycle.
1
1.18
Precision, speed, surface quality
1.8
1.8 Precision, speed, surface quality
CAD -> CAM -> CNC process chain
CAD ) CAM Many CNC programs for freeform surface machining come from CAM systems. The CAM system
obtains the workpiece geometry from a CAD system.
CAM ) CNC The CAD -> CAM -> (post-processor) -> CNC process chain is particularly important in the machi-
ning of freeform surfaces.
CAD systems construct higher-order surfaces

".
1
For example, in order to be able to mill an entire
surface, or for collision checking, the CAM sys-
tem generally converts the CAD surfaces into a
polyhedron.
2 In other words, the smooth design surface is

approximated by numerous tiny planes #.
This inevitably produces some minor deviations.
The CAM programmer overlays this polyhedron

with tool paths, which the postprocessor uses
to create CNC blocks within the speciÞed error
tolerances. These usually comprise numerous
G1
short straight lines, G1 X Y Z $.
G1 That is why the machining result is a polyhed-

3 ron, i.e. the small planes can be visibly mapped
on the surface.
G1 G1
This can mean that rework is necessary, howe-
ver, which is undesirable.
1.19
Programmable corner rounding
Sinumerik 840D includes various functions

which can help to avoid rework.
One of these is deÞned corner rounding at block

4
boundaries. This involves inserting geometrical
elements ' at the corners, the tolerance of
which can be altered.
Compressor function
2
Linear interpolation at the block transitions leads
1 to acceleration jumps in the machine axes,
which in turn can cause resonance in the machi-
ne elements and can ultimately be detected on
the workpiece surface as a beveled pattern " or
as vibration #.
Analogously to the speciÞed tolerance band "

1 2 3 the compressor combines a sequence of
G1 commands # and compresses them to form
a spline $, which is directly executable by the
control system.
This makes the surface much smoother, since

the machine axes can move more harmoniously
and machine resonance is avoided.
This allows higher traversing speeds and redu-

ces the load on the machine.
1.20
1.8
If the tolerance band for the CAM system is known, this or a slightly higher value should be used
NOTE for the compressor tolerance.
In COMPCAD this value is typically between 1.2 and 1.5 of the programmed chord tolerance of
the CAM system. If this value is not known, the default setting for CYCLE832 should be used as a
starting value.
High-speed setting cycle
With Sinumerik 840D, COMPCAD spline com-

pression " can now be easily switched on and
off in CYCLE832.
The CAM program sequence can be inßuenced

with CYCLE832. It provides technological
support for the machining of freeform contours
1 (surfaces) in the 3- and 5-axis high-speed machi-
ning range. More information about its use can
be found in subsequent chapters.
1.21
Structure of CNC mold making programs
1.9 Structure of CNC mold making programs
A CNC program for machining freeform surfaces is made up of many CNC blocks and is generally not
edited on the CNC control system.
Structure of a CNC mold making program
The most clearly structured CNC program is one in which the CAM programmer uses the following
program structure:
Example
Main program with subroutine call
N10 T1D1
Tool call
N20 M3 M8 S8000 F1000

Technology
Zero point N30 G0 G54 X10 Y10 Z5 ;Settable zero offset

Start position
High-speed N40 CYCLE832(0.01) ;CYCLE832 sets the compressor

setting cycle tolerance and deÞnes other path
conditions.
N50 EXTCALL “Roughing”; Calls the “Roughing” subroutine,

Subroutine
which contains the geometry of the CAM
call
program.
The subroutines contain the typical traversing blocks, which owing to the complexity of the programs
should not be changed.
The zero offset, all technology values, start point and high-speed settings are deÞned in the main
program. The high-speed setting parameters can be used to inßuence the quality of the workpiece.
A well structured CNC program can also be resumed from a chosen point after a program interrupti-
on.
1.22
Orientation in 5-axis applications
1.10
1.10 Orientation in 5-axis applications
A 5-axis machine can position the tool in any orientation to the workpiece, subject of course to the
machine kinematics. In order to move from one orientation to another, intermediate positions must be
interpolated. The path from the start to the end orientation is described in this way.
Just as in the 2D range between 2 points, there

are any number of paths between 2 orientations.
In 2D interpolation we are limited to

! Straight line (G1) "
! Circle (G2, G3) #
! Polynomial, B-spline $ or Fig.
1 2
In orientation interpolation we have a choice of linear interpolation, great circle interpolation, conical
surface interpolation and curve interpolation.
Linear interpolationORIAXES
In linear interpolation from a start " to an end orientation # the necessary rotary axis movements are
broken down into equidistant sections.
This means that the orientation vector does not

describe a deÞned surface.
This interpolation is therefore not always suitable

for circumferential milling.
The movement can be very similar to the surface

of a cone, so it is important not to confuse the
function with conical surface interpolation.
1
2
1.23
Great circle interpolation ORIVECT/ORIPLANE
In this interpolation process the path from the start " to an end orientation # is interpolated in such
a way that the orientation vector runs in the plane that is spanned by the starting vector and the Þnal
vector.
Each rotary axis approaches equidistant angles.

This type of orientation interpolation can be used
for the precise machining of inclined, plane walls
in one block, for example.
Applications:
Structural components in the aviation industry.
ORIVECT should also be used for face milling in
1
mold making applications.
2
Conical surface interpolation ORICONCW

In conical surface interpolation from a start " to an end orientation # the tool moves on a program-
mable peripheral surface of a cone anywhere in the area.
ORICONCW
Interpolation on the peripheral surface of a cone
in the clockwise direction with speciÞcation of the
end orientation and taper direction or aperture
angle of the cone.
ORICONCCW
Interpolation on the peripheral surface of a
cone in the counterclockwise direction with
speciÞcation of the end orientation and taper
direction or aperture angle of the cone.
ORICONIO
with speciÞcation of the end orientation and an
intermediate orientation.
1
2
ORICONTO
with tangential transition and speciÞcation of the
end orientation.
1.24
1.10
Example
Let‘s have a look at an example:
In great circle interpolation the orientation should change from start A3 = sx, B3 = sy, C3 = sz to
end A3 = ex, B3 = ey, C3 = ez. No value is zero, i.e. the orientation is inclined (s = start orientati-
on, e = end orientation).
Reorientation in great circle interpolation takes place in a plane $. The line on the cone is referred
to as a great circle '. In the illustration the C axis rotates through 85°. The A axis swivels from 60°
to 30°. Speed control for the reorientation is continuous.
" = start orientation, # = end orientation
1 A=6
° 0°
= 30
A
C = 85°
1.25
Example
The situation is quite different if interpolation goes through the point &.
This is the case if for example sx = 0 and ex = 0, i.e. the start and end orientation
are parallel to the Y/Z plane.
In this example the A axis should not be allowed to swivel.
What happens next? The C axis starts at 0°, the A axis at 45°, for example.
During the orientation interpolation C remains at 0°, while the A axis

approaches the position &. Here the position of the C axis is undeÞned,
but just one interpolation phase later C must rotate abruptly to 180°,
A moves away from point & and C remains at 180°.
To maintain the orientation speed, i.e. in position &, the

C axis would have to accelerate inÞnitely, which of course is not possible. In this case
we speak of a pole. In conventional 5-axis machines the deÞnition of a pole is that when the Þrst
rotary axis rotates, the tool orientation remains unchanged. In CA kinematics A=0 corresponds to
the pole orientation. To avoid such an extreme speed control, in the vicinity of the pole Sinumerik
840D switches to linear interpolation.
1.26
1.10
Let‘s take another look at great circle interpolation in the vicinity of the pole in practice:
Certain machine kinematics, especially the commonly used fork head, feature poles or singularities.
Example
Example: When milling a pocket with a
45° incline $ the A and C axis rotate harmo-
niously when traversing from one corner to the
other - everything is OK.
In this example the incline is now

85° '.
What happens? The steeper the tool angle, the

faster the C axis has to rotate in the center of
the path in order to sustain the orientation on the
second half of the path.
Incidentally, the pole situation is a physics problem rather than a control technology problem.
In fact Sinumerik 840D alleviates the problem substantially.
Poles can be avoided by appropriate clamping. For example, an inclined chuck can be helpful.
NOTE
1.27
Curve interpolation ORICURVE (spline orientation)
In curve interpolation the movement of the orientation vector is described by the paths at the tool tip
(spline curve ") and the path of a second point on the tool (spline curve #).
To machine an inclined surface by circumferential milling, for example, the upper and lower contour
would be described. This type of interpolation results in a faster path speed and improved surface
quality.
For an overview of orientation interpolation, see section 3.7.
1.28
Machine operators -
at the machine
Contents Page
2.1 Workpiece - determining the zero point 2.2
2.2 Gauging tools 2.13
2.3 Program data transfer 2.16
2.4 Testing a program 2.17
2.5 Calling and executing a program 2.18
2.6 Interrupting a program 2.20
2.7 High-speed settings - CYCLE832 2.25
2.8 ShopMill 2.28
2
2.1 Machine operators - at the machine
Workpiece – determining the zero point
2.1 Workpiece - determining the zero point
Determining the zero offset and basic rotation of the workpiece

about the workpiece axis
Function
Once the machine has been switched on and the reference point approached, the axis positions rela-
te to the machine coordinate system. The position of the workpiece in the machine coordinate system
is signaled to the control system by the zero offset.
Previously, the workpiece was clamped, manually aligned paraxially to the machine axes, and then
the zero offset was determined, e.g. by scratching. By looking at two examples that commonly occur
in practice, we can see how much easier it is with probes and SINUMERIK cycles. We will show how
the control system compensates the basic rotation of the workpiece, eliminating the need for time-
consuming, manual alignment.
Example Determining the zero point + measuring the basic rotation about the tool axis
P3
P4
P1
P2
Task assignment
After being clamped, the workpiece is rotated relative to the machine coordinate system in the wor-
king area. You have to determine the zero offset and the position of the coordinate system, in other
words the basic rotation.
2.2
2.1
Prerequisites
! Probe is calibrated, active and clamped in the spindle; tool offset is valid
! Measuring cycles are installed
! Workpiece is clamped
If only one workpiece is to be machined, as is usually the case in tool and mold making,
NOTE
measurement takes place in JOG mode (as described below). If several similar parts are to be
machined in the same device, two measuring cycles are used in automatic mode (the approxi-
mate zero point must be set up).
Determining the zero offset and basic rotation
Select the “Machine” operating area.

Machine
Call “Jog” mode at the machine control panel.
Measure Call “Measure workpiece”.

workpiece
Call “Corner” measurement.

Corner
1 G54
Select zero offset " for data transfer, e.g. G54, G55, G56 or G57. In this
example G54 was used.
Choose a corner as a reference point by toggling # and then pressing

“Select”.
2.3
2.1 Machine operators – at the machine
To measure a corner in the G17 plane, an offset is measured in X, Y and

a rotation in Z for zero offset. To measure an edge in the Z direction, an
offset is measured in Z for zero offset.
The result of the measuring operation is a frame comprising offset and
rotation.
P3
P4
P1
P2
Using the “axis keys”, position the probe in front of the touch point P1 on
the
workpiece.
Press “NC Start”. The measuring operation proceeds automatically: the

probe approaches the workpiece, trips, and returns to the start position.
Save P1 Save touch point P1.
Save P2 For touch points P2, P3 (P4) position the probe in front of the workpiece
again and proceed as for P1. Note: Point P4 is only required for non-rec-
Save P3 tangular workpieces.
Calculate
corner Press “Calculate corner”:
The control system calculates

a) the X and Y values for the zero offset from the intersection of the two
straight lines
b) the basic rotation of the workpiece coordinate system about the
Z axis.
c) The values are entered in the zero point table, zero offset G54, taking
into consideration the basic zero offset.
An offset in the X-Y plane and a basic rotation about “Z” has now been
determined.
2.4
2.1
Determining the Z value for the zero offset
Measure Go back one level in “Measure workpiece”.

workpiece
Call “Edge” measurement.

Edge
Choose the Z axis.

Z
In the screen form choose G54.
Choose the upper side of the workpiece as the measuring edge.

Position the probe above the workpiece.
Press “NC Start” to start the measuring operation. The Z value is added to
the zero point table.
Determination of the zero point and basic rotation for a 3-axis machine is now complete. If the basic
rotation is not equal to zero, the control system converts programmed, paraxial movements into corre-
sponding XY movements.
Depending on the machine kinematics, two situations

are now possible:
• Effect of zero offset on machines with a If the machine has a fourth axis, e.g. C axis, and
rotary axis in the table the workpiece is to be machined paraxially to the
machine coordinate system, the basic rotation of
• Effect of zero offset on machines without a the workpiece must be compensated with the C
rotating table axis.
2.5
Offset and basic rotation on machines with a

C axis in the table. Moving the C axis value manually into position
After the probing operation go to the zero offset table.

Parameter
Zero offset
Rotation Select basic rotation table.
The Z axis Þeld contains the measurement result for the rotation. Copy this
value into the C axis Þeld. First overwrite the value for “Z” with 0.
X [degrees] Y [degrees] Z [degrees]

G54 0 0 24,894
X [degrees] Y [degrees] Z [degrees]

G54 0 0 0
Call the zero offset table to transfer the display to the rotary axes.
Offset
Axes +
Enter the value from “Z” under “C”.
X [mm] Y [mm] Z [mm] C [degrees]

G54
238,968 172,384 25,728 24,894
Align the workpiece paraxially to the machine coordinate system with

a program in “MDA” mode:
Call the “Machine” operating area.

Machine
Call “MDA” mode and enter the program.

MDA
N01 G54 ; Call zero offset.

N02 T27D1
N03 G0C0 ; Paraxial alignment of C axis.
N04 M30
Press “NC Start”. The turntable rotates about C = 24.894° and aligns the
workpiece paraxially to the machine coordinate system.
2.6
2.1
Repeat the entire measuring procedure from page 2.3 onwards, but this
time on the paraxially aligned workpiece. This is necessary because the
rotation means that the X, Y values are no longer correct and need to be
determined again. The Z value has not changed.
Start by selecting the “Measure workpiece” and “Corner” functions. Then

Measure
continue as before.
workpiece
Corner
The angle of rotation that was entered manually under “C” in the zero point
table is not overwritten.
To check whether paraxial traversing is possible, a short program could

again be created in MDA.
N01 G54 ; Call zero offset.

N02 T27D1
N03 G0X0Y0Z10 ; Approach zero point with a clearance of 10 mm.
N05 M30
When you press “NC Start”, the zero point is approached in “Z” with a safety
clearance.
Example Production – Machine kinematics “with” and “without” a C axis in the table
1 2
In production the same CNC program results in different movements of the machine axes, depending
on the machine kinematics.
" Machine with C axis in the table

The table was rotated. Milling paths running parallel to the edges of the workpiece
also run paraxially to the machine coordinate system. When programming the
X axis, the machine axis also moves in X.
# Machine without C axis

In machines without a rotating table, the machine puts together milling paths running
parallel to the workpiece edges through traversing movements. When programming the
X axis the machine axes X and Y traverse by rotation around Z.
2.7
Overview of advanced measuring functions
On request, the “Measure workpiece” function in Sinumerik 840D can include measuring functions
tailored to speciÞc tool and mold making requirements.
These can include the “Spigots” function, which makes zero point deter-
Spigots mination much easier on cast parts with no deÞned workpiece edges. This
function is used when it is not possible to touch the workpiece edges.
Example Overview - Measuring function for tool and mold making with reference to “Spigots”
2.8
2.1
Zero offset with swiveling of working plane
Requirements
! Swivel cycle CYCLE800 set up

! AUTOMATIC mode selected
Task, function
To determine the zero point for a workpiece with an inclined plane" and rectangular base. According
to the CAM program the tool must be aligned perpendicularly to this plane for the subsequent opera-
tions. The entire sequence can be divided into 4 individual steps. The approximate zero offset must
be known.
Sequence
Measure inclined plane" – CYCLE998,
Measure angle:
Using 3-point measurement in CYCLE998 the

position of the inclined plane is determined in
the machine coordinate system. To this end the
control system automatically calculates 2 angles
which clearly deÞne the incline. In the subse-
quent machining the angles are written to the
1 active zero offset, e.g. G54.
3-point measurement can be used up to an ang-

le of about 20°. For larger angles,
e.g. 48°, the working plane is Þrst swiveled to
45° with CYCLE800. 3-point measurement is
then used to determine the exact angle, but as
the difference from 45°, so in this case it would
be 3°.
Swivel the working plane# - CYCLE800,

Swivel:
Now swivel the working plane with CYCLE800

so that the tool is perpendicular to this working
plane.
2 To do this, call CYCLE800 in the program with

“Rotation equals zero”. CYCLE800 automatically
takes the angle determined by CYCLE998 and
swivels the working plane so that it is perpendi-
cular to the tool.
Machine kinematics with two rotary axes in

the table:
The table swivels about the A and C axis. The
working plane is aligned to the tool.
2.9
Measure corner $ -CYCLE961, Measure

corner:
Use CYCLE961 to touch 3 points to determine

the X and Y value of the new zero point. Since
the base is rectangular, 3 points are sufÞcient to
determine the corner.
Result:
3 The translatory values X and Y and the basic
rotation of the tool axis Z for zero offset are
determined.
Determine the Z value % - CYCLE978, Measu-

re edge:
Using CYCLE978 touch the working

4
plane perpendicular to the probe in the Z direc-
tion.
Note:
This operation is entirely unrelated to the machi-
ne kinematics.
2.10
2.1
Programming
Call the “Program” operating area.
Program
170 Press the Input key.
Open the program.
Example N01 G56 ; Call zero offset.
N02 T1D1 ;Use the “Measure”, “Mill”, “Measure workpiece”, “Measure angle” soft-
keys
to call the cycle. Select the measuring function as shown in the screen
form below
and enter all parameters.
N03 CYCLE998 ; Press “OK” to add the cycle to the program.
; Press “Mill”, “>>”, “Swivel cycle” to call the cycle. Do not

make any changes to the next screen form.
2.11
; Use the “Measure”, “Mill”, “Measure workpiece”, “Corner” softkeys to call

the cycle, select measuring functions as shown in the screen form below
and enter all parameters.
; Use the “Measure”, “Mill”, “Measure workpiece”, “Surface” softkeys

to call the cycle, select measuring functions as shown in the
screen form below and enter all parameters.
N06 CYCLE978 ;Press “OK” to add the cycle to the program.
N07 M30 ;End of program
Start swiveling.
To change the parameters, use the cursor to highlight the cycle in the pro-
NOTE
Recompile
gram and press the “Recompile” softkey. The parameters are copied back
into the screen form for the cycle, the screen form is opened and you can
make your changes.
2.12
Gauging tools
2.2
2.2 Gauging tools
Function
T1 1 2 D1
The tool magazine is loaded, the tool numbers
Taper
base T1, T2, etc. " entered in the tool table and the
tools assigned a tool offset D # - consisting of
L1 radius “R” and length “L1” - in the usual way.
L1 L1
The CAM programmer speciÞes the tool type
and
geometry. You specify the tool length in the
associated tool parameter.
TCP TCP TCP

Regarding the tool length, you must check
whether the CAM programmer has included the
tool tip
( = tool center point or TCP) in L1. Depending
on the tool shape, some CAM programmers
position the TCP higher up the tool. If that is the
case, this distance must be taken into account in
the tool length.
Come to an agreement with the CAM programmer: to avoid major tool deßection, the CAM
NOTE programmer should choose as short a tool length as possible.
Depending on the tool type, you can specify

Radius mill Ball end mill End mill End mill with additional tool data for face milling.
Type 110 Type 111 Type 120, 130 corner radius
Type 121, 131
In a CNC program the control system uses this
data and the path corrections G41, G42 deÞned
in the program to execute the necessary path
and length corrections.
Truncated cone Truncated cone Tapered die mill

mill mill with Type 157
Type 155 corner radius
Type 156
2.13
Gauging tools
Operation - manually entering tool offset data
Using a tool presetting device the tool offset data “L” and “R” has been determined externally and the
tool placed in the tool magazine. The tool offset data is then entered:
Select the “Parameters” operating area.

Parameter
Tool Select “Tool offset”.

offset
T no. Select tool or

+
D no. select offset data.

+
&
7
*
8
(
9 Enter new values.
$ % ^
4 5 6
! @ #
1 2 3
- ) >
- 0 .
Operation - tool offset data with tool probe
An easier option is to use a tool probe in JOG or AUTOMATIC mode and the tool gauging cycle CY-
CLE971. The measurement data “L” or “R” can be determined in a single operation and automatically
stored in the tool offset memory.
2.14
Gauging tools
2.2
To do this, call CYCLE971 in the program, select radius or length and the appropriate measurement
strategy, and enter the parameters. If you call the tool offset memory after the probing operation, the
offset data for the active tool will have been entered automatically.
!L
Sinumerik 840D also offers measuring functions in “Machine” mode.
2.15
Program data transfer
2.3 Program data transfer
CNC programs are saved on the HMI control unit and gradually loaded onto the control unit via a
", loaded into the NCK CNC memory # and network connection %.
executed with the machine.
In the case of mold making programs consisting

of technology and geometry programs, however,
at up to 100 MB the geometry program is often
too large for the NCK CNC memory and so has
to be swapped out onto a server $, for example,
3
Disk drive
7
Server Directory FIXTURE.SPF
...
N5120 X Y Z A3 B3 C3
N5130 X Y Z A3 B3 C3
...
TCP/IP Ethernet
Advanced
6
LAMP.MPF
...
1 N 50 EXTCALL
“FIXTURE.SPF”
PCU 50 ...
2 PCU 20
Setting data
5
HMI/PCU hard disk
...
Server/disk drive/
NCK CNC memory
directory/.....
Production
Hardware conÞguration Program data transfer
The program data storage is deÞned in conjunc- In the main program ' an EXTCALL command
tion with the network administrator and Siemens. is programmed, which calls the swapped out
Sinumerik 840D supports a number of options, geometry program ( in accordance with the net-
including: work path on the server, the PCMCIA card, etc.
! TCP/IP Ethernet, serial interface

RS232/V.24
! Hard disk with PCU 50, Compact Flash
Card with PCU 20
! PCMCIA, ßoppy disk
Setting data Production
In the setting data & the path to the swapped The EXTCALL ensures that the program data is
out program data is deÞned in close consultation gradually transferred to the NCK CNC memory.
with the network administrator.
2.16
Testing a program
2.4
2.4 Testing a program
Checking the machine
The machine must be checked at regular inter-

vals to discover whether it is producing errors in
the mechanical system. This is done by approa-
ching a , with TRAORI enabled and with widely
diverging orientations.
Since the sphere diameter is known, it is also

very easy to create a short test program con-
taining points on the peripheral surface of the
sphere. If the dial gauge shows no deviation
in traversing movement, starting position and
destination position, everything is Þne. If errors
outside the speciÞed machine tolerances are
found, however, the machine manufacturer
should be informed.
Note Alternatively the dial gauge can of course be

Þxed to the table and the sphere clamped in the
tool spindle.
Testing a program
Program User interface - DIN/ISO standard:

control
Before machining, the CAM program can be
checked for syntax errors. This is done in the
“Machine” operating area in “Auto” mode by
calling the program and pressing the “Program
control” softkey. Then highlight “Program test” in
2
this screen form.
When “NC Start” is pressed, the program is

executed at an accelerated feed rate but the
machine does not perform any axis movements.
1
If a syntax error is found, the program test is

interrupted and the incorrect block is highligh-
ted. Press the “Program correction” softkey to
display the incorrect block " in a program editor,
where it can be overwritten #, for example.
Press “OK” to close the editor and then press

“NC Start” again. The program test continues to
the end of the program.
2.17
Calling and executing a program
2.5 Calling and executing a program
Call.MPF (Aufruf.MPF) 1
Main program
N1 G55 6
N2 T1 D1 ;Tool change
N3 M3 S15000
N4 CYCLE832 (0.1,103) 4
N5 EXTCALL “CAM_Roughing”5 ;The search path for
;the swapped out programs
;must already be deÞned in
;the setting data. All
;programs should be located
;in the same directory.
N6 T2 D2 ;Tool change
N7 M3 S20000
N8 CYCLE832 (0.01,102001)
N16 EXTCALL “CAM_Finishing”
N17 M30
Subroutine CAM_Roughing.SPF (CAM_Schrupp.SPF) 2

N1 G90
N2 G0 X0 Y0 Z10
N3 G1 Z0 F500 7
N4 G1 X-1.453 Y0.678 F10000
N17 G1 X-1.814 Y0.842
N18 G1 X-1.879 Y0.684 Z-0.001
...
N5046 G1 X-4.118 Y-11.442
N5047 G0 Z10
N5048 Z50
N5049 X10.663 Y-3.67 A3=0.34202 B3=0 C3=0.939693 8
N5050 Z2.868 A3=0.34202 B3=0 C3=0.939693
N5051 G1 Z-2.132 A3=0.34202 B3=0 C3=0.939693 F5000
...
N6582 G1 X7.609 Y3.555 A3=0.34202 B3=-0 C3=0.939693
N6583 G0 Z50 A3=0.34202 B3=-0 C3=0.939693
N6584 M17 9
Subroutine CAM_Finishing.SPF (CAM_Schlicht. SPF) 3

N1 G90
N2 G0 X0 Y0 Z10 A3= B3= C3=
.... .......
Ideal program structure

A main program " containing all the technology data is obtained from the CAM station. The main
program calls one or more subroutines #, $, which contain the geometry data for the workpiece. The
breakdown into subroutines is determined by the tool change.
2.18
Calling and executing a program
2.5
Main program: The main program contains the two key functions for milling, CYCLE832 % and
EXTCALL&.
CYCLE832 %: CYCLE832 was developed speciÞcally for the program structure illustrated here, with
separation of technology and geometry data. The machining technology for 5-axis milling is deÞned
in CYCLE832. For the roughing program “CAM_ROUGHING” (CAM_SCHRUPP.SPF) with T1, the
parameters in CYCLE832 have been set to favor high speed. For the Þnishing program “CAM_FINIS-
HING” (CAM_SCHLICHT. SPF), the parameters have been set to favor high precision.
TRAORI can also be called in CYCLE832. The current zero offset is retained. See section 2.7 below
for more information about CYCLE832.
EXTCALL&: Since CAM programs are generally very large, they are swapped out to an external
storage device. EXTCALL calls the subroutines from the external storage device.
Subroutine: In the subroutine G90 for absolute programming is immediately followed by the geomet-
ry blocks. In our example these are blocks for 3-axis milling(, followed by blocks for 5-axis simultane-
ous milling ), identiÞed by the vector details A3, B3 and C3.
Selecting/starting/stopping/interrupting/continuing a program
2 1
Machine Select the “Machine” operating area.
Select “Automatic” mode.

AUTO
Program Select “Program overview”, “Workpiece overview”. Highlight the “Workpiece

overview directory” you require and open it.
Workpieces
In the workpiece directory highlight the part program " - in this case the
Select program “CALL.MPF” (AUFRUF.MPF) - and press “Select”.
Press “NC Start” to start the part program. This calls the geome-
try programs “ROUGHING.SPF” (CAM_SCHRUPP.SPF) # and
“FINISHING.SPF” (CAM_SCHLICHT. SPF), which are loaded block by
block onto the control system from the external drive during the machining
process.
Press “NC Stop” to stop the part program.
Press “Reset” to interrupt the part program.

Note A part program interrupted with “NC Stop” can be continued by pressing “NC Start”. A part program
interrupted with “Reset” is executed from the beginning if “NC Start” is pressed.
2.19
Interrupting a program
2.6 Interrupting a program
REPOS - repositioning after an interruption
Function
When a program is interrupted with “NC Stop”, the tool can be moved away from the contour in
JOG mode, e.g. to perform a measurement. The control system saves the breakpoint coordinates.
The differential travel of the axes is displayed.
Operation
Initial situation: program interrupted with “NC Stop”.
Machine Select the “Machine” operating area.
Select “JOG” mode.

JOG
Repositioning after program interrupt.
Select axes.
2
Move the axes to the breakpoint according to the differential travel display-
ed. The breakpoint cannot be overrun.
Switch from “JOG” mode to “Automatic” mode.

AUTO
Continue machining.
TOROT - retraction from an inclined hole or undercut
Function
When 5-axis transformation is enabled, TOROT generates a frame whose Z axis coincides with the
current tool orientation. This allows the tool to be retracted in a 5-axis program, after a tool breakage,
for example, without the risk of collision, by retracting the Z axis. After tool orientation has been pro-
grammed with TOROT, all the programmed geometry axis movements refer to the frame generated
by this programming.
2.20
2.6
Settable frame
(programmed frame)
Basic
coordinate system
Workpiece
coordinate system
Tool retraction
along the Z axis
Current
workpiece orien-
tation
Select the “Machine” operating area.

Machine
MDA Select “MDA” mode.

Enter the program as follows:
N10 TRAORI ; Transformation ON

N20 TOROT ;Calculate and select retraction frame
N30 G1 G91 Z50 F500 ;Straight retraction movement in Z direction by 50 mm
N40 M17 ;End of subroutine
Select single block. Start the program block by block.
As an alternative to incremental retraction in MDA mode, the tool can be retracted in JOG mode by
pressing the direction key in the tool direction.
Notice: For retraction in JOG mode the machine must be conÞgured accordingly
(Z axis as the geometry axis).
NOTE
TOROT must be deselected before the start of the next program: TOROTOF
2.21
Accelerated external block search without calculation
Function
This function was developed speciÞcally for programs called with EXTCALL. It is therefore ideal for
large programs obtained from a CAM station.
If machining has been interrupted with the “Reset” key, the “Accelerated external block search without
calculation” function can be used to select any point in the part program from which to start or conti-
nue machining.
Operation
Initial situation: program interrupt with “Reset”.
Example Call.MPF (Aufruf.MPF) 1

N1 G54
N2 T1 D1
N3 M3 S15000
N4 CYCLE832 (0.1,103)
N5 EXTCALL “CAM_Roughing”
N6 T2 D2
N7 M3 S20000
N8 CYCLE832 (0.01,102001)
N16 EXTCALL “CAM_Finishing” 3
N10 M30
CAM_Roughing.SPF (CAM_Schrupp.SPF) 1
N1 G90
N2 G0 X0 Y0 Z10
N3 G1 Z0 F500
N4 G1 X-1.453 Y0.678 F10000
N17 G1 X-1.814 Y0.842
N18 G1 X-1.879 Y0.684 Z-0.001
CAM_Finishing.SPF (CAM_Schlicht.SPF)
N1 G90
Block Press the “Block search” softkey.

search
Press the “Search pointer” softkey.

Search pointer
Break Press the “Breakpoint” softkey.

point
2.22
2.6
Pressing the “Breakpoint” softkey inserts the
entire program sequence " up to the breakpoint
into the screen form.
In this example the main program “Call.MPF”

(Aufruf.MPF) calls the subroutine
“CAM_Roughing.SPF” (CAM_Schrupp.SPF).
The EXTCALL for the subroutine is loca-
3
ted in block N16 $. Block 3044 in “CAM_
Roughing.SPF” (CAM_Schrupp.SPF) is where
1 the program was interrupted.
2 There are now two possibilities:
1. Jump directly to the breakpoint in the sub-

routine:
Press the “External without calc.” softkey.
The program jumps directly to block 3044.
2. Jump to any point in the subroutine:

To do this you must select a (search) type
# - for “External without calc.” you can
choose between “1-Block number” and
“5-Line number” - and then enter the type
number followed by the desired block or line
number.
External Press the “External without calc.” softkey.

without calc.
The function combines all active
M commands and loads them at the destination
block.
Continue machining at the destination block.
Corrections
Overstoring During input the “Overstore” function can be

used to correct the destination block before star-
ting the program.
A typical case is shown here, where the com-

pressor tolerance needs to be changed. CYC-
LE832 is called and the compressor tolerance
manually changed to 20 µm". This can be
done by entering just one parameter (tolerance
= 0.02). CYCLE832 is now executed before the
main program is started.
The tolerance is activated by pressing NC Start.
2.23
Quick View
Function plane, X/Z plane, Y/Z plane
Quick View can be used to view mold making The two editor lines $ display the block current-
part programs containing G01 blocks. Program ly highlighted in the graphic. Scrolling through
loops, polynomials, transformations and G02/03 the editor window automatically highlights the
blocks are not supported. position in the graphic %.
Four views # are available: 3D view ", X/Y
The following functions are also available:
! Search for a speciÞc block

! Zoom in/out
! Shift, rotate
! Measure between two points
! Edit the NC part program displayed
Simulation
Quick Call the “Quick View” function.

View
Choose the view you require - in this case the

X/Z plane.
Use the cursor to select a point in the graphic.

The associated block is displayed in the editor
line.
Call the block, e.g. to change it in the program.
2.24
High-speed settings – CYCLE832
2.7
2.7 High-speed settings - CYCLE832
Function
The CAM program sequence can be inßuenced with CYCLE832. It provides technological support for
the machining of freeform contours (surfaces) in the 3- and 5-axis high-speed machining range.
Surface quality
Precision Speed
Operation
Call the “Programs” operating area.

Machine
>> Show other softkeys.
High-speed Press “High-speed settings”. The cycle is

settings called.
The cycle combines the essential G codes and machine and setting data that are required for HSC
machining. These are speciÞed in the parameter Þelds. Depending on the parameter choice " the
trend triangle # shows a trend towards either “Speed” or “Precision”.
2.25
Parameters for the high-speed setting cycle
The user simply chooses between Þnishing, preÞnishing and roughing in the Machining Þeld and
enters a value in the Tolerance Þeld. The values in all other Þelds have already been entered by the
machine manufacturer. The machine manufacturer can enable the other Þelds by means of the Adap-
tation Þeld.
Machining ! Finishing (default)

! PreÞnishing
! Roughing
! Deselection
Tolerance_Tol. ! Chord tolerance Tolerance of linear/rotary axes,

default settings:
(chord tolerance should -> 0.01 mm/ 0.08° (Þnishing)
be taken from the CAM -> 0.05 mm/ 0.4° (preÞnishing)
system or weighted with -> 0.1 mm/ 0.08° (roughing)
a factor of 1,2 ... 1.5) -> 0.1 mm/ 0.1° (deselection)
Transformat. ! TRAFOOF -> Transformation “off”

! TRAORI -> First transformation “on”
! TRAORI(2) -> Second transformation “on”
Adaptation ! yes -> Subsequent Þelds can be modiÞed

! no -> Subsequent Þelds are locked
The Þelds are unlocked by the
machine manufacturer
Compression ! no (COMPOF) -> Compressor OFF

! COMPCAD (default) -> Compressor ON, constant acceleration
for mold making applications
! COMPCURVE -> Jerk-free for circumferential milling
! B-SPLINE -> Spline interpolation
Continuous-path ! G64 -> Continuous-path mode

control ! G641 -> Programmable rounding clearance
! G642 -> Corner rounding with single axis
tolerances
! G643 -> Block-internal corner rounding with
single axis tolerances
! G644 -> Speed-optimized corner
rounding with settable tolerances
Feedforward ! FFWON-SOFT -> With feedforward control, with jerk

control limitation
! FFWOF-SOFT -> Without feedforward control, with jerk
limitation
! FFWOF-BRISK -> Without feedforward control, without
jerk limitation
2.26
High-speed settings - CYCLE832
2.7
Note If changes are made you should be guided by are becoming more and more rigid, feedforward
the tolerance value speciÞed in the CAM pro- control is used less and less. It allows following
gram. Smaller tolerances than those speciÞed errors to be reduced almost to zero.
there are not recommended. Transformation
TRAORI is used for 5-axis simultaneous milling. More information can be found in Chapter 3,
If TRAORI is already included in the NC pro- which contains detailed descriptions of the indivi-
gram, there is no need to specify it here. dual parameters.
Please bear in mind that the Þelds are inter-

dependent: for example, if Compression is
switched off, various types of rounding can be
selected under Continuous-path control.
The preset for Feedforward control is deÞned
by the machine manufacturer. Since machines
Programming
CYCLE832 is ideally programmed in the hig- dual program sections or freeform surfaces. See
her-order NC control program which calls the also the programming examples in the previous
geometry program. In this way you can apply the chapter.
cycle to the entire geometry or, depending on
the transparency of the CAM program, to indivi-
Fast cycle call
The following call options with reduced parameter transfer can be used for CYCLE832:
! CYCLE832() Corresponds to selecting the “Machining” screen form, “Deselection”

! CYCLE832(0.01) To enter the tolerance value. The active G commands are
not changed in the cycle.
A detailed explanation of these parameters can be found in Chapter 3.
2.27
ShopMill
2.8 ShopMill
In Sinumerik 840D, software version 6.4, the restricted to sequencer programming by means
user-friendly ShopMill interface provides a real of partial machining steps and even supports
alternative to the universal Sinumerik 840D stan- demanding 5-axis applications.
dard DIN/ISO user interface.
A complete description of the ShopMill functions
ShopMill features many additional mold making can be found in
functions, greatly simplifying its use for mold “Sinumerik 810D/840D Using and
makers. Programming ShopMill (SW06) 11/03
6FC5298-6AD10-0AP2 (German)”
As a consequence, ShopMill is now no longer
ShopMill user interface
ShopMill:
Simple operation
and
programming
in the workshop
Switching by
machine
manufacturer
function
Standard
DIN/ISO:
multifunctional
user interface
for production
machines
2.28
ShopMill
2.8
ShopMill functions
Setup
1 2 Powerful setup functions in ShopMill ensure
rapid and accurate detection of the component
position. Any offsets are compensated automati-
cally by the control system.
" Edge
# Corner
3 4
$ Hole
% Spigot
Sequencer
1 2
ShopMill sequencer programming allows easy
programming of simple
2 1/2D machining tasks directly on the machine.
An ideal add-on for mold makers.
3
" Program
# 2D representation
$ 3D representation
G code editor
ShopMill comes with a powerful G code editor,
which easily supports mold making programs
of up to 100 MB in size, eliminating the need to
switch to the standard DIN/ISO interface.
“High-speed setting” cycle

1
The “High-speed setting” cycle now also comes
as standard with the ShopMill user interface.
2
" Program editor

# CYCLE832, high-speed settings
2.29
ShopMill
Block search
The extended block search function described
in section 2.6 also now comes as standard with
ShopMill.
1 " “External without calc.”

block search
3D viewing
1 2
ShopMill also allows simple viewing of 3D forms.
Cutouts can also be deÞned.
" Workpiece
# 2D representation
$ 3D representation
3
Tool management
ShopMill tool management is clearly structured
and supports various tool types, tool names in
plain text, sister tools and tool geometry with
length, radius and number of cutters.
Ethernet
The ShopMill program manager allows direct
access to external drives via a high-speed
Ethernet connection.
Extensive mold making programs can be stored
1
! on the HMI hard disk (PCU 50 ) or

! on the Flash Card (PCU 20)
" Network access function
2.30
Information for
programmers
Contents Page
3.1 Introduction 3.2
3.2 Kinematic-independent CNC programs 3.3
3.3 Five-axis transformation - TRAORI 3.5
3.4 Tool orientation - A3= B3= C3=, ... 3.6
3.5 High-speed settings – CYCLE832 3.9
3.6 Feedrate proÞle - FNORM, FLIN, ... 3.18
3.7 Orientation interpolation - ORI... 3.19
3-8 Tool offsets - CUT3DFS, ... 3.21
3-9 Programming at the machine 3.22
3-10 Example - bending device for pipes 3.25
3-11 Example - motorcycle headlight 3.36
3
3.1 Information for programmers
Introduction
3.1 Introduction
Introduction
In the programming of freeform surfaces, the The postprocessor is of the utmost importance
entire CAD/CAM/CNC in gaining the maximum beneÞt from the
process chain is of vital importance. capabilities of Sinumerik 840D.
The CAD system generates the geometry of the The postprocessor has to ensure that the higher-
desired workpiece. On the basis of this geometry order functions of Sinumerik 840D are activated
Þle the CAM system generates the corresponding in the best possible way. An overview of all
processing strategy with associated technology higher-order Sinumerik 840D functions can be
information. found in Chapter 4.
The initial data format from the CAM system

is usually an APT or CL data Þle, which in the
postprocessor is converted into executable CNC
code.
CAD software CAM software PP software CAD software

(design creation) (NC programming) (NC programming) (machining)
Geometry Tool path NC program Workpiece

APT source
3.2
Kinematic-independent NC programs
3.2
3.2 Kinematic-independent CNC programs
1. Tool orientation and TRAORI

Programming with Sinumerik 840D independently of the machine kinematics simply requires a few
conventions to be followed.
N15 TRAORI The TRAORI ! command is used to call 5-axis

N16 G1 X Y Z A3= B3= C3= transformation. The control system is then re-
sponsible for converting position and orientation
data into machine movements (see Chapter 2).
1
RI
TRAO
G1
N16 G1 X Y Z When TRAORI is enabled, the positional data

X, Y, Z " relate to the tool tip (TCP, tool center
point).
G1
N16 G1 X Y Z A3= B3= C3= To program orientation on a 5-axis machine, we

do not recommend programming the machine
axes A, B or C directly. An NC program of that
type is dependent on the kinematics of the
machine.
C3
3
Instead, the directional vectors with addresses
A3, B3 and C3 # should be programmed in
B3 conjunction with TRAORI.
A3
G1
When TRAORI is activated, we recommend
starting swivel movements close to the proÞle
in order to keep within the conÞgured work area
limits.
3.3
Kinematic-independent NC programs
2. Tool gauging
In machine kinematic-neutral programs, the tool
data are calculated directly from the tool Þle.
Freeform surfaces are generally machined with-

out radius compensation in the CNC.
Although Sinumerik 840D does offer correspond-
ing compensation options, we are working on
L1 the assumption here that the necessary data are
rarely available. For that reason we recommend
outputting the tool center point.
This also simpliÞes tool gauging at the machine.
3. Inßuencing speed and quality
Tolerance band High-speed settings CYCLE832
Compressor To simplify programming and to improve pro-

gram structure, we have combined all these
Continuous-path control: technology functions into a single cycle.
Corner rounding
Velocity feedforward control

+ Jerk limitation
4. Feedrate proÞle
Feedrate proÞle The feedrate proÞle is not part of CYCLE832

and has to be programmed separately.
3.4
Five-axis transformation – TRAORI
3.3
3.3 Five-axis transformation – TRAORI
Programming TRAORI offers several advantages. In particular: the program is independent of the
tool length and machine kinematics; the feedrate relates to the tool center point, and compensation
movements to compensate the rotary axis movements are performed automatically.
Programming
TRAORI(n)
TRAFOOF
Explanation of the commands
TRAORI Activates the Þrst programmed orientation transformation

____________________________________________________________________________
TRAORI(n) Activates the orientation transformation programmed with n
____________________________________________________________________________
n Transformation number (n = 1 or 2), TRAORI(1) corresponds to
TRAORI.
____________________________________________________________________________
TRAFOOF Switches transformation off
Function
To obtain optimum cutting conditions when ma-

chining surfaces with a three-dimensional curve,
the setting angle of the tool must be able to be
varied.
In addition to the three linear axes X, Y, Z, this

requires at least one or two rotary axes. The NC
blocks are extended with the orientation informa-
tion A3, B3, C3.
When transformation is enabled, the positional

data (X, Y, Z) always relate to the tip of the tool
(TCP). Changing the position of the rotary axes
involved in the transformation causes so many
compensating movements of the remaining
machine axes that the position of the tool tip is
unchanged.
! without 5-axis transformation 1

" with 5-axis transformation
2
Note: Depending on the conÞguration, TRAORI

can reset the zero offset.
Fluctuating orientation changes should be avoided along the tool paths.

TIP
3.5
Tool orientation - A3= B3= C3=, ...
3.4 Toolorientation - A3= B3= C3=, ...
We recommend using directional vectors to program the tool orientation. Sinumerik 840D supports
all types that are relevant in practice for programming the tool orientation. Orientation transformation
TRAORI must be activated.
Programming
G1 X Y Z A3= B3= C3=
G1 X Y Z A B C Direct programming of the movement of the rotary axes

A, B or C.
The rotary axes are moved synchronously to the
tool path.
____________________________________________________________________________
ORIEULER Orientation programming on the basis of Euler angles (default)
ORIRPY Orientation programming on the basis of RPY angles.
This is only effective if
$MC_ORI_DEF_WITH_G_CODE = 1 is set.
Otherwise deÞned on the basis of machine data.
G1 X Y Z A2= B2= C2= Programming on the basis of Euler angles or RPY angles
(roll pitch yaw)
The interpretation is deÞned on the basis of machine data
Programming in Euler or RPY angles via A2, B2, C2

or programming of directional vector. The directional
vector points from the tool tip towards the tool
holder.
G1 X Y Z A3= B3= C3= Programming of the directional vector (recommended)

____________________________________________________________________________
G1 X Y Z A4= B4= C4= Programming of the surface normal vector at start of block
This information is used by CUT3DF for 5-axis machining.
Lead and Tilt can also be used to program the

tool orientation. The
lead and tilt angle relates to the normal vector A4 B4 C4.
G1 X Y Z A5= B5= C5= Programming the surface normal vector at end of block
____________________________________________________________________________
LEAD Lead angle for programming tool orientation.
Angle relative to the surface normal vector in the plane
spanned by the path tangent and surface normal vector.
TILT Tilt angle for programming tool orientation.

The TILT angle describes the rotation of the lead
angle about the surface normal vector (see illustration on p. 3.8).
3.6
Tool orientation – A3= B3= C3=, ...
3.4
Variants for deÞning the tool setting
This section covers only the most important functions. More information can be found on the DOCon-
CD.
Programming the directional vector
The components of the directional vector ! are

programmed with A3, B3, C3. The vector points
towards the toolholder; the length of the vector is
meaningless. Vector components that have not
1
been programmed are set equal to zero.
C3
The resolution should be set as high as possible.
Experience shows that 8 to 10 decimal places
produce good results.
A3 B3
Example ORIVECT.MPF
N020 TRAORI
N030 G60 F10000
X0 Y0 Z0
N050 A3=0 B3=0 C3=1
N060 A3=0 B3=1 C3=0
N070 A3=1 B3=0 C3=0
N080 A3=1 B3=1
N090 A3=1 B3=1 C3=1
N100 A3=1 B3=0 C3=1
N110 A3=0 B3=1 C3=1
N160 A3=0 B3=-1 C3=0
N170 A3=-1 B3=0 C3=0
N180 A3=-1 B3=-1
N190 A3=-1 B3=-1 C3=1
N200 A3=-1 B3=0 C3=1
N210 A3=0 B3=-1 C3=1
N888888 M30
Programming in RPY angles

1 2 2
The values programmed with A2, B2, C2 for ori-
entation programming are interpreted as an RPY
angle (in degrees).
Starting from the normal position !: The orienta-
tion vector results from turning a vector in the Z
where C2 = 90°
rotated about the direction Þrstly with C2 around the Z axis ", then
Z axis with B2 around the new Y axis # and lastly with
A2 around the new X axis. In contrast to Euler
3
angle programming, all three values here have
an effect on the orientation vector.
Example
ORIRPY.MPF
where B2 = +45° N020 TRAORI
rotated about the N030 G60 F10000 X0 Y0 Z0
rotated Y axis
N050 C2=0 B2=0
N060 C2=90 B2=90
3.7
Tool orientation – A3= B3= C3=, ...
N070 C2=0 B2=90

N080 C2=45 B2=90
N090 C2=45 B2=45
N100 C2=0 B2=45
N110 C2=90 B2=45
N160 C2=90 B2=-90
N170 C2=0 B2=-90
N180 C2=-135 B2=90
N190 C2=-135 B2=45
N200 C2=0 B2=-45
N210 C2=90 B2=-45
N888888 M30
Programming the tool orientation with Euler

angles
Programming in Euler angles is analogous to

programming in RPY angles.
Example ....
N020 TRAORI
N030 G60 F10000 X0 Y0 Z0
N050 A2=0 B2=0 C2=0
N060 A2=0 B2=-90 C2=0
...
Programming the tool orientation with LEAD

and TILT in conjunction with ORIPATH
1
The resulting tool orientation is determined
from:
$ the path tangent
$ the surface normal vector
$ the lead angle LEAD !
$ the tilt angle TILT " at end of block
LEAD describes the angle between the surface

normal and the new tool orientation, in the direc-
tion of the path tangent. If the tool is also rotated
about the surface normal from this position, this
corresponds to the TILT angle.
Example
2
....
N100 G54
N110 G64
N120 ORIWKS
N130 CUT3DF
N110 ORIC
N120 START: ROT X=R20
N130 G0 X=260 Y0 A3=1 B3=0 C3=0
N140 G1 Z0 LEAD=5 TILT=10 G41
N150 X240.000 Y0.000 A5=1 B5=0.000
C5=0.000
...
3.8
3.5
3.5High-speed settings – CYCLE832
To simplify programming and clarify program structure, Sinumerik 840D includes CYCLE832, which
contains the most important functions for freeform surface milling.
CYCLE832 also makes it easier for the machine operator to inßuence the program.
Programming
CYCLE832(_TOL,_TOLM) Programming the cycle
CYCLE832() Abbreviated program call. Corresponds to

selecting the “Machining” screen form
“Deselection”.
CYCLE832(0.01) Abbreviated program call. To enter the tolerance

value. The active G commands are
not changed in the cycle.
Explanation of the parameters
_TOL real Tolerance on machining axes -> unit: mm/inches; degrees

_____________________________________________________________________________
_TOLM 7 integer Mode tolerance
Decimal place 2) Input

__________________________________________________
0 0= Deselection
1= Finishing (default)1)
2= PreÞnishing
3= Roughing
__________________________________________________
1 0=
1=
__________________________________________________
2 0= TRAFOF (default)1)
1= TRAORI(1)
2= TRAORI(2)
__________________________________________________
3 0= G64
1= G641
2= G642 (default)1)
3= G643
4= G644
__________________________________________________
4 0 FFWOF SOFT (default)1)
1 FFWON SOFT
2 FFWOF BRISK
__________________________________________________
5 0= COMPOF
1= COMPCAD (default)1)
2= COMPCURV
3= B spline
__________________________________________________
6 Reserved
7 Reserved
1)
Setting can be changed by machine manufacturer.
2)
Sequence of parameters (CYCLE832(_TOL,76543210)
3.9
Decimal place 0 Adaptation, technology adaptation

Tolerance (_TOL) $ yes
Tolerance of the axes used for machining. The $ no
tolerance value applies with G642 and COMP- If CYCLE832 is programmed via the screen
CURV or COMPCAD. If the machining axis is a form on the control system, the following input
rotary axis, the tolerance value is written to MD parameters can only be modiÞed if Adaptation is
33100: COMPRESS_POS:_TOL (AX) for the set to “yes”.
rotary axis with a factor (default factor = 8).
Decimal place 3
With G641 the tolerance value corresponds to Continuous-path control (_TOLM)
the ADIS value. On initial input the tolerance is 0 G64 (default)
preset with the following values: 1 G641 Corner rounding with ADIS,
0 Deselection: 0.1 (linear axes) ADISPOS
0.1 degrees (rotary axes) 2 G642 Corner rounding with single-axis
Measurement system mm/inches is tolerance
taken into account 3 G643 Block-internal corner rounding
1 Finishing: 0.01 (linear axes) 4 G644 Speed-optimized
0.08 degrees (rotary axes) corner rounding
2 PreÞnishing: 0.05 (linear axes) With the NC block compressor with COMPCAD,
0.4 degrees (rotary axes) COMPCURV, G642 is always selected.
3 Roughing: 0.1 (linear axes)
0.8 degrees (rotary axes)
If the tolerance value is also to apply to the rotary Decimal place 4
axes, 5-axis transformation must be set up by Compression, NC block compressor (_TOLM)
the machine manufacturer. 0 FFWON SOFT
with feedforward control, with jerk limi-
tation
Decimal place 2 1 FFWOF SOFT
Transformation (_TOLM) without feedforward control, with jerk
The Transformation input Þeld is only displayed if limitation
the NC option is set (5-axis machining package 2 FFWOF BRISK
set). without feedforward control, without
0 TRAFOOF jerk
CAM programs with open limitation
rotary axis positions are supported In order for feedforward control (FFWON) and
1 TRAORI jerk limitation (SOFT) to be selected, the control
2 TRAORI (2) system and machining axes must have been
Deselection of the transformation number of the optimized by the machine manufacturer.
manufacturer cycle to call 5-axis transformation.
The parameter is used in conjunction with the
following GUD7 variable _TOLT2. Decimal place 5
This can be followed by the name of a manufac- Compression, NC block compressor (_TOLM)
turer cycle which calls the manufacturer trans- 0 none (COMPOF)
formation cycle. If _TOLT2 is empty (“default”), 1 COMPCAD
selecting transformation 1, 2 ... calls 5-axis 2 COMPCURV
transformation with TRAORI(1), TRAORI(2). 3 B spline
In order for feedforward control (FFWON) and
jerk limitation (SOFT) to be selected, the control
system and machining axes must have been
optimized by the machine manufacturer.
In order for these functions to be used, the CNC/machine must have been optimized by the machine
TIP manufacturer in the proper manner.
3.10
3.5
Using the high-speed setting cycle
CYCLE832 combines the essential G codes and In CAM programs in the HSC range the three
machine and setting data that are required for machining types have a direct bearing on
HSC machining. the precision and speed of the path contour.
By specifying a tolerance value the operator/
programmer can weight these factors accordin-
Surface quality gly.
Different tolerances and settings (technology

adaptation) can be assigned to the three machi-
ning types.
The cycle is positioned ahead of the geome-

try subroutine in the main program (see call
example below). The various interpretations of
Precision Speed the tolerance values are taken into account. For
example, with G641 the tolerance value is trans-
ferred as ADIS=, and with G642 the axis-speciÞc
machine data MD 33100 $MA_COMPRESS_
A distinction is made in CYCLE832 between POS_TOL (AX) is updated.
three machining technologies:
$ Finishing Calling the “Machining deselection” cycle resets

$ PreÞnishing and the modiÞed machine/setting data to the machi-
$ Roughing ne manufacturer‘s value.
Example of CYCLE832 call

Example
N01 T1 D1
N02 G54
N03 M3 S12000
N04 CYCLE832(0.2,110003)* ;0.2 tolerance value
;1003 from back to front:
;3 = Roughing, 0 = TRAFOF,
;0 = G64, 1 = FFWON SOFT, 1 = COMPCAD
N05 EXTCALL “CAM_Mold_Roughing” ; “Roughing” subroutine call
N06 CYCLE832(0.01,102001)* ; 0.01 = tolerance value
;102001 from back to front:
;1 = Finishing, 0 = TRAFOF,
;2 = G642, 0 = FFWOF SOFT,
;1 = COMPCAD
N07 EXTCALL “CAM_Mold_Finishing” ;”Finishing” subroutine call
N08 M02
*Note: Decimal place 1 has no function.

(0.2,110003)
Decimal place 0
Decimal place 1
3.11
Compressor - COMPCAD, COMPCURV, ...
The compressor is ideally called in CYCLE832. To program it separately you should use the following
procedure.
Programming
COMPCURV
COMPCAD
COMPOF
COMPCURV Compressor on:
Approximation by polynomial, 5th degree.

G1 blocks are approximated by a polynomial.
The block transitions are jerk-free.
Preferably for circumferential milling

______________________________________________________________________________
COMPCAD Compressor on:
COMPCAD smoothes the point proÞle before approximation
(B spline) and at high path speed offers
maximum precision with constant-acceleration transitions
(compression rate unlimited, but max. path length 5 mm)
Preferably for the milling of freeform surfaces

(recommended)
______________________________________________________________________________
COMPOF Compressor off
Additional commands for a combination of path and orientation axes:
UPATH Parameter settings for the orientation axes correspond to those

for the path axes X, Y, Z. This means that for the movement
of a synchronous axis, A = f(u), where u denotes the path
parameter for the path movement.
UPATH is recommended for programming.
______________________________________________________________________________
SPATH Parameter settings for the synchronous axes follow the arc
length for the path axes. This means that for the movement
of an orientation axis A, A= f(s) where s denotes the arc length
for the path movement.
3.12
3.5
Function of the spline compressor
According to the speciÞed tolerance band ! the

1 2 3 compressor combines a sequence of G1 com-
mands " and compresses them into a spline
#, which is directly executable by the control
system.
This makes the surface much smoother, since

the machine axes can move more harmoniously
and machine resonance is avoided.
This allows higher traversing speeds and redu-

ces the load on the machine.
Notes on programming
If the high-speed setting cycle CYCLE832 is Writing of machine data [MA] must be unlocked
not available, then the compressor should be by the machine manufacturer.
programmed as follows. This is the case with
software versions prior to 6.4.
Example
N010 FGROUP (X, Y, Z) ; Feed relates to the path axes
N020 UPATH G642
N020 $MA_COMPRESS_POS_TOL [X] = 0.01 ; Path tolerance setting
N030 $MA_COMPRESS_POS_TOL [Y] = 0.01 ; Path tolerance setting
N040 $MA_COMPRESS_POS_TOL [Z] = 0.01 ; Path tolerance setting
N050 $MA_COMPRESS_POS_TOL [A] = 0.08 ; Rotary axis tolerance setting
N060 $MA_COMPRESS_POS_TOL [B] = 0.08 ; Rotary axis tolerance setting
; (The value for the rotary axes should be
; factor 8 - 10 of the path tolerance.)
N070 NEWCONF
N080 COMPCAD ;Compressor on
N090 G1 X.37 Y2.9 F600 ;G1 before end point and feed!
N100 X16.87 Y-4.698 A3=0.1736482 B3=-0.84950947 C3=0.49817663
N110 X16.865 Y-4.72 A3=0.1736482 B3=-0.84950664 C3=0.49818147
N120 X16.91 Y-4.799 A3=0.17364925 B3=-0.84774706 C3=0.5011695
...
N1037 COMPOF ;Compressor off
...
3.13
Continuous-path mode, Look ahead - G64, G642, G643
If continuous-path mode is called within CYCLE832, the ADIS value in G641 corresponds to the tole-
rance value TOL_. If you are programming without CYCLE832, you should include the ADIS value.
Programming the retraction clearance with ADIS
G64
G642 ADIS=… or ADISPOS=…
G643 ADIS=… or ADISPOS=…
G64 Continuous-path mode - Look ahead with braking

at corners only
______________________________________________________________________________
G642 Corner rounding with axial tolerance (recommended)
Look ahead with additional corner rounding corresponding to
MD 33100 (machine data)
For G642 and G643 there are 2 ways of specifying the
tolerance. 1. Specifying single axes - see programming
example on the previous page or
2. Programming the retraction clearance with ADIS
Preferably for the milling of freeform surfaces
______________________________________________________________________________
G643 Block-internal corner rounding
Look ahead with additional block-internal corner rounding
corresponding to MD33100)
______________________________________________________________________________
G644 Speed- and acceleration-optimized corner rounding
for rapid positioning outside the contour
______________________________________________________________________________
ADIS= Rounding clearance for path functions G1, G2, G3
______________________________________________________________________________
ADISPOS= Rounding clearance for rapid traverse G0 (not suitable for free
form surfaces)
Use of G64, ..., G644
The purpose of continuous-path control is to

increase speed and harmonize traversing perfor-
mance. In path control function G64, etc., this is
achieved with two functions.
1
Look ahead - look-ahead speed control !

The control system calculates several CNC
2
blocks ahead and determines a modal speed
proÞle. The way in which this speed control is
G1 calculated can be set with functions G64, etc.
G1 G1
G1 G1
G1
3.14
3.5
Corner rounding "
The look ahead function also means that the
control system is able to round the corners it
detects. The programmed corner points are
therefore not approached exactly. Sharp corners
are rounded.
These two functions mean that the contour is

created with a uniform path velocity proÞle. This
establishes better cutting conditions, improves
the surface quality and reduces the machining
time.
3
1
2 To round sharp corners #, the continuous-path

commands G642 and G643 form transition
elements !, " at the block boundaries. The
continuous-path commands differ in the way they
form these transition elements.
G1 G1
With G641, G642, G643 you can deÞne the de-
gree of rounding " with the ADIS value.
G642 inserts constant-curve transition polynomi-

als. This avoids acceleration jumps at the block
boundaries. We recommend G642 for mold
making applications.
G643 inserts constant-curve transition polyno-

mials. It does not form intermediate blocks but
rounds the corners within the blocks.
3.15
Feedforward control and jerk limitation - FFWON, SOFT, ...
Feedforward control and jerk limitation can only be called in CYCLE832 as a combination of the two
functions. This is because this combination offers ideal conditions for freeform surface milling. Both
functions can of course also be programmed separately.
Programming
FFWON/
FFWOF
BRISK
SOFT
FFWON Feedforward control “on”

______________________________________________________________________________
FFWOF Feedforward control “off”
______________________________________________________________________________
BRISK Without jerk limitation
Brisk acceleration of path axes
______________________________________________________________________________
SOFT With jerk limitation
Soft acceleration of path axes
Axial jerk limitation (maximum jerk in
machine data JOG_AND_PS_MAX_JERK
(jog and positioning) MAX_AX_JERK
(path mode)
Jerk limitation function
To make acceleration as gentle on the machine

as possible, the acceleration proÞle of the axes
can be inßuenced by means of the commands
Soft, Brisk. If Soft is activated, the acceleration
behavior does not change abruptly but is incre-
ased by a linear characteristic. This reduces
the load on the machine. It also has a beneÞcial
effect on the surface quality of workpieces, since
machine resonance is excited far less frequently.
BRISK:
Acceleration behavior: abrupt acceleration of the
path axes according to the speciÞed machine
data
The axis slides travel with maximum accelerati-

on until the feedrate is reached. BRISK enables
time-optimized machining, but with jumps in the
acceleration curve.
3.16
3.5
SOFT:
Acceleration behavior: soft acceleration of path
axes.
The axis slides travel with constant acceleration

until the feedrate is reached. SOFT acceleration
enables higher path accuracy and less wear and
tear on the machine.
Feedforward control function
Following errors cause contour violation !. The

inertia in the system means that the cutter tends
to leave the setpoint contour " tangentially, i.e.
the actual contour # that is produced deviates
from the setpoint contour. Following errors are
2
due to a combination of the system (positioning
control) and the speed.
3 Feedforward control FFWON reduces speed-de-

pendent following errors when contouring almost
1 to zero. Traversing with feedforward control
permits higher path accuracy and thus improved
machining results.
Recommendations
CYCLE832 includes the following

combinations:
FFWON SOFT
The emphasis is on high path accuracy. This is
Feedforward
achieved by a soft speed control which is largely
control Acceleration
free from following errors.
FFWOF SOFT
High path accuracy is not a priority. Additional
FFWON BRISK
rounding is achieved by means of following er-
without high
rors. For use with older part programs/machines.
following errors/ acceleration
tolerance
FFWON BRISK
not recommended
FFWOF SOFT
FFWOF BRISK
with gentle
For use in roughing and when maximum speed
following errors/ acceleration
is required.
tolerance
3.17
Feedrate profile – FNORM, FLIN, ...
3.6 Feedrate proÞle - FNORM, FLIN, ...
Programming
F… FNORM
F… FLIN
F… FCUB
F=FPO(endfeed, quadf, ufb)
FNORM Basic setting. The feedrate is applied over the entire path of
the block and is subsequently regarded as the modal value.
_______________________________________________________________________________
FLIN Path velocity proÞle linear:
The feedrate is traversed linearly from the current value at the
beginning of the block to the end of the block and is
subsequently regarded as the modal value.
_______________________________________________________________________________
FCUB Path velocity proÞle cubic:
The non-modally programmed F values, relative to the
end of the block, are connected through a spline. The spline
starts and ends tangentially to the previous or
following feedrate setting. If the F address is missing
from a block, the last programmed F value is
used.
_______________________________________________________________________________
F=FPO... Polynomial path velocity proÞle:
The F address denotes the feedrate proÞle via a
polynomial from the current value to the end of the block. The
Þnal value is
subsequently regarded as the modal value.
_______________________________________________________________________________
endfeed: Feedrate at block end
_______________________________________________________________________________
quadf: Quadratic polynomial coefÞcient
_______________________________________________________________________________
ubf: Cubic polynomial coefÞcient
Function
What is a feedrate proÞle?
To allow a more ßexible programming of the gram continuously smooth velocity characteris-
feedrate proÞle, linear and cubic characteristics tics depending on the curvature of the workpiece
have been added to the feedrate programming in to be machined.
accordance with DIN 66025.
The cubic characteristics can be programmed These speed characteristics make it possible to
either directly or as interpolating splines. These program limiting acceleration changes and the-
additional characteristics make it possible to pro- reby to produce uniform workpiece surfaces.
3.18
Orientation interpolation – ORI...
3.7
3.7 Orientation interpolation - ORIVECT, ...
Programming
N.. ORIMKS Reference system for orientation

N.. ORIWKS
_________________________________________________________________________
N.. ORIAXES/ORIVECT/... Type of orientation interpolation
N.. G1 X Y Z A B C
Orientation reference
ORIMKS The reference system for the orientation vector is the machine
coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0 it is also
identical to ORIAXES
ORIWKS The reference system for the orientation vector is the workpiece
coordinate system. If $MC_ORI_IPO_WITH_G_CODE = 0 it is
also identical to ORIVECT
Orientation interpolation
Axis interpolation
ORIAXES Linear interpolation of the machine axes or interpolation of the

rotary axes using polynomials (if POLY is active)
______________________________________________________________________________
Vector interpolation
ORIVECT Interpolation of the orientation vector in one

plane (great circle interpolation)
ORIPLANE Interpolation in one plane (great circle interpolation), synonym of

ORIVECT
ORIPATH Tool orientation relative to the path. A surface is

spanned with the normal vector and path tangent, which deÞnes the
meaning of LEAD and TILT at the end point. This means that
the path reference applies only for the deÞnition of the end orientation
vector. Great circle interpolation is performed from the start to the end
orientation. LEAD and TILT do not simply mean lead and
tilt angle. They are deÞned as follows: LEAD describes
the rotation in the plane that is spanned by the normal vector and path
tangent; TILT then deÞnes the rotation around the normal vector.
In other words they both have the meaning of theta and phi in a spherical
coordinate system, with the normal vector as the Z axis and the
tangent as the X axis.
ORICONCW Interpolation on the peripheral surface of a cone in the clockwise direction
ORICONCCW Interpolation on the peripheral surface of a cone in the counterclockwise

direction. Also required in both cases:
A3=… B3=… C3=... or XH=…, YH=…, ZH=… end orientation
3.19
Orientation interpolation - ORI...
Rotary axis of the cone: A6, B6, C6 Aperture angle: NUT=…
ORICONIO Interpolation on the peripheral surface of a cone with intermediate

orientation setting with A7=... B7=... C7=....
Also required:
ORICONTO Interpolation on the peripheral surface of a cone with tangential transition
Also required:
With POLY, PO[PHI]=..., PO[PSI]=... can also be programmed here.

This is a generalization of great circle interpolation, in
which the polynomials for lead and tilt angle are programmed.
The polynomials have the same meaning in conical interpolation as in
great circle interpolation for the given start and end orientations. The
polynomials can be programmed with ORIVECT, ORIPLANE,
ORICONCW, ORICONCCW, ORICONIO, ORICONTO.
ORICURVE Orientation interpolation with deÞnition of the movement of the

tool tip and of a second point on the tool.
The path of the second point is deÞned with XH=... YH=... ZH=..., in
conjunction with BSPLINE as the control polygon with POLY as the
polynomial:
PO[XH] = (xe, x2, x3, x4, x5) PO[YH] = (ye, y2, y3, y4, y5)
PO[ZH] = (ze, z2, z3, z4, z5)
If additional BSPLINE or POLY information is not available, simple linear
interpolation is performed accordingly from the start to the end orientation.
The main orientation interpolations
1 2 Orientation interpolation functions are described in

section 1.10.
! Linear interpolation ORIAXES

" Great circle interpolation ORIVECT
# Conical surface interpolation ORICONCW
& Curve interpolation ORICURVE
3 4
3.20
3D tool offsets - CUT3DFS
3.8
3.8 Tool offsets - CUT3DFS, ...
G40 Deactivation of all variants

G41 Activation in circumferential milling compensation direction left
G42 Activation in circumferential milling compensation direction right
G450 Circles at external corners (all compensation types)
G451 Intersection traveling at external corners (all compensation types)
2 ½D circumferential milling
CUT2D 2 1/2D COMPENSATION with compensation plane determined with

G17 - G19
______________________________________________________________________________
CUT2DF 2 1/2D COMPENSATION with compensation plane determined by frame

______________________________________________________________________________
ORID No orientation changes in inserted circle blocks at external
corners. Orientation movement is executed in the linear blocks.
______________________________________________________________________________
ORIC Travel path extended with circles. The orientation change
is executed proportionately in the circle as well.
Face milling
CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the

coordinate system deÞned with G17 - G19. Frames have no
inßuence.
______________________________________________________________________________
CUT3DFF Constant orientation (3-axis). Tool in Z direction of the current

coordinate system deÞned with frame.
______________________________________________________________________________
3D circumferential milling with limitation surface (combined circumferential/face milling)
CUT3DCC CNC program refers to the contour on the machining surface.

______________________________________________________________________________
CUT3DCCD The CNC program refers to the tool center path.
3.21
Programming at the machine
3.9 Programming at the machine
Machining inclined surfaces or holes
Programmers can also program 5-axis movements at the machine.
Example: Inclined holes

To produce 4 holes on an inclined slide in a large tool.
With the user-friendly functions in Sinumerik 840D the program can be easily programmed at the
control system.
Example
%_N_slide
N10 T1
N20 S1000 M3
N30 M8 M60
N40 ORIWKS TRAORI
N50 ORIVECT
N60 G54 ;Zero point at !.
N70 TRANS X25 Y10 Z70 ;Coordinate system moved to ".
N80 AROT Y+60 ;Coordinate system rotated into inclined plane. From this point
;the static transformation is calculated automatically.
N90 G0 X20 Y15 Z5 ;Approach Þrst drilling position and with A3, B3, C3 tool
A3=0 B3=0 C3=1 ;parallel to Z axis, i.e. tool perpendicular to the plane.
N110 Drilling cycle :From this point you can carry on programming as for
;a 2 ½D situation. The 840D does everything else
;for you.
...
3.22
3.9
Example of orientation interpolation
Pocket with draft
In the following program we have assumed that the pocket has already been produced with straight
walls, so only the programming of the inclines is described here.
The programming is carried out in G90, the tool starts parallel to the Z axis.
The contour at the base of the pocket is programmed.
Example
2 3
5
4
N110 TRAORI(1) ;Activate TRAFO

N120 G54 ;Select tool zero point
N130 TRANS X 80 Y80 ;Move tool zero point to center of pocket !
/N140 AROT Z .. ;(rotate pocket if necessary)
N150 ORIWKS ;Tool orientation in WCS
N160 ORIVECT ;Great circle interpolation of orientation
N170 CUT3DC ;3D tool radius compensation (TRC)
N180 ISD=0 ;Engaged length of tool = 0
The contour was programmed on the workpiece surface,
not on the pocket base (then ISD = 41, 231), see also
notes at end of CNC program.
N190 G0 X0 Y-40 Z-39 ;Approach path "
N200 G1 G41 X0 Y-50 Z-40
A3=0 B3= - 10 C3=40 ;As the contour is approached, the
orientation changes
3.23
; Select TRC and approach 1st machining position with

;required orientation.
;The components of the orientation vector
;can be taken directly from the
;drawing. #
N210 X20 ;1. machining step. Traverse to the corner. &
N220 ORICONCCW ;Selects conical surface interpolation for the orientation
;interpolation
N230 A6=0 B6=0 C6=1 ;DeÞnes the taper axis (parallel to the Z axis of the
;TCS). DeÞnition that the taper is perpendicular to the Z
;axis.
N240 G3 X30 Y-40 CR=10
A3=10 B3=0 C3=40 ;Pocket rounding with radius programming
;Orientation change on the conical surface '
N250 ORIVECT ;Great circle interpolation
N260 G1 Y40 ;from this point the individual machining steps are repeated (
N270 ORICONCCW
N280 A6=0 B6=0 C6=1
N290 G3 X20 Y50 CR=10
A3=0 B3=10 C3=40
N300 ORIVECT
N310 G1 X-20 ;)
N320 ORICONCCW
N330 A6=0 B6=0 C6=1
N340 G3 X-30 Y40 CR=10 A3= - 10 B3=0 C3=40
N350 ORIVECT
N360 G1 Y-40
N370 ORICONCCW
N380 A6=0 B6=0 C6=1 ;*
N390 G3 X-20 Y-50 CR=10 A3=0 B3= - 10 C3=40
N400 ORIVECT
N410 G1 X0 ;+
N420 G40 Y-40 Z-39 A3=0 B3=0 C3=1 ;Deselects TRC
N430 G0 Z100 ;Retraction
N440 TRAFOOF ;Switch off TRAFO (if necessary)
This pocket can be produced with various strategies:
1. If the contour of the pocket is programmed at the pocket base, ISD = 0 mm, where ISD
is the depth of engagement of the tool.
2. The pocket contour can also be programmed at the workpiece surface.

In this case the cutter must be plunged in with an ISD of 41.231 mm, which corresponds to
the wall length. The radii should be adjusted.
In this example the depth of engagement is calculated using Pythagoras‘

theorem:
ISD:
402 + 102 = 41, 231
3.24
Example – bending device for pipes
3.10
3.10 Example - bending device for pipes
1 BENDINGRADIUS.SPF
3 GUIDESLOT.SPF
2 HOLES.SPF
8
5
3.25
Workpiece
Milling work is required on a bending device for pipes:
! Bending radius, die (BENDINGRADIUS.SPF, 5-axis simultaneous milling

of a freeform surface)
" Holes (HOLES.SPF, 3-axis drilling with frame shifting)
# Guide slot (GUIDESLOT.SPF, 3-axis milling with frame shifting)
On the lower side of the workpiece is a central threaded hole & for clamping the device in the ben-
ding machine. The threaded hole should also be used in the milling machine for clamping or at least
centering. This allows a reproducible clamping for other parts. All key dimensions relate to this hole
and as a consequence the tool coordinate system & is also positioned in the hole by adjustable zero
offset G54 '.
Machine kinematics
In our example the workpiece is machined with a rotating/swivel head. The machine zero is outside
the table. The axes of the machine( and workpiece coordinate system & are parallel to one another
in this case. G54 therefore comprises only translatory values. Any 5-axis machine with any machine
kinematics can be used for milling.
The prerequisite is of course that the necessary orientations can be achieved. For example, the tool
in point * must be able to adopt a swivel angle of A = –90°.
Between each subroutine call a tool change position ) is approached, which is positioned so that the
tool can approach the machining position along a straight path without colliding with the workpiece.
The safe position is at the very top of the work area at X0 Y0 Z999.
The procedure is the same for all three basic kinematics (see Chapter 1). The same program can be
run on all three machine types.
CNC program
The postprocessor in a CAM system generates the CNC program, which consists of a main program
and subroutines. A CAM system is not necessary for the holes " and guide slot #, however. Both
machining operations can easily be programmed with Sinumerik 840D.
The subroutines correspond to the machining positions !, " and #. The program structure is
therefore very clear for machine operators. The main program contains the workpiece coordinate
system &, to which two temporary axis systems (frames) refer, which use the subroutines “Holes.spf”
and “Guideslot.spf”. These temporary axis systems are deÞned with the commands TRANS and
AROT. TRANS and AROT deÞne the workpiece coordinate system for programming.
Subsequent changes can be made by the machine operator. A few tips are included in our comments
on the subroutines. The standard version of the postprocessor only generates a program with no
main program and subroutine technology.
Note:
The programs shown here are not complete. They are intended only to illustrate the structure of the
programs from a technological perspective.
3.26
3.10
Main program
The main program contains only the technology data. The geometry data are all contained in the
subroutines. The frame deÞnitions for the two subroutines “Holes.spf” and “Guideslot.spf” are also
included in the main program.
Mainprogram.mpf
N10 G17 G54 G90 ; Working plane, absolute dimensions
; Zero offset from machine to workpiece
; coordinate system, in the threaded hole on the
; lower side of the workpiece
; The frame deÞnitions in “Holes.spf” and
; “Guideslot.spf” relate to this
; workpiece zero.
N20 MSG (“CAM program”)
______________________________________________________________________________
; Note:
; The swivel movement in the approach position does
; not occur in the subroutine.
; Feedrates are programmed in the subroutines.
N30 MSG (“1st OPERATION: ; Comment by CAM programmer on the type of

5-AXIS MACHINING”) ; subroutine
N40 T1 D1 ; Approach the tool change position and tool
; change. This is a simpliÞed version only,
; depending on the machine manufacturer other
; commands are necessary.
N50 S16800 M3 ; Spindle speed, clockwise
N60 CYCLE832(0.05,112101) ; High-speed settings “on”, settings are as follows:
; 0.05 = Tolerance of machining axes 0.05 mm
; 112101 = COMCAD, FFWON SOFT, G642,
; TRAORI(1), Finishing
N70 EXTCALL”BENDINGRADIUS.SPF” ; Call the “BENDINGRADIUS.SPF” subroutine.
N80 CYCLE832() ; Deselect high-speed settings since they are not
; required for the subsequent program “holes.spf”.
______________________________________________________________________________
; Note:
; The swivel movement in the working position is
; included here in block N170.
; CYCLE832 is not programmed, since it is only

; useful for 3-axis and 5-axis transformations
N90 MSG (“2nd OPERATION: ; Comment by CAM programmer on the type of

Drilling with frame support”) ; subroutine
N100 T2 D2 ; Approach the tool change position
N110 S850 M3 ; Spindle speed, clockwise
N120 TRAORI() ; Selects 5-axis transformation
N130 G54 ; Select zero offset again
N140 TRANS X45 Y-69.529 Z109.393 ; Frame deÞnition, translatory component
; From the lower side of the workpiece to the center of
; the top hole
3.27
3.10 Information for CAM programmers
N150 AROT X45 ;Frame deÞnition, rotary component

N160 AROT Z-60 ;The frame was positioned so that after rotation
;both holes lie on the same axis, namely
;the X axis. The required clearance of
;26 mm between the two drill holes can clearly
;be seen in the program.
;This makes it easier to modify the hole
;positions in the program at a later date.
;The frame offset is carried out with TRANS and ROT,

;since they have to be based on G54.
N170 G0 A3=0 B3=0 C3=1 ;Tool orientation perpendicular to the machining
;plane
N180 EXTCALL”HOLES.SPF” ; Call the “holes.spf” subroutine.

N190 TRANS ;Translation and rotation off. Since TRANS
;clears all transformations (ROT, SCALE, MIRROR,
;TRANS), a CNC block “N22 ROT” to
;switch off rotation is not required.
______________________________________________________________________________
;Note:
;The swivel movement in the working position is
;included here in block N280.
N200 MSG (“3rd OPERATION: Contour ;Comment by CAM programmer on the type of
milling with frame support”) ;subroutine
N210 G0 A3=0 B3=0 C3=1 ;To avoid collision with the workpiece
;(TRAORI is still enabled)
N220 T3 D3 ; Approach the tool change position
N230 S10500 M3 ;Spindle speed, clockwise
N240 TRANS X75 Y0 Z0 ;Frame deÞnition, translatory component. From the

;lower side of the workpiece to the lower side of the
;side wall.
N250 AROT Z90 ;Frame deÞnition, rotary component. The frame
N260 AROT X90 ;is positioned so that the Z axis in this frame
;corresponds to the infeed direction and the main
;direction of movement to the Y axis.
N270 CYCLE832(0.05,112101) ;High-speed settings “on”, settings are

;as follows:
;0.05 = Tolerance of machining axes 0.05 mm
;112101 = COMCAD, FFWON SOFT, G642,
;TRAORI(1), Þnishing
N280 G0 A3=0 B3=0 C3 =1 ;Tool orientation perpendicular to the
;machining plane
N290 EXTCALL”GUIDESLOT.SPF” ;Call the “GUIDESLOT.SPF” subroutine
N300 CYCLE832() ;Deselect high-speed settings

N310 TRANS ;Translation (TRANS) and rotation (ROT) off, see
;CNC block N240
N320 A3=0 B3 =0 C3=1 ;Tool parallel to Z axis in G54 coordinate
;system
N330 TRAFOOF ;Transformation off
______________________________________________________________________________
3.28
3.10
N340 G0 G53 Z999 D0 ;Move in rapid traverse to the safe position at the
;top of the work area in the machine coordinate
;system at Z999.
;After G53 all subsequent movements relate
;not to G54 but to the
; machine coordinate system.
;Since G54 is modal, the command is used
;if further blocks follow. Otherwise
;the CAM system could also simply output
;the non-modal command SUPA:
;SUPA Z999 D0
;D0 clears the existing tool offset
;N220 T3 D3.
3.29
BENDINGRADIUS.SPF subroutine
Machining strategy:
The milling paths ! were generated by the CAM program. They run parallel to the Y axis in the work-
piece coordinate system.
Milling with 3+2 axes or with 5-axes simultaneously? Both types of machining are possible here.
5-axis simultaneous milling has the clear advantage, however:
$ Much better cutting conditions in 5-axis simultaneous milling.

The result is a higher cutting speed and improved surface quality.
$ In contrast to milling with 3+2 axes, the tool can be kept shorter.
In order to reach the convex contour on the extreme
left and right, 3+2 axis milling would require a very long
tool.
$ In 5-axis simultaneous milling the work can be completed in a single machining operation.
3+2 axis milling would require milling for the left, right and center die or
radius segment with 2 or 3 machining operations.
Sequence:
The tool moves in a straight line, without risk of collision, from the tool change position " to the
approach position #. The approach position # and retraction position & are at safe positions outside
the workpiece. From there the tool moves down vertically to the start position (.
Machine operators:
2
6
3.30
Information for CAM programmers
3.10
In contrast to the “Holes.spf” and “Guideslot.spf” subroutines, all positions refer to the workpiece coor-
dinate system ' and not to the coordinate systems deÞned in these subroutines.
If as in this case the workpiece coordinate system and subroutine are clearly identiÞed in the
CNC program, the accuracy of the movements can be roughly checked at the machine before
the start of the program. Compare the clamped workpiece, e.g. with the main milling direction
TIP in the CNC program. By way of example we have highlighted the Y values ( in the program
which correspond to the main milling direction. Compare: the values increase
in the Þrst tool path since they lead from the negative range from -y to +y.
5-axis simultaneous milling makes it almost impossible for the machine operator to modify the subrou-
tine.
The program can only be executed with a tool of the deÞned radius, since the CAM system includes
the tool radius in the calculation of the travel.
BENDINGRADIUS.SPF
N10...180 ;Not relevant, user-speciÞc CNC blocks
N190 G0 A3=0.1736482 B3=-0.84951514 C3=0.49816696
;Swiveling of the tool to the tool change
;position "
N200 G0 X-20.54042 Y-117.80997 Z175 ;Approach position #
N210 G0 Z63.87603 ;Moving down to the start position (
N220 G1 X-21.40866 Y-113.5624 Z61.3852 F8500
;Start of modal G1 blocks and call
;for feed
______________________________________________________________________________
N230 N370 CIP X-21.89062 Y-109.77512 Z63.23548 I1=AC(-21.74533) J1=AC(-111.5367)
K1=AC(61.4569) ;Programming of a quadrant via CIP
;(see SINUMERIK 840D documentation, Circular
;interpolation through intermediate point, CIP)
____________________________________________________________________________
N380 X-21.86959 Y-109.74489 Z63.60494 A3=0.1736482 B3=-0.84951231 C3=0.4981718
;5-axis simultaneous milling with permanent
;change of tool setting with A3, B3, C3
N390 X-21.84803 Y-109.71466 Z63.9744 A3=0.1736482 B3=-0.84950947 C3=0.49817663
N400 X-21.82647 Y-109.68443 Z64.34386 A3=0.1736482 B3=-0.84950664 C3=0.49818147
N410 X-21.79376 Y-109.63744 Z64.82612 A3=0.17364925 B3=-0.84774706 C3=0.5011695
...
N281930 X21.86959 Y-109.74488 Z63.60495 A3=-0.17364815 B3=-0.84951232 C3=0.4981718
N281940 X21.89115 Y-109.77511 Z63.2355 A3=-0.17364815 B3=-0.84951515 C3=0.49816697
_____________________________________________________________________________
N281950 Y-109.94584 Z62.85898 ;Soft retraction from the contour on a quadrant,
;with no change of tool setting, i.e. the
;vector A3, B3, C3 does not change.
N281960 X21.87787 Y-110.20695 Z62.44206

...
N282080 X21.4767 Y-113.18568 Z61.28948
N282090 X21.40867 Y-113.56239 Z61.3852
_____________________________________________________________________________
N......... ;End position)
N282100 G0 Z175 ;Move up to the retraction position/safety
;plane & above the workpiece
N282110 M17 ;End of program, return to main program
3.31
“HOLES.SPF” subroutine
Machining strategy:
In the main program, using TRANS and AROT in the workpiece coordinate system G54 !, a tem-
porary frame " was placed in the position of the Þrst hole, in which the Z axis corresponds to the
infeed direction of the drill. Using this temporary frame a drilling pattern can very easily be program-
med on the inclined surfaces.
Sequence:
The tool swivels to the tool change position # in the tool orientation for the subsequent machining -
see CNC block N15 in the main program. From there it moves to the start position above the Þrst hole
&, drills, then moves with a clearance of 50 mm from the workpiece surface to the second hole ',
where it executes the drilling cycle again. In this example the drilling cycle “CYCLE81” is used.
Machine operators:
Since both holes are on the X axis in the current tool coordinate system, the hole positions
can be easily corrected or the drilling cycle modiÞed subsequently.
TIP
1
2
5
3.32
3.10
HOLES.SPF
N1 G0 X0 Y0 Z50 ;In rapid traverse to the Þrst hole with a safety
;clearance Z=50 &
N2 F50 ;DeÞnition of the drilling feed = infeed movement
;The traversing movement from hole to hole takes
place
;in rapid traverse (deÞned by the drilling cycle).
N3 MCALL CYCLE81 (50,0.5,-20) ;DeÞnition of the drilling cycle = no movement yet
;(Safety plane, surface, safety clearance,
;drilling depth). MCALL calls CYCLE81 modally.
N4 X0Y0 ;Drills the Þrst hole at position X0Y0 &
N5 X26 ;Moves to the second hole 50 mm above the
;workpiece ' and drills at X26
N6 MCALL ;Deselects the modal CYCLE801
N7 M17 ;End of program, return to main
;program
3.33
“GUIDESLOT.SPF” subroutine
Machining strategy:
In the main program a temporary frame " was placed by the workpiece coordinate system G54 !
on the lower edge of the workpiece using TRANS and rotated by 90° about Z and X using AROT,
since the guide slot was measured from here in accordance with the tool drawing (. The Z axis again
corresponds to the infeed direction of the cutter. All traversing movements relate to the temporary
frame. The main milling direction ' runs parallel to the Y axis of the frame ".
Since the contour was programmed with active tool radius compensation (see block N330 G42), the
machine operator can use a milling tool of any diameter.
The maximum possible diameter of the milling tool is calculated from the smallest radius of the con-
tour to be milled (see block N360, lower semicircle radius 10 mm)
Sequence:
The tool swivels to the tool change position # in the tool orientation for the subsequent machining
- see CNC block N280 in the main program. From there it moves to the start position &, which is
outside the open side of the groove, outside the tool.
From the start position the cutter Þrst moves down. Infeed takes place 5 times in the Z direction.
4
1
3.34
3.10
GUIDESLOT.SPF
N10 ... N290 ;Not relevant, user-speciÞc CNC blocks
N300 G0 X-2 Y126 Z50 ;& Approach start position = safety plane
N310 Z1
______________________________________________________________________________
N320 G1 G64 Z-2 F575 ;) The cutter is moved from top to bottom and
;is now exactly at the start of machining.
;This is point X-2 and Y126 (see N300, X-2,
;Y126 still modally valid).
;Infeed rate = 575 mm/min
N330 G42 Y132 F6333 ;Tool radius compensation right of contour
;Switch to machining feedrate = 6333 mm/min
N340 G2 X10 Y120 I0 J-12 ;Soft approach to contour along quadrant
N350 G1 Y40 ;Description of contour (slot)
N360 G2 X-10 I-10 J0 ; -” -
N370 G1 Y120 ; -” -
N380 G2 X2 Y132 I12 J0 ;Soft retraction from contour along quadrant
N390 G40 ;Deselection of tool radius compensation
N400 G1 Y126
N410 G0 Z-1 ;Retract by 1 mm in the tool axis direction
N420 X-2 ;Positioning at start point (see N300)
______________________________________________________________________________
N430 G1 Z-4 F575 ;Infeed to Z-4 at infeed rate
...
______________________________________________________________________________
...
_____________________________________________________________________________
N860 M17 ;End of program, return to main program
Note:
3.35
Example – motorcycle headlight
3.11 Example - motorcycle headlight
7
1
d b
a, c
5
G54 4
g k l 3
i, j
e, f, h
3.36
3.11
Workpiece
The mold for a motorcycle headlight casing is milled in two clamps.
In clamp 1 ! the lower side of the housing is milled from a block with 4 subroutines.
In clamp 2 " the top and front side of the housing are each milled with 4 subroutines.
! Clamp 1 - lower side of lamp
a) Lower side of housing 1x (1_CLAMP_1.SPF, 3-axis plane roughing)

b) Lamp holder (1_CLAMP_2.SPF, 3-axis plane Þnishing)
c) Lower side of housing 2x (1_CLAMP_3.SPF, 3-axis plane Þnishing)
d) Small surface (1_CLAMP_4.SPF, 3-axis proÞle Þnishing)
" Clamp 2 - top of lamp
e) Top of housing 1x (2_CLAMP_1.SPF, 3-axis plane roughing)

f) Top of housing 2x (2_CLAMP_2.SPF, 3-axis plane Þnishing)
g) Constriction (2_CLAMP_3.SPF, 3-axis, equidistant Þnishing)
h) Top of housing 3x (2_CLAMP_4.SPF, 5-axis ISO machining)
# i) Reßector ring 1x (2_CLAMP_5.SPF, 5-axis ISO machining)

j) Reßector ring 2x (2_CLAMP_6.SPF, 5-axis, equidistant Þnishing)
k) Reßector internal incline (2_CLAMP_7.SPF, 5-axis, equidistant Þnishing)
l) Reßector base (2_CLAMP_8.SPF, 5-axis, equidistant Þnishing)
Machine kinematics
The axes in the machine ( and workpiece coordinate system & are not parallel to one another. G54
' consists of a translation and a rotation about the Z axis.
Between each subroutine call a tool change position ) is approached, which is positioned so that the
tool can approach the machining position along a straight path without colliding with the workpiece.
CNC program
The postprocessor in a CAM system generates all subroutines. The main program that calls the
subroutines is created by the machine operator (see next page).
In the second clamp the workpiece coordinate system remains at the same X/Y/Z position but is
rotated so that the tool axis and Z axis are parallel to one another.
This does not apply to subroutines i) onwards, in which infeed takes place along the Y axis.
Program changes at the machine should only be made during the Þrst NC blocks of the subroutine,
before the NC blocks for freeform surface milling begin.
Just a few of the subroutines are set out on the following pages, since the structure of the subroutines
is similar.
Note:
3.37
Main program
The main program contains only the technology data. The geometry data are contained in the subrou-
tines. The frame deÞnitions for the two subroutines “Holes.spf” and “Guideslot.spf” are also included
in the main program.
Mainprogram.mpf
N10 G17 G54 G90 ; Working plane, absolute dimensions
;Zero offset from machine to workpiece
;coordinate system, zero point down
;Milling of Þrst clamp, workpiece lower
;side
______________________________________________________________________________
N20 T01 D01 ;Tool: Radial cutter, Ø 20, corner radius 1.0
;Approach the tool change position
N30 S4200 M3 M8 ;Spindle speed, clockwise, coolant on
N40 CYCLE832 (0.10.300220) ;High-speed settings “on”, roughing values
N50 EXTCALL”1_CLAMP_1.SPF” ;Call subroutine a, 3-axis program
______________________________________________________________________________
N60 T30 D30 ;Tool: Radial cutter, Ø 12, corner radius 1.5
;Approach the tool change position
N70 S12.400 M3 ;Spindle speed, clockwise
N80 CYCLE832(0.1, 300220) ;Change high-speed settings, roughing values
N90 EXTCALL”1_CLAMP_2.SPF” ;Call subroutine b, 3-axis program
______________________________________________________________________________
...
______________________________________________________________________________
N510 CYCLE832() ;Set default values
N340 G0 G53 Z999 D0 ;Move in rapid traverse to the safe position at the
;top of the work area in the machine coordinate
;system at Z999
;After G53 all subsequent movements relate
;not to G55 but to the
; machine coordinate system.
;Since G55 is modal, the command is used
;if further blocks follow.
;Alternatively, the CAM system could also
;simply output the non-modal command SUPA:
;SUPA Z999 D0
;D0 clears the existing tool offset
;N220 T3 D3.
3.38
3.11
Clamp 1
a) Lower side of housing 1x (1_Clamp_1.SPF, 3-axis plane roughing)
Sequence:
In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane
to the start point #. From the start point in rapid traverse towards the workpiece and then plunge into
the material at milling feedrate on a helical path &. Roughing one layer at a time ' without changing
the cutter orientation.
4
Sa 2
fety 5
pla
ne
Z11
5
1_CLAMP_1.SPF
N10 G0 G54 Z115 M08 ;In rapid traverse to the safety plane = Z115"
N40 X110.54685 Y-37.6 ;Along the X/Y safety plane to the start point #
N50 Z106.205 ;Infeed in rapid traverse in the Z direction
N60 G1 Z101.205 F800 ;At milling feedrate in the Z direction
N70 G1 X111.6 Z101.11286 F3650 ;Plunge with helix &
N80 G1 X111.79875 Y-37.58005 Z101.09539
;Helix with X/Y/Z values
N90 G1 ... ;Surface machining
... ;Surface machining
N332080 G0 Z115 ;Retraction movement in rapid traverse to safety
;plane = Z115 "
3.39
Clamp 1
c) Lower side of housing 2x (1_Clamp_3.SPF, 3-axis plane Þnishing)
Sequence:
In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane
to the start point #. From the start point in rapid traverse towards the workpiece and then at milling
feedrate onto the surface &. Finishing ' with clockwise travel, back to the safety plane (, plunge
again and counterclockwise milling.
Sa
fety
pla 2
ne
Z11
5 4
5
6
1_CLAMP_3.SPF
N10 G0 G54 Z115 M08 ;In rapid traverse to the safety plane = Z115"
N40 X5.24099 Y17.78397 ;Along the X/Y safety plane to the start point #
N50 Z86.40075 ;Infeed in rapid traverse in the Z direction
N60 G1 Z81.40075 F1850 ;Infeed at milling feedrate in the Z direction &
N70 G1 X5.10055 Y17.28025 F2600 ;Start Þnishing
N80 G1 X5.04972 Y16.75979 ;Finishing with clockwise and counterclockwise traver-
sing
... ;Surface machining
N1388700 G0 Z115 ;Retraction movement in rapid traverse to safety
;plane = Z115 "
3.40
3.11
Clamp 2
h) Top of housing 3x (2_Clamp_4.SPF, 5-axis ISO machining)
Sequence:
In rapid traverse from the tool change position ! to the safety plane ", then along the safety plane to
the start point #. During this movement the tool swivels into the orientation for the subsequent machi-
ning. From start point in rapid traverse & below the safety plane. Finishing ' with 5-axis machining.
Sa
fety
pla
ne
Z50 3
2_CLAMP_4.SPF
...
N40 G0 G54 Z50 M08 ;In rapid traverse to the safety plane = Z50 "
N50 X-90.69083 Y-7.39829 A3=-1 B3=0.000618 C3=0.000008
;Along the X/Y safety plane to the start point #
N60 Z-50.11765 A3=-1 B3=0.000618 C3=0.000008
;In rapid traverse in Z direction, without orientation
;change &
N70 G1 X-85.69083 Y-7.40138 A3=-1 B3=0.000618 C3=0.000008 F1000
;Plunge at milling feedrate in X direction
N80 G1 ... ;5-axis surface machining
... ;5-axis surface machining
N162970 G0 Z50 A3=1 B3=0.000618 C3=0.000008
;Retraction movement in rapid traverse to safety
;plane = Z50 "
N162980 A3=0 B3=0 C3=1 ;Tool is parallel to Z axis and is therefore
;ready for the next tool change. Block
;must already have been programmed in the main program.
3.41
Clamp 2
k) Reßector internal incline (2_Clamp_7.SPF, 5-axis, equidistant Þnishing)
Sequence:
In rapid traverse from the tool change position ! to the Z coordinate of the start point ", then along
the safety plane to the start point #. During this movement the tool swivels into the orientation for
the subsequent machining. Infeed from start point in rapid traverse & in Y direction. Finishing ' with
5-axis machining.
Operators:
The same tool is used for the next program l) (see main program). A tool change is therefore unne-
cessary and could be deleted from the main program.
Saf
ety
1 pla
ne
Y30
2
5
4
2_CLAMP_7.SPF
N10 ...N30 ;User-speciÞc CNC blocks
N40 G0 G54 Z-64.91412 M08 ;In rapid traverse to Z component of start position "
N50 X2.10222 Y30 A3=-0.000864 B3=0.987688 C3=0.156432
;In rapid traverse to start point # along safety
;plane = Y30
N60 Y8.44899 A3=-0.000864 B3=0.987688 C3=0.156432
;In rapid traverse in Y direction, without orientation
;change &
N70 G1 X2.10654 Y3.51055 Z-65.69628 A3=-0.000864 B3=0.987688 C3=0.156432 F1850
;Plunging at milling feedrate, 5-axis machining '
N80 G1 ... ;5-axis machining
... ;5-axis machining
N687620 G1 ... ;5-axis machining
N687630 G0 Y30 A3=-0.00987 B3=0.987688 C3=0.156123
;plane = Y30 "
;ready for the next tool change.
3.42
3.11
Clamp 2
l) Reßector base (2_Clamp_8.SPF, 5-axis, equidistant Þnishing)
Sequence:
In rapid traverse from the tool change position ! to the Z coordinate of the start point ", then along
the safety plane to the start point #. During this movement the tool swivels into the orientation for
the subsequent machining. Infeed from start point in rapid traverse & in Y direction. Finishing ' with
5-axis machining.
Saf
ety
pla
ne
1 Y30
2 5
2_CLAMP_8.SPF
...
N40 G0 G54 Z-43.3831 M08 ;In rapid traverse to Z component of start position "
N50 X-2.10801 Y30 A3=0 B3=0.965926 C3=0.258819
;In rapid traverse to start point # along safety
;plane = Y30
N60 Y-7.79506 A3=0 B3=0.965926 C3=0.258819
;In rapid traverse in Y direction, without orientation
;change &
N70 G1 Y-12.62469 Z-44.67719 A3=0 B3=0.965926 C3=0.258819 F1850
;Plunging at milling feedrate, 5-axis machining '
... ;5-axis surface machining
N177690 G0 Y30 A3=0 B3=0.965926 C3=0.258819
;plane = Y30
;ready for the next program start.
3.43
3.44
References
Contents Page
4.1 Overview of higher-order functions 4.2
4.2 Index 4.10
4
4.1 References
Overview of higher-order functions
4.1 Overview of higher-order functions
The higher-order functions of 840D for mold making and aerospace are set out on the following pages. This
gives you an overview of the commands that go beyond the requirements laid down in DIN 66025 and allow
signiÞcant improvements in the areas of aerospace and mold making.
4.1.1 Traversing commands
Conventional
G00, G01, G02, G03 Rapid traverse, linear interpolation, circular interpolation,
counterclockwise circular interpolation
Additional circular interpolation programming
CIP Circular interpolation through intermediate point

CIP X… Y… Z… I1=… J1=… K1=…
CT Circle with tangential transition
CT X… Y… Z…
TURN Number of full circles to be traversed
G3 X… Y… I… J… TURN =
Additional parameters:
CR= Circle radius
I1, J1, K1 Intermediate points in Cartesian coordinates (in X, Y, Z direction)
AP= End point in polar coordinates, polar angle, also in linear interpolation
RP= End point in polar coordinates, polar radius, also in linear interpolation
AR= Aperture angle
Involutes
INVCW Travel on an involute path in clockwise direction

INVCW X... Y... Z... I... J... K... CR=...
INVCW I... J... K... CR=... AR=...
INVCCW Travel on an involute path in counterclockwise direction
INVCCW X... Y... Z... I... J... K... CR=...
INVCCW I... J... K... CR=...AR=...
IJK Center point of base circle in Cartesian coordinates
CR= Radius of base circle
AR= Arc angle (angle of rotation)
840D spline variants
CSPLINE Activation of cubic interpolating spline

ASPLINE Activation of Akima spline
4.2
References
4.1
Start and end condition
BNAT/ENAT Zero curvature
BTAN/ETAN Tangential transition
BAUTO/EAUTO Constant C3 at Þrst and last spline segment
transition
BSPLINE Activation of B spline

SD=... B spline order (max. 3)
PL=... Interval length (vector node), “non uniformity”
PW=... Weights, i.e. denominator of rational B spline in polynomial representation
Example
N20 BSPLINE X... Y... SD=... PL=... PW=...
POLY Activation of polynomial interpolation, B spline representation in polynomial form

SD=... B spline order (max. 5!! -> different from BSPLINE)
PL=... Interval length (vector node), “non uniformity”
Syntax
PO[axis] = (block end position, a2 (quadratic coefÞcient),
a3 (cubic coefÞcient), a4, a5) -> numerator polynomial
PO[ ] = (Nend of block, b2, b3, b4, b5) -> denominator polynomial
Example
N10 POLY PO[X] = (0.25,0.5,0) PO[Y] = (0.433,0,0) PO[] = (1,1,0)
Compressors
COMPON Constant-speed transitions
COMPCURV Constant-acceleration and jerk-free transitions
COMPCAD Surface-optimized compressor (constant acceleration)
With corresponding single-axis tolerances:

$MA_COMPRESS_POS_TOL[X] = …
Or in later software versions with the following tolerances:
$SC_COMPRESS_CONTOUR_TOL: maximum tolerance for the contour

$SC_COMPRESS_ORI_TOL: maximum angular displacement for the
tool orientation
$SC_COMPRESS_ORI_ROT_TOL: maximum angular displacement for
the angle of rotation of the tool (only available on 6-axis machines).
The machine data $MC_COMPRESSOR_MODE can be used to set

the way in which tolerances can be deÞned:
0: axial tolerances with $MA_COMPRESS_POS_TOL for all axes

(geometry axes and orientation axes).
1: contour tolerance with $SC_COMPRESS_CONTOUR_TOL,

tolerance for orientation via axial tolerances with
$MA_COMPRESS_POS_TOL.
4.3
4.1 References
2: maximum angular displacement for tool orientation with

$SC_COMPRESSORITOL, tolerance for contour via axial tolerances with
$MA_COMPRESS_POS TOL
3: contour tolerance with $SC_COMPRESS_CONTOURTOL and maxi-

mum angular displacement for tool orientation with
$SC_COMPRESS_ORI_TOL.
Additional commands for a combination of path and synchronous axes

UPATH Parameter settings for the synchronous axes correspond to those for the
path axes, i.e., for the movement of a synchronous axis A: A = f(u), where
u denotes the path parameter for the path movement
SPATH Parameter settings for the synchronous axes follow the arc length for the
path axes, i.e. for the movement of a synchronous axis A: A= f(s) where s
denotes the arc length for the path movement.
4.1.2 Dynamic behavior
Look Ahead
G60, G60n Exact stop at block end
G601 Block change on reaching the Þne positioning window

G602 Block change on reaching the coarse positioning window
G603 Block change at end of interpolation
G64 Overrun of block end
G64n Corner rounding
G641 ADIS = … rounding clearance

ADISPOS =… Rounding clearance for G0, constant speed
G642 Corner rounding with single-axis tolerances ($MA_COMPRESS_POS_
TOL[X] = …) or ADIS, ADISPOS with intermediate blocks, constant-acce-
leration
G643 Block-internal corner rounding with single-axis tolerances ($MA_COM-
PRESS_POS_TOL[X] = …) or ADIS, ADISPOS, constant-acceleration
G644 Speed-optimized corner rounding with settable tolerances ($MA_COM-
PRESS_POS_TOL[X] = …. ADIS, ADISPOS) or maximum frequency
($MA_LOOKAH_FREQUENCY), constant-acceleration
G60, G64, G641, G code group 10

G642, G643, G644
G601 – G603 Internal G code group (group 12), i.e., G64n replace G64, G60n, do not
replace G60
4.4
References
4.1
Speed programming
Conventional non-modal speed programming via

G94 inches, mm/min
G93 inverse time
G95 inches, mm per spindle rotation
G96 Constant cutting rate
Programming of speed proÞles

FLIN Linear F-word interpolation inches, mm/min
FCUB Cubic spline interpolation for F-word inches, mm/min
F=FPO(…) Speed proÞle in polynomial form inches, mm/min
Path reference
FGROUP(X, Y, Z,…) DeÞnes the path axes with regard to the feedrate, i.e.
overall feedrate refers to the axes deÞned here.
Example: FGROUP(X, Y), then:
Acceleration
ACC[axis]=… Programmable acceleration as a percentage of the maximum acceleration
Jerk
SOFT Jerk limitation (maximum jerk in machine data)

JOG_AND_POS_MAX_JERK (jog and positioning)
MAX_AX_JERK, MAX_PATH_JERK (path mode)
BRISK Without jerk limitation
Feedforward control
FFWON Feedforward control on

FFWOF Feedforward control off
4.1.3 5-axis functions
Transformation
TRAORI Enable transformation 1

TRAORI(1) Enable transformation 1
TRAORI(2) Enable transformation 2
TRAORI(1, …, …, …) Enable transformation 1, generic transformation, additional
3 parameters for basic orientation vectors
TRAORI(2, …, …, …) Enable transformation 2, generic transformation, additional
3 parameters for basic orientation vectors
TRAFOOF Disable transformation
4.5
4.1 References
Orientation programming
ORIEULER Orientation programming on the basis of Euler angles (default)

ORIRPY Orientation programming on the basis of RPY angles
Both are only effective if $MC_ORI_DEF_WITH_G_CODE = 1 is set.
Otherwise deÞned on the basis of machine data.
In older systems the only difference is the machine data $MC_ORIENTATI-
ON_IS_EULER.
A2=… B2=… C2=... Euler or RPY angle

A3=… B3=… C3=... Cartesian orientation vector
XH=…, YH=…, ZH=… In ORIVECT or ORIPLANE synonymous with A3=... etc.
Extended meaning in conjunction with ORICURVE, here either with BSPLI-
NE as control polygon, or in conjunction with POLY polynomial deÞnition,
otherwise linear interpolation for the upper straight line,
geometrical great circle, but not speed-related.
LEAD, TILT Lead/tilt angle relative to normal vectors and path tangent. The normal vec-
tors at the start and end of the block are deÞned by A4=… B4=… C4=...
and A5=… B5=… C5=...
Only in conjunction with ORIPATH.
Orientation reference
ORIMKS The reference system for the orientation vector is the basic coordinate
system. If $MC_ORI_IPO_WITH_G_CODE = 0, it is also identical to ORI-
AXES.
ORIWKS The reference system for the orientation vector is the workpiece coordinate
system. If $MC_ORI_IPO_WITH_G_CODE = 0, it is also identical to ORI-
VECT.
Orientation interpolation
The following G codes are only effective if $MC_ORI_IPO_WITH_G_

CODE = 1 is set.
Axis interpolation
ORIAXES Linear interpolation of the machine axes, or interpolation of the rotary axes
using polynomials (if POLY is enabled)
Vector interpolation
ORIVECT Interpolation of the orientation vector in one plane (great circle interpolati-
on)
ORIPLANE Interpolation in one plane (great circle interpolation), synonymous with
ORIVECT
ORIPATH Tool orientation relative to the path. Here a surface is spanned with the
normal vector and path tangent, which deÞnes the meaning of LEAD and
TILT at the end point. This means that the path reference applies only for
the deÞnition of the end orientation vector. Great circle interpolation is per-
formed from the start to the end orientation. LEAD and TILT do not simply
mean lead and tilt angle. They are deÞned as follows: LEAD describes
the rotation in the plane which is spanned by the normal vector and path
tangent, TILT then deÞnes the rotation around the normal vector. In other
words, they both have the meaning of theta and phi in a spherical coordi-
nate system with the normal vector as the Z axis and the tangent as the X
axis.
4.6
References
4.1
ORICONCW Interpolation on the peripheral surface of a cone in the clockwise direction
ORICONCCW Interpolation on the peripheral surface of a cone in the counterclockwise
direction
Also required in both cases:
A3=… B3=… C3=... or XH=…, YH=…, ZH=… end orientation rotary axis of
the cone: A6, B6, C6
Aperture angle: NUT=…
ORICONIO Interpolation on the peripheral surface of a cone with speciÞcation of an
intermediate orientation via A7=… B7=… C7=….
Also required:
ORICONTO Interpolation on the peripheral surface of a cone with tangential transition
Also required:
With POLY, PO[PHI]=..., PO[PSI]=... can also be programmed here. This

is a generalization of great circle interpolation, in which the polynomials for
lead and tilt angle are programmed. The polynomials have the same mea-
ning in conical interpolation as in great circle interpolation for the given start
and end orientations. The polynomials can be programmed in ORIVECT,
ORIPLANE, ORICONCW, ORICONCCW, ORICONIO, ORICONTO.
ORICURVE Orientation interpolation with deÞnition of the movement of the tool tip and
of a second point on the tool
The path of the second point is deÞned with XH=... YH=... ZH=... , in con-
junction with BSPLINE as control polygon with POLY as the polynomial:
PO[XH] = (xe, x2, x3, x4, x5) PO[YH] = (ye, y2, y3, y4, y5)
PO[ZH] = (ze, z2, z3, z4, z5)
If additional BSPLINE or POLY information is not available, simple linear
interpolation is performed accordingly from the start to the end orientation.
4.1.4 Tool radius correction

G40 Deactivation of all variants
G41 Activation in circumferential milling, compensation direction left
G42 Activation in circumferential milling, compensation direction right
G450 Circles at external corners (all compensation types)

G451 Intersection traveling at external corners (all compensation types)
2½ D circumferential milling
CUT2D 2 1/2D COMPENSATION with compensation plane determined with G17 - G19
CUT2DF 2 1/2D COMPENSATION with compensation plane determined by frame
ORID No orientation changes in inserted circle blocks at external corners. Orien-

tation movement is executed in the linear blocks.
ORIC Travel path extended with circles. The orientation change is executed pro-
portionately in the circle as well.
4.7
4.1 References
Face milling
CUT3DFS Constant orientation (3-axis). Tool faces in Z direction of the coordinate

system deÞned with G17-G19. Frames have no inßuence.
CUT3DFF Constant orientation (3-axis), tool in Z direction of the coordinate system
currently deÞned with frame
3D circumferential milling with limitation surface - combined circumferential/face milling
CUT3DCC NC program refers to the contour on the machining surface.

CUT3DCCD NC program refers to the tool center path.
5. FRAMES
Programmable frames
TRANS X… Y… Z… Absolute offset

ATRANS X… Y… Z… Incremental offset, relative to the currently active frame
ROT X… Y… Z… Absolute rotation
AROT X… Y… Z… Incremental rotation, relative to the currently active frame
ROTS X… Y… Absolute rotation described by two angles. The angles are the angles of
the lines of intersection of the inclined plane with the main planes against
the axes.
AROTS X… Y… Incremental rotation, relative to the currently active frame, angles as for
ROTS
RPL=… Rotation in the plane
MIRROR X… Y… Z… Absolute mirroring
AMIRROR X… Y… Z… Incremental mirroring, relative to the currently active frame
SCALE X… Y… Z… Absolute scaling
ASCALE X… Y… Z… Incremental scaling, relative to the currently active frame
Frame operators
Frame operators can be used to deÞne frame variables as a chain of indivi-

dual frame types:
CTRANS (X… Y… Z…) Absolute offset

CROT (X… Y… Z…) Absolute rotation
CROTS (X… Y… Z…) Absolute rotation
CMIRROR (X… Y… Z…)Absolute mirroring
CSCALE (X… Y… Z…) Absolute scaling
FRAME = CTRANS(…) : CROT (X… Y… Z…) : CMIRROR (X… Y… Z…)
4.8
References
4.1
Special frames
TOFRAME Tool frame, coordinate system with Z axis in tool direction,

zero point is tool tip
TOFRAMEX Tool frame, coordinate system with X axis in tool direction,
TOFRAMEY Tool frame, coordinate system with Y axis in tool direction,
TOFRAMEZ Tool frame, coordinate system with Z axis in tool direction,
zero point is tool tip, identical to TOFRAME
TOROT Tool frame, coordinate system with Z axis in tool direction, contains only
the rotation component of TOFRAME. The zero point remains unchanged.
TOROTX Tool frame, coordinate system with X axis in tool direction, contains only
TOROTY Tool frame, coordinate system with Y axis in tool direction, contains only
TOROTZ Tool frame, coordinate system with Z axis in tool direction, contains only
Identical to TOROT.
4.9
4.2 References
Index
4.2 Index
A I
ADIS 3.14 Inclined plane measurement
B
CYCLE998 2.9
Interruption 2.20
Block search 2.22
J
BRISK 3.17
Jerk limitation 3.16
C
K
CAM 1.19
Compressor 1.20, 3.12 Kinematic-independent programming
Conical surface interpolation Machine-independent programming 1.10
ORICONCW 1.24
Continuous path mode 3.14 L
Coordinate systems 1.17 LEAD 3.8
Corner measurement Linear interpolation
CYCLE961 2.10 Oriaxis 1.23
Corner rounding 1.20
M
Curve interpolation
ORICURVE 1.28 Machine kinematics
CUT3D... 3.21 Machine kinematics 1.9
CUT3DCC 1.15 Measuring functions 2.8
CUT3DF 1.14 Measuring sphere 2.17
CYCLE800 2.9, 2.11
N
CYCLE832 1.21, 2.25, 3.9
CYCLE961 2.10, 2.12 Network connection 2.16
CYCLE971 2.15 Nutated axis 1.9
CYCLE978 2.10, 2.12
CYCLE998 2.9, 2.11 O
E ORIAXES 1.23
ORICONCCW 1.24
Ethernet 2.16 ORICONCW 1.24
EXTCALL 2.16, 2.22 ORICONIO 1.24
ORICONTO 1.24
F
Orientation 1.23, 3.6, 3.19
Feedforward control 3.16 ORIVECT 1.24
Feedrate proÞle 3.18
Frame 2.21 P
Frames 1.17 PCU 20 2.16
G PCU 50 2.16
Pole 1.26
Gauging tools 2.13 Pole 1.26
Great circle interpolation 1.25 Program structure 1.22, 2.18
ORIVECT 1.24 Process chain
H CAD CAM CNC 1.19
High-speed setting cycle 1.21 Q

High-speed settings 2.25, 3.9 Quick View 2.24
4.10
References
Index
4.2
R
Radius changes 1.14
REPOS 2.20
Retraction 2.21
S
Serial interface 2.16
ShopMill 2.28
SOFT 3.17
Spigots 2.8
Spline orientation 1.28
Subroutine 1.22
Surface normal 1.14
Surface normal vector 3.6
Swivel cycle
CYCLE800 2.9
T
Testing a program 2.17
Tool probe 2.2
TCP
Tool center point 1.15, 2.13
TILT 3.8
Tool offset 3.21
Tool offset data 2.14
Tool compensations 1.16
Tool radius compensation 1.14
Tool type
Cutter types 2.13
TOROT 2.20
TOROTOF 2.21
TRAORI 1.12
Z
Zero point 2.2
4.11
4.2 References
Index
4.12
Siemens AG
Automation and Drives
Motion Control Systems
P.O. Box 3180, D – 91050 Erlangen © Siemens AG 2004
Subject to change without prior notice
Federal Republic of Germany
Order no.: 6FC5095-0AB10-0BP0
www.siemens.com/automation/mc Printed in the Federal Republic of Germany

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Manual Edition 04/2004

4.1 Overview References

Status code in the „Remarks“ column:

A .... New documentation.

Edition Order No. Remarks

Order No. 6FC5095-0AB10-0BP0 Siemens Aktiengesellschaft

First for the theory

1.1 Introduction.......................................................................................... 1.2

1.3 Milling with 3 axes, 3 + 2 or 5 axes?.................................................... 1.6

1.4 What moves and how? ........................................................................ 1.8

1.5 Machine-independent CNC programs ............................................... 1.12

1.6 Theory of tool radius compensation .................................................. 1.14

1.7 What are frames? .............................................................................. 1.17

1.8 Precision, speed, surface quality....................................................... 1.19

1.9 Structure of CNC mold making programs.......................................... 1.22

1.10 Orientation in 5-axis applications....................................................... 1.23

Machine operators – at the machine

2.1 Workpiece – determining the zero point .............................................. 2.2

2.2 Gauging tools .................................................................................... 2.13

2.3 Program data transfer........................................................................ 2.16

2.4 Testing a program.............................................................................. 2.17

2.5 Calling and executing a program....................................................... 2.18

2.6 Interrupting a program ....................................................................... 2.20

2.7 High-speed settings – CYCLE832..................................................... 2.25

2.8 ShopMill ............................................................................................ 2.28

Information for programmers

3.1 Introduction.......................................................................................... 3.2

3.2 Kinematic-independent CNC programs............................................... 3.3

3.3 Five-axis transformation – TRAORI..................................................... 3.5

3.4 Tool orientation – A3= B3= C3=, ... ..................................................... 3.6

3.5 High-speed settings – CYCLE832....................................................... 3.9

3.6 Feedrate proÞle – FNORM, FLIN, ... ................................................. 3.18

3.7 Orientation interpolation – ORI... ....................................................... 3.19

3.8 Tool offsets – CUT3DFS, ... ............................................................... 3.21

3.9 Programming at the machine ............................................................ 3.22

3.10 Example – bending device for pipes.................................................. 3.25

3.11 Example – motor cycle headlight....................................................... 3.36

4.1 Overview of higher-order functions...................................................... 4.2

4.2 Index.................................................................................................. 4.10

1.1 Introduction 1.2

1.3 Milling with 3 axes, 3 + 2 or 5 axes? 1.6

1.4 What moves and how? 1.8

1.5 Machine-independent CNC programs 1.12

1-6 Theory of tool radius compensation 1.14

1.7 What are frames? 1.17

1.8 Precision, speed, surface quality 1.19

1.9 Structure of CNC mold making programs 1.22

1.10 Orientation in 5-axis applications 1.23

Prototype Object design standards in all areas of applicati-

Nevertheless, the skilled machine tool operator

Impeller Sinumerik 840D from Siemens is a control sys-

The demands placed on molds, surface quality

To obtain optimum cutting conditions when

Dynamic 5-axis machining

In addition to the 3 linear axes X, Y and Z, 2

The linear axes X, Y and Z are used to

2 rotary axes, e.g. B and C, are used to

Theoretically, with 3 linear axes and 2 rotary

1.3 Milling with 3 axes, 3 + 2 or 5 axes?

Sinumerik 840D naturally supports all machining strategies.

1.4 What moves and how?

A 5-axis machine can control tool movements in 5 axes: the 3 familiar