Manual 5-axis Machining - Siemens

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Milling with SINUMERIK5-axis machiningManualSINUMERIK

SINUMERIK5-axis machiningBasic information1General information on workpiece production2Key functions for 5-axismachining3Aerospace, structural parts4Driving gear and turbine components5Complex free-form surfaces6Reference section7ManualValid for:Control systemsSINUMERIK 840DSINUMERIK 840D slSINUMERIK 840DiEdition 05/2009DocOrderNo. 6FC5095-0AB10-0BP1

00IntroductionPrinting history, registered trademarksIntroductionSINUMERIK documentationPrinting history, registered trademarksBrief details of this edition and previous editions are listed below.The status of each edition is shown by the code in the "Remarks" column.Status code in the "Remarks" column:A . New documentationB . Unrevised reprint with new order numberC . Revised version with new edition statusIf substantive changes have been made on a particular page since the last edition, this is indicatedby the new version code in the header on that page.EditionOrder No.Remarks05/20096FC5095-0AB10-0BP1ARegistered trademarksSIMATIC, SIMATIC HMI, SIMATIC NET, SIROTEC, SINUMERIK, SIMODRIVE and SINAMICS areregistered trademarks of Siemens AG. Other names in this publication may be trademarks whoseuse by third parties for their own purposes could violate the rights of the owner.More information is available on the Internet at:http://www.siemens.com/sinumerikOther functions not described in this documentation might beexecutable in the control. This does not, however, representan obligation to supply such functions with a new control orwhen servicing.This document was created using a number of layout andgraphic tools.The reproduction, transmission or use of this document or its We have checked that the contents of this document correcontents is not permitted without express written authority.spond to the hardware and software described. However, difOffenders will be liable for damages. All rights, including rights ferences cannot be ruled out and we can assume no liabilitycreated by patent grant or registration of a utility or design, are for ensuring full consistency. Nevertheless, the informationreserved.contained in this document is reviewed regularly and any necessary changes will be included in subsequent editions. Sug Siemens AG 1995 - 2009. All rights reserved.gestions for improvement are welcome.Technical data subject to change.Order No.Siemens-Aktiengesellschaft4 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

56Basic information . 71.1Introduction .81.2Requirements of 5-axis machining .91.3Linear axes, rotary axes and kinematics .101.4Surface quality, accuracy, speed .14General information on workpiece production. 172.1Process chain for producing 5-axis workpieces .182.2CAM system .192.3Program structure for 5-axis machining .212.4Introduction - Measuring in JOG and AUTOMATIC .232.5Setting up and measuring workpiece in JOG .242.6Measure tool in JOG .272.7Measure workpiece in AUTOMATIC .302.8Measure tool in AUTOMATIC .332.9Checking/calibrating the machine with the kinematics measuring cycle CYCLE996 352.10Quick View / Fast display .372.11ShopMill - Graphical interface .38Key functions for 5-axis machining . 393.1Introduction .403.2Explanation of the terms swivel, frames and TRAORI .413.3Transforming coordinate systems - Frames .423.4Swivel - CYCLE800 .443.5TRAORI 5-axis transformation .463.6High speed settings – CYCLE832 .633.7Tool radius compensation with CUT3D .733.8Volumetric compensation system (VCS) .763.9VNCK - Virtual machine .77Aerospace, structural parts . 794.1Special functions for structural parts .804.2Programming example for the pocket on a structural part .81Driving gear and turbine components. 855.1Special functions for driving gear and turbine components .865.2Example: Turbine blade .87Complex free-form surfaces . 916.1Special functions for free-form surfaces .926.2Example: Milling a manta ray .935 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

0IntroductionContentsPage7Reference section . 977.1Overview of higher-order functions . 987.2Further information/documentation . 1087.3Index . 1106 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

Basic ents of 5-axis machining91.3Linear axes, rotary axes and kinematics101.4Surface quality, accuracy, speed14

1.1Basic information1.1IntroductionWith multi-axis machining, the main objectives are to achieve perfect surface quality, precision,and speed without any need for remachining. Within this context, workflow is typically characterized by the CAD-CAM-CNC process chain. From the CAD system right through to the controlsystem, Siemens can offer an integrated solution for these requirements in the form of its SINUMERIK products.SINUMERIK controls are equipped with powerful, advanced functions which, when intelligentlyused, make the whole process of multi-axis programming and machining (particularly 5-axismachining) considerably easier while at the same time improving the results of production.This manual is a compact resource aimed at experts working in industrial and research environments who need to get acquainted with the key basic principles of multi-axis machining. Buildingon this, it also provides machine users with practical tips so that they can organize their work efficiently and provides programmers with an insight into the functions of the control and the CAD/CAM system.As regards the various application areas of multi-axis machining, the dedicated functions thathave been specifically developed for each area are briefly introduced and considered in context.Although many of the aspects cannot be covered in depth by this manual, you will find additionalinformation in the appropriate Sinumerik documentation and relevant literature (See "Furtherinformation/documentation" on page 108.)This manual is designed to supplement the Tool and Mold Making (3 axes) manual, which dealswith the typical functions of 3-axis machining. Please refer to this original manual for more indepth information about the basic principles and functions involved.Range of5-axis machining8 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.2Basic information1.2Free-form surfaces,mold makingRequirements of 5-axis machiningDesign standards in all application areas arebecoming increasingly more demanding.Expectations in terms of ergonomics, the airdrag coefficient (CW value) or simply aestheticappeal are creating a need for more complexsurface geometries to be achieved in less timeand with greater precision. The design primarily comes from CAD systems, the machiningprograms from CAM stations.Nevertheless, the skilled machine tool operator still has overall responsibility (in terms oftechnology) for the quality of the mold and thecomplete tool.Driving gear and turbine components,e.g. impellersWith SINUMERIK, Siemens can provide CNCsystems that are perfectly suited to thedemands of 5-axis machining as well as HSCapplications: Simple to operate User-friendly programming at the machine Optimum performance throughout theCAD - CAM - CNC process chain Maximum control over quality at themachine Optimized 5-axis functionsDifferent requirements depending on the application areaStructural parts,aviation industryDepending on the application, the requirements imposed on the control will vary and awhole range of different functions may bedemanded.Within this context, 5-axis machining can bebroken down into three broad areas: Free-form surfaces (mold making) Turbine and driving gear components(impellers, blisks) Structural parts (aviation industry)SINUMERIK can provide optimum support foreach of these areas.9 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.3Basic information1.3Linear axes, rotary axes and kinematics1.3.1 Axes and programmingLinear and rotary axesTo accommodate machining scenarios involving tools set at an angle or in order to millgeometries located anywhere in space, thethree linear axes X, Y and Z are requiredalong with two of the rotary axes A, B or C. Itmust be possible to control the axes simultaneously.Tool tip motionThe tool position is approached in space usinglinear axes X, Y and Z. This enables the tooltip to adopt any position.With 3-axis machining, you program the threelinear axes to achieve the desired machiningoperations. The contour is milled line by lineby moving the three linear axes.If the tool also has to be set at an angle, youwill need rotary axes as well.Setting the toolat an angleThe inclination of the tool (i.e. the tool orientation) is changed using two axes of rotation,e.g. B and C.This is necessary, for example, if the toolneeds to be angled in relation to the machining surface or if you want to mill a pocket withinclined walls within the context of circumferential milling.Using three linear axes and two rotary axes,theoretically any point in space can beapproached with any tool orientation. This isthe basis of 5-axis machining.10 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.3Basic informationCNC programming optionsFor the purpose of 5-axis machining, the orientation of the tool needs to be defined inaddition to the position setpoint of the machining point. The position setpoint is defined inthe CNC program by means of the coordinateaxes X, Y, and Z.Direction vectorprogrammingC3A3B3When describing the tool orientation, it makessense to specify the direction vector A3, B3,and C3 so that the orientation can be programmed independently of the machine kinematics.This enables the position setpoint and tool orientation to be defined in a unique manner.The example shows the tool in the position(0,0,0) as a diagonal of a cube (35.26 in relation to X-Y plane).N100 G1 X0 Y0 Z0 A3 1 B3 1 C3 1Rotary axisprogrammingThe same position can be achieved as withtool orientation by specifying it on the basis ofthe rotary axis positions.The position in the above example would beexpressed as follows:N100 G1 X0 Y0 Z0 B 54.73561 C 45The example shows the tool in the position(0,0,0) as a diagonal of a cube (35.26 inrelation to X-Y plane).NOTEIn addition to programming based on the direction vector and rotary axis positions, other forms ofangle programming are also common. These include, for example, Euler or RPY angles. Furtherinformation regarding this can be found in Section “Tool orientation” on page 50.11 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.3Basic information1.3.2 Kinematics of 5-axis machining centersA 5-axis machine can control tool motion in 5 axes. These are the 3 linear axes (with which youwill already be familiar) and an additional 2 rotary axes. There are different kinematic solutionsfor the two rotary axes. We will present the most common of these schematically. Machine toolmanufacturers are constantly developing new kinematic solutions for different requirements.With SINUMERIK controls, even special kinematics can be controlled on the basis of the integrated, kinematic transformation feature. Special cases such as hexapods, etc. will not beexplored in further detail here.Two rotary axes in the headForkNutated fork *Two rotary axes in the tableRotate/swivelRotate/swivel nutated **: If the axis of rotation is not perpendicular to a linear axis, then this is known as a "nutated" axis.12 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

Basic information1.3One rotary axis in the head / One rotary axis in the table13 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.4Basic information1.4Surface quality, accuracy, speedSpecial attention must be paid to the CAD - CAM - (post processor) - CNC process chainwhen machining three-dimensional geometries, e.g. free-form surfaces. CAM systems generateNC programs for free-form surface machining. The CAM system receives the workpiece geometry from a CAD system. The CNC machine has to process the NC data generated and convert itinto axis movements.In CAD systems, surfaces 1 of higher ordersare constructed (free-form surfaces).For example, in order to be able to mill anentire surface - or for collision checking - theCAM system generally converts the CAD freeform surface into a polyhedron.1This means that the smooth design surface isapproximated by a number of individual smallplanes 2 .2This produces deviations from the originalfree-form surface.G13G1G11G1The CAM programmer overlays this polyhedron with tool paths. From these, the post processor generates NC blocks within thespecified error tolerances. These usually comprise many short straight line elements, G1 XY Z. 3Thus, the machining result is no longer a freeform surface, but a polyhedron. The smallplanes of the polyhedron can be visiblymapped on the surface.This can result in undesirable remachining.14 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.4Basic informationSINUMERIK controls offer various functions so that remachining can be avoided:Compressor function (COMPCAD)At the block transitions, the linear interpolationleads to step changes in velocity in themachine axes, which in turn can cause resonance in the machine elements and can ultimately be detected as a beveled pattern 1 oras the effects of vibrations 2 on the workpiece surface.21123In accordance with the specified toleranceband, 1 the compressor takes a sequence ofG1 commands, 2 combines them and compresses them into a spline 3 , which can bedirectly executed by the control.The compressor generates smooth paths andpaths with constant curvature. The constantcurvature results in a steady velocity andacceleration characteristic, meaning that themachine can run at higher speeds, therebyincreasing productivity.Programmable smoothing4Discontinuous block transitions can besmoothed with the smoothing function to create steady characteristics. This involvesinserting geometrical elements 4 at the corners (block transitions).The tolerance of these geometrical elementscan be adjusted.15 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

1.4Basic information16 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

General information on workpiece productionContents2.1PageProcess chain for producing 5-axis workpieces182.2CAM system192.3Program structure for 5-axis machining212.4Introduction - Measuring in JOG and AUTOMATIC232.5Setting up and measuring workpiece in JOG242.6Measure tool in JOG272.7Measure workpiece in AUTOMATIC302.8Measure tool in AUTOMATIC332.9Checking/calibrating the machine with thekinematics measuring cycle CYCLE996352.10Quick View / Fast display372.11ShopMill - Graphical interface38

2.1General information on workpiece production2.1Process chain for producing 5-axis workpiecesThe production process chain generally starts with workpiece design. The data generated at thisstage provides the basis for further processing and, ultimately, for production.CAD/CAMProductionCAD modelCAM strategiesCalculation oftool pathsSimulation oftool pathsPost processorSetting up the machineQualityMachiningGenerating a CAD modelUsing the CAM system's internal strategies and methodsto generate the individual machining steps and tocalculate the paths.Simulation of the calculated tool paths with collisionchecking.Generation of the NC code in the post processor.Generally, it is the path at the tool tip (TCP) that isoutput in the NC code.Data transmission of NC programs and setting up of tooland workpiece. Possible creation of a main program thatwill call the generated geometry programs.Definition of the high speed settings, e.g. in CYCLE832, ifnot already taken into account by the post processor.These consist of the following: tolerance, compressor,continuous-path control, smoothing, jerk and speed.Production of workpiece on the machine.18 Siemens AG All rights reserved. SINUMERIK, Manual, 5-axis machining

2.2General information on workpiece production2.2CAM systemWithin the context of the process chain, it is the CAM system that is responsible for the key taskof generating the NC programs. The quality of this data plays a decisive role in determining theresults of workpiece production.This section outlines the procedure for generating the NC programs. Given the diverse range ofsystems available on the market, only a brief summary can be provided.Tool definitionPlane roughing strategyProcedure when working with a CAM system:X CAD dataRead CAD data into the CAM system. When reading the data in, a check should be performed to ensure that the surface geometries are free from defects, i.e. that there are nosteps or jumps. Flaws in the data such as these will manifest themselves on the surface ofthe finished workpiece.X Chucking situationDefine the chucking situation and

SINUMERIK, Manual, 5-axis machining Basic information 1.3 11 CNC programming options Direction vector programming Rotary axis programming In addition to programming based on the direction ve ctor and rotary axis positions, other forms of angle programming are also common. These include, for example, Euler or RPY angles. Further

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