SINUMERIK Live: Multi-face Machining Milling (3 2 Axes) - Siemens

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SINUMERIK live:Multi-face machining milling(3 2 axes)Principles, handling and use cases with SINUMERIK OperateUnrestricted Siemens AG 2017siemens.com/cnc4you

SINUMERIK liveApplication engineering made easyMulti-face machining milling(3 2 axes)Video series with the goal of presentingPrinciples, handling and useindividual topics on the use of SINUMERIKcases with SINUMERIK Operateat a practical level in minimal time!Consisting of short slide presentations andpractical application!Unrestricted Siemens AG 2017

Multi-face machining milling (3 2 axes)Principles, handling and use cases with SINUMERIK Operate1234Fundamentals of milling1.1Definition1.2Milling tools1.3Milling kinematics1.4Comparison 3 2 and 5-axis simultaneous3 2-axis milling with SINUMERIK Operate2.12D milling technologies in a tilted plane2.2Tilting planes: Cycle800Live example application on the SINUMERIK3.1Workpiece example3.2Swiveling with ShopMill and with G code programmingSummaryUnrestricted Siemens AG 2017

1 Fundamentals of millingDefinitionDefinition of milling:Axes:Milling is a metal cutting process. In this process, the material isremoved by the milling tool, which is rotating at high speedabout its own axis, while either the tool moves along theprogrammed contour or the workpiece is moved accordingly. Rotation of the tool about its own axis (Z axis) Movement in the direction X, Y or Z Rotation about rotary axes A, B or C via tool head or tableCBAUnrestricted Siemens AG 2017

1 Fundamentals of millingMilling toolsMilling tools: Have one or more cutting edges The material is removed by the rotating motion of the tools No rotation in the center point of the toolDistinguishing milling tools by type of tool clamping (end mill or shell-type milling cutter) cutting material (solid carbide or HSS) shape of the cutting edges (for roughing or finishing) milling strategy (groove milling, face milling, right-angle cutting, )Unrestricted Siemens AG 2017

1 Fundamentals of millingMilling kinematics3-axis machining3 2 axis machiningDynamic 5-axis machiningFor 3-axis machining, the machining isdone via programming the three linearaxes. The contour is milled in asynchronized way by the movement of thethree linear axes. The tool is positionedvertical to the workpiece.With three linear axes and two rotaryaxes, any point in space can theoreticallybe reached with any tool orientation.Thus, the tool can be statically aligned tothe machining surface.The three linear axes (X, Y and Z) andtwo of the rotary axes (A, B or C) are alsoused for orientating the tool. The axes arepositioned dynamically andsimultaneously.Unrestricted Siemens AG 2017

1 Fundamentals of millingMilling kinematics3-axis machining3 2 axis machiningDynamic 5-axis machiningThe milling machining is limited to the XYplane and can thus follow 2-dimensionalcontours.The machining itself is limited to2-dimensional contours. The thirddimension is achieved by tilting andsecuring the machining plane.To machine the free-form surfaces, the5 axes move dynamically andsimultaneously.2D machiningUnrestricted Siemens AG 20172½D machining3D machining

1 Fundamentals of millingMilling kinematicsFor both the 3 2-axis machining and the 5-axis simultaneous machining, you need two rotary axes (A, B or C) fororientating the tool in addition to the three linear axes (X, Y and Z).Depending on the kinematic characteristics of the machine, these 2 axes can be set using a tiltable head and/or a tiltable table.Head kinematicsMixed kinematicsTiltable headTiltable headand tiltable rotary tableUnrestricted Siemens AG 2017Table kinematicsSwivel rotary table

1 Fundamentals of millingComparison 3 2 and 5-axis simultaneousTool orientation3 2-axis StaticAdvantages5-axis simultaneous DynamicProgramming3 2-axis "manually"5-axis simultaneous CAD/CAMUse in the SINUMERIK3 2-axis Swivel cycle Cycle8005-axis simultaneous 5-axis transformation TRAORIWorkpieces3 2-axis Tool and equipmentmanufactureUnrestricted Siemens AG 20175-axis simultaneous Free-form surfaces andmold making3 2-axis5-axis simultaneous"Manually" programmable,nevertheless with greatflexibility Maximum flexibility Noncuts are avoided Optimum positioning of thetool

2 3 2-axis with SINUMERIK Operate2D milling technologies in a tilted planeStandard geometriesContour millingThe SINUMERIK provides a large selection of machining cyclesfor the drilling and milling of standard geometries. Machining of contour pockets and pins Automatic detection of residual material Free contour generation with contour computer/DXF readerThe full range of SINUMERIK technology cycles is also available in tilted planes– from simple drilling all the way to contour machining with residual material detection.Unrestricted Siemens AG 2017

2 3 2-axis with SINUMERIK OperateTilting planes: Cycle800The center for programming the 3 2-axis machining is the Cycle800 swivel cycle. Thanks to the graphically interactive inputscreen, all of the swivel tasks can be quickly and conveniently programmed directly on the CNC controller.Swivel cycle Cycle800: Graphical input screen in ShopMill Selection of the swivel data set Control of the swivel sequence(retract, swivel direction) Definition of the swivel mode (by axis/projectionangle/direct) Entry of the swivel parametersThe swivel axes are always turned in so that the machiningplane is vertical to the tool axis for the subsequent machining.Unrestricted Siemens AG 2017

3 Live example application on the SINUMERIKExample workpiece with ShopMillExample workpiece for multi-facemachining 3 2 milling:1)1Preparation of blank:face milling of the 5 cube facesUnrestricted Siemens AG 20171)2Pocket milling on untilted G17plane1)4Swiveling about Y and Z and millinga rhombus-shaped pocket1)3Swiveling about Y and engraving ofthe tilted plane1)5Re-swiveling about Y and Z andinclined drilling according to adrilling pattern

3 Live example application on the SINUMERIKExample workpiece with ShopMillExample: Programming of theengraving on a tilted plane1) Swivel cycle Cycle8002) Face milling cycle Cycle613) Engraving cycle Cycle60Unrestricted Siemens AG 20171) Swivel cycle Cycle800During parameterizing or programming of swiveling, the controller provides support inthe form of the graphical overview display - "Animated Elements".All of the swivel axes can be programmed directly on the machine. The rotation ofthe workpiece coordinate system in the program is then automatically converted torotations of the respective swivel axes of the machine when the workpiece ismachined.

3 Live example application on the SINUMERIKExample workpiece with ShopMill2) Face milling cycleIf the plane is tilted, the inclined plane can be milledwith the aid of the face milling cycle.It must be observed that you must imagine themilling plane as rectangular, even if the intersectionof the milling plane and the swiveled workpieceresult in a triangular face.3) Engraving cycleOn the prepared inclined plane, all of the standardgeometries, such as engraving, can then be appliedas usual.The input screen of ShopMill provides support forentering the parameters.Unrestricted Siemens AG 2017

4 SummaryMilling in general:During milling, the tools rotate about their own axes and run along the contour of theworkpiece for chip removal or the workpiece is moved in a corresponding way.Milling kinematics:3-axis milling is limited to movement of the workpiece and of the tool in 3 axes - X, Yand Z. In 5-axis machining, two of the rotary axes (A, B and C) are also needed to mill2½D and 3D contours.Why is 3 2 not equal to 5?The difference between 3 2-axis machining and 5-axis simultaneous milling is in thepositioning of the tool or workpiece. This is done statically for 3 2 machining with theCycle800; dynamically, on the other hand, for the 5-axis simultaneous milling.Swivel cycle Cycle800:The swivel cycle can easily be applied in both ShopMill and in the programGUIDE.During this, different parameters, which define the tilting of the plane about the axes,can be entered in the input screen.Unrestricted Siemens AG 2017

Thank you for your attention!Technology and Application Center Erlangensiemens.com/cnc4youUnrestricted Siemens AG 2017

The milling machining is limited to the XY plane and can thus follow 2-dimensional contours. The machining itself is limited to 2-dimensional contours. The third dimension is achieved by tilting and securing the machining plane. To machine the free -form surfaces, the 5 axes move dynamically and simultaneously. 2D machining . 2½D machining

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