Application of Siemens SINUMERIK 840D in five-axis machining (2)

In addition, it makes it easy to use the measurement cycle and FRAME functions to compensate for errors in part mounting. This is done by measuring the workpiece position by measuring 3 measuring points in the machine coordinate system. With this function, the deviation of the control system from the ideal position can be quickly and easily compensated by the coordinate transformation of the FRAME function, which can be achieved by moving and rotating the appropriate coordinate system.

Large circular interpolation

For milling thin-walled cavities, Siemens has developed a directional interpolation function, ORIVECT, which allows the cylindrical milling cutter to determine the correct direction relative to the inclined inner wall. This interpolation function synchronizes the movement of a single rotary axis with the machining path, and the tool vector moves in the correct direction in a plane defined by the inner wall of the cavity. This avoids the conic profile error produced by conventional profile milling, meaning that longer linear motions can be programmed without destroying the conical profile.

Smooth track transition

The tool vector moves along a smooth surface and the edge of the tool has a problem at the transition of the contour milling path. If they do not meet the processing requirements, they can be avoided by the smooth track transition function, resulting in a smooth orientation curve.

In CAM systems, point-to-point programming is used to describe irregular surfaces that can be smoothed out in a control system that integrates a spline compressor. The control system provides two options for B-spline and polynomial in linear conversion. The smoothing process also incorporates the programmable vector setting of the specific tool, which means that the workpiece surface profile velocity is related to the tool center point (TCP), so a higher track transition speed is achieved based on a good surface finish quality.

3D tool radius correction

This feature allows tool wear to be calculated online within the control system so that the tool can be reground and reused without modifying the post processor settings. Moreover, the control system does not require any additional information about the surface being machined to correct the contour milling process. For face milling, the normal direction of the machined surface, TCP and tool direction vectors are also required.

The FRAME concept allows the use of coordinate system movement, rotation, scaling, and mirroring in Cartesian space. FRAME is associated with tool rotation, which also makes complex workpiece programming more flexible.

Convenient HSC control

SINUMERIK offers easy default settings (HSC settings) that the user can modify to achieve optimum machining speed, space accuracy and surface quality. Depending on the type of machining (roughing or finishing), it is possible to selectively set the tolerance zone, cutting transition type or JERK rating of the compressor.

Feedforward and JERK restrictions

This function "sees" a certain number of (settable) blocks in advance and calculates the speed profile of all blocks. By setting a smooth, tangent transition between the blocks, the speed is not lost and the speed is maintained at the limit speed. This method can be achieved by setting the grinding transition function G64X.

Contour errors can cause distortion of the contour. Because of the machining inertia, the tool deviates from the ideal contour resulting in a contour error. Due to the feedforward function of the SINUMERIK 840D, the contour error on the machining path can be reduced to zero.

If the machine movement has a JERK limit, the acceleration will not mutate, but will increase linearly. In this way, the machine does not vibrate suddenly, reducing mechanical wear and damage.

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