Nx8 NC Simulation Examples

CAM/SIM MACH Content
DOCUMENTATION ABOUT WORKING WITH THE MACH

SIMULATION CONTENT (NX8)
1
2
3
4
5
6
Highlights - new with NX8 ....................................................................................................... 2

Overview ................................................................................................................................. 2
Load Options .......................................................................................................................... 2
CAM-Setup ............................................................................................................................. 3
MCS-Handling ........................................................................................................................ 4
About Post Processors ........................................................................................................... 5
6.1
6.2
6.3
7
8
9
Creating file with tool and offset data.............................................................................................................. 5

MOM variable for MCS handling..................................................................................................................... 6
Differences between pure template posts and OOTB posts ......................................................................... 7
About CAM Programming ....................................................................................................... 8

Using the library tools ........................................................................................................... 10
About CSE Simulation Drivers .............................................................................................. 10
9.1
9.2
9.3
Handling of Offsets: ...................................................................................................................................... 10

Handling of the tool change .......................................................................................................................... 11
Handling the reference point (Fanuc) ........................................................................................................... 12
10 About Sinumerik Cycles in the content ................................................................................. 12

11 About swiveling cycles .......................................................................................................... 13
11.1
11.2
PLANE SPATIAL .......................................................................................................................................... 13

CYCLE800 .................................................................................................................................................... 13
12 Example specific considerations ........................................................................................... 15

12.1
12.2
12.3
12.4
12.5
12.6
SIM01: ........................................................................................................................................................... 15
SIM03: ........................................................................................................................................................... 15
SIM07 and SIM09 CSE: ................................................................................................................................ 15
SIM07 with MTD: .......................................................................................................................................... 15
SIM10: ........................................................................................................................................................... 15
SIM13: ........................................................................................................................................................... 15
13 The Mill-Turn Example sim15 ............................................................................................... 16

13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
Kinematics Configuration .............................................................................................................................. 16

ONT Coordinate systems setup .................................................................................................................... 17
Tool Change ................................................................................................................................................. 18
About Spindles .............................................................................................................................................. 18
TRANSMIT Operation and other milling motion types .................................................................................. 19
TRAORI simultaneously 5-Axis milling ......................................................................................................... 20
Part transfer from Main to Sub Spindle......................................................................................................... 20
Definition of Tools and related Settings (not specific for sim15) .................................................................. 21
14 Creating your own CSE examples based on the OOTB mach examples ............................. 22
15 Appendix ............................................................................................................................... 22
A.
B.
C.
D.
E.
F.
G.
H.
Example NC code TRAORI and circles ........................................................................................................ 22

Detailed information about ini files ................................................................................................................ 23
Example of a tool change subprogram ......................................................................................................... 23
Post Processor features of the OOTB examples .......................................................................................... 24
Example of an INI file .................................................................................................................................... 25
PLANE SPATIAL .......................................................................................................................................... 26
CYCLE800 .................................................................................................................................................... 29
History ........................................................................................................................................................... 34
Working-with-OOTB-MACH-Simulation-Examples-NX8.docx
Page 1 / 34
Highlights - new with NX8

Provide an example for complex dual channel dual spindle Mill-Turn machine tool (sim15)
Support PLANE SPATIAL function of TNC Heidenhain controller OOTB for most 5 axis
machine tools.
Support CYCLE800 function of Sinumerik controller OOTB for many machine tools.
Cycle support for Sinumerik (In the template Post and with the delivered machine tools)
The MACH content includes an example to simulate external NC code for many different
Sinumerik Cycles.
Overview
This document explains the handling and usage of the simulation examples provided out-of-thebox (OOTB) with NX Version 8.0. The example data is mainly contained in two locations: one is
for the library machine tool models in the
$UGII_CAM_BASE_DIR/resource/library/machine/installed_machines folder, the other for the
CAM examples utilizing the library machine tools. These CAM examples can be found under
$UGII_CAM_BASE_DIR/samples/nc_simulation_samples. All of the machine tools in the library have
preconfigured geometry, assembly and kinematics models as well as post processors and CSE
controller models for the major controller types Siemens SINUMERIK 840D, Fanuc family and
TNC Heidenhain Conversational; posts are available for metric and inch units. For all machine
tools in the library there is one CAM setup example available. The intention of these examples is
to show best practice and to demonstrate the features of the NX CAM built-in machine
simulation. Another intended use of the examples is as seed parts for customer specific
simulation.
NOTE: The examples cannot contain or show every possible feature of NX CAM, NX Post and
ISV. In certain cases such as complex or multi-function machine tools, and in order to achieve
advanced capabilities, specific customization of the provided posts and/or controller models will
be necessary.
Load Options
To ensure all related assembly component parts are loaded correctly it is recommended to use
the following load options and not using USE Partial Loading:
Page 2 / 34
CAM-Setup
When creating a new CAM setup with the provided set of machine tools, the following best
practice is suggested. It is assumed that the CAD geometry of the part to be machined already
exists.
Open the CAD part file in NX
Select New and pick an appropriate entry in the Manufacturing tab.
The system will automatically create a master-model-concept-part-file referencing your

CAD geometry.
Create a Wave link to the CAD geometry
Select the body of the CAD model for the Wave object and hide the CAD component in the
assembly navigator
To prepare for material removal simulation it is recommended to have the blank geometry
pre-defined as well. In the example shown it is a simple cylinder added to the assembly.
Page 3 / 34
MCS-Handling
In order to achieve a complete and reliable machine simulation, different modules need to play
together. These are: the CAM programming structure in the Operation Navigator (ONT), the
internal Post Processor (MOM inside NX), the TCL based post processor and the simulation
controller model.
Consider a few rules for the NX CAM setup to support the assigned post processor creating a
valid NC code which can be used at the physical machine tool as well as for simulation. Our
examples are using only one MCS, which is set to Purpose Main (see picture below). The post
processor output depends on MCS Purpose, Special output and Fixture Offset settings.
Each CAM setup example using one of our OOTB MACH machine tools must not include
more than one single MCS with the purpose Main
The Main MCS needs to be placed at the same location and orientation as the
MACHINE_ZERO coordinate junction of the machine tool.
NOTE: This is necessary to tell the post processor the position of the machine zero position. In
future releases it is planned to enhance the Post-TCL interface to access the kinematics model.
Once this is implemented, the rule to place the main MCS at the same location as machine zero
junction will become obsolete.
Page 4 / 34

All other used MCSs in the ONT need to be of purpose Local
If the Special Output of the local MCS is Fixture Offset, the post processor will output a
fixture offset statement based on the number of the Fixture Offset.
E.g. if Fixture Offset is 2:
G55
-> SINUMERIK
G55
-> Fanuc
CYCL DEF 7.0
-> TNC (7.1/2/3 will include the offset values e.g. CYCLDEF 7.1 X 100)
If the Special Output of the local MCS is CSYS Rotation the postprocessor will output a
special statement to indicate a translation and/or a rotation
ROT
-> SINUMERIK
G68
-> Fanuc
PLANE SPATIAL
-> TNC (supported for 5 axis milling sim05-sim09 & sim14)
With these settings the example will look like:
MCS Name
MCS_MAIN
| MCS_G54
| MCS_G55
|
ROT
Purpose
Main
Local
Local
Local
Fixture Offset
0
1
2
2 (inherit)
Special Output
Fixture Offset
Fixture Offset
CSYS Rotation
Post S840D
Post Fanuc
Post TNC
G54
G55
ROT
G54
G55
G68
CYCL DEF 7.0

CYCL DEF 7.0
PLANE SPATIAL
About Post Processors
All the OOTB delivered post processors are created with the Post Builder Version 8.0. based on
the template post for Sinumerik S840D. Some differences between pure template post and
OOTB post are listed in the 3rd subchapter.
6.1
Creating file with tool and offset data
The SINUMERIK 840D post processor creates a CAM setup specific initialization data file for
offset values and the tool data. The post processor creates an additional ini file (to_iniChannel.ini) in the SINUMERIK format. This file will be located in the cse_files/subprog subfolder
of the CAM setup part:
MACH/samples/nc_simulation_samples/cse_files/subprog
This to_ini.ini file is handled as an subprogram and in the ini files of the machine tool in the library
this file gets called (executed and loaded). When working with CSE controller models, the
different ini files are loaded and executed before the simulation starts. The format and syntax of
the files is controller specific and their purpose is to initialize certain settings upfront. For more
details about ini files please see Appendix.
Before the post create a new file to_ini.ini it will back up the existing ini file by renaming it to
*.bck.
Note: With the Sinumerik template Post within PostBuilder Version 8 you are able to configure
the behavior of creating the ini file.
Page 5 / 34

NOTE: The OOTB example machine tool ini files for Sinumerik (e.g. sim07_mill_5ax-Main.ini)
have the entry TO_INI to call the post created file as a subprogram. If the creation of the file not
work properly or the file gets deleted or the post does not have write access to create this file and
the CSE Simulation starts it will give you a warning, that the related TO_INI file could not be
found.
6.2
MOM variable for MCS handling
For coordinate rotation NC codes output inside the post, the related coordinate matrix is changed
in PB_CMD_set_csys. Reason for this is because the Main MCS is representing Machine zero
and Local fixture offset representing machining coordinate G54, G55, but mom_csys_origin
and mom_csys_matrix still map current local MCS to Main MCS. For CSYS rotation coordinate
output, the value of linear offset (G68, CYCLE800 ) should be the offset between current local
MCS to parent local MCS(e.g. G54,G55). Therefore, mom_parent_csys_matrix replaced
mom_csys_matrix in this command.
MCS-Main (G53)
|----MCS-Local-for-G54
|-----MCS-for CSYS rotation or other-purpose
mom_csys_matrix
mom_parent_csys_matrix
Page 6 / 34
6.3
Differences between pure template posts and OOTB posts
The OOTB posts are created based on the latest template posts for Sinumerik S840D. Some
settings and or features are slightly different, which are listed here.
6.3.1
Order of Position rotary Axis and activate TRAORI mode
The order of the posted output between the initial positioning motion of the rotary axis and the
activation of the TRAORI mode is different.
Posts of OOTB Examples
Preset the rotary axis angles before TRAORI
/TRAFOOF output in Initial Move and First Move
Posts from template post

Preset the rotary axis angles after TRAORI
/TRAFOOF output in initial move and First Move.
This can be easily changed by drag the box G0 AC and drop it under TRAORI.
6.3.2
Automatic detection on operation type
OOTB post will automatically detect 3 axis and 3+2 axis operation. This function is not
implemented in template post, it is added in PB_CMD_before_motion. The command name is
PB_CMD_detect_3axis_milling. With this function TRAFOOF will be output for 3 axis operations
and TRAORI will be output for 3+2 operations.
Page 7 / 34
6.3.3
Output of 3DCUTCOM
This mode will not be outputted in the OOTB posts mainly because it is not supported by
simulation at this point in time.
No output for 3D-CutCom Mode

Output for 3D-CutCom Mode
To restore 3Dcutcom output in OOTB post, remove the # before PB_CMD_calculate_cutcom in

PB_CMD_before_motion. And put PB_CMD_output_cutcom_mode into Initial move and First
Move as below.
6.3.4
COMPRESS Function
The output of the compress functions is disabled in the OOTB Posts, mainly because it is not
supported by simulation at this point in time.
No output for compress mode

Output for compress mode
PB_CMD_set_sinumerik_default_setting to make circular motion is available. The Compressor

mode also could be changed by Sinumerk_840D UDE on operations.
About CAM Programming
About Cutter Compensation for contact contour and circle statements in the NC code file:
Whenever the NC code contains statements which refer to a plane such as G02/G03 or
G41/G42, the controller needs to have a working plane defined. Therefore it is necessary to
define the correct plane upfront. The initialization files provided with the machine tool examples
define a default working plane. This is typically the XY-Plane (G17) for the milling machine tools
and ZX-Plane (G18) for the turning machine tools.
Important to understand are cases where the surfaces to be machined are not parallel to one of
the orthogonal machine tool planes and the post processor has a specific transformation like
TRAORI activated to achieve this operation. A typical example is shown with the external NC
code listed in Appendix simulated with the machine tool example
sim06_mill_5ax_cam_sinumerik_mm.prt.
Page 8 / 34

Activating cutter comp or circle output will only be correct if a related working plane is defined.
This can be seen e.g. in the following picture for the green area and the operation
PLANAR_PROFILE_TOP. It is taken from the example sim05 (head/head configuration). Here,
the operation PLANAR_PROFILE_TOP includes circle statements for a plane which is not
aligned with xy, yz, or zx. Circle records can correctly processed only because a ROT
command was executed in a previous NC line and switched the plane in the TRAORI mode.
The example shown below (POCKET2_PLANAR_CUTCOMP, example sim05) is an alternative

method when machining within a plane which is not aligned with xy, yz, or zx. Here, the working
plane is not defined by a ROT statement; circular or cut comp output would not work and
therefore are deactivated in the operation.
Page 9 / 34
Using the library tools
The CAM setup simulation examples use as many as possible tools available from the OOTB tool
library (ASCII in NX native)
9
9.1
About CSE Simulation Drivers

Handling of Offsets:
Like any physical NC controller, CSE drivers can process offset information (activated e.g.
through G55) only if the required data is provided, i.e. coordinate values between the actual
chosen offset e.g. G55 and the machine tool zero position. There are two ways to achieve this
with CSE and both are used in the OOTB examples.
9.1.1
Alternative 1 (Fanuc)
In the case of Fanuc, the controller queries the information during simulation from the application
(ISV NX). This is done internally by a command called LoadOffset during interpretation of an
offset statement in the NC code like G55. When the simulation is executed from the operation in
the ONT, the system used the related MCS information where the operation is located under.
Note: This mechanism will not work if more MCS levels are used and the related MCS, which
defines the offset e.g. G54 is NOT one where the operation is located under. Example:
MCS-Main
|----MCS-Local-for-G54
|-----MCS-for-other-purpose
|----Operation
When the simulation is executed by selecting an external NC code file, the system looks for an
MCS by searching the MCS objects in the GEOMETRY view of the ONT for the related fixture
offset number. The first which is found will be used.
Example: In the NC code a G55 (2nd offset) is used. In this case the system cycles through all
MCS objects and compares the value use in Fixture Offset with the given offset in the NC code.
9.1.2
Alternative 2 (Sinumerik and TNC)
The SINUMERIK 840D CSE and the TNC controller doesnt use the LoadOffset mechanism as
described above but follows an alternative implementation. On the physical controller in the shop
floor, the offset values are typically measured by probing operations or are manually set in the
controller. The controller stores these values in an offset table and in controller variables.
The SINUMERIK OOTB post processors create an initialization file for the actual CAM setup
including information about the offsets and tool data. This initialization file is loaded before the
simulation starts. So the offset definition is achieved by the definition of the variables in the
initialization file.
Page 10 / 34

Snapshot of the SINUMERIK ini file:
Later, when one of the offsets is activated in the NC code, the CSE controller uses these
variables to calculate the offset transformation.
The TNC OOTB post processors outputs the offset data into the main program based on the
actual CAM setup. The offset gets activated right away by parsing these NC code lines.
Example for TNC offset data:
8 CYCL DEF 7.0

9 CYCL DEF 7.1 X -0.0000
10 CYCL DEF 7.2 Y -225.0000
11 CYCL DEF 7.3 Z -327.4470
9.2
Handling of the tool change
Tool changes with CSE controller models in the existing examples are achieved by calling a tool
change subprogram. This subprogram is located under the subprog folder for each CSE driver;
its kept in the corresponding NC code syntax and basically positions the tool to the tool change
location. Using one of these subprograms for a different machine tool will typically require an
adjustment of the tool change position. Another section in the tool change subprogram is the
Anycontroller (AC) part, which mimics the PLC portion of the tool change. This mainly takes care
of the mounting and un-mounting of the tool itself. Refer to NX Help for more details about the AC
language. The OOTB examples demonstrate different kinds of tool change methods.
The standard way is that one spindle is defined on the kinematics model of the milling
machine tool and the tools are mounted on the fly during simulation. This can be seen in
sim02 to sim09 as well as sim14.
sim08 is similar, but shows how an advanced tool change mechanism can be animated
using the AC language to open and close doors.
In sim01, tools are already pre-mounted and visible in the CAM scenario on an eight
pocket tool changer. During simulation, the system moves the spindle and the tool
changer to mount and un-mount the tool.
The turning examples sim10 to sim13 dont mount tools during simulation. Here, all tools
are already pre-mounted on the turret in the CAM scenario. The tool change subprogram
takes care of the rotation of the turret and the activation of the selected tool.
An example of a tool change subprogram can be found in Appendix
Note: The machine tool view in the ONT reflects the definition of turrets and pockets in the
kinematics model. Each time the machine tool is retrieved from library, the ONT is updated based
on the kinematics model. It is strongly recommended not to add or remove turrets and pockets in
the ONT machine tool view when working with machine tools.
Page 11 / 34
9.3
Handling the reference point (Fanuc)
In Fanuc NC code, the G command G28 is often used to move the reference point. The OOTB
examples include this in the post and in the CSE controller models. This section describes how
the position of the reference point is defined and stored to get good simulation results.
On physical machine tools, the reference point is stored inside of the controller. To mimic this in
the virtual CSE simulation, the position of the reference point is defined in the *.ini file along with
the machine tool. The NC code to define reference points in Fanuc syntax is shown in the sim01
example (sim01_mill_3ax_fanuc-Main.ini) as:
(This part sets the position of the
G54
G17
G90
G10L52
N1240P1R0000
-> X Position
-> Y Position
N1240P2R225.425
N1240P3R406.425
-> Z Position
G11
reference point G28)
of the reference point related to machine zero

If needed, the values of the reference point can easily be changed in the ini file. All coordinates
are assumed to be metric.
10 About Sinumerik Cycles in the content

With NX8 the NX comes OOTB with a list of Sinumerik cycles for simulation. The cycles are
covered by an encrypted archive file (*.cyc) and placed in the subprog folder of the Sinumerik
CSE simulation. Two versions are added to the system one for the older Sinumerik controller
Sinumerik Powerline and one for the actual new one Sinumerik Solutionline. The last one is
used by default in the CSE simulation.
The cycles of the Solutionline are in the file: SinumerikSL_Cycles.cyc
The cycles of the Powerline are in the file SinumerikPL_Cycles.cyc_powerline
To use the cycle from Powerline instead of the one from Soluitonline the files need to be
renamed like:
SinumerikSL_Cycles.cyc_solutionline
SinumerikPL_Cycles.cyc
Here the list of cycles in the archives files:
PowerLine

CYCLE71
CYCLE81 CYCLE90
CYCLE801
HOLES1, HOLES2
LONGHOLE
SLOT1, SLOT2
POCKET1, POCKET2, POCKET3, POCKET4
CYCLE800 (kinematic specific, customized per machine tool)
Solutionline

CYCLE71
CYCLE81 CYCLE90
CYCLE801
HOLES1, HOLES2
LONGHOLE
SLOT1, SLOT2
POCKET3, POCKET4
Page 12 / 34

CYCLE800 (kinematic specific, customized per machine tool)
11 About swiveling cycles

This will give an overview about what are swiveling cycles, how they are used. The man target is
to machine on a plane not perpendicular to an existing linear axis. What it would take without
swiveling:
You have to create a rotated coordinate system
Figure out how to move the rotary axis so that X, Y, Z can be used for the motions in the plane
Solve the problem that your work piece coordinate system does not rotate with the rotary axis
Working with swiveling cycles will make the life easier and let the controller do the work. In the
following subchapters it is explained in detail how the swiveling Cycle PLANE Spatial on
Heidenhain controllers and the CYCLE800 on Sinumerik S840D controllers work and how this is
implemented n the CSE and the OOTB examples. In addition you will see a section how this is
configured and can be reused for a different machine tool.
11.1
PLANE SPATIAL
With NX8 for the following machine tool the PLANE SPATIAL implementation will be part of the
OOTB examples.

Sim05
Sim06
Sim07
Sim08
Sim09
Sim14
More details about the cycle and the ay how it is implemented in CSE can be found in the
Appendix
11.1.1
How the ONT needs to be defined to achieve a proper Post output
To achieve an output of PLANE SPATIAL by the Post the following prerequisites needs to be
fulfilled.
milling operations and drilling operations needs to be 3+2 orientation
The MCS need to be set to CSYS Rotation
11.2
CYCLE800
11.2.1
Includes in the OOTB examples:
With NX8 the following OOTB examples include a CYCLE800 implementation:

Sim05
Sim06
Sim07
Sim08
Sim14
Page 13 / 34

The Sinumerik Solutionline version is implemented in this approach. Much more details about the
cycle itself and the ay how it is implemented in CSE can be found in the Appendix
11.2.2
Example and parameter
11.2.3
How the ONT needs to be defined to achieve a proper Post output
To achieve an output of PLANE SPATIAL by the Post the following prerequisites needs to be
fulfilled.
milling operations and drilling operations needs to be 3+2 orientation
Sinumerik 840 UDE should be added on the operations, Transformation option should
choose Swiveling as
11.2.4
Machine Tool dependent data customized ini files
This is the list of variables defined for each machine tool in the ini file and others files to define
data for the CYCEL800. These are the data, which need to match the related machine tool.
Content of the OOTB INI file
SMAC; adopt the original DEF file from MC
PGUD; need remove the line with REDEF
TC_CARR; define tool holder data
G40 D0
$MN_MM_NUM_TOOL_CARRIER=1
M17
Definition data of the TC variables:

$TC_CARR7
$TC_CARR8
$TC_CARR9
$TC_CARR10
$TC_CARR11
$TC_CARR12
$TC_CARR23
x component of rotary axis v1

y component of rotary axis v1
z component of rotary axis v1
x component of rotary axis v2
y component of rotary axis v2
z component of rotary axis v2
kinematic type
Page 14 / 34

$TC_CARR24 Offset of rotary axis v1
$TC_CARR25 Offset of rotary axis v2
$TC_CARR30[1]=-90; software minimum limit of rotary axes
$TC_CARR31[1]=-9999999
$TC_CARR32[1]=90; software maximum limit of rotary axes
$TC_CARR33[1]=9999999
$TC_CARR34 tool holder name
$TC_CARR35 Axis name 1
$TC_CARR36 Axis name 2
$TC_CARR37 Identifier how to set it?
$TC_CARR40 Z axis retract value
12 Example specific considerations

12.1
SIM01:
This example has a somewhat fancy tool change mechanism including a real tool changer. Reusing this example for other machines without a similar tool changer can cause unexpected
behavior. In this case, use sim02 as reference for a simple 3 axis milling machine tool.
12.2
SIM03:
This metric Sinumerik example includes a cam setup, which handles operation using milling tool
(T-Cutter and Step-Mill) dealing with multiple tracking points. (New enhancement of NX8)
12.3
SIM07 and SIM09 CSE:
These two machine tools are characterized by a rotary axis in the head and another rotary axis in
the table. When using a Local MCS with the special settings CSYS Rotation, the following
restriction exists for placing the MCS. In these cases, the parent MCS (e.g. MCS_G54) and the
rotated MCS (e.g. ROT) need to be placed in the center of the rotation of the table. The following
figure shows this case in sim07. Ignoring this rule will result in invalid G code. This restriction
applies to NX CAM Post and Fanuc only.
12.4
SIM07 with MTD:
This case is only supported with CSE but not with MTD in the OOTB examples. As a workaround
to allow MTD simulation with sim07, all related junctions and MCS need to be placed at the
center of the table.
12.5
SIM10:
This machine tool is only available with a Fanuc controller model, no material removal or tool
path based simulation.
12.6
SIM13:
This machine tool is only available with a Fanuc controller model.
Page 15 / 34
13 The Mill-Turn Example sim15

With NX8 we provide an OOTB Mill-Turn example with a Post Processor and Simulation Driver
for Sinumerik S840D. The machine tool is a two channel B-Axis head and lower turret
configuration with a main and sub spindle additionally the kinematics includes a non orthogonal
X,Y,Z configuration and allows simultaneously 5-Axis milling on the main spindle (TRAORI). The
CAM example includes different operations for milling and turning including TRANSMIT and Part
Transfer. The goal of this example is to show the power of the CSE simulation capability.
Note: Due to the general complexity and variations of mill turn machine tools it could not
expected that these example can be reused for a different mill turn machine tool type. For such
complex manufacturing centers a customization for Post and Driver is always mandatory.
Note: This example is available in Sinumerik CSE only. No TPB and no MTD
13.1
Kinematics Configuration
Main Spindle and B-Axis Head
Sub Spindle and Lower Turret
+ Z3
+ X1
+ B1
+ Y1
+ C2
+ C3
+ C4
+ Z2
+ Z1
+ X2
Page 16 / 34
13.2
ONT Coordinate systems setup
G53
MZJ
G59
G54
Local 1
ATRANS AND AROT

based on G59
G59
MCS
Description
G53
The machine zero point is placed at the center of

the main turning spindle
MSC is main and fixture offset number is set
to0
G54
The Main Offset G54 is placed at the center of the

front face at the chuck
It is represented as a local MCS with Fixture
Offset number set to1
(Main refers to the main spindle not to the MCS
purpose)
G55
Local 2
Picture
Page 17 / 34

At the front face of the work piece a MCS is placed.
Due to the fact, that for turning and milling different
MCS Objects required two of them are added
The G59 is an additional offset based on G54.
The G59 is similar as a TRANS but will not be reset
or overwritten by a new TRANS.
TURN_G59 and MILL_G59 are Local, None
and inherit the fixture offset number from the
parent.
G59
For arbitrary/ rotated work planes

ATRANS This will be indicated as an additional
AROT
transformation ATRANS and AROT
based on the G59-MCS.
G55
The Main Offset for the sub spindle G55 is placed

at center of chuck face on sub spindle. It is
represented as a local MCS with Fixture Offset
number set to2
G59
Same as above, but for the part on the sub spindle
13.3
Tool Change
The Toll change on the B-Axis is done by calling a sub program TC.SPF. The parameter
definition is defined as:
TC(tool number, B-Axis position, Spindle position )
Example:
13.4
About Spindles
The machine tool has 4 spindles

C1 Tool spindle in the B-Axis Head

C2 The spindle for life tools on the lower turret
C3 The work piece spindle of the sub spindle - right side
C4 The work piece spindle of the main spindle - left side
The post outputs related code to activate (M3/M4) and stop (M5) them. At the beginning of an
operation the related spindle will be set as main spindle with the SETMS command. At the
beginning the main spindle C4 is assigned to the first channel (B-Axis Head) and the sub spindle
C3 is assigned to the second channel (lower turret). If necessary to change this the post will
output the command GETD(channel) to assigned the related spindle/axis to the channel which
drive this spindle/axis
Page 18 / 34
13.5
TRANSMIT Operation and other milling motion types
The example includes the TRANSMIT option (CX Polar Mode) for one operation. To activate and
deactivate a start and end UDE needs to be used.
N5520
N5530
N5540
N5550
N5560
N5570
N5580
N5590
N5600
N5610
N5620
N5630
N5640
N5650
N5660
N5670
N5680
N5690
N5700
N5710
N5720
N5730
N5740
N5750
N5760
N5770
N5780
N5790
N5800
N5810
N5820
;Operation : PLANAR_MILL_ROUGH
GETD(C4)
;Tool Change
G17
DIAMOF TOWSTD
TC(5,0.,0.)
MSG("MILL_TRANSMIT")
SETMS(1)
;
;Initial Move
G0 B0.0 C4=0.0
TRANSMIT(1)
G54
TRANS X0.0 Y0.0 Z300.
G0 G90 X-42.544 Y-70.87 Z10. S1=2000 D1 M1=3
;Approach Move
Z-52.
;Engage Move
G94 G1 Z-55. M8 F200.
X-45.041 Y-66.538
;Cutting
X-80.152 Y-5.636
;Retract Move
X-82.649 Y-1.304
Z-52.
;Departure Move
G0 Z10.
;End of Path
TRANS X0 Y0 Z0
TRAFOOF
M1=5
For other milling modes like XYZ motions (example operation is FACE_MILLING_AREA) and for
axial drilling XYC motion (example operation DRILL_IN_CENTER_S1H) the post figure out this
automatically by the operation.
Page 19 / 34
13.6
TRAORI simultaneously 5-Axis milling
The example includes some multi axis operation, which simulated using the TRAORI function. As
a show case one operation (CONTOUR_PROFILE_1) are created Vector output instead of Axis
positioning. To achieve the vector output the following UDE is used.
13.7
Part transfer from Main to Sub Spindle
The part transfer is defined with two UDE one for start and one for end.
UDE description
Contact point: define the contact
point on the work piece on the main
spindle
Main and Sub spindle Distance:
The distance between the part mount
junction on the sub spindle and the
machine zero (G53).
See Picture below
Approach Distance: Distance to
where sub spindle move in rapid
mode.
Fixed Stop Torque: used for FXST
Fixed Stop Window: used for FXSW
Retract Distance: This is the
distance for the retract motion after
part cut off.
Subspindle Z position: This defines
the final position of sub spindle Z3
Figure
NC Code Example
N50 M130; subspindle chuck open

N60 R200=-1250.
N70 GETD(C3)
N80 G0 C3=0 C4=0
N90 G0 G53 Z3=R200+100.
N100 G1 G53 Z3=R200 F100. FXS[Z3]=1
FXST[Z3]=12.3 FXSW[Z3]=2.
N110 ERR1: IF $AA_FXS[Z3] <> 2 GOTOF
CONT1
N120 MSG("Travel to fixed stop not
reached")
N130 M0
N140 STOPRE
N150 GOTOB ERR1
N160 CONT1:
N170 M131; subspindle chuck close
N280 M140; mainspindle chuck open

N290 G1 G53 Z3=R200+100. F100.
FXS[Z3]=1
N300 G0 G53 Z3=0.0
To achieve the mounting of the work piece from the main to the sub spindle the subprogram
part_takeover.spf located in the subprog folder of sim15 takes the responsibility. The kernel
Page 20 / 34

command deal with junction names, so that it is important to have the correct names of the
junctions. The two junctions with the name WORKPIECE_TAKE_OVER are used in this subprog
and need to be placed and named correctly in the CAM setup.
13.8
Definition of Tools and related Settings (not specific for sim15)
This chapter explains the dependencies between tool angle data, the related orientation and
mounting in to a machine tool. This will be used to created specific operations and achieve the
desired orientation. Even if this is done based on one operation of the sim15 example, this is not
specific but can be seen as some more general CAM tool related information. As the example we
are using the operation ROUGH_BACK_TURN. Desired is the following manufacturing.
13.8.1
Settings in the tool
Page 21 / 34

Selecting the tool in the ONT the tool will be displayed with the tracking point on the WCS in that
orientation as it will be mounted into the pocket. In the case above this is the B-Axis head. To
achieve the correct orientation the tool holder angle (OA), the insert position and the tool holder
type can be changed accordantly. Usually the turning tool (if it is a parameter tool without tool
assembly graphic) is mounted into the spindle with the tracking point. To change these values in
the tab More section Simulation are used. In this example 100 / 0 will result in:
100mm
13.8.2
Settings in the Operation:
To achieve the desired position for the operation the tool needs to be more orientated vertical
instead of horizontal (B-Axis motion) this will be set into the operation. Here to achieve 80
degree. To achieve the rotation about 180 degree in the spindle of the B axis, so that the cutting
edge is more on the right as on the left, the Flip Tool Holder is used.
14 Creating your own CSE examples based on the OOTB mach

examples
It is possible to re-use the OOTB examples to build your own machine tool simulation by either
selecting an alternative controller (SINUMERIK, Fanuc and TNC) or a comparable machine tool.
If the target machine tool is too complex to be derived from one of our OOTB examples, please
contact you Siemens PL service representative.
15 Appendix
A.
Example NC code TRAORI and circles
The used NC code example of TRAORI and circle handling

N90 G40 G17 G710 G94 G90 G60 G601 FNORM
N340 T="UGT0203_005"
N350 M6
G54
D6
G0 X0.0 Y0.0 Z0.0
; This NC code example should explain and demonstrate how circle handling
; and TRAORI plays together.
;
; TEST A:
; Position to a point on the geometry
G0 X26.750670246 Y42.242178464 Z0.0
; make a circle
F1000
G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464
;
; TEST B:
Page 22 / 34

; rotate the table including the part and do the motion again.
G0 B-60 C0.0
G0 X26.750670246 Y42.242178464 Z0.0
G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464
; For sure the motion is the same - no one tell the controller to do different
;
; TEST C:
; Activate TRAORI and try again
ORIWKS
TRAORI
G0 X0.0 Y0.0 Z0.0
G0 X26.750670246 Y42.242178464 Z0.0
G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464
; TRAORI activates the compensation for the moved coordinate system.
; so the circle is done in the rotated plane.
;
; TEST D:
; There are cases where the machine should do the circle still in the XY-Plane
; of the machine tool,
; (not in the rotated plane defined by the rotation and TRAORI
; Deactivate output TRAORI, to have circle in the original (XY) plane
TRAFOOF
G0 X0.0 Y0.0 Z0.0
;
; TRAORI is off
; so the NC code needs to have the offset of the rotation calculated (!).
;
; The values are based on the rotation -60 around B and 0 around C
; on the position of the original coordinate system in respect to the rotary
; NC axis (kinematics model)
;
G0 X141.506583681 Y0.0 Z-254.902851038
G0 X=141.506583681+13.375335123 Y=0.0+42.242178464 Z=-254.902851038-23.166760002
G3 X=141.506583681+13.375335123 Y=0.0-42.242178464 I-26.750670246 J-42.242178464
;
;
;
;
;
;
Summary:
The NC code examples shows, that the case 'D is general possible,
but this not supported by the OOTB post processors.
So the rule here is:
Activate TRAORI and avoid outputting circle statements G2/G3
after activating TRAORI and have NC axes rotated
M30
B.
Detailed information about ini files
A setup-specific INI file could contain, for example

a list of setup-specific tools and tool count

initial machine positions
default fixture offset register
inch or metric unit selection
Putting such INI files directly into the mach kit affects all setups that share the same machine.
When creating your own copies of the OOTB machine tool examples, consider the following
execution order for INI files:
All INI files in the MACH kit directory
All INI files in the part working directory
All INI files in the directory specified by the UGII_CAM_CSE_USER_DIR environment
variable
Within a directory, the execution order is specified by the optional last hyphen. If the order is
omitted then execution order 0 is implied, and the ordering is further determined alphabetically by
programName. Should programName be the same then the entire programName-ChannelexecutionOrder is compared.
C.
Example of a tool change subprogram
This example is taken from the sim05 Sinumerik. (ToolChange.SPF)

G0 G90
Page 23 / 34

; Set the tool change position values in metric X,Y,Z
R501=800.000
R502=-1000.000
R503=700.000
; check the active unit and change values if inch is in use
IF ($P_GG[13] == 2)
R501 = R501 / 25.4;
R502 = R502 / 25.4;
R503 = R503 / 25.4;
ENDIF
; move to the tool change position
G0 G53 X=R501 Y=R502
G0 G53 Z=R503
;Activate AC and do the tool mount based on preselected tool data
##LANGUAGE AC
INT nToolID;
STRING sToolName;
nToolID
= getVariable("$P_TOOLP");
sToolName = getArrayElement("$TC_TP2",nToolID);
IF (sToolName != "");
generateTool (sToolName, "S");
ELSE;
IF (nToolID > 0);
generateTool (getToolNameByNumber(nToolID), "S");
ELSE;
// ERROR no Tool preselected - ?? Send error message ??
ENDIF;
ENDIF;
IF (exist(getCurrentTool("S")));
collision (OFF, getCurrentTool("S"));
visibility (
getCurrentTool("S"), OFF, TRUE);
release
(
getCurrentTool("S"));
ENDIF;
IF (exist(getNextTool("S")));
grasp
(
getNextTool("S"),
position
(
getNextTool("S"),
visibility (
getNextTool("S"),
collision (ON, getNextTool("S"),
activateNextTool ("S");
ENDIF;
; switch back to Sinumerik syntax
##LANGUAGE NATIVE
getJunction("SPINDLE", "S"));
0.0, 0.0, 0.0, 0.0, 0.0, 0.0);
ON, TRUE);
2, -0.01);
; return t o main program

RET
D.
Post Processor features of the OOTB examples
This chapter describes the supported functions of the example posts of the MACH library
machine tools. All post processors are available as inch and metric versions.
Milling Machine Posts
Standard functions for 3-5 milling machines:
Standard linear, circular and rapid motion (G0,G1, G2 and G3)
Standard drilling cycles supported by NX. (G80-G89/CYCLE81-CYCLE89)
Cutter compensation (G40, G41 and G42)
Tool length compensation (G43/G43.1 for Fanuc)
Multiple plane circular interpolation (G17, G18 and G19)
Work coordinate offsets (G53-G59 /G505/G54.1 P1 etc )
Spindle control (M03, M04, M05, S)
Coolant (M08, M09)
The five- axis posts support coordinate system output on machines that have two rotary
axes. This is commonly a G68/ROT/CYCLE SPATIAL. The posts will create a local
coordinate system on the fly using the tool axis.
Five axis tool tip control G43.4/TRAORI/M128

Page 24 / 34

Turning Machine Posts
Standard functions for two axis lathes.

Standard linear, circular and rapid motion (G0,G1, G2 and G3)

Standard centerline drilling cycles supported by NX (G80-G85)
Cutcom (G40, G41 and G42)
Work coordinate offsets (G53-G59)
Spindle control (M03, M04, M05)
Coolant (M08, M09)
Specific Functions in Sample Posts

Specific functions supported:
ini file will be generated by post for SINUMERIK controller including fixture offset values
and tool information.
Remove the tool at end of program for milling machine: example: T0 M06
For 4 or 5 axis machine, rotary axis limit setting in postprocessor should be same as the
machine model.
For SINUMERIK machine, tool offset value D is decided by adjust register number in CAM
setup.
Fixture offset registers range
SINUMERIK G54-G57 G505-G599
Fanuc G54-G59 G54.1 P1 G54.1 P2.
Fixture offset number in CAM setup will decide fixture offset output.
For SINUMERIK machine, if number is between 1 and 4, corresponding output is G54G57, if number is 5 output will be G505 and so on.
For Fanuc machines, if number is between 1 and 6, corresponding output is G54-G59, if
number is greater than 6, G54.1 Px will be output. X = number -6.
Tool tip control
TRAORI and M128 are similar function in Sinumerik and Heidenhain T530. They are both
kinematics independent, means mom_mcs_goto should be output instead of mom_pos for
X Y Z position.
But for OOTB Fanuc examples, G43.4 only has capability to compensate tool axis length
in variable axes milling operations. G43.1 should be used in fixed axes milling with head
rotation. G43 is used in all operations with Z orientation spindle.
E.
Example of an INI file

CHANDATA(1)
; define the offsets G54 is for $P_UIFR[1]
; define the offsets G55 is for $P_UIFR[2]
; define the offsets G...is for $P_UIFR[...]
$P_UIFR[1]=CTRANS(X,100.0,Y,80.0,Z,110.0)
;
; What is needed to place tool data into this file without having alarms.
; This is related to the tool handling mechanism in the archive.
;
;
;
;
;
;
;
;
;
;
;
;
;
;
;
1. The used tool ID is needed to be assigned to a magazine

Therfore use:
TC_MPP6[1,2]=100
This places the tool with the number 100 to the second pocket
on the first magazine
Set the tool name or number
$TC_TP1[100]=1
$TC_TP2[100]="1401631125" ;
$TC_TP7[1]=1
;
$TC_TP8[1]=10
;
used inside the NC code to the tool 100

Tool identifier in the NC code
Magazin number for the tool
Release status of the tool
set Bit 1 - release and bit 3 tool is measured.
this is the default on the machine tool
Set tool offset values for the related D number of the tool 100
Page 25 / 34

;
;
;
;
;
$TC_DP1[100,1]=120
$TC_DP2[100,1]=133.00
$TC_DP3[100,1]=133.00
$TC_DP6[100,1]=68.500
$TC_DP7[100,1]=0
;
;
;
;
;
tool type 120->milling

flute length
length
radius
corner radius
$TC_TP1[1]=1
$TC_TP2[1]="UGT0203_065"
$TC_TP7[1]=1
$TC_TP8[1]=10
$TC_DP1[1,1]=120
$TC_DP2[1,1]=29.00
$TC_DP3[1,1]=109.00
$TC_DP6[1,1]=4.0
$TC_DP7[1,1]=4.0
$TC_MPP6[1,1]=1
;$TX_TOOLCOUNT = 9 ; tool numbers
M17
F.
PLANE SPATIAL
Inside the used MCF one global variable is set related to the type of the machine tool.
Name of the variable is:GV_strMachineType (HeadHead, HeadTable,TableTable)
About SEQ+/- parameter in PLANE SPATIAL
Choose the shortest way as the preferred solutions. Implement this in the CCF file. First check if
both solutions are achievable due to limits of the axis. If neither solution is within traverse
range, error message will be generated. This mechanism uses the axis limits set in the MCF file.
About TABLE ROT/COORD ROT in PLANE SPATIAL
Transformation mode is an optional parameter for Plane function and TABLE ROT will used as
default if omitted.
Support PLANE SPATIAL for sim05 TNC
For dual-head machine, except rotation of coordinate, tool tip offset after rotation should be
compensated.
Create coordinate matrix by SPA SPB SPC
Calculate IKS angles from new coordinate Z vector(two results)
Call method GMe_GetPlaneSolution to choose rotation angles by SEQ option.
Get linear offset by calculateIKSlinears
Reset transformation PLANE origin, compensate offset values of setp4 and subtract tool
length compensation.
Set transformation rotation, the order is SPA->SPB->SPC
Add tool length compensation in modal transformation PLANE.

Support PLANE SPATIAL for sim07 and sim09 TNC

For head-table machine, both of rotation angle and origin point offset and tool tip offset should be
compensated in TABLE ROT mode.
Calculate IKS angles from new coordinate Z vector
Get linear offset by calculateIKSlinears, if its COORD ROT, only consider head ration in
calculateIKSlinears, and set Q122 to 0.
Reset transformation PLANE origin, compensate offset values of setp2 and subtract tool
length compensation.
Set transformation rotation, its about table C axis rotation.
Set transformation rotation modal, the order is SPA->SPB->SPC
Add tool length compensation in modal transformation PLANE.
Page 26 / 34

Support PLANE SPATIAL for sim08 sim06, and sim14 TNC
For dual-table machine, both of rotation angle and origin point offset should be compensated in
TABLE ROT mode.
Calculate IKS angles from new coordinate Z vector
Get linear offset by calculateIKSlinears
Reset transformation PLANE origin, compensate offset values of setp2
If its TABLE ROT, set transformation rotation, it is rotated about fourth-axis then fifth-axis
vector.
Set transformation rotation modal, the order is SPA->SPB->SPC

Page 27 / 34

Plane spatial Process in CCF file figure needs to be updated
Working-with-OOTB-MACH-Simulation-Examples
Examples-NX8.docx
Page 28 / 34
G. CYCLE800
Basic Workflow
The CYCLE800.SPF consists of two subprograms, which are:
On Powerline: TOOLCARR.SPF
On Solutionline: CUST_800.SPF
In addition CYCLE800 makes use of lots of system-variables and machine data, e.g.
TC_CARRxx[x] that holds the kinematic configuration and also needs some definition files like
PGUD.DEF and SMAC.DEF so on Powerline even more.
Page 29 / 34

Basic about TCARR and PAROT
The subprogram TCARR calculates rotational axis angle, and calculates the translation
compensation based on current kinematics, and apply it to the according transformation.teh
subprogram PAROT rotates the transformation PARTFRAME for the table.
Depending on the mode of $P_GG[42] (TCOABS, TCOFR) the compensation is calculated in
TCARR.
With TCOABS
Based on the angles defined in TC_CARR13 and TC_CARR14
With TCOFR
Based on the current tool orientation the angles are calculated first IKS and picker
required simCYCLE800 consists of two subprograms: CYCLE800.SPF(Siemens),
TOOLCARR.SPF(CUST_800 is the name used in current CYCLE800.SPF) It moves and rotates

the tool or table according to the input mode. Currently it is implemented for M20 M40 M41
cases.
M20 Rotate the tool or table according to $TC_CARR13 and $TC_CARR14
M40 The initiation behavior defined by the user
M41 Tool retract Axis Z
Page 30 / 34

Workflow of TCARR
Start TCARR
YES
0 >= Value
Reset
transformation
NO
TCOFR
TCOABS
Assign
TC_CARR13&14
to
partAngle&toolAng
le
Calculate IKS
Angles
Set $P_TCSOL &
$P_TCANG value
Gme_GetRotateS
olution
TRUE
TCOABS or
TCOFR
Gme_Caculateline
ars
$P_TCSOL>0
Assign
TCANG1&2 to
partAngle&toolAng
le
YES
CARR13==TC
ANG3 AND
CARR14==TC
ANG4AND
CARR13!=0AN
D CARR14!=0
Assign
TCANG3&4 to
partAngle&toolAng
le
FALSE
NO
Gme_Caculateline
ars
End TCARR
Page 31 / 34

Workflow of PAROT
Page 32 / 34

How to set $TC_CARR37
The OOTB examples uses the Solutionline example:$TC_CARR37[1]=201003003
Page 33 / 34

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CAM/SIM MACH Content

DOCUMENTATION ABOUT WORKING WITH THE MACH

Highlights - new with NX8 ....................................................................................................... 2

Creating file with tool and offset data.............................................................................................................. 5

About CAM Programming ....................................................................................................... 8

Handling of Offsets: ...................................................................................................................................... 10

10 About Sinumerik Cycles in the content ................................................................................. 12

PLANE SPATIAL .......................................................................................................................................... 13

12 Example specific considerations ........................................................................................... 15

13 The Mill-Turn Example sim15 ............................................................................................... 16

Kinematics Configuration .............................................................................................................................. 16

Example NC code TRAORI and circles ........................................................................................................ 22

CAM/SIM MACH Content

Highlights - new with NX8

CAM/SIM MACH Content

The system will automatically create a master-model-concept-part-file referencing your

Create a Wave link to the CAD geometry

CAM/SIM MACH Content

CAM/SIM MACH Content

CYCL DEF 7.0

About Post Processors

Creating file with tool and offset data

CAM/SIM MACH Content

MOM variable for MCS handling

CAM/SIM MACH Content

Differences between pure template posts and OOTB posts

Posts from template post

CAM/SIM MACH Content

Posts from template post

To restore 3Dcutcom output in OOTB post, remove the # before PB_CMD_calculate_cutcom in

Posts from template post

PB_CMD_set_sinumerik_default_setting to make circular motion is available. The Compressor

About CAM Programming

CAM/SIM MACH Content

The example shown below (POCKET2_PLANAR_CUTCOMP, example sim05) is an alternative

CAM/SIM MACH Content

Using the library tools

About CSE Simulation Drivers

CAM/SIM MACH Content

8 CYCL DEF 7.0

Handling of the tool change

CAM/SIM MACH Content

Handling the reference point (Fanuc)

reference point G28)

of the reference point related to machine zero

10 About Sinumerik Cycles in the content

CAM/SIM MACH Content

11 About swiveling cycles

CAM/SIM MACH Content

Example and parameter

Definition data of the TC variables:

x component of rotary axis v1

CAM/SIM MACH Content

12 Example specific considerations

SIM07 and SIM09 CSE:

SIM07 with MTD:

This machine tool is only available with a Fanuc controller model.

CAM/SIM MACH Content