Tust

Turning made easy with ShopTurn Introduction 1
___________________
Advantages of working with
___________________
ShopTurn 2
Ensuring everything runs
___________________
smoothly 3
SINUMERIK Operate
___________________
Basics for beginners 4
SinuTrain
Turning made easy with ShopTurn ___________________
Well equipped 5
___________________
Example 1: Taper shaft 6
Training Documents
___________________
Example 2: Input shaft 7
___________________
Example 3: Guide shaft 8
___________________
Example 4: Hollow shaft 9
___________________
Example 5: Plunge-turning 10
And now you can start
___________________
manufacturing! 11
How accomplished are you
___________________
in the use of ShopTurn? 12
09/2011
6FC5095-0AB80-1BP1
Legal information
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indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
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CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
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The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
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avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
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Siemens products may only be used for the applications described in the catalog and in the relevant technical
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Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
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Siemens AG Order number: 6FC5095-0AB80-1BP1 Copyright © Siemens AG 2011.

Industry Sector Ⓟ 09/2011 Technical data subject to change
Postfach 48 48
90026 NÜRNBERG
GERMANY
Table of contents
1 Introduction................................................................................................................................................ 7
2 Advantages of working with ShopTurn....................................................................................................... 9
2.1 You will save time for training.... ....................................................................................................9
2.2 You will save time for programming.............................................................................................11
2.3 You will save time for manufacturing... ........................................................................................14
3 Ensuring everything runs smoothly.......................................................................................................... 17
3.1 Using ShopTurn ...........................................................................................................................17
3.2 The contents of the main menu ...................................................................................................19
3.2.1 Machine........................................................................................................................................19
3.2.2 Parameters...................................................................................................................................22
3.2.3 Program .......................................................................................................................................24
3.2.4 Program Manager ........................................................................................................................27
3.2.5 Diagnosis .....................................................................................................................................29
4 Basics for beginners ................................................................................................................................ 31
4.1 Geometrical basics ......................................................................................................................31
4.1.1 Tool axes and work planes ..........................................................................................................31
4.1.2 Points in the work space ..............................................................................................................31
4.1.3 Absolute and incremental dimensioning ......................................................................................32
4.1.4 Cartesian and polar dimensions ..................................................................................................34
4.1.5 Circular motions ...........................................................................................................................36
4.2 Technological basics....................................................................................................................38
4.2.1 Cutting rate and speeds...............................................................................................................38
4.2.2 Feed .............................................................................................................................................39
5 Well equipped.......................................................................................................................................... 41
5.1 Tool management ........................................................................................................................41
5.1.1 The tool list...................................................................................................................................41
5.1.2 The tool wear list..........................................................................................................................43
5.1.3 Magazine list ................................................................................................................................44
5.2 Tools used....................................................................................................................................44
5.3 Tools in the magazine..................................................................................................................46
5.4 Gauging tools ...............................................................................................................................47
5.5 Setting the workpiece zero...........................................................................................................49
6 Example 1: Taper shaft............................................................................................................................ 51
6.1 Overview ......................................................................................................................................51
6.2 Program management / creating programs .................................................................................53
6.3 Calling a tool ................................................................................................................................57
Turning made easy with ShopTurn

Training Documents, 09/2011, 6FC5095-0AB80-1BP1 3
Table of contents
6.4 Specifying the distance to be traversed ...................................................................................... 59

6.5 Creating contours with the contour calculator and machining sequence ................................... 63
6.6 Thread undercut.......................................................................................................................... 79
6.7 Thread ......................................................................................................................................... 82
6.8 Grooves....................................................................................................................................... 84
7 Example 2: Input shaft ............................................................................................................................. 89
7.1 Overview ..................................................................................................................................... 89
7.2 Face turning ................................................................................................................................ 90
7.3 Creating the contour, stock removal and residual stock removal ............................................... 91
7.4 Thread ....................................................................................................................................... 110
8 Example 3: Guide shaft ......................................................................................................................... 113
8.1 Overview ................................................................................................................................... 113
8.2 Face turning .............................................................................................................................. 114
8.3 Creating any blank contour ....................................................................................................... 116
8.4 Creating the machined part contour and stock removal ........................................................... 118
8.5 Residual stock removal ............................................................................................................. 128
8.6 Groove....................................................................................................................................... 133
8.7 Thread ....................................................................................................................................... 136
8.8 Drilling ....................................................................................................................................... 138
8.9 Milling the rectangular pocket ................................................................................................... 143
9 Example 4: Hollow shaft ........................................................................................................................ 147
9.1 Overview ................................................................................................................................... 147
9.2 Creating the first workpiece side............................................................................................... 148
9.2.1 Face turning .............................................................................................................................. 149
9.2.2 Drilling ....................................................................................................................................... 150
9.2.3 Blank contour ............................................................................................................................ 152
9.2.4 Machined part contour of the first side, external....................................................................... 153
9.2.5 Undercut.................................................................................................................................... 164
9.2.6 Machined part contour of the first side, internal........................................................................ 168
9.2.7 The work step editor.................................................................................................................. 174
9.2.8 Copying the contour .................................................................................................................. 175
9.3 Creating the second workpiece side ......................................................................................... 176
9.3.1 Face turning .............................................................................................................................. 176
9.3.2 Drilling ....................................................................................................................................... 178
9.3.3 Specifying a blank contour ........................................................................................................ 180
9.3.4 Machined part contour of the second side, external ................................................................. 181
9.3.5 Creating an asymmetrical groove ............................................................................................. 185
9.3.6 Machined part contour of the second side, internal .................................................................. 188

4 Training Documents, 09/2011, 6FC5095-0AB80-1BP1
Table of contents
10 Example 5: Plunge-turning..................................................................................................................... 195

10.1 Overview ....................................................................................................................................195
10.2 Plunge-turning............................................................................................................................196
10.3 Creating the contour ..................................................................................................................197
10.4 Stock removal with the plunge-turning cycle .............................................................................198
11 And now you can start manufacturing!................................................................................................... 203
11.1 And now you can start manufacturing! ......................................................................................203
12 How accomplished are you in the use of ShopTurn?............................................................................. 207
12.1 Exercise 1 ..................................................................................................................................207
12.2 Exercise 2 ..................................................................................................................................209
12.3 Exercise 3 ..................................................................................................................................211
12.4 Exercise 4 ..................................................................................................................................213
Index...................................................................................................................................................... 217

Table of contents

Introduction 1
Faster from the drawing to the workpiece - but how?
The technological development of machine tools is highly dynamic. Particularly with the
creation of NC programs, the range has extended from pure CAM system programming to
programming directly at the CNC machine. Special, productive programming methods are
available for each area. With ShopTurn, SIEMENS therefore offers a programming method
specially tailored to the shop floor which allows quick and practical programming of
machining steps from the manufacture of single parts up to small batches. In conjunction
with SINUMERIK Operate, the new operator interface for the control system, intuitive and
effective working in the workshop is possible even for series production.
The solution is: Creating a process plan instead of programming

The creation of a process plan with intuitive and operator-friendly handling sequences,
allows the ShopTurn user to create the NC program directly from the drawing. Even changes
and different variants of a workpiece can be quickly programmed due to the clear structure.
Even the most complicated contours and workpieces are simple to manufacture with
ShopTurn thanks to the integrated, powerful tools for creating traversing paths. For this
reason:
Simpler and faster from the drawing to the workpiece - with ShopTurn.
Although ShopTurn is easy to learn, these ShopTurn Training Documents allow you to enter
this world even faster. Before, however, it comes to actually working with ShopTurn, the first
sections cover a few important basics:
● First, we will show you the advantages of working with ShopTurn.
● Then, we will explain the basics of the operation.
● And next, the geometrical and technological fundamentals will be introduced to the
beginner.
● A short introduction to tool management will be given in a further section.
The theory is followed by practical exercises with ShopTurn:
● Five examples have been chosen to explain the machining possibilities with ShopTurn,
whereby the degree of difficulty is increased continuously. At the beginning, all key
actions are specified; later you will be prompted to proceed without help.
● Then you will learn how to cut in AUTOMATIC mode using ShopTurn.
● If you wish, at the end you may test your knowledge of ShopTurn.

Introduction
Please note that the technology data used here are only examples due to the wide variety of
situations in the workshop.
Just as ShopTurn itself was created with the help of skilled workers, these Training
Documents were also drawn up by practical users. On that note, we wish you much pleasure
and success in your work with ShopTurn.

Advantages of working with ShopTurn 2
This section shows you the special advantages of working with ShopTurn.
2.1 You will save time for training....

● ShopTurn does not use any foreign-language terms you would otherwise have to learn.
All required inputs are requested in plain text.
● When working with ShopTurn, you are offered clear assistance by colored help displays.

Advantages of working with ShopTurn
2.1 You will save time for training....
● You can also integrate DIN/ISO commands into the Graphical Process Plan of ShopTurn.
You may also program in DIN/ISO 66025 and use DIN cycles.
● You may switch between the individual work step and the workpiece graphic (broken-line
graphics) at any time during the creation of a process plan.
Figure 2-1 Work step in a process plan
Figure 2-2 Broken-line graphics

2.2 You will save time for programming...

● ShopTurn offers optimum assistance when it comes to entering technological values: You
only have to enter the handbook values feedrate (or feed) and cutting rate – the speed is
calculated by ShopTurn automatically.
● ShopTurn enables you to describe a complete machining sequence using only one work
step, and the required positioning motions (in this case, from the tool change point to the
workpiece and back) are created automatically.
● All work steps are represented by ShopTurn in a compact and clear fashion in the
Graphical Process Plan. This provides you a complete overview and thus better editing
possibilities even if comprehensive manufacturing sequences are to be performed.
● During stock removal, for example, several machining operations and contours can be
linked together.

● The integrated contour calculator can process all standard dimensions (Cartesian, polar);
it is nevertheless very easy to handle and understand - thanks to colloquial input and
graphic support.
Figure 2-3 Technical drawing
Figure 2-4 Screenform

● You may switch between the graphic view and parameter screenform with help display at
any time.
Figure 2-5 Graphic view
Figure 2-6 Help display
● Process plan and manufacturing do not exclude each other. With ShopTurn, you can
create a new process plan parallel to manufacturing.

2.3 You will save time for manufacturing...

● You can optimize tool selection during the stock removal of contours:
Large volumes are removed using roughing tools, any residual material ① is then
detected and removed automatically using a pointed tool.
● The exact specification of the selected retraction plane avoids the use of unnecessary
traversing paths and thereby saves valuable manufacturing time. This is possible using
the settings normal, extended and all.
Retraction plane: normal Retraction plane: extended Retraction plane: all

● You can optimize your machining sequence with a minimum of work - thanks to the
compact structure of the process plan (in this case, by saving of a tool change, for
example).
Figure 2-7 Original machining sequence
Figure 2-8 Optimized machining sequence with cutting and pasting
● With ShopTurn, you can achieve extremely high feedrates with optimum repeat accuracy
based on consistent digital technology (SINAMICS drives, ...., SINUMERIK control
systems).


Ensuring everything runs smoothly 3
In this section you will learn the basics of ShopTurn operation with the help of examples.
3.1 Using ShopTurn

A powerful software is one thing, but it must also be easy to operate. Regardless of whether
you work with the SINUMERIK 840D sl or SINUMERIK 828D shown here - you are always
assisted by the clearly laid-out machine operator panel. The operator panel consists of 3
parts - the flat operator panel ①, the CNC full keyboard ② and the machine control panel
(MCP) ③.

Ensuring everything runs smoothly
3.1 Using ShopTurn
The most important keys on the CNC full keyboard for navigation in ShopTurn are listed in
the following:
Key Function
<HELP>
Calls the context-sensitive online help for the selected window.
<SELECT>
Selects a listed value.
Cursor keys
The cursor is moved using the 4 cursor keys.
Use the <Cursor to the right> key to open a directory or program (e.g. a cycle) in the
editor.
<PAGE UP>
Scrolling upwards in a menu screen.
<PAGE DOWN>
Scrolling downwards in a menu screen.
<END>
Moves the cursor to the last input field in a menu screen or a table.
<DEL>
• Edit mode:
Deletes the first character to the right.

• Navigation mode:
Deletes all characters.

<BACKSPACE>
• Edit mode:
Deletes a character selected to the left of the cursor.

• Navigation mode:
Deletes all of the selected characters to the left of the cursor.

<INSERT>
• Pressing the <INSERT> key opens the "Editing" mode, and when you press the key
again, you will leave the "Editing" mode and you can call the "Navigation" mode.
<INPUT>
• Completes input of a value in the input field.
• Opens a directory or program.
The actual function selection in ShopTurn is performed using the keys located around the
screen. Most of them are assigned directly to the individual menu items. Since the contents
of the menus change depending on the situation, the term 'softkeys' is used.

3.2 The contents of the main menu
All main functions can be called using the horizontal softkeys.

All subfunctions in ShopTurn can be called using the vertical softkeys.
The main menu can be called with this key at any time - irrespective of in which operating
area you are at the moment.
Main menu
3.2.1 Machine
Machine - Manual
Select the "Machine" softkey.
Press the "JOG" key.

In this mode, the machine is set up; the tool is traversed in the MANUAL mode. It is also
possible to gauge tools and to set workpiece zeros.
Figure 3-1 Call of a tool and input of technological values
Figure 3-2 Input of a target position

Machine - AUTO
Select the "Machine" softkey.
Press the AUTO key.

During manufacturing, the current work step is displayed. It is possible to switch to a running
simulation using the relevant key ("Drawing"). When executing a process plan, you may
insert work steps and/or create a new process plan.
Figure 3-3 Executing a process plan
Figure 3-4 Simultaneous recording of the execution

3.2.2 Parameters
Parameter lists
This key can be used to edit data for the tool management and for programs.
Tool lists
No cutting without tools.
The tools can be managed in a tool list.
Figure 3-5 Tool list

Magazine
Tools can be organized into a magazine.
Figure 3-6 Magazine
Work offsets
Zero points are saved in a clearly laid-out zero-point table.
Figure 3-7 Work offsets

3.2.3 Program
Editing programs
This key can be used to edit programs.
If you have created a ShopTurn program in the Program Manager, you can now create the
process plan with the complete machining sequence for the appropriate workpiece. An
optimum sequence can only be achieved by a skilled worker with suitable experience.
The contour to be machined is entered graphically as a machining step.

Geometry and technology constitute a unit in programming. The subsequent technological

machining operations are applied to the contour.
Example for the dovetailing of geometry and technology:
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0DFKLQHGSDUWFRQWRXU
6WRFNUHPRYDOURXJKLQJLQFOXGLQJDSSURDFKDQGUHWUDFWVWUDWHJLHV
5HVLGXDOVWRFNUHPRYDO
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This geometrical-technological interrelation is represented very clearly in the graphical

display of the work steps by putting the appropriate symbols in brackets. The brackets mean
linking of geometry and technology to one work step.
Simulating programs
Before machining a workpiece on the machine, it is possible to display the program
execution graphically on the screen.
● To this end, select the "Simulation" and "Start" softkeys.
● To stop simulation, select the "Stop" softkey.
● To cancel simulation, use the "Reset" softkey.

The following views are available, among others, for simulation:
Figure 3-8 Side view (display tool path, activated)
Figure 3-9 3D view

Figure 3-10 2-window view
3.2.4 Program Manager
Managing programs
With the Program Manager, you can create new programs at any time. You can similarly
open existing programs to execute, modify, copy or rename them. Programs no longer
required can be deleted.

Active programs are marked with a green symbol.
USB flash drives can be used for data exchange. For example, programs which were
created on an external device can be copied and executed on the NC.
Creating a new workpiece

You can manage your programs and other files, such as tool data, zero points, magazine
mapping, in a workpiece.
Creating a new program

If you create a new program, you can specify the type of programming using the following
softkeys:
ShopTurn program
G code program

3.2.5 Diagnosis
Alarms and messages
Here you can see alarm lists, messages and alarm logs.
Figure 3-11 Alarm log


Basics for beginners 4
This section explains the general basics of the geometry and technology for turning. No
inputs for ShopTurn are planned yet.
4.1 Geometrical basics
4.1.1 Tool axes and work planes

During turning, it is the workpiece, and not the tool, that rotates. The axis is the Z axis.
● G18 plane = machining with turning tools
● G17 plane = drilling and milling operations on the front face
● G19 plane = drilling and milling operations on the peripheral surface
Since the diameter of the turned workpieces is relatively easy to control, the dimensions of
the transverse axis are based on the diameter. This means that you can directly compare the
actual dimensions with the dimensions in the drawing.
4.1.2 Points in the work space

Various important reference points are provided for a CNC - such as the SINUMERIK 828D
with ShopTurn - for orientation in the working space by means of the measuring system.

Basics for beginners
Machine zero (M)

The machine zero (M) is specified by the manufacturer and cannot be changed. It lies in the
origin of the machine coordinate system.
Workpiece zero (W)

The workpiece zero (W) - also called program zero - is the origin of the workpiece coordinate
system. It can be selected freely and should be located at a point from which the most
dimensions start in the drawing.
Reference point (R)

The reference point (R) is approached to set the measuring system to zero, as the machine
zero cannot be approached in most cases. Thus, the control system finds the start of
counting in the position measuring system.
Toolholder reference point T

Toolholder reference point T is used to set up machines with tool revolvers with default tools.
Its position and location hole permit setup with cutter holders for shank tools in accordance
with DIN 69880 and VDI 3425.
4.1.3 Absolute and incremental dimensioning
Absolute input
The entered values refer to the workpiece zero.
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With absolute inputs, the absolute coordinate values of the end point must always be
entered (the current position is not taken into account).

Incremental input
The entered values refer to the current position.
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With incremental inputs, the difference values between the current position and the end point
must always be entered, observing the direction.
Switching between absolute and incremental input is possible at any time using the SELECT
key.
A few examples for the absolute/incremental combination can be found below:

4.1.4 Cartesian and polar dimensions
Cartesian input
Input of the X and Z coordinates. The gray values in the example were calculated
automatically.
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With absolute inputs, the absolute coordinate values of the end point must always be
entered (the current position is not taken into account).

Polar input
Input of the length and angle. The gray values in the example were calculated automatically.
The angles can be entered...

positive and/or...
α1 = Angle to the positive Z axis

α2 = Angle to the preceding element
... negative.
The Cartesian and polar inputs can also be combined. Here are two examples:

Input of the end point in X and the length
Input of the end point in Z and an angle
4.1.5 Circular motions

In accordance with DIN, circular arcs are specified with the end point of the arc (X and Z
coordinates in the G18 plane) and the center point (I and K in the G18 plane).
The ShopTurn contour calculator gives you the freedom to use any dimension from the
drawing for circular arcs, without having to carry out conversions.
The following example shows two circular arcs, one of which is only partially determined.

Input of the R10 arc: Input of the R20 arc:
After the input: After the input:
The following displays of all values appear when you have entered all known dimensions
and pressed the All parameters softkey in the input window of the respective arc.
In DIN format: In DIN format:

G2 X50 Z-35 CR=10 G3 X30 Z-6.771 K-20

4.2 Technological basics
4.2.1 Cutting rate and speeds

The cutting rate is usually directly programmed for turning, in particular for roughing, finishing
and plunge-cutting. The speed is programmed only for drilling and (usually) for thread
cutting.
Determination of the cutting rate

First, the optimum cutting rate is determined using either the manufacturer catalogs or a
handbook.
Material of the tool: Hard metal

Material of the workpiece: Machining steel
Value: vc = 180 m/min
Constant cutting rate vc (G96) for rough cutting, finishing and plunge-cutting:
To ensure that the selected cutting rate

remains constant for each workpiece
diameter, the control uses the G96 command
(= constant cutting rate) to adjust the
appropriate speed. This is performed using
direct-current or frequency-controlled three-
phase motors. As the diameter reduces, the
speed will theoretically increase to infinity. To
prevent danger caused by excessive
centrifugal forces, a speed limitation
of n = 3000 rpm, for example, must be
programmed.
In DIN format, the block would have the
following form:
G96 S180 LIMS=3000
(LIMS = limit).

Constant speed n (G97) for drilling and thread cutting:

Since a constant speed is used for drilling, the command G97 (= constant speed) must be
used here.
The speed is dependent on the desired cutting rate (120 m/min selected here) and the tool
diameter.
The inputs are then G97 S1900.
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Q
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G PPWRROGLDPHWHU
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Q
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4.2.2 Feed
In the previous chapter, you learned how to determine the cutting rate and the speed. The
tool can only perform machining if the cutting rate or the speed is assigned a tool feedrate.
Determination of the feed

Like the cutting rate, the value for the feed is also taken from the handbook, the documents
of the tool manufacturer or from empirical knowledge.
Cutting material of the tool: Hard metal

Material of the workpiece: Machining steel
Determined value (handbook): f = 0.2 - 0.4 mm
The mean value will be chosen: f = 0.3 mm

Relationship between feed and feedrate:

The constant feed f and the associated speed n produce the feedrate:
P YI IyQ P
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PLQ PLQ
G PP G PP

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YI yPP YI yPP
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PP PP
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Since the speed is different, the feedrate is different for the various
diameters, despite having the same feed.

Well equipped 5
In this section you will learn how to create the tools required for the examples in the following
sections. Furthermore, it is explained how to take into account the tool lengths and how to
set the workpiece zero.
5.1 Tool management

ShopTurn offers three lists for tool management:
● the tool list
● the tool wear list
● the magazine list.
5.1.1 The tool list

The tool list displays all parameters and functions required to create and set up the tools.
Figure 5-1 Example for tool lists

Well equipped
5.1 Tool management
Meanings of the most important parameters:
Location Location number

Type Tool type
Tool name The tool is identified by the name and the replacement tool number. You
may enter the names as text or numbers.
ST Replacement tool number (for replacement tool strategy)
D Cutting edge number
Length X Geometry data, length X
Length Z Geometry data, length Z
Diameter Tool diameter
Holder angle, point angle, Holder angle (roughing tool and finishing tool), point angle (drill) and
board width board width (plunge-cutter)
Direction of spindle rotation
Coolants 1 and 2 (e.g. internal and external cooling)
ShopTurn features various tool types (favorites, milling cutters, drills, turning tools and
special tools). Tools can be created in the tool list by means of a predefined tool catalog.
Various mounting positions and geometrical parameters exist (e.g. holder angle), depending
on the tool type.
Figure 5-2 Example of Favorites list

Well equipped
5.1 Tool management
5.1.2 The tool wear list

The wearing data for the appropriate tools are defined here.
Figure 5-3 Tool wear list
The most important tool wearing parameters are:
Δ Length X Length X wear

Δ Length Z Length Z wear
Δ Radius Radius wear
TC Selection of tool monitoring
• by tool life (T)
• by count (C)
• by wear (W)
Tool life or Tool life
workpiece count or Number of workpieces
wear * Tool wear
*Parameter depends on
selection in TC
Setpoint Setpoint for tool life, workpiece count, or wear
Prewarning limit Specification of the tool life, workpiece count or wear at which a
warning is displayed.
G The tool is disabled when the checkbox is selected.

Well equipped
5.2 Tools used
5.1.3 Magazine list

All tools that are assigned to one or several tool magazines are contained in the magazine
list. This list displays the condition of each tool. Individual magazine locations can be
reserved or disabled for existing tools.
Figure 5-4 Magazine list
Meanings of the most important parameters:
G Disabling of the magazine location

Ü Marking of a tool as oversized. The tool occupies two half locations left, two half locations right,
one half location top and one half location bottom in a magazine.
P Fixed location coding
The tool is permanently assigned to this magazine location.
5.2 Tools used

In this section you will learn how to enter tools required for the later machining in the tool list.
Select the "Parameters" area in the main menu.
Select the "Tool list” softkey.

Well equipped
5.2 Tools used
To create a new tool, call the tool list and search for a free location.
Figure 5-5 Tool list - free location
Select the "New tool" softkey.

Select the desired tool type from the tool catalog displayed. This tool type is inserted in the
tool list and you can enter the data of the tool.
Note
Milling cutter 8 (CUTTER_8) must immerse, as it is used for milling a pocket.

Well equipped
5.3 Tools in the magazine
5.3 Tools in the magazine

In the following you will learn how to insert the tools into the magazine.
In the tool list, select a tool without a location number.
Figure 5-6 Select the tool in the magazine
Press the "Load" key. The following dialog offers the first free magazine location for you to
change or accept directly.
Figure 5-7 Enter and/or accept a magazine location

Well equipped
5.4 Gauging tools
After acceptance, the tool list may look like this.
Figure 5-8 Tool list following acceptance
5.4 Gauging tools

In the following you will learn how to calculate tools.
Procedure
Insert a tool from the tool list into the spindle using the "T,S,M" softkey.

Well equipped
5.4 Gauging tools
Then switch to the "Gauge tool" menu.
Enter the probed or turned diameter.
Figure 5-9 Tool measurement - input of the X value
The current position of the tool is calculated taking into account the workpiece diameter.
Figure 5-10 Tool measurement - set length X

Well equipped
5.5 Setting the workpiece zero
Repeat for Z.
Figure 5-11 Tool measurement - set length Z

In the following you will learn how to set the workpiece zero.
Procedure
To set the workpiece zero, switch to the Machine - Manual mode in the main menu.
Move the workpiece zero if this does not lie on the end face of the workpiece.
Figure 5-12 Enter the work offset

Well equipped
Confirm your input.
Figure 5-13 Work offset set

Example 1: Taper shaft 6
6.1 Overview
Learning objectives
This section will explain the first steps to create a workpiece in detail. You will learn how to...
● create and manage programs;
● call tools;
● enter traversing paths;
● create any contours with the contour calculator;
● rough and finish contours;
● create a thread undercut,
● thread and
● grooves.
Task
Figure 6-1 Workshop drawing - Example 1:

Example 1: Taper shaft
6.1 Overview
Figure 6-2 Workpiece - Example 1:
Note
ShopTurn always saves the last setting selected with the toggle key. Therefore, make sure
that all units, texts and symbols are specified as in the dialog boxes shown here in the
relevant input fields and all toggle fields.
Whenever it is possible to switch, this is indicated in the help text (see screenshot below).
Figure 6-3 Example toggle field

6.2 Program management / creating programs
Operating sequences
After power-up of the control system, you are in the main menu.
Figure 6-4 Main screen
Open the main menu using the MENU SELECT key. You can call the various areas of
ShopTurn from the main menu.
Figure 6-5 Main menu
Select the Program Manager softkey. The Program Manager is opened.

In the Program Manager, you can manage process plans and contours (e.g. "New", "Open",
"Copy", ...).
Figure 6-6 Program Manager
The Program Manager displays a list of the existing directories. Use the cursor key to select
the 'Workpieces' directory.
Open the "Workpieces" directory.
Enter the name 'EXAMPLE1' for the workpiece.
Figure 6-7 Creating a workpiece
Confirm your input. The following dialog box is opened:
Figure 6-8 Creating a step sequence program
Select the input format using the ShopTurn and ProgramGUIDE G code softkeys.
The program type can be specified via the ShopTurn softkey.
Specify the name of the process plan, in this case 'TAPER_SHAFT'.
Confirm your input.

After confirming, the following interactive screenform is displayed to enter the workpiece
data.
Figure 6-9 Program header - Help display
Enter the workpiece data and general program specifications in the program header.
Enter the following values:
Field Value Selection via toggle key Notes

Unit of measurement mm X
Work offset X
Blank Cylinder X Select the blank shape
(here cylinder) using the
toggle button.
XA 80
ZA 1
ZI -100 abs X
ZB -92 abs X The value ZB indicates
the distance from the
chuck.
Retraction normal X See below Retraction
XRA 5 inc X The dimensions of the
ZRA 5 inc X retraction planes
(absolute or incremental)
Tool change point WCS X and the tool change point
XT 120 are entered here.
ZT 200
Safety clearance SC 1
Speed limits S1 3500
Machining direction Synchronous X

Accept the entered values. After confirming, the program header is displayed.
Figure 6-10 Program header, example 1 - Work step editor
Now the program has been created as the basis for further machining steps. It has a name
(in the blue bar), a program header (pictogram "P") and a program end (pictogram "END").
The individual machining steps and contours are stored in the program one beneath the
other. The later machining is performed from top to bottom.
You may call the program header again at any time to make changes or check the values.
Retraction
It is possible to switch the retraction plane between normal, extended and all. Depending on
the retraction setting, the associated fields are enabled for the input of the distances.
normal extended all

(for simple cylinders) (for complex workpieces with (for complex workpieces with
internal machining) internal machining and/or relief
cuts)

6.3 Calling a tool
Softkeys
Use this softkey to switch to the online graphic of the workpiece (see screenform below).
Figure 6-11 Program header - graphical view
Use this softkey to switch back to the help display.
6.3 Calling a tool
Operating sequences
To call the required tool, proceed as follows:
Use this key to extend the horizontal softkey menu.
Select the Straight line Circle softkey.
Select the Tool softkey.

6.3 Calling a tool
Open the tool list.
Figure 6-12 Tool list
Use the cursor key to select the ROUGHING_T80 A tool.
Accept the tool into your program. After accepting the tool, enter the following values in the
interactive screenform (if necessary, change the unit using the toggle key):

Spindle V1 X Select main spindle V1.
Cutting rate 240 m/min X
Plane selection Turning X
Figure 6-13 Tool - input
Accept the entered value.

6.4 Specifying the distance to be traversed
Operating sequences
Now enter the distances to be traversed:
Select the Straight line softkey.
Select the "Rapid traverse" softkey.

Enter the following starting point for roughing in the interactive screenform:

X 82 abs X
Z 0.3 abs X
Enter the starting point for the traversing path
"Apply" the set values.

Enter the following values in the interactive screenform:

X -1.6 abs X The tool has a 0.8 radius,
so it must be traversed to
diameter X -1.6.
F 0.3 mm/rev X

Figure 6-14 Specify the traversing path
Select the "Rapid traverse" softkey. Move the tool away from the end face in rapid traverse.

Z 1 abs X
Figure 6-15 Enter the traversing path - moving away from the end face

Select the "Rapid traverse" softkey.


X 82 abs X This entry returns the tool
to the starting point.
Figure 6-16 Enter the traversing path - returning to the starting point

Create the four further traversing paths according to the following list of work steps.
Figure 6-17 Enter the traversing path - four further traversing paths
Start the simulation.
Figure 6-18 Simulation – side view
You may end simulation by selecting either the Simulation softkey again or any other
softkey.

6.5 Creating contours with the contour calculator and machining sequence
6.5 Creating contours with the contour calculator and machining

sequence
Contour calculator
The integrated ShopTurn contour calculator allows you to enter even the most complicated
contours easily.
With the graphical contour calculator,

you can enter the contours faster and
more easily than with conventional
programming - and even without any
mathematical knowledge.
Operating sequences
Proceed as follows to enter the contour:
Select the Contour turning softkey.
Select the New contour softkey. Enter the name 'TAPER_SHAFT_CONTOUR' for the
contour.
Each contour is assigned its own name. This provides for better legibility of the programs.
Figure 6-19 Creating the 'TAPER_SHAFT_CONTOUR' contour
Confirm your input.

You can accept the starting point for the contour line without making any changes (see
illustration below).
Note
The contour line is in one sense the roughing limit and in another the finishing path.
Figure 6-20 Specifying the starting point
Note
If you deselect the Graphic view softkey, detailed help displays are shown.
Confirm your input.

Enter the following values for the vertical straight line in the interactive screenform:

X 30 abs X
Transition to next element Chamfer X Attach the chamfer (FS)
FS 1.5 directly to the straight line
as a transition element.
Figure 6-21 Specifying the vertical straight line contour
Accept the entered values.

Enter the following values for the horizontal straight line in the interactive screenform:

Z -17 abs X A straight line appears up
Transition to next element Chamfer X to Z-17.
FS 0
The thread undercut is

inserted later as an
individual element.
Figure 6-22 Specifying the horizontal straight line contour

Enter the following value for the vertical straight line in the interactive screenform:

X 40 abs X Draw the vertical straight
Transition to next element Radius X line up to the
dimensioned intersection
R 2.5 including the rounding to
the next element.

In the interactive screenform, enter the following values for the end point of the inclined
straight line:

X 50 abs X
Z -30 abs X
Transition to next element Chamfer X
FS 0
Figure 6-24 Specifying the contour end point of the inclined straight line


Z -44 abs X
Transition to next element Radius X
R 2.5


X 60 abs X The paths (= main
elements) do not meet
tangentially.
5RXQGLQJ
PDLQHOHPHQWV


Z -70 abs X The grooves are entered
Transition to next element Radius X later as individual
elements in exactly the
R 1 same way as the thread
undercut.


X 66 abs X
R 1


Z -75 abs X
R 1


X 80 abs X End point X80 with a
Transition to next element Chamfer X 2x45° chamfer
FS 2


Z -90 abs X
FS 0
The contour end point lies

at X80 and Z-90 (2mm in
front of the chuck).
Figure 6-31 Specifying the contour end point
Figure 6-32 Full contour

Accept the contour into your process plan.
Figure 6-33 Contour in the process plan
To be able to machine the created contour, you must now create the following work steps.
To this end, proceed as follows:
Select the Stock removal softkey.
Open the tool list and select ROUGHING_T80 A.
Accept the tool into your program.

Enter the following values for roughing in the interactive screenform:

F 0.3
V 240 m/min X
Machining longitudinal X
external X
roughing X
D 2.5
UX 0.5
UZ 0.2
DI 0.0
BL Cylinder X
XD 0.0 inc X
ZD 0.0 inc X
Relief cuts No X
Set machining area limits No X

Figure 6-34 Roughing the contour
Open the tool list and select FINISHING_T35 A.

Enter the following values for finishing in the interactive screenform:

F 0.15
V 200 m/min X
Machining Finishing X

Figure 6-35 Finishing the contour

The two machining steps are linked in the work step editor.
Figure 6-36 Linking of the work steps in the process plan
Select the Simulation softkey.
Select the Side view softkey.

6.6 Thread undercut
The following simulation shows the manufacturing sequence for you to check before
manufacturing the workpiece.
6.6 Thread undercut
Operating sequences
Proceed as follows to create a thread undercut:
Figure 6-38 Thread undercut
Select the Turning softkey.
Select the Undercut softkey.
Select the Undercut thread softkey.
Open the tool list and select the finishing tool FINISHING_T35 A .

6.6 Thread undercut


F 0.15
V 200 m/min X
Machining Roughing/ X
finishing
Longitudinal X
Position X (see illustration above)
X0 30
Z0 -17
X1 1.15 inc X
Z1 4.5 inc X
R1 0.8
R2 0.8
α 30
VX 1 inc X
D 0.8
U 0.1 X (field)
Figure 6-39 Thread undercut

6.6 Thread undercut
Switch between the graphic view and the help display as required.
Figure 6-40 Thread undercut - graphic view
Select the Simulation softkey. Check the thread undercut via the detailed view in the 3D
view, for example.
Select the 3D view softkey.
Select the Details softkey. You can manipulate the display using the Zoom +, Zoom -,
Magnifying glass, etc. softkeys.
Figure 6-41 Detailed view of the simulation in the 3D display

6.7 Thread
6.7 Thread
Operating sequences
Proceed as follows to create a thread:
Figure 6-42 Thread
Select the Thread softkey.
Open the tool list and select THREADING_T1.5.

Enter the following values for the thread in the interactive screenform:

P 1.5 mm/rev X
G 0
S 800 rpm X
Machining Roughing/finishi X
ng
Linear X
External thread X
X0 30 X The following inputs
Z0 0 define the thread
geometrically.
Z1 -16 abs X
LW 2
LR 1
H1 0.92
αP 29 X
ND 8
U 0.1
NN 0
VR 2
Multiple threads No X
α0 0

6.7 Thread
Figure 6-43 Thread - graphic view
Switch to the help display when necessary.
Figure 6-44 Thread - help display

6.8 Grooves
Figure 6-45 Thread simulation
6.8 Grooves
Operating sequences
Proceed as follows to create the two grooves:
Figure 6-46 Grooves
Select the Groove softkey.
Select the Groove 2 softkey.
Open the tool list and select the PLUNGE_CUTTER_3 A plunge cutter.

6.8 Grooves
Enter the following values for the grooves in the interactive screenform:

F 0.1
V 150 m/min X
Machining Roughing/finishi
ng
Position (see illustration above)
X0 60 The following inputs
Z0 -65 define the grooves
geometrically.
B1 6 X (field)
T1 3 inc X
α1 0
α2 0
FS1 0.5 X (field)
R2 1 X (field)
R3 1 X (field)
FS4 0.5 X (field)
D 3
U 0.1 X (field)
N 2
DP 10
Figure 6-47 Grooves - graphic view

6.8 Grooves
Figure 6-48 Grooves - help display
Figure 6-49 Process plan with grooves
Start the simulation in the side view or in the 2-window view, for example.

6.8 Grooves
Select the Further views softkey.
Select the 2-window softkey.
Figure 6-51 Simulation – 2-window view

6.8 Grooves

Example 2: Input shaft 7
7.1 Overview
Learning objectives
In this section you will learn the following new functions. You will learn how to...
● perform face turning;
● work with the contour calculator (advanced application);
● machine residual material.
Task
Figure 7-2 Workpiece - Example 2:

Example 2: Input shaft
7.2 Face turning
Preparation
Perform the following steps without help:
1. Create a new workpiece with the name 'EXAMPLE2'.
2. Create a new step sequence program with the name 'DRIVE_SHAFT' .
3. Specify the blank dimensions (for the procedure, see example 1).
Figure 7-3 Creating a program header
Following creation of the program header, the process plan looks like this.
Figure 7-4 Work step program
7.2 Face turning
Operating sequences
Proceed as follows to face turn the workpiece:

7.3 Creating the contour, stock removal and residual stock removal
Since face turning should be completed in one cut, switch to finishing during machining.
Select the ROUGHING_T80 A tool and enter the following values.
Figure 7-5 Face turning the workpiece
Operating sequences
Proceed as follows to enter the contour:

Select the New contour softkey. Enter the name 'DRIVE_SHAFT_CONTOUR' for the
contour.
Figure 7-6 Creating the contour
Confirm your input.

You can accept starting point X0/Z0 directly (see illustration below).
Figure 7-7 Accepting the starting point
Confirm your input.


X 16 abs X
R 2


Z -16 abs X
FS 0


X 24 abs X
FS 2


Z -38 abs X
FS 0

Enter the following values for the sloping straight line in the interactive screenform:

X 20 abs X
α2 45 X
FS 0 The entered angle refers
to the preceding element.
Figure 7-12 Specifying the sloping straight line contour


Z -53 abs X
R 1


X 36 abs X
R 0.4
Round the transition to
the next element with
R0.4.

Enter the following values for the next section in the interactive screenform:

X X
Z X
α1 165.167°
Transition to next element Radius X Nothing more is known of
R 0.4 the path than the angle to
the Z axis, 165.167°. In
such cases, simply
continue the construction
with the next element.
Figure 7-15 Specifying the inclined straight line contour


Direction of rotation Right X
R 13
X
Z The missing points of the
I 60 abs X previous contour element
are calculated using the
K -78 abs X
known dimensions of the
Transition to next element Chamfer X arc.
R 0 Since there are several
possibilities, it is
important that the correct
selection is made.
Figure 7-16 Specifying the arc contour
Select the recommended solution in accordance with the below illustration.
Figure 7-17 Confirming the contour selection

Select the desired construction, then accept.

Since the end point of the arc is not known, simply continue with the construction. You could
also use the All parameters softkey to enter the exit angle here.
Figure 7-18 Accepting the arc contour
Accept the contour section.

A tangential path follows.
Select the Tangent to prec.elem. softkey.

X 80 abs X
R 0.4


Z -100 abs X
FS 0
The end point of the
contour is at Z-100.
Figure 7-21 Accepting the contour

Stock removal, residual stock removal and finishing

To be able to machine the created contour, you must now create the following work steps.
Open the tool list and select the ROUGHING_T80 A tool.


F 0.3
S 240 rpm X
Machining contour-parallel X The machining of the
external X contour, for example, is
roughing X performed parallel to the
contour here.
D 2.0
UX 0.2
UZ 0.2
DI 0.0
BL Cylinder X
XD 0.0 inc X
ZD 0.0 inc X
Relief cuts No X

Figure 7-23 Roughing the contour - side view simulation
Select the Residual stock removal softkey.
Open the tool list and select the FINISHING_T35 A tool.

Enter the following values for residual stock removal in the interactive screenform:

F 0.12
V 240 m/min X
external X
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
Relief cuts Yes X To be able to cut all
residual material, you
must switch the input field
to Yes .
FR 0.2
Figure 7-24 Cutting contour residual material
Extend the menu.

Activate the display of traversing paths.
Figure 7-25 Cutting residual material - side view simulation


F 0.12
S 280 rpm X
external X
finishing X
Allowance No X
Relief cuts Yes X

Accept the entered values. After acceptance, the process plan looks like this.
Figure 7-27 Process plan
Select the Details softkey. Here you can expand or minimize the view.

7.4 Thread
The Zoom + softkey expands the view.
Figure 7-28 3D view simulation - details
7.4 Thread
Operating sequences
Proceed as follows to create a thread.

7.4 Thread

P 1.5 mm/rev X
G 0
S 800 rpm X
Machining Roughing + X
finishing
Linear X
External thread X
X0 24
Z0 -16
Z1 -40 abs X
LW 2
LR 1
H1 0.92
αP 29 X
Infeed with X
alternating
flanks
ND 8
U 0.1
NN 0
VR 2
α0 0
Figure 7-29 Producing a thread

7.4 Thread

Example 3: Guide shaft 8
8.1 Overview
Learning objectives
● create any blank;
● perform stock removal of the difference material between the blank and the machined
part;
● drill on the front face;
● mill on the front face;
Task

Example 3: Guide shaft
8.2 Face turning
Preparation
2. Create a new step sequence program with the name 'GUIDE_SHAFT'.
3. Fill in the program header (see illustration below).
Note
Although you can do this for any blank, select the Cylinder blank here. ShopTurn ignores
this input and selects an arbitrary blank.
8.2 Face turning
Operating sequences
Proceed as follows to create a new program and face turn the blank to Z0:

Select the ROUGHING_T80 A tool.

8.2 Face turning

F 0.25
V 240 m/min X
Machining Finishing X
Position (see illustration X
below)
Machining direction Chart X
X0 60 Since the blank has a
diameter of 60mm, you
must also set dimension
X0 to 60 in this work step.
Z0 2
X1 -1.6 abs X
Z1 0.0 abs X
D 1.5
UX 0.0
UZ 0.2
Start the simulation to check the work step.

8.3 Creating any blank contour
You can activate the display of traversing paths via the extended menu.
Figure 8-4 Face turning simulation
Operating sequences
Enter the following blank contour without help:

Select the New contour softkey. Enter the name 'GUIDE_SHAFT_BLANK' for the contour.
In the contour calculator, create the blank contour with the starting point at X0/Z0 (see
illustration below).
Figure 8-6 Any blank contour
Note
The contour must be closed.

8.4 Creating the machined part contour and stock removal
Operating sequences
Proceed as follows to enter the machined part contour:
Select the New contour softkey. Enter the name 'GUIDE_SHAFT_CONTOUR' for the
contour.
Confirm your input.

Since the blank was assigned to Z0 in the first work step, you can accept the starting point
X0/Z0 directly (see illustration below).
Figure 8-8 Specifying the contour starting point
Confirm your input.


X 48 abs X
R 3


Z
R 4
The end point of the

horizontal straight line is
unknown. Enter only the
transition to the next
element with R4. The end
point of the straight line is
calculated automatically
from the subsequent
contour constructions.


R 23
X 60 abs X
Z
I 80 abs X If several solutions are
possible when entering
the contour data (e.g. in
the case of circular arcs
here), you can select
these via the Selection
dialog softkey.
Figure 8-12 Selecting an arc contour

Figure 8-13 Selecting an arc contour
Figure 8-14 Accepting the selected arc contour

To complete the arc, proceed as follows:

1. Enter center point K-35 (absolute dimension).
Figure 8-15 Specifying the arc contour center point
2. Enter the transition to the next element with R4.
Figure 8-16 Specifying the arc contour radius
You can use the existing contour data and the calculated selection options to construct the
arc and the straight line (with unknown end point).


Z -75 abs X
R 6

Enter the following values for the inclined straight line in the interactive screenform:

X 90 abs X
Z -80 abs X
R 4


Z -90 abs X
FS 0
To prevent damage to the

chuck, end the
construction at Z-90.
Figure 8-20 Accepting the contour

Stock removal
In the following work step you will perform contour stock removal.


F 0.3
V 260 m/min X
external X
roughing X
D 2.5
UX 0.2
UZ 0.2
DI 0.0
BL Contour X The blank description
must be switched to
contour here.
Relief cuts No X To ensure that the recess
of radius 23 is not
machined, you must
switch to No.
Figure 8-21 Contour stock removal

8.5 Residual stock removal
Accept the entered values. Both contours and the work step are linked together following
acceptance.
Figure 8-22 Contour stock removal simulation (with display of the traversing paths).
The traversing paths in the simulation clearly indicate how the previously constructed blank
is taken into consideration.
Operating sequences
Proceed as follows to cut the residual material:

The following illustration shows the process plan up to roughing machining:
Figure 8-23 Process plan including roughing machining
Open the tool list and select the BUTTON_TOOL_8 tool.

Enter the following values for residual stock removal in the interactive screenform:

F 0.25
V 240 m/min X
external X
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
Relief cuts Yes X Machining with relief cuts
must be switched to Yes
here.
FR 0.2

Figure 8-24 Cutting contour residual material
Accept the entered values. After acceptance, the list of work steps looks like this:
Figure 8-25 Process plan with residual stock removal

Figure 8-26 Residual stock removal simulation
After roughing the contour, it must then be finished.



F 0.12
S 280 m/min X
external X
finishing X
Allowance No X
Relief cuts Yes X

Figure 8-28 Finishing simulation - 3D view

8.6 Groove
8.6 Groove
Operating sequences
Proceed as follows to create a groove:
After residual stock removal, the list of work steps looks like this:
Figure 8-29 Process plan following stock removal
Select the second groove shape (groove 2).
Open the tool list and select PLUNGE_CUTTER_3 A.

8.6 Groove

Enter the following values for the groove in the interactive screenform:

F 0.1 mm/rev
V 150 m/min X
finishing
Position see illustration X
below
X0 60 Here, you enter the
Z0 -67 position and allowance of
the groove.
B1 4.2 X (field)
T1 4 inc X
α1 15 Here, you enter the flank
α2 15 angle and rounding at the
corners.
FS1 1 X (field)
R2 1 X (field)
R3 1 X (field)
FS4 1 X (field)
D 4
U 0.2 X (field)
N 1
Figure 8-30 Creating a groove

8.6 Groove
Figure 8-31 Process plan including groove
Start the simulation. You can check subareas of the workpiece using the Magnifying glass
softkey.
Figure 8-32 Simulation - 3D view (magnifying glass)

8.7 Thread
8.7 Thread
Operating sequences
Proceed as follows to create a thread.


P 1.5 mm/rev X
G 0
S 800 rpm X
Machining Roughing X The thread is created with
Diminishing X the diminishing setting.
This setting causes the
External thread X
cutting division to be
reduced for each cut, and
so ensures that the
cutting cross-section
remains constant.
X0 48
Z0 -3
Z1 -23 abs X
LW 4 X (field)
LR 2

8.7 Thread

H1 0.92
αP 29 X (field)
Infeed with X
alternating
flanks
ND 8 X (field)
U 0.1
VR 2
α0 0
Figure 8-33 Producing a thread
Figure 8-34 Help display - thread exit

8.8 Drilling
Start the simulation. You can check subareas of the workpiece using the Details softkey.
8.8 Drilling
Operating sequences
Proceed as follows to create drill holes on the front face (C axis or complete machining
sequence).

8.8 Drilling
After the thread has been created, the list of work steps looks like this:
Figure 8-36 Process plan following thread creation
Select the Drilling softkey.
Select the Drilling Reaming softkey. The workpiece is drilled directly, i.e. without centering.
Open the tool list and select DRILL_5.

Enter the following values for the drill hole in the interactive screenform:

F 0.06 mm/rev X
V 140 m/min X
Face X
Shank X The depth reference is
switched to Shank.
Z1 10 inc X The hole depth can be
entered as 10mm
incremental or -10mm
absolute.
DT 0s X

8.8 Drilling
Figure 8-37 Drilling
Figure 8-38 Process plan following drilling
During the drilling work step, an open connector appears in the list of work steps. This is
automatically linked to the drilling positions in the next step.
Select the Positions softkey.

8.8 Drilling
For the purposes of the exercise, the four drill holes are entered as single positions. A
simpler solution here would be to use the position circle.
Figure 8-39 Entering the positions
Figure 8-40 Process plan following input of the position pattern
The drill holes are now linked to the drilling positions.

8.8 Drilling
Figure 8-41 Simulation - 3D view
Figure 8-42 Simulation - front view

8.9 Milling the rectangular pocket
Operating sequences
Proceed as follows to create a rectangular pocket on the front face (C axis or complete
machining sequence).
Select the Milling softkey.
Select the Pocket softkey.
Select the Rectangular pocket softkey.
Open the tool list and select CUTTER_8.

Enter the following values for the rectangular pocket in the interactive screenform:

F 0.03 mm/tooth X
V 220 m/min X
Face X
Machining Roughing X
Single positions X
X0 0 X (field)
Y0 0 X (field)
Z0 0
W 23
L 23
R 4


α0 0
Z1 3 inc X
DXY 75% X
DZ 1.5
UXY 0
UZ 0
Insertion Helical X see insertion below
EP 1
ER 7
Figure 8-43 Producing a rectangular pocket
Figure 8-44 Process plan following rectangular pocket

Insertion
Vertical insertion Helical insertion Oscillating insertion


Example 4: Hollow shaft 9
9.1 Overview
Learning objectives
● perform internal machining on workpieces;
● work with the work step editor;
● create an undercut and
● an asymmetrical groove.
Task
Figure 9-2 Blank contour

Example 4: Hollow shaft
9.2 Creating the first workpiece side
All non-dimensioned radii R10.
Note
On account of improved clamping, side 1 is manufactured first.
Creating a process plan

Since the workpiece is to be machined from two sides (and produced without
counterspindle), two process plans must be created.
Create the process plan for the left-hand side first ('HOLLOW_SHAFT_SIDE1')
Operating sequences
Create the program 'HOLLOW_SHAFT_SIDE1' without help.
Figure 9-3 Creating a ShopTurn program
Enter the following data in the program header (see illustration).
Figure 9-4 Workpiece dimensions in the program header

9.2.1 Face turning
Operating sequences
Proceed as follows to face turn the blank to Z0:


F 0.2
V 240 m/min X
Machining Roughing X Since a large amount of
material (5mm) remains
on the front face, set the
machining to roughing.
below)
X0 105
Z0 5
X1 -1.6 abs X
Z1 0 abs X
D 2.5
UX 0.0
UZ 0.2

Accept the entered values. After acceptance, your work step program looks like this:
Figure 9-6 Process plan following face turning
9.2.2 Drilling
Operating sequences
Proceed as follows to drill the workpiece at the center.
Select the Drilling Centric softkey.



F 0.1 mm/rev X
S 2500 rpm X
Chip removal X
Z0 0
Tip X
Z1 -57 inc X
D 57
Figure 9-7 Hole
"Apply" the set values. After acceptance, the list of work steps looks like this:
Figure 9-8 Process plan following drilling

9.2.3 Blank contour
Operating sequences
Enter the following blank contour without help. Since the workpiece is only machined on one
side for each process plan, the blank contour only needs to be constructed to Z-65.
Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_BLANK' for the contour.
Create the blank contour in the contour calculator (see illustration below).
Figure 9-10 Creating a blank contour

9.2.4 Machined part contour of the first side, external
Operating sequences
Note
The (red) contour of the machined part is intended not to correspond to the drawing. The
machined part contour serves as the roughing machining limit, but more importantly it
specifies the precise traversing path for finishing. Thus, the construction begins here at the
drill hole diameter. This ensures that the end face is finished cleanly. The contour end is an
extension of the chamfer extending outside the blank. The large diameter is produced only in
the second clamping.
Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE1_E' for the
contour.
Confirm your input.

Set the starting point to X32/Z0.
Confirm your input.

X 68 abs X
F 1


Z -5 abs X
FS 0


R 20
X 68 abs X
Z -25 abs X
FS 0
Select the desired construction.
Accept your selection.


Z -55 abs X
FS 0
The undercut is inserted

later as an individual
element.


X 98 abs X
FS 0
The inclined straight line

remains as chamfer after
the second side has been
machined.

Enter the following values for the inclined straight line in the interactive screenform:

X 106 abs X
α1 135 X
FS 0
Figure 9-19 Contour in the contour calculator

After acceptance, the process plan looks like this. Both contours are automatically linked
together.
Figure 9-20 Process plan following input of the contours



F 0.3
V 260 m/min X
external X
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0


BL Contour X In the blank descriptions
you can choose between
the following settings:
Cylinder:
Blank = cylinder
Contour:
Blank = constructed
contour
Allowance:
Blank = constructed
contour with defined
allowance
Relief cuts No X Insertion with the
roughing tool is not
recommended. Therefore,
switch the Relief cuts field
to No.
Accept the tool into your program. Before finishing, the residual material is cut in the concave
fillet.

Enter the following values for stock removal of residual material in the interactive
screenform:

F 0.2
V 240 m/min X
external X
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
Relief cuts Yes X To ensure that the
concave fillet is taken into
consideration, the Relief
cuts field must be
switched to Yes.
FR 0.2
Figure 9-22 Stock removal of residual material contour



F 0.15
V 280 m/min X
external X
finishing X
Allowance No X
Relief cuts Yes X Switch Relief cuts to Yes
here, too.

Accept the entered values. After acceptance, your work step program looks like this: The
contours are automatically linked to the stock removal work steps.
Figure 9-24 Process plan following stock removal of the contour
9.2.5 Undercut
You can select from four different types of undercut:
Undercut form E Undercut form F Undercut DIN thread Undercut thread

Operating sequences
Proceed as follows to create an undercut.
After residual stock removal, the list of work steps looks like this:
Figure 9-25 Process plan following stock removal
Select the Undercut form E softkey.


F 0.15
V 200 m/min X
below
E 1.0 x 0.4 X
X0 68
Z0 -55
X1 0 inc X
VX 70 abs X
Figure 9-26 Specifying the undercut
Figure 9-27 Process plan with undercut

Figure 9-28 Simulation - Cut active
Figure 9-29 Simulation - Side view with display of the traversing paths

9.2.6 Machined part contour of the first side, internal
Operating sequences
Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE1_I' for the
contour.
Confirm your input.

Confirm your input.

Create the contour without help (see illustration below).
Figure 9-32 Machined part contour of the first side, internal

In the following work step you will perform contour stock removal. Enter the geometries into
your process plan as follows.
Figure 9-33 Broken-line graphics
Open the tool list and select the ROUGHING_T80 I tool.


F 0.25
V 250 m/min X
Machining longitudinal X You must switch the
internal X machining to Inside.
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
BL Cylinder X Since drilling has already
taken place, you do not
need to take a blank
contour into consideration
for internal machining.
Switch to Cylinder.
XD 32 abs X
ZD 0 inc X
Relief cuts No X

Open the tool list and select the FINISHING_T35 I tool.


F 0.12
V 280 m/min X
internal X
finishing X
Allowance No X
Relief cuts No X

Start the simulation to perform checks.
Figure 9-36 Simulation - Cut active
Undercut
Proceed as follows to create an undercut:
Select the Undercut form E softkey.

Create the undercut (see illustration below).
Figure 9-37 Creating an undercut

Note
Make sure that the undercut is in the correct position.
Figure 9-38 Undercut simulation (with display of the traversing paths)
The process plan for the first side of the workpiece looks like this.
Figure 9-39 Process plan with undercut

9.2.7 The work step editor
Functions of the work step editor

The following information provides you with an overview of the functions of the work step
editor.
Use this softkey to switch to the broken-line graphics.
Use this softkey to search for texts in the program.
Use this softkey to select several work steps for further processing (e.g.,
"Copy" or "Cut").
Use this softkey to copy work steps to the clipboard.
Use this softkey to paste work steps from the clipboard to the process
plan. The copied step is always inserted after the currently highlighted
step.
Use this softkey to copy work steps to the clipboard; at the same time, it
is deleted at its origin. This softkey can also be used for "pure" deletion.
Use this softkey to switch to the extended menu.
Use this softkey to renumber the work steps.
Use this softkey to open the "Settings" dialog. Here you can specify, e.g.
automatic numbering or whether you wish the end of the block to be
represented as a symbol.
Use this softkey to return to the previous menu.

You will need some of these functions in order to reuse the blank contour of the first side in
the process plan for the second side of the workpiece. The blank contour will be copied to
the clipboard and pasted into the process plan for the second side.
Figure 9-40 Blank contour
9.2.8 Copying the contour
Operating sequence
Proceed as follows to copy the blank contour to the clipboard:
Navigate to the 'HOLLOW_SHAFT_BLANK' contour.
Figure 9-41 Copying the contour to the clipboard.
Copy the blank contour to the clipboard. The contour remains on the clipboard until you copy
another work step to the clipboard or shut down the control system.

9.3 Creating the second workpiece side
Creating a process plan

Proceed as follows to create a process plan for the second side of the workpiece.
Operating sequences
Create the program 'HOLLOW_SHAFT_SIDE2' without help.
Figure 9-42 Creating a ShopTurn program
Enter the following data in the program header (see illustration).
Figure 9-43 Workpiece dimensions in the program header
9.3.1 Face turning
Operating sequences
Proceed as follows to face turn the blank to X-1.6 and Z0:



F 0.2
V 240 m/min X
Machining Roughing X Since a large amount of
material (5mm) remains
on the front face, set the
machining to roughing.
below)
X0 105
Z0 5
X1 -1.6 abs X
Z1 0 abs X
D 2.5
UX 0.0
UZ 0.2

Figure 9-45 Process plan following face turning
9.3.2 Drilling
Operating sequences
Proceed as follows to drill the workpiece at the center.


F 0.1 mm/rev X
S 2500 rpm X
Chip removal X
Z0 0
Tip
Z1 -67 abs X
D 67
DT 0 X
Figure 9-46 Hole
"Apply" the set values. After acceptance, the list of work steps looks like this:
Figure 9-47 Process plan following input of the drilling position

9.3.3 Specifying a blank contour
Operating sequences
Proceed as follows to paste the blank contour from the clipboard into your process plan:
First, navigate in the process plan to the most recently entered work step (see illustration).
Figure 9-48 Position for inserting the blank contour
Paste the blank contour from the clipboard. After pasting the contour, your process plan
should look like this.
Figure 9-49 Pasting the contour

9.3.4 Machined part contour of the second side, external
Operating sequences
Note
The asymmetrical groove is produced later.
Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE2_E' for the
contour.
"Apply" your input.

"Apply" your input.

Create the contour up to the end point to Z-65 and X100 without help (see illustration below).
Stock removal and finishing



F 0.3
V 260 m/min X
external X
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
BL Contour X
Relief cuts No X

"Apply" the set values. After acceptance, your work step program looks like this:
Figure 9-53 Process plan following roughing


F 0.15
V 200 m/min X
external X
finishing X
Allowance No X
Relief cuts No X
"Apply" the set values. After acceptance, your work step program looks like this:
Figure 9-55 Process plan following stock removal of the contour

9.3.5 Creating an asymmetrical groove
Operating sequences
Proceed as follows to create an asymmetrical groove.
Select the Groove 2 softkey.
Open the tool list and select the PLUNGE_CUTTER_3 A tool.


F 0.08
V 180 m/min X
finishing
below
X0 70
Z0 -55
B1 10 X (field)
T1 5.5 inc X
α1 0
α1 15
R1 0 X (field)
R2 2 X (field)
R3 0 X (field)
R4 0 X (field)
D 3
U 0.2 X (field)
N 1
Figure 9-57 Specifying a groove

Figure 9-58 Process plan following groove
Figure 9-59 Simulation - 3D view (cut active)

9.3.6 Machined part contour of the second side, internal
Operating sequences
Select the New contour softkey. Enter the name 'HOLLOW_SHAFT_SIDE2_I' for the
contour.
"Apply" your input.
"Apply" your input.

Create the contour without help (see illustration below).
Figure 9-61 Machined part contour of the second side, internal
Note
When creating the contour, ensure that the arc elements merge tangentially.
Tangential merging applies only to main elements, i.e. the rounding is attached to the main
element.
(See illustration below)
0DLQHOHPHQWV
5RXQGLQJ
WDQJHQWLDO
QRQWDQJHQWLDO

Accept the contour. After accepting the contour, your work step program looks like this.
Figure 9-62 Process plan following input of the contour

Open the tool list and select the ROUGHING_T80 I tool.


F 0.25
V 280 m/min X
Machining longitudinal X You must switch the
internal X machining to Inside.
roughing X
D 2.0
UX 0.2
UZ 0.2
DI 0.0
BL Cylinder X Since drilling has already
taken place, you do not
need to take a blank
contour into consideration
for internal machining.
Switch to Cylinder.


XD 32 abs X
ZD 0 abs X
Relief cuts No X


F 0.2
V 240 m/min X
internal X
finishing X
Allowance No X
Relief cuts Yes X
FR 0.2

Figure 9-64 Contour residual stock removal


F 0.12
V 280 m/min X
internal X
finishing X
Allowance No X
Relief cuts Yes X

Start the simulation to perform checks.
Figure 9-66 Simulation - 3D view (cut active)


Example 5: Plunge-turning 10
10.1 Overview
Learning objectives
In this section you will learn how to use the plunge-turning functions.
Task

Example 5: Plunge-turning
10.2 Plunge-turning
Preparation
2. Create a new step sequence program with the name 'PLUNGE_TURNING'.
3. Fill in the program header (see illustration below).
10.2 Plunge-turning
The achievable level of productivity during turning is limited, among other things, by the
possible number of tools in the revolver and the frequent tool changes required for effective
turning machining. With standard turning tools alone, not all possible contours can be
produced, and residual material machining, therefore, is often performed by means of
plunge-cutting. For the complete machining of a contour, therefore, it is always necessary to
change between standard turning tools and plunge-cutting tools.
The aim of the plunge-turning cycle is to reduce the number of tool changes and to avoid
empty cuts, such as those that occur during the backward movement of the turning tool, for
example.
As a general rule, hardly any empty cuts exist during the plunge-turning cycle, as stock
removal is performed during both forward and backward movement. This must be taken into
account during program creation. ShopTurn offers optimum support for this. As you already
know, you only need to describe the contour of the turning part and during the stock removal
cycle you can select whether you wish to perform stock removal using a conventional
procedure or by means of plunge-cutting or plunge-turning. ShopTurn automatically
calculates the cuts and traversing movements of the tool based on the cycle. This means
that empty cuts are eliminated to a great extent.
During the simulation, you can clearly analyze the calculated traversing movements of the
tool. Even a combination of conventional turning machining and plunge-turning is possible,
i.e. a standard tool is used for roughing, while plunge-turning is used for machining residual
material, meaning that the contour can be thoroughly machined without the risk of damage.

10.3 Creating the contour
10.3 Creating the contour
Operating sequences
Create the contour without help.
Select the New contour softkey. Enter the name 'CONTOUR_E' for the contour.
Confirm your input.
Create a contour (see illustration below).

10.4 Stock removal with the plunge-turning cycle
Operating sequences
Select the Plunge-turning softkey.


FX 0.2
FZ 0.25
V 150 m/min X
external X
roughing X
D 2.5
UX 0.2
UZ 0.2
DI 0.0
BL Cylinder X
XD 50 abs X
ZD 0 abs X
N 1

Roughing the contour
Select the Plunge-turning softkey.


FX 0.15
FZ 0.15
V 200 m/min X
external X
finishing X
Allowance No X
N 1

Finishing the contour
Figure 10-5 Work step program

Figure 10-6 Simulation - Side view (with display of the traversing paths)
Figure 10-7 Simulation - 3D view (with display of the traversing paths)


And now you can start manufacturing! 11
After you have acquired a well-founded knowledge of the creation of process plans in
ShopTurn by working with the examples, we will now machine workpieces.
To machine a workpiece, proceed as follows:
Approaching reference point

After turning on the control system and before traversing the axes according to the process
plans or traversing manually, you will have to approach the reference point of the machine.
In this way, ShopTurn will find the start of counting in the position measuring system of the
machine.
Since approaching of the reference point is different depending on machine type and
manufacturer, only a few hints can be given here for orientation:
1. If necessary traverse the tool to a free point in the work space from which traversing is
possible in all directions without collision. Make sure that the tool is then not beyond the
reference point of the corresponding axis (since reference point approach is only
performed in one direction for each axis; otherwise, this point cannot be reached).
2. Perform the reference point approach exactly according to the specifications of the
machine manufacturer.
Clamping the workpiece

To guarantee machining in accordance with the specified dimensions and, naturally, also for
your own safety, it is imperative to clamp the workpiece tightly. A three-block chuck is usually
used for this.
Setting the workpiece zero

Since ShopTurn cannot guess where in the work space the workpiece is located, you must
determine the workpiece zero in Z.
The workpiece zero is usually determined through sampling with a calculated tool in the Z
axis.
Executing the process plan

Now the machine is prepared, the workpiece is set up, and the tools are gauged. At last we
can start!

And now you can start manufacturing!
11.1 And now you can start manufacturing!
First select the program you want to execute in the Program Manager, e.g.
HOLLOW_SHAFT_SIDE2.
Figure 11-1 Selecting the program
Open the program.
Figure 11-2 Opening the process plan

Select the NC selection softkey.
Figure 11-3 Executing
Due to the fact that the process plan has not yet been executed with control, turn the
feedrate potentiometer to zero position to ensure that you keep everything under control
from the beginning.
If you also want to see a simulation during machining, select the Drawing softkey before
starting. Only then are all traversing paths and their effects are displayed.
Start machining and check the speed of the tool motions using the feedrate potentiometer.


How accomplished are you in the use of ShopTurn? 12
12.1 Exercise 1
Will you manage this task using ShopTurn within 10 minutes?
Figure 12-1 Workshop drawing DIYS1
Notes
In the process plan, the workpiece is milled to size in two work steps (see model below). For
this reason, you can assign the the starting point of the CONTOUR_1 contour to the start of
the first chamfer.
Model

How accomplished are you in the use of ShopTurn?
12.1 Exercise 1
Figure 12-4 Workpiece simulation

12.2 Exercise 2
12.2 Exercise 2
Notes
You can use the automatic cutting of residual material to great effect here.
Model

12.2 Exercise 2

12.3 Exercise 3
12.3 Exercise 3
Notes
Construct radius 5 in two steps.
Model

12.3 Exercise 3

12.4 Exercise 4
12.4 Exercise 4
Notes
In the process plan, the end face is roughed and finished first (see model below). Then the
entire external area, including the undercut, is produced. Following this, the internal part of
the contour is machined. The starting point of the internal contour is set to X70/Z0. You can
copy the external and internal machining sequences using the work step editor by means of
cut and paste.

12.4 Exercise 4
Model
Figure 12-15 External contour in the contour calculator

12.4 Exercise 4
Figure 12-16 Internal contour in the contour calculator

12.4 Exercise 4
Figure 12-18 Workpiece simulation - Cut active

Index
Flank angle, 134
A G
Absolute input, 32 Graphical process plan, 11
Alarms, 29 Grooves, 84
Axes, 31
H
B Handbook, 38, 39
Basics of operation, 17
Blank description, 127
Blank shape I
Cylinder, 55 Incremental input, 33
Tube, 55 Internal machining, 170
Blank shapes, 161
Broken-line graphics, 174
L
C Load magazine, 46
C axis, 138
Calling dialogs, 56 M
Cartesian input, 34
Circular motions, 36 Machine zero, 32
Clipboard, 175 Magazine, 23
Complete machining sequence, 138 Magazine list, 44
Concatenation, 25 Main menu, 19
Constant speed, 39 Main screen, 53
Contour calculator, 12 Measure workpiece, 49
Accept dialog, 122 Messages, 29
Selection dialog, 121
Creating process plan, 90
Cut, 15 P
Cutting rate, 11, 38 Paste, 15
Plunge-turning, 196
Points in the working space, 31
D Polar input, 35
Directory, 54 Production, 203
Drilling positions, 141 Program header, 55
Program management, 54
Program Manager, 27, 54
F
Face turning, 90 R
Feed, 39
Feed, 39 Reference point, 32
Feedrates, 39 Relief cuts, 107

Index
Residual material, 14, 107 DIN thread, 164

Residual stock removal, 107 Form E, 164
Retraction Form F, 164
all, 56 Thread, 164
extended, 56
normal, 56
Retraction plane, 55 W
Work offsets, 23
Workpiece zero, 32
S
Safety clearance, 55
Sequence editor
Copy, 174
Cut, 174
Graphic view, 174
Highlight, 174
Menu backward, 174
Menu forward, 174
Paste, 174
Renumber, 174
Searching, 174
Settings, 174
Setting up the machine, 21
Simulation, 25
2-window view, 87
3D view, 62
Cut active, 167
Details, 81
Displaying tool paths, 108
Magnifying glass, 135
Side view, 79
Simultaneous recording, 205
Softkeys, 18
Speed, 38
Speed limitation, 38
Start key, 205
T
Thread, 82, 110
Diminishing, 136
Thread undercut, 79
Toggle field, 52
Tool list, 22, 42
Tool wear list, 43
Toolholder reference point, 32
Tools for the examples, 44
U
Undercut


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 Turning made easy with ShopTurn Introduction 1

Siemens AG Order number: 6FC5095-0AB80-1BP1 Copyright © Siemens AG 2011.

Turning made easy with ShopTurn

6.4 Specifying the distance to be traversed ...................................................................................... 59

Turning made easy with ShopTurn

10 Example 5: Plunge-turning..................................................................................................................... 195

Turning made easy with ShopTurn

Turning made easy with ShopTurn

The solution is: Creating a process plan instead of programming

Turning made easy with ShopTurn

Turning made easy with ShopTurn

2.1 You will save time for training....

Turning made easy with ShopTurn

Figure 2-1 Work step in a process plan

Figure 2-2 Broken-line graphics

Turning made easy with ShopTurn

2.2 You will save time for programming...

Turning made easy with ShopTurn

Figure 2-3 Technical drawing

Figure 2-4 Screenform

Turning made easy with ShopTurn

Figure 2-5 Graphic view

Figure 2-6 Help display

Turning made easy with ShopTurn

2.3 You will save time for manufacturing...

Retraction plane: normal Retraction plane: extended Retraction plane: all

Turning made easy with ShopTurn

Figure 2-7 Original machining sequence

Figure 2-8 Optimized machining sequence with cutting and pasting

Turning made easy with ShopTurn

Turning made easy with ShopTurn

3.1 Using ShopTurn

Turning made easy with ShopTurn

Deletes the first character to the right.

Deletes all characters.

Deletes a character selected to the left of the cursor.

Deletes all of the selected characters to the left of the cursor.

Turning made easy with ShopTurn

All main functions can be called using the horizontal softkeys.

3.2 The contents of the main menu

Select the "Machine" softkey.

Press the "JOG" key.

Turning made easy with ShopTurn

Figure 3-1 Call of a tool and input of technological values

Figure 3-2 Input of a target position

Turning made easy with ShopTurn

Select the "Machine" softkey.

Press the AUTO key.

Figure 3-3 Executing a process plan

Figure 3-4 Simultaneous recording of the execution

Turning made easy with ShopTurn

Figure 3-5 Tool list

Turning made easy with ShopTurn

Figure 3-6 Magazine

Figure 3-7 Work offsets

Turning made easy with ShopTurn

This key can be used to edit programs.

The contour to be machined is entered graphically as a machining step.

Turning made easy with ShopTurn

Geometry and technology constitute a unit in programming. The subsequent technological

Turning made easy with ShopTurn Introduction 1

G PP G PP