Sinumerik 840D Solution Line Turning With Shopturn

Preface
Introduction 1
System overview 2
SINUMERIK
Manual machine 3
840D solution line
Turning with ShopTurn Graphical program input 4
DIN/ISO programming 5
Control system overview for
machine tools' sales people
Setup functions 6
Tool management 7
Program management, user
memory 8
Simulation 9
Complete machining 10
In-process measuring 11
PC software 12
Automatic mode 13
Velocity control 14
Integrated safety functions 15

Option list for the
SINUMERIK package 16
06.2006 Edition
Summary of unique selling
points 17
Safety Guidelines
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
Danger
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
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 corresponding 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.
Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
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
editions.
Siemens AG Ⓟ 04/2007 Copyright © Siemens AG 2006.

Automation and Drives Technical data subject to change
Postfach 48 48
90437 NÜRNBERG
GERMANY
Preface
Scope of validity
This document provides you with an overview of the functional range of ShopTurn version
7.1, in use with the SINUMERIK 840D sI.
The document is oriented towards vendors and dealers of machine tools.
Organization of information
• Of the varied functional possibilities of this SINUMERIK product, we only designate those
qualities which are of direct value to the machine's user.
• All functions contained in the machine's basic configuration will be identified as follows:
☑ Basic configuration
• All functions not contained in the machine's basic configuration will be identified as
follows:
☑ Option: ...
• A summary of the unique selling points of ShopTurn in comparison with competitors may
be found in chapter "Summary of unique selling points".
• For information on marketing options through the machine manufacturer, please see the
technical description of each machine.
Subject to change without prior notice
Turning with ShopTurn

Control system overview for machine tools' sales people, 06.2006 Edition 3
Table of contents
Preface ...................................................................................................................................................... 3
1 Introduction................................................................................................................................................ 9
1.1 Application......................................................................................................................................9
1.2 Machine spectrum..........................................................................................................................9
2 System overview...................................................................................................................................... 11
2.1 SINUMERIK 840D sl....................................................................................................................11
2.2 Operator panel fronts ...................................................................................................................12
2.3 Operator panel equipment ...........................................................................................................16
3 Manual machine ...................................................................................................................................... 17
3.1 Introduction ..................................................................................................................................17
3.2 Simple workpiece machining in manual mode.............................................................................17
3.3 Complex machining in manual mode...........................................................................................18
4 Graphical program input .......................................................................................................................... 19
4.1 Introduction ..................................................................................................................................19
4.2 Dynamic broken-line graphics......................................................................................................20
4.3 Online help ...................................................................................................................................21
4.4 Standard machining steps ...........................................................................................................22
4.5 Example Thread-cutting...............................................................................................................23
4.6 Example Repair thread ................................................................................................................23
4.7 Contour calculator (graphical programming) ...............................................................................24
4.8 Contour stock removal cycle........................................................................................................25
4.9 Residual material detection, segmental processing ....................................................................26
4.10 Contour slots, contour spigots .....................................................................................................27
4.11 Detection of residual material when milling .................................................................................27
4.12 Path Milling Cycle ........................................................................................................................28
5 DIN/ISO programming ............................................................................................................................. 29
5.1 DIN/ISO language........................................................................................................................29
5.2 DIN/ISO editor / G code editor .....................................................................................................30
5.3 Machining cycles..........................................................................................................................31
5.4 Contour calculator (DIN/ISO) .......................................................................................................32

Table of contents
6 Setup functions ........................................................................................................................................ 33

6.1 Measure workpiece ..................................................................................................................... 33
6.2 Zero/work offset .......................................................................................................................... 34
6.3 Measure tool ............................................................................................................................... 34
6.4 TSM universal cycle .................................................................................................................... 35
6.5 Positioning cycle ......................................................................................................................... 35
6.6 Stock removal ............................................................................................................................. 36
7 Tool management.................................................................................................................................... 37
7.1 Tool table..................................................................................................................................... 37
7.2 Tool monitoring, sister tools ........................................................................................................ 38
8 Program management, user memory ...................................................................................................... 39
8.1 Program manager ....................................................................................................................... 39
8.2 User memory and data management ......................................................................................... 40
8.2.1 Buffered CNC work memory ....................................................................................................... 40
8.2.2 USB memory stick....................................................................................................................... 40
8.2.3 CompactFlash card ..................................................................................................................... 41
8.2.4 Ethernet networking .................................................................................................................... 41
8.2.5 Hard disk drive ............................................................................................................................ 42
8.2.6 Disk drive..................................................................................................................................... 42
9 Simulation................................................................................................................................................ 43
10 Complete machining ................................................................................................................................ 45
10.1 Counterspindle ............................................................................................................................ 45
10.2 Counterspindle machining........................................................................................................... 46
10.3 Additional components................................................................................................................ 47
10.4 Front surface machining.............................................................................................................. 48
10.5 Peripheral surface machining...................................................................................................... 49
11 In-process measuring .............................................................................................................................. 51
12 PC software ............................................................................................................................................. 53
12.1 CAD reader for PC ...................................................................................................................... 53
12.2 ShopTurn on PC, SinuTrain ........................................................................................................ 54
12.3 ShopTurn for self-learning........................................................................................................... 54
13 Automatic mode....................................................................................................................................... 55
13.1 Program control........................................................................................................................... 55
13.2 Simultaneous recording .............................................................................................................. 56
13.3 Block search................................................................................................................................ 56
13.4 Basic block display...................................................................................................................... 57

6 Control system overview for machine tools' sales people, 06.2006 Edition
Table of contents
14 Velocity control ........................................................................................................................................ 59

14.1 Jerk limitation ...............................................................................................................................59
14.2 Dynamic feedforward control .......................................................................................................60
15 Integrated safety functions....................................................................................................................... 61
15.1 SINUMERIK Safety Integrated.....................................................................................................61
16 Option list for the SINUMERIK package .................................................................................................. 63
17 Summary of unique selling points ............................................................................................................ 65
Index........................................................................................................................................................ 67

Introduction 1
1.1 Application
ShopTurn is a customized technology package for all standard single-slide CNC turning
machines used worldwide.
ShopTurn enables the simple operation of machine tools, supporting all operator actions with
graphic help displays.
The functions in the manual mode enable a quick, practical machine set-up. More
specifically, this consists of calculating the workpiece position in the machine, as well as the
maintenance and measuring of the tools in use.
ShopTurn offers two options for programming:
The DIN/ISO editor is used to create DIN/ISO programs on the machine and correct
externally created DIN/ISO programs.
The work plan editor is used for graphic programming on the machine. Here are the typical
applications for finishing individual parts and small series. For example, DIN/ISO sections
may be flexibly inserted for complex part machining steps.
ShopTurn offers a uniform control configuration which covers all required areas of
application without additional start-up and training costs:
• Easy-to-use interface for all machine functions
• DIN/ISO programming on the machine or offline via CAD/CAM system
• Graphical programming
• Complete machining
• Measuring functions for workpieces and tools
1.2 Machine spectrum

ShopTurn is especially well-suited for the following types of machine:
1. Single-slide turning machines with X and Z axes
– Turning
– Centric drilling on the end face
2. Like 1.) with rotating tools (C axis mode)
– Any drilling or milling on the end face and outer surface
3. Like 1.) or 2.) with additional Y axis
– Any drilling or milling on the end face and outer surface
4. Like 1.) or 2.) or 3.) with additional counterspindle for front and rear machining

System overview 2
2.1 SINUMERIK 840D sl
The new SINUMERIK 840D sl offers modularity, openness, flexibility and a uniform structure
for operation, programming and visualization. Integrated into the new, especially compact
and reliable SINAMICS S120 drive system, it constitutes a completely digital system. It is
best-suited for medium and high performance ranges.
• Digital drive controller
• Modular design for drive controller and power unit
• Up to 31 axes/spindles in up to 10 processing channels
• Intelligent control functions meeting the highest standards of machining technology
You can find further information in catalog NC 61
Highlights
• Flexible application and guaranteed future through modular design and
comprehensive CNC functions
• Best dynamics, precision and surface quality through use of
high performance processors
• Integrated, certified safety functions for man and machine are possible with
Safety Integrated

System overview
2.2 Operator panel fronts

These operator panel fronts have an integrated CNC keyboard. We offer matched machine
control panels for the version with mechanical keys (protection class IP54) and the version
with membrane keys (protection class IP65). You have two choices:
OP 010C
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
with frontal USB port for memory stick,
version with mechanical keys,
separate machine control panel
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Highlights
• All relevant functions at a glance, thanks to horizontal and vertical softkeys
• Brilliant color display, balanced and high-quality design of operator components
• Simple data handling with easily accessible USB memory stick

System overview
OP 010
Operator panel 483mm wide, 10.4" display, integrated CNC keyboard,
version with membrane-type keys,
separate machine control panel
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System overview
OP 010S
Operator panel 310mm wide, 10.4" display, mechanical keyboard,
separate CNC keyboard and machine control panel
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Highlights
• Option of especially slim design

System overview
OP 015
Operator panel 483mm wide, 15" display, membrane keys,
separate CNC keyboard and machine control panel
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• Option of especially large display for better readability and graphic display for high-class
machines

System overview
2.3 Operator panel equipment
2.3 Operator panel equipment

The ShopTurn software, the Ethernet connection and the slot for a CompactFlash Card are
located directly on the SINUMERIK 840D sI module in the control cabinet. The slot for a USB
memory stick is directly on the front side of the operator panel.
TCU
The Thin Client Unit (TCU) for the distributed configuration permits the spatial separation of
the SINUMERIK operator panel front and the SINUMERIK NCU.
• Fewer parts for specifically flat design
• Competitive purchase price and inexpensive replacement parts
7&8
Highlight
• Rugged and cost-optimized solution, as there is no hard disk
• Signal transmission between PCU/NCU and operator panel front via Industrial Ethernet
PCU 50
For customers who require a hard disk and a Windows operating system, we offer the
PCU 50.
• Windows XP operating system
• Additional CNC memory through hard disk
• Additional PCI slots on board
3&8
Highlights
• Flexible software expansion on Windows platform
• Flexible hardware expansion via PCI slots

Manual machine 3
3.1 Introduction
☑ TCU ☑ PCU 50 ☑ Option: Manual machine
We offer the manual machine function for beginners switching over from conventional
machines, but also for experienced CNC machine operators who often only use individual
machining steps.
The basic screen MANUAL is displayed

immediately after booting the machine
offering the direct machining options
without having to create a part program.
3.2 Simple workpiece machining in manual mode

You can perform simple types of machining directly in "Manual" mode:
• Taper turning
• Straight, face or longitudinal turning
Simply select the tool, feedrate, spindle speed, direction of spindle rotation and, when
necessary, the machining angle. Press start. Machining will begin immediately.
The active direction is graphically displayed in the basic screen by means of a wind rose.

Manual machine
3.3 Complex machining in manual mode
3.3 Complex machining in manual mode

Each execution cycle can be started directly in manual mode, too:
• Drilling: Drill centered, thread centered, centering, drilling, reaming, deep hole drilling,
threading, thread milling
• Turning: Stock removal, groove, undercut, threading, thread undercut, thread re-
machining
• Milling: Rectangular/circular slot, rectangular/circular spigots, longitudinal/circumferential
slot, multiple edge, engraving
Simply traverse to the start point of the machining, select the desired function, enter the
required value in the dialog screen and press start.
Highlights
• Save time with simple machining, as no part program is required
• Arrange your machining steps flexibly with MANUAL mode

Graphical program input 4
4.1 Introduction
☑ TCU ☑ PCU 50 ☑ Option: Machining step programming
The graphical programming is done via a graphic, interactive work plan editor. Each program
line represents a machining step (ex.: Stock removal, groove, thread cutting) or geometric
data required for the machining steps (turning / milling contours or position patterns).
Machining steps belonging together are linked to each another. The interlinked machining
steps are performed consecutively at the appropriate contours or position patterns.
Graphical programming offers, in comparison to DIN/ISO programming, a compact and
easily comprehensible program overview.
Entering individual machining steps requires no knowledge of DIN/ISO. All required technical
and geometric parameters are entered in screen forms.
Simple and intuitive programming with machining steps can always be flexibly expanded via
entry of DIN/ISO blocks and control functions.
Highlights
• Intuitive program input, without knowledge of DIN/ISO or Operator Manual
• Thanks to the interlinking of maching steps, the position patterns and contours need only
be entered or changed once, offering benefits in time and security.
• Compact, clearly arranged machining programs

Graphical program input
4.2 Dynamic broken-line graphics
4.2 Dynamic broken-line graphics
☑ TCU ☑ PCU 50 ☑ Basic configuration of

machining step programming
While programming, the previously entered machining steps will be continuously displayed to
scale. A simulation is not required for this.
• Turning display
• End face and outer surface
Highlight
• More certainty during program input thanks to quick review of the resulting contour

4.3 Online help
4.3 Online help

All input parameters are clarified with dynamic help displays. In addition, explanatory cursor
text is displayed. This enables creation of programs on the machine without a programmer
handbook.
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Toggles between the work plan and programming graphics as well as between
the parameterization screen form with programming graphics and the
parameterization screen form with the help display.
Highlight
• Programming on the machine without a handbook
• Help key to toggle between help displays

4.4 Standard machining steps
4.4 Standard machining steps

A number of different machining operations are available in the work plan editor:
• Turning operations
– Face turning
– Stock removal, groove, threading
– Undercut form E, F, thread undercuts
– Longitudinal / face / taper threads, thread
re-machining
– Plunge-turning
– Plunge-cutting
• Drilling and milling operations

– Centric drilling and threading
– Centering, drilling, boring, reaming, deep-
hole drilling
– Threading, thread milling
– Circular and rectangular slots / spigots
– Longitudinal / circular groove
– Multiple edge
• Engraving cycle
– Any text with special characters
– Date, time, workpiece count, variable
• Position pattern
– Position list, hide positions
– Line / pitch circle / full circle / grid / frame
• Basic elements
– Straight / circle / helix
• Miscellaneous
– Marks / repetitions
– Offset, rotation, scaling, mirroring
Drilling and milling operations may be linked any way with position patterns.
Highlights
• Time saving through program input completely by dialog; complete with tool, feedrate and
spindle speed or cutting rate
• Expanded selection of ready-made machining operations, including the innovative plunge
turning

4.5 Example Thread-cutting
4.5 Example Thread-cutting

A threading cycle is available in the work plan editor:

The following threads can be generated:
• Longitudinal thread
• Face thread
• Tapered thread
• Linked threads via DIN/ISO cycle
The following parameters can be specified:

• Outer / inner thread
• Roughing, finishing, roughing & finishing
• Linear / degressive infeed
• Thread pitch in mm/rev, inch/rev, gear/inch, module
• Variable pitch
• Infeed at one or changing edge
• Number of non-cuts
• Start angle offset
• Multiple threads (up to 6)
Highlight
• All popular thread forms possible
4.6 Example Repair thread

By positioning the threading tool in the recutting thread, the synchronization point (starting
angle) of the thread can be determined.
Then the thread can be remachined following the thread-cutting cycle.
Highlight
• Support for thread repair as standard

4.7 Contour calculator (graphical programming)
4.7 Contour calculator (graphical programming)

A contour calculator is available in the work plan editor.
The following contours may be generated with this geometry calculator:

• Blank and finished-part contours for turning
• Contours for milling on the end face and outer surface
The contour calculator provides the following possibilities:
• Up to 250 geometry elements programmable
• Automatic calculation of only partly defined elements
• Chamfer or radius programmable in contour transitions
• Chamfer or radius programmable as the contour start or end element
• Definition of undercuts (form E, F, thread undercut) directly in the contour
• Polar geometry for milling contours on the end face and outer surface
• Separate feedrate for individual contour elements; chamfer and radius programmable
• Separate grinding allowance for contour elements programmable
• Direct entry of fitting measurements (ex.: F60H7)
• Conversion of contours and position patterns in DXF format with CAD Reader for PC;
continued processing with the contour calculator in the control
Highlights
• Easy input of workpiece geometry: "Drawing dot to dot"
• Determination of contours with many unknown intermediate values is possible
• Speedy and certain from drawing to finished workpiece

4.8 Contour stock removal cycle
4.8 Contour stock removal cycle

With the intelligent contour stock removal cycle, free contours can be processed in a variety
of ways:
• Processing any contour calculator geometry

• Cylindrical blank, freely-defined blank, blank as allowance of finished-part contour
• Longitudinal / face / contour-parallel roughing on outside and inside
• Processing sloping contours (relief cuts)
• Consideration of tool's setting and plate angle
• Grooving any contours on outside, inside or end face
• Plunge turn any contours on outside, inside or end face
• Finishing with negative allowances (for machining electrodes)
• Roughing with feed interruption to reduce flow chips
• Optional number of cutting passes with orientation to workpiece edges
• Finishing with alternating cutting depth for longer tool life
• Arbitrary limitation to the machining segment with automatic blank actualization
Highlights
• Effective processing through orientation to the actually existing material
• Lower risk of accident and better chip disposal through feed interruption
• Reduced machining time through selectable cut segmentation
• Save on tool costs through finishing with alternating cutting depth

4.9 Residual material detection, segmental processing
4.9 Residual material detection, segmental processing
☑ TCU ☑ PCU 50 ☑ Option: Residual material detection

and machining
Identification of residual material

Contour regions which do not permit machining by tools with large plate angles are
automatically recognized in the stock removal cycle. The operator can rework these regions
using a suitable tool with a smaller plate angle.
Segmental processing
The contour stock removal cycle allows any segmentation of the desired machining region.
This enables individual segments to be processed with the technically suitable tools and
cutting values.
Application examples:
• Inside machining first with small tools, then with larger and more stable tools
• A degressive infeed avoids an overly high cutting pressure for small workpiece diameters
A variety of stock removal strategies may be used here, such as longitudinal turning, contour
grooving, plunge turning or any combination of these. The current machining procedure
automatically actualizes the blank contour for the following step, so that programming time is
kept to a minimum.
Highlights
• Detection of residual material: Time saving through avoiding idle cuts during residual
stock removal
• Segmentation: Limit the machining process to always apply the optimum tool and cutting
values

4.10 Contour slots, contour spigots
4.10 Contour slots, contour spigots

ShopTurn offers stock removal for processing contour slots and spigots on the end face and
outer surface. Up to 12 islands can be considered for each slot. The slot and island contours
can be entered with the contour calculator directly into the control.
The following operations are available:

• Emptying, edge / base finishing
• Direct or helical plunging
• Manual or automatic allocation
of plunging point
• Optional predrilling at plunging point
Highlight
• Also program and machine complex contour slots within a short time
4.11 Detection of residual material when milling
☑ TCU ☑ PCU 50 ☑ Option: Residual material detection

and machining
Contour regions which do not permit milling with large diameter tools are automatically
recognized in the contour slots cycle. The operator can rework these regions using a smaller
tool.
Highlight
• Shorter machining times through automatic detection of residual material

4.12 Path Milling Cycle
4.12 Path Milling Cycle

A path milling cycle is available for path machining of milling contours:

• Milling with or without radius
compensation
• Traversing in quarter circle, half circle or
straight
• Grooving on parallel walls of the outer
surface
Highlight
• Soft approach and retraction on any milling contour

DIN/ISO programming 5
5.1 DIN/ISO language
☑ TCU ☑ PCU 50 ☑ Basic configuration
The SINUMERIK 840D sI's CNC interpreter can also process complex CNC commands, in
addition to DIN66025 standard commands. The commands are presented in clearly readable
form.
The following commands are available:
• G Functions
G0, G1, G2, G71, etc.
• Language commands (extended G functions)
CIP, DIAMON, SOFT, BRISK, FFWON, etc.
• Frame operations (programmable work offsets)
The workpiece coordinate system can be shifted, scaled, mirrored or rotated with the
commands TRANS, SCALE, MIRROR, ROT.
• Arithmetic operations
Arithmetic operations are available to combine the variables:
– Arithmetic operations + - * / sin cos exp etc.
– Logical operations == <> >= etc.
• User data
The user can define his/her own variables by name and type.
• R parameters (calculation parameters)
100 predefined R parameters are available as arithmetic parameters (floating comma
format).
• System variables
System variables can be read / written in all programs. They enable access to zero
offsets, tool offsets, axis positions, measurement values, control conditions etc.
• Program control structures
BASIC-style language commands are available for flexible programming of the user
cycles: IF-ELSE-ENDIF, FOR, CASE etc.
Highlights
• Unbeatable range of language commands for flexible and time-optimzed part programs
• Better program overview via user variables in plaintext format

DIN/ISO programming
5.2 DIN/ISO editor / G code editor
5.2 DIN/ISO editor / G code editor
ShopTurn can accept direct input of DIN/ISO programs.

To this end, a line-oriented DIN/ISO editor is available.
The DIN/ISO editor enables one to directly enter or edit CNC language commands. Thereby,
the complete range of CNC functions are available for the most complex machining.
The following possibilities arise:
• Creation of DIN/ISO programs at the control
• Edit externally rendered DIN/ISO programs (ex.: CAD/CAM programs)
The following functions are included in the DIN/ISO editor:

• Contour calculator
• Tool selection directly from tool list
• Support screens for standard machining and measuring cycles
• "Copy", "Insert" and "Cut" key group
• "Find", "Replace" and "Replace All" character string
• Renumber program
• Direct execution from any NC program block (block search)
• Jump to program start and program end
Highlight
• Save time by programming with efficient DIN/ISO editor

DIN/ISO programming
5.3 Machining cycles
5.3 Machining cycles
Machining cycles for standard machining, turning, milling and drilling may be started from the
DIN/ISO editor. Input screens with dynamic help displays are available for the convenient
input of machining parameters.
The following machining cycles are available:

• Turning
Face turning, stock removal, groove, undercut (form A, B, C, D, E, F), thread cutting,
thread chaining
• Drilling
Centering, drilling, boring, reaming, deep-hole drilling, threading
• Position pattern
Line, circle, grid
• Milling
Face milling, elongated holes, circumferential slot, slot milling, path milling, engraving,
circular pockets and spigots, rectangular pockets and spigots, contour slot
Highlight
• Graphical support of cycles as an expansion of the highly flexible DIN/ISO programing

DIN/ISO programming
5.4 Contour calculator (DIN/ISO)
5.4 Contour calculator (DIN/ISO)
A contour calculator is available in the DIN/ISO editor.
The following contours may be generated with this geometry calculator:

• Contours for turning
• Contours for milling on the end face and outer surface
The contour calculator provides the following possibilities:
• Up to 250 geometry elements programmable
• Automatic calculation of unknown elements ("drawing dot to dot")
• Chamfer or radius programmable in contour transitions
• Open DIN/ISO input field (e.g. for element-based feedrates)
• Conversion of contours and position patterns in DXF format with CAD Reader for PC;
Highlights
• Easy input of workpiece geometry: Drawing dot to dot
• Determination of contours with many unknown intermediate values is possible
• Speedy and certain from drawing to finished workpiece

Setup functions 6
6.1 Measure workpiece
The workpiece can be measured as follows:

• Reference tool
Highlight
• Fast zero point definition by dialog

Setup functions
6.2 Zero/work offset
6.2 Zero/work offset
The following settable work offsets are available in ShopTurn:

• A basic offset
• Maximum of 99 work offsets
(G54, G55 ...)
• Each work offset with its own
fine offset
Highlight
• Flexible machining due to great number of settable work offsets
6.3 Measure tool
The tool compensation value can be directly

determined in the machine set-up.
The following variants are available:
• Touch chuck
• Determine lengths via reference diameter
• Tool measuring probe (tooleye) or
magnifier
Highlight
• Save time by determining the tool measurements directly in the machine

Setup functions
6.4 TSM universal cycle
6.4 TSM universal cycle
A universal cycle is available in the setup for the most commonly used machine functions:
• Tool change with direct access via the tool table (T)
• Spindle speed and direction (S)
• M functions (M)
• Activation of work offsets
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Highlight
• Take-over and change-in tools directly from the tool table
6.5 Positioning cycle
The machine axes can be positioned directly via input

screens in the setup:
• Linear axes / spindles
• Feedrate / rapid traverse
Highlight
• Simple axis positioning without manual input, directly over the dialog screen

Setup functions
6.6 Stock removal
6.6 Stock removal
Stock removal is conveniently available in

the set-up. Soft collet chucks can, for
example, be turned with this cycle.
The following parameters can be specified:
• Roughing or finishing
• Undercut for soft collet chucks
Highlight
• Preparation of workpiece or collet chuck without having to create a part program

Tool management 7
7.1 Tool table
Tools with their complete information may be managed in the tool list. The cutting plate
geometry is displayed to scale.
(The maximum number of tools is defined by the machine manufacturer.)
Tools are assigned to the desired turret positions with the load function. With the unload
function, you may remove tools from the turret but retain the tool data.
The following data can be stored for each tool:
• Tool type (rougher, finisher, engraver, drilling and milling tools ....)
• Tool name in plaintext (ex.: "ROUGHING_80")
• Max. of 9 cutting edges per tool
• Tool length and cutting plate geometry
• Nose angle for drills or number of teeth for milling tools
• Direction of spindle rotation and coolant (level 1 and 2)
Highlights
• All tool data at a glance
• Simple and secure handling via unmistakable tool names
• Take over tools directly from the list to the program

Tool management
7.2 Tool monitoring, sister tools
7.2 Tool monitoring, sister tools
ShopTurn offers efficient tool management for the activation of replacement tools.
• Monitor cutting time (T) or number of exchanges (C)
• Prewarning limit for timely preparation of new tools
• Automatic exchange of sister tools for automatic operation possible (duplo number DP)
Highlights
• Reduction of machine standstill times via tool monitoring
• Support of tool life monitoring or job time monitoring as standard

Program management, user memory 8
8.1 Program manager
The program manager supports plaintext file names up to 24 characters.
Part programs can be saved complete with set-up data like tool data and zero points.
Highlights
• Part programs can be created, retrieved and saved within a very short time
• User-friendly data handling in typical PC style with copying, pasting, renaming, etc.

Program management, user memory
8.2 User memory and data management
8.2.1 Buffered CNC work memory
☑ TCU ☑ PCU 50
SINUMERIK 840D sl Basic configuration: 3 MByte, expandable to

NCU 710 9 MByte
SINUMERIK 840D sl Basic configuration: 3 MByte, expandable to
NCU 720 and NCU 730 15 MByte
Highlight
• Exceptionally large storage space in basic configuration already
8.2.2 USB memory stick
☑ TCU ☑ PCU 50 ☑ Option: Only USB memory stick

required
A USB memory stick can be used on the front side of the operator panel.
User data stored on the PC can be quickly transferred to the
internal CNC memory. Execution from USB memory sticks is
not possible for security reasons. Instead, we offer a
CompactFlash Card solution.
Highlights
• User-friendly solution, as memory slot is located at front
• Extremely cost-efficient, as no software option required

8.2.3 CompactFlash card
☑ TCU ☑ PCU 50 ☑ Option: Additional 256MB user

memory
on the CompactFlash Card of the NCU
You can find a CompactFlash Card for the system software as standard in the SINUMERIK
840D sI control cabinet. An additional 256 MB may be used as additional user memory.
Executing the part program directly from the CompactFlash Card is possible. Furthermore,
Ethernet networking is recommended.
Highlight
• Efficient and reliable solution for handling a large volume of user data
8.2.4 Ethernet networking
☑ TCU ☑ PCU 50 ☑ Option: Manage network drives
Sinumerik 840D sI NCU comes ready for Ethernet as

standard (RJ45 connection). The data transfer rate is 10 /
100 Mbit/s.
Access to the network drive is available directly from the
ShopTurn program manager. No additional software is
required on the server.
Highlight
• Easy and economical connection via Ethernet (TCP/IP) to Windows PCs or Unix
workstations

8.2.5 Hard disk drive
☐ TCU ☑ PCU 50 ☑ Basic configuration
A hard disk with 12GB of user memory is available on the PCU 50 for expansion of the CNC
memory.
Highlights
• Hard disk can still be used as a data carrier
8.2.6 Disk drive
☑ TCU ☑ PCU 50 ☑ Option: Only a disk drive required
TCU and PCU 50 prepared for connection to

a USB disk drive as standard. Access to the
disk drive is available directly from the
ShopMill program manager.
Highlights
• Disk can still be used as a data carrier

Simulation 9
The simulation integrated in ShopTurn offers an optimal process reliability. This is

guaranteed as it is calculating with exactly the same tool geometry as for the actual
machining process.
The simulation can be controlled by start, stop and reset softkeys. For critical machining, the
simulation can be operated in single block mode. The current data for axis position,
machining block, tool and feedrate will be displayed.
The ShopTurn simulation allows the display of the following programs:
• DIN/ISO program, also with machining cycles
• Sequence program, counterspindle machining also included
The following displays are possible:
• 3-window view as standard
• Single block operation and start / stop possible at any time
• Simulation velocity adjustable with the feedrate override of the machine control panel
• The required machining time is automatically calculated and displayed in the simulation
☑ Option: 3D simulation of the finished part
• 3D volume model of the finished part with section planes and detailed view
3-window view volume model
Highlight
• Simulation as real assistance for programming and offer calculation

Complete machining 10
10.1 Counterspindle
☑ TCU ☑ PCU 50 ☑ Option: Synchronous spindle

☑ Option: Travel to fixed stop
The SINUMERIK 840D solution line enables the use of a fully-fledged counterspindle. The
main spindle and counterspindle can be operated under conditions of angular synchronism.
DIN/ISO programming
The commands for spindle synchronization and the axis movements for workpiece transfer
can be programmed as DIN/ISO language commands.
Machining step programming
A counterspindle cycle is conveniently available for spindle synchronization and axis
movements for workpiece transfer.
Highlights
• Simple and secure programming of all counterspindle functions
• High quality of workpieces by workpiece transfer in synchronous spindle mode

Complete machining
10.2 Counterspindle machining
10.2 Counterspindle machining

A control cycle for counterspindle machining is available in the work plan editor with the
following functions.
• Gripping
Gripping the workpiece with
counterspindle in synchronous mode
• Pulling
Pulling long workpieces with the
counterspindle
• Rear side
Machining the rear side of the workpiece
in the counterspindle.
The programming is the same as with
machining the main spindle. The Z axis
value is mirrored.
• Front
Switchover from counterspindle
machining to main spindle machining for
bar stock
• Complete
Gripping, pulling, threading and
counterspindle machining with bar stock
All main spindle machining steps are supported by the counterspindle.
Highlights
• Easy programming of complete machining process by dialog
• Security while programming the counterspindle machining via familiar cycle support; Z
axis value is mirrored

Complete machining
10.3 Additional components
10.3 Additional components
Control cycles and input screens for the DIN/ISO and machining step programming are
available for the following additional components: bar loaders, parts grippers and tailstocks.
The control cycles and input screens must be adjusted by the machine manufacturer to the
machine's actual conditions.
Highlight
• Simple programming of additional components

Complete machining
10.4 Front surface machining
10.4 Front surface machining
☑ TCU ☑ PCU 50 ☑ Option: TRANSMIT and peripheral

surface transformation
Drilling and milling can be performed on the front surface of workpieces in the main and
counterspindle with ShopTurn.
The part program is easily created in a right-angle coordinate system with the front surface
transformation TRANSMIT (C axis mode) .
The path movements are conducted with the linear
axes X / Z and the rotary axis C.
Machine without Y axis
• Machining with TRANSMIT
Machine with Y axis
• Machining with Y axis
• Machining with TRANSMIT
Highlights
• Full functional range for drilling and milling on the front surface
• Reduction of set-up times by complete machining on one machine

Complete machining
10.5 Peripheral surface machining
10.5 Peripheral surface machining
☑ TCU ☑ PCU 50 ☑ Option: TRANSMIT and peripheral

surface transformation
Drilling and milling can be performed on the outer surface of workpieces in the main and
counterspindle with ShopTurn and the outer surface transformation TRACYL.
Machine without Y axis
• Any drill holes on the outer surface
• Any milling without slot wall offset on the outer
surface
Machine with Y axis
• Any drill holes on the outer surface
• Any milling without slot wall offset on the outer
surface
• Any milling with slot wall offset on the outer
surface
• Grooving on parallel walls of the outer surface
with milling radius correction
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Highlights
• Full functional range for drilling and milling on the outer surface
• Reduction of set-up times by complete machining on one machine

In-process measuring 11
☑ TCU ☑ PCU 50 ☑ Option: Measuring cycles
Measuring cycles are available in the DIN/ISO editor for measuring tasks in automatic mode.
Input screens with dynamic help displays are used for convenient entry of the measuring
parameters.
The following measuring variants are available:

• Calibrate workpiece and tool measuring inputs
• Tool measurement with tool measuring input
• Single-point workpiece measurement with reversal
• Two-point workpiece measurement
The following measuring tasks can be made:
• Automatic value correction for tool geometry or work offset
• Display measurement results
• Log measurement results
Highlights
• Reliable quality of the manufactured parts by automatic measurement in the machine
• Easy adjustment via input displays with graphic support

PC software 12
12.1 CAD reader for PC
☑ TCU ☑ PCU 50 ☑ Option: CAD reader for PC
Contours and position patterns can be converted on the PC from DXF files into a format
understandable to the control with the software package "CAD Reader for PC". The contours
can be reworked in the contour calculator on the controller.
Highlight
• Time saving with conversion of contours and position patterns from DXF files
• Work preparation and training at the PC without occupying the machine
• Further editing at the controller using the contour calculator possible at any time

PC software
12.2 ShopTurn on PC, SinuTrain
12.2 ShopTurn on PC, SinuTrain
☑ TCU ☑ PCU 50 ☑ Option: SinuTrain ShopTurn
Controller-identical PC system for work

preparation and CNC training
• Full functional range of ShopTurn
• Networking of several student and trainer
units possible
Highlight
• PC software for training and work preparation without occupying the machine
12.3 ShopTurn for self-learning
☑ TCU ☑ PCU 50 ☑ Option: ShopTurn for self-learning
Multimedia introduction to turning technology with ShopTurn.

• Programming exercises with directed examples
Highlight
• Graphically supported instruction software for beginners

Automatic mode 13
13.1 Program control
Single block
Single block mode can be activated for startup of the program. For this purpose a program
stop occurs after each traversing block.
Work plan programs offer the alternative of halting processing after each plane infeed.
Program test
Programs can be checked before processing in a program test mode. The program is
executed to completion with stationary axes.
Program editing
In machine status STOP, the program can be edited directly at the location of the fault, e.g.
erroneous DIN/ISO blocks or falsely parameterized machining steps. After editing of the
program, the machining process can be directly continued (a block search is carried out for
machining step programs).
Repositioning to the contour
In machine status STOP, the machining axes can be moved to and away from the workpiece
surface during machining using the handwheel or the direction keys.
Highlights
• Secure startup of new part programs
• Continue machining quickly after interruptions

Automatic mode
13.2 Simultaneous recording
13.2 Simultaneous recording
☑ TCU ☑ PCU 50 ☑ Option: Simultaneous recording

(Simulation of the current machining)
The tool paths can be simultaneously recorded

on the control screen while machining.
• Workpiece graphics and views correspond to
the graphic simulation
• Color-coordinated differentiation of rapid
traverse and feedrate
Highlights
• Machining can also be monitored in a complex machine room
13.3 Block search

A block search may be performed in machine condition RESET, e.g. after a program
interruption or to search for a resume point. The program data will be readied so as all
relevant parameters (tool, zero offsets, M functions, etc.) are available upon continuation of
the program.
The following search variants are available:
• To the interruption point
• To any CNC block in a DIN/ISO program
• To any subroutine levels in DIN/ISO programs
• To any sequence in work plan programs
• To any position in the position patterns for the work plan programming
Highlights
• Time-saving and secure re-start at any program point, as no editing of the part program is
required
• Highlight: Direct continuation from an individual position of a position pattern during work
plan programming is possible, providing huge savings in time

Automatic mode
13.4 Basic block display
13.4 Basic block display
The individual traversing blocks are displayed as DIN/ISO commands during execution of
machining steps or machining cycles.
The basic block display guarantees an especially high process security while running-in
programs in single block mode.
Highlights
• Optimal control of the program execution, as well in complex sequences or machining
cycles, especially in single block mode

Velocity control 14
14.1 Jerk limitation
The control calculates a steady acceleration profile instead of jumps in acceleration. This
enables jerk-free velocity characteristics for the involved path axes. The jerk limitation can
also be directly activated in the part program with the »SOFT« NC language command.
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ZLWKMHUNOLPLWDWLRQ ZLWKRXWMHUNOLPLWDWLRQ
Highlights
• Longer machine lifespan through protection of the mechanical components
• Higher path accuracy through softer acceleration

Velocity control
14.2 Dynamic feedforward control
14.2 Dynamic feedforward control
Inaccuracies in the resulting workpiece contour due to following errors can practically be
eliminated using dynamic feedforward control FFWON. The result is excellent machining
precision even at high tool path feedrates. This is clarified with a circularity test on the
machine.
Example:
ZLWKRXWIHHGIRUZDUG ZLWKIHHGIRUZDUGFRQWURO
FRQWURO
$FWXDOJHQHUDWHG $FWXDOJHQHUDWHG
FRQWRXU FRQWRXU
3URJUDPPHGFRQWRXU 3URJUDPPHGFRQWRXU
Highlight
• Higher path accuracy through compensation of contouring errors

Integrated safety functions 15
15.1 SINUMERIK Safety Integrated
☑ TCU ☑ PCU 50 ☑ Option: Safety Integrated
SINUMERIK Safety Integrated provides integrated safety functions that support the
implementation of highly effective personnel and machine protection. The safety functions
comply with the requirements of Category 3 according to EU standard EN 954-1 and safety
integrated level SIL2 of IEC 61508. Consequently, important requirements for functional
safety can be easily and efficiently implemented. Secure monitoring of velocity and standstill
belong to the range of functionalities.
Highlights
• High level of flexibility: With Safety Integrated, setup with an open guard door is possible
• High level of security: Complete implementation of the safety functions in Category
3/SIL 2
• Increased availability: Absence of interference-susceptible electromechanical switching
elements

Option list for the SINUMERIK package 16
The basic options and their Siemens order numbers are listed in the following:
ShopTurn additional functions

Manual machine 6FC5800-0AP11-0YB0
Machining step programming 6FC5800-0AP04-0YB0
Residual material detection and machining 6FC5800-0AP13-0YB0
3D simulation of the finished part (volume 6FC5800-0AP20-0YB0
model)
Simultaneous recording (real-time simulation 6FC5800-0AP24-0YB0
of current machining)
Memory expansion and networking
CNC user memory in NCU expanded by 6FC5800-0AD00-0YB0
2 MB each 1)
Additional 256 MB user memory on the 6FC5800-0AP12-0YB0
CompactFlash Card of the NCU 1)
Network drive management via Ethernet 1) 6FC5800-0AP01-0YB0
Hard disk (PCU 50) instead of TCU 1), 2)
Diskette drive 1), 2)
CNC additional functions
TRANSMIT and peripheral surface 6FC5800-0AM27-0YB0
transformation when using driven tools 1)
Travel to fixed stop and synchronous spindle when using counterspindle 1), 2)
Turning, drilling and milling measuring 6FC5800-0AP28-0YB0
cycles for workpiece and tool measurement
1)
Safety Integrated 1), 2)

PC software
SinuTrain ShopTurn, without CAD Reader 6FC5463-0GA50-0AG0
(CD-ROM)
SinuTrain ShopTurn, with CAD Reader 6FC5463-0GA51-0AG0
(CD-ROM)
CAD Reader for PC (CD-ROM) 6FC5260-0AY00-0AG0
ShopTurn for self-learning (CD-ROM) 6FC5095-0AB00-0BG0
1) Notice: Commissioning expense required.
2) Please discuss with machine manufacturer.

Summary of unique selling points 17
The control and drive package which Siemens offers in the SINUMERIK 840D solution line
and ShopTurn has the following prominent characteristics.
Especially in comparison to European control providers:
• Increased productivity
– Blank contours with path optimization avoid idle cuts and reduce the machining time
for pre-formed parts, e.g. castings.
– Stock removal with orientation to workpiece edges instead of a uniform number of
cutting passes avoids an unfavorable minimum infeed and thereby raises the quality of
the workpiece.
– With the manual machine function, individual machining steps can be executed
without having to create a part program.
• Better result for workpieces
– Programmable jerk limiting and velocity feedforward control provide for a better
workpiece surface in conjunction with extremely dynamic drives.
– Reliable parts quality through in-process measuring with automatic correction of the
tool data or work offsets
• More flexibility with DIN/ISO programming
• Unbeatable command range with G codes, variables and HLL elements
And in further comparison to Asian control providers:

• User-friendlier interface
– Plaintext descriptions for part programs and tools offer greater transparency.
– Take-over or change-in tools directly from the tool list to the program.
– Machining step programming complete with specifications for the tool, feedrate and
spindle speed or cutting rate; no entries required in DIN/ISO
• Greater guarantee for the future via intelligent control functions
– Residual material detection and engraving cycle save time for programming and
machining.
– Chaining of machining steps avoids multiple entry of contours/pattern positions.
• PC software enabling the machine more time available for production
– Conversion of contours and position patterns in DXF format with CAD Reader for PC;
– Controller-identical PC software SinuTrain for training and work preparation

Index
( E
(Simulation of the current machining), 56 Engraving cycle, 22
Ethernet, 41
A
F
Additional components, 47
Application, 9 Feedforward control, 60
Arithmetic operations, 29 FlashCard, 41
Arithmetic parameters, 29 FRAMES, 29
Front surface machining, 48
B
G
Bar loader, 47
Basic block display, 57 G code editor, 30
Blank actualization, 26 G Functions, 29
Block search, 56 Graphical programming, 19
Broken-line graphics, 20
H
C Hard disk, 42
CAD Reader, 53
CNC memory, 40
CompactFlash card, 41 M
Contour calculator (DIN/ISO), 32
Machine spectrum, 9
Contour calculator (graphical programming), 24
Machining Cycles, 31
Contour slots, 27
Machining steps, 19
Contour spigots, 27
Measure tool, 34
Contour stock removal cycle, 25
Measure workpiece, 33
Control structures, 29
Measuring cycles, 51
Counterspindle machining, 46
N
D
Networking, 41
Detection of residual material when milling, 27
DIN/ISO editor, 30
DIN/ISO language, 29
DIN/ISO programming, 29, 30
O
Disk drive, 42 Operator panel equipment, 16
DXF converter, 53 Operator panel fronts, 12
DXF import, 24 Operator Panels, 12
Option list, 63

Index
P Standard machining steps, 22

Stock removal, 36
Parts gripper, 47
System variables, 29
Path milling cycle, 28
PC software, 53
PCU 50, 16
Peripheral surface machining, 49
T
Positioning cycle, 35 Tailstock, 47
Program control, 55 TCP/IP, 41
Program editing, 55 Thread-cutting, 23
Program manager, 39 Tool life monitoring, 38
Program test, 55 Tool management, 37
Programmable work offsets, 29 TRACYL, 49
Training CD, 54
TRANSMIT, 48
R TSM universal cycle, 35
Repair thread, 23
Replacement tools, 38
Repositioning to the contour, 55
U
Residual material detection turning, 26 Unique selling points, 65
User data, 29
User memory, 40
S
Safety Functions, 61
Safety Integrated, 61
V
Segmental processing, 26 Velocity control, 59
ShopTurn on PC, 54
Simultaneous recording, 56
Single block, 55 W
SINUMERIK 840D sl, 11
Work offsets, 34
SinuTrain, 54
Standard cycles, 31


Sinumerik 840D Solution Line Turning With Shopturn

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Preface

Integrated safety functions 15

Siemens AG Ⓟ 04/2007 Copyright © Siemens AG 2006.

Turning with ShopTurn

Turning with ShopTurn

6 Setup functions ........................................................................................................................................ 33

Turning with ShopTurn

14 Velocity control ........................................................................................................................................ 59

Turning with ShopTurn

1.2 Machine spectrum

Turning with ShopTurn

Turning with ShopTurn

2.2 Operator panel fronts

Turning with ShopTurn

Turning with ShopTurn

Turning with ShopTurn

Turning with ShopTurn

2.3 Operator panel equipment

Turning with ShopTurn

☑ TCU ☑ PCU 50 ☑ Option: Manual machine

The basic screen MANUAL is displayed

3.2 Simple workpiece machining in manual mode

Turning with ShopTurn

3.3 Complex machining in manual mode

Turning with ShopTurn

☑ TCU ☑ PCU 50 ☑ Option: Machining step programming

Turning with ShopTurn

4.2 Dynamic broken-line graphics

☑ TCU ☑ PCU 50 ☑ Basic configuration of

Turning with ShopTurn

4.3 Online help

☑ TCU ☑ PCU 50 ☑ Basic configuration of

Turning with ShopTurn

4.4 Standard machining steps

☑ TCU ☑ PCU 50 ☑ Basic configuration of

• Drilling and milling operations

Turning with ShopTurn

4.5 Example Thread-cutting

☑ TCU ☑ PCU 50 ☑ Basic configuration of

A threading cycle is available in the work plan editor:

The following parameters can be specified:

4.6 Example Repair thread

☑ TCU ☑ PCU 50 ☑ Basic configuration of

Turning with ShopTurn

4.7 Contour calculator (graphical programming)

☑ TCU ☑ PCU 50 ☑ Basic configuration of

The following contours may be generated with this geometry calculator:

Turning with ShopTurn

4.8 Contour stock removal cycle

☑ TCU ☑ PCU 50 ☑ Basic configuration of

• Processing any contour calculator geometry

Turning with ShopTurn

4.9 Residual material detection, segmental processing

☑ TCU ☑ PCU 50 ☑ Option: Residual material detection

Identification of residual material

Turning with ShopTurn

4.10 Contour slots, contour spigots

☑ TCU ☑ PCU 50 ☑ Basic configuration of

The following operations are available: