mot ion world CNC Innovations for the 21 st Century Sinumerik system platform The Magazine for CNC Automation Volume 8, Number 2, 2009

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1 mot ion world The Magazine for CNC Automation Volume 8, Number 2, 2009 Sinumerik system platform CNC Innovations for the 21 st Century

2 Contents motion world Siemens AG Handtmann Goratu Siemens offers a set of innovative hardware and software technologies for all CNC tasks Daimler makes models of car body parts with a perfect surface quality Goratu benefits from turnmilling with Sinumerik in the machining of large workpieces Page 4 Page 10 Page 24 p Title Integrated CNC platform 4 CNC Innovations for the 21 st Century Sinumerik system platform p Technology Milling 10 Perfectly Smooth Daimler AG, Germany 12 One for All Wincor Nixdorf AG, Germany 14 Improved Surface Quality in a Flash EiMa Maschinenbau GmbH, Germany Product lifecycle management 16 A Bridge Between Two Worlds CAD-CAM-CNC integration Energy efficiency 20 Delivered with Energy Savings Energy efficient drive technology Complete machining 22 Ideal for Delicate Parts Carl Benzinger GmbH, Germany Turn-milling 24 Innovative Machining Strategy Goratu Máquinas Herramienta, Spain p Service 26 News 27 Dialog, Imprint 2 motion world

3 Editorial Dear reader, Uwe Häberer Global Head of Machine Tools at Siemens The current economic crisis presents all of us with considerable challenges, particularly in the field of machine tool manufacturing. Companies need to come up with innovative ideas that can quickly tap into cost-saving potentials while simultaneously providing investment security. To significantly increase productivity with innovations, you simply have to have technological expertise. Another essential factor is a holistic view from the design and production of machine tools through to commissioning, sales and service. This is the only way to save time and money for the machine tool, and the parts produced on it and, as a result, increase productivity. This is where we can help by providing machine manufacturers and their customers with innovative products and solutions in 2009 especially. We see it as our main objective to anticipate, adopt and initiate technology trends for machine tools at an early stage. Consequently, we will be showcasing many innovations at this year s EMO, plus three key innovations: Sinumerik 828D the new powerhouse in the compact class Sinumerik MDynamics the all-in-one technology package for milling Sinumerik Operate the new integrated programming and operating interface These innovative products are complemented by solutions for both machine tool and workpiece lifecycle management and improving energy efficiency. Siemens provides energy-efficient machine equipment and services ranging from the infeed to the motor. Comprehensive energy management on the controller maximizes savings. Together with our colleagues from Siemens PL, we open new horizons in the CAM- CNC chain and offer continuity between the virtual world and the real world in terms of the planning and operation of machine tools and production. If you want to find out more, why not read this issue of motion world? We hope you enjoy it. Sincerely yours, motion world

4 Title Integrated CNC platform p Sinumerik system platform CNC Innovations for the 21 st Century The new Sinumerik 828D complements the unique, consistent Sinumerik CNC portfolio for every production-related task. 4 motion world

5 The financial crisis has left its mark on virtually all areas of the economy, and the machine tool market is no exception. The best opportunities for surviving the crisis relatively unscathed can be found in innovative concepts for the manufacturing industries including shopfloor production, tool- and mold-making, the aerospace sector, power engineering as well as the automotive industry and medical part production. All these industries share a common trait: They have to utilize new and innovative machine tools to implement forward-looking projects, be it for machining processes, such as milling, turning and grinding, or for forming and laser cutting. Automation and drive technology is crucial in all of these processes. Integrated technology for all machine tool applications Siemens AG The unique CNC portfolio unveiled at this year s EMO in Milan features impressive universality, robustness, openness, modularity, scalability and ease-ofoperation. Through integration into a continuous CAD-CAM-CNC chain, Sinumerik enables productivity gains right from product design and tool setup. Considerably shorter implementation times are another benefit, a great advantage especially with timeto-market becoming increasingly important in international competition. The core components of the Sinumerik platform are the CNC controllers. Machine manufacturers can choose from three categories entry-level, compact and premiums, so there is a matching Sinumerik machine tool control system for the specific requirements of the machine tool operator. All Sinumerik solutions are equipped with drives from the Sinamics S120 drive series and matching motors. Even the entry-level CNC control system, the Sinumerik 802D sl, provides all functions necessary for the main applications in three-axis turning, milling, nibbling and grinding. The open and flexible Sinumerik 840D sl CNC system represents the high- motion world

6 Title Integrated CNC platform performance or premium class of CNC systems from Siemens. It features a distributed, scalable, fully open and network-capable architecture. Its wide range of functions makes it suitable for use with virtually all kinds of technology, for up to 31 axes. The brand new Sinumerik 828D is positioned right between these two performance levels. With its compact, strong and simple design, it sets new standards in the compact category of CNC systems. The 828D has extremely small dimensions so it can be easily integrated into the most compact of machines without compromising usability and performance. 80-bit NANO fp precision enables maximum hardware performance and system functionality even in the compact CNC segment, thus allowing machine concepts with a degree of precision in the range of 0.1 μm. And high performance does not have to mean complexity; on the contrary, the new Sinumerik 828D is extremely simple, both to set-up and operate. Milling expertise Siemens has combined its wealth of milling expertise with powerful CNC hardware, intelligent CNC func- Compact, strong and simple Sinumerik 828D Siemens AG The new Sinumerik 828D is tailored to the requirements of sophisticated machine tools typically used in a modern job shop. The milling version is perfect for machining centers right up to machining operation with statically swiveled workpiece levels. Featuring Advanced Surface, an innovative method of controlling both path and speed, the Sinumerik 828D is also perfectly suited to machine challenging mold-making workpieces. The turning version is designed to meet the requirements of inclined-bed turning machines with a machining turret, and the range of functions even extends to machining with a Y-axis and counter spindle. An extensive CNC programming package makes the Sinumerik 828D perfectly ready for all global CNC consumption markets. During development, the key design requirements were compactness, optimum performance, extreme ease-of-use, and simple commissioning and service. Highlights: 3 Compact and robust control panel-based CNC in horizontal and vertical versions 3 Maintenance-free design without a hard disk, fan or buffer battery 3 Easy operation thanks to a high-resolution 10.4 color display and full QWERTY keyboard fp 3 Maximum machining accuracy with 80-bit NANO precision 3 Intelligent kinematic transformations for milling and drilling on the workpiece end- and lateral-faces, as well as in any swiveled level on milling machines 3 ShopMill/ShopTurn: extremely short programming time when manufacturing individual parts and small batches 3 programguide: extremely short machining time and maximum flexibility for large-scale production runs 6 motion world

7 tions and the unique CAD-CAM-CNC process chain to create Sinumerik MDynamics. The MDynamics technology package provides the latest technology-oriented milling solutions for both the Sinumerik 828D and the Sinumerik 840D sl. For the Sinumerik 840D sl, Sinumerik MDynamics is available in both a fiveaxis and three-axis version. The new, compact Sinumerik 828D CNC already includes a technology package for three axes. All versions feature Advanced Surface, an innovative function that enables users to achieve practically identical speed and contour profiles in milling free-formed surfaces. This results in extremely smooth workpiece surfaces and eliminates costly and time-consuming manual finishing work. Integration in operation and programming A further highlight of the Sinumerik 840D sl and Sinu merik 828D CNC control systems is Sinumerik Operate, the new, integrated operating and programming interface. Sinumerik Operate combines the existing user interfaces for shopfloor applications, HMI Advanced, ShopMill and ShopTurn into a single, inte Process information Production data Tool data Alarms Operator Set-up staff Service/ Maintenance GSM modem GSM network * # 0 Operator * # 0 Set-up staff * # 0 Service/ Maintenance Easy Message: a SIM card and a user profile with his mobile phone number is all the user needs to receive the production status of his machine via text message (SMS) With programguide, CNC programs can be generated quickly and easily including the integration of the technology cycles 3 Maximum compatibility thanks to an integrated online ISO dialect interpreter 3 Unique range of technology cycles from machining userdefined turning and milling contours with residual material detection right through to process measuring 3 Animated Elements: unique operating and programming support with moving image sequences 3 State-of-the-art data transfer via USB stick, Compact Flash (CF) card and factory network (Ethernet) 3 Easy Message: maximum machine availability owing to production status monitoring by text message (SMS) 3 Simple commissioning thanks to technology-specific system software with optimum pre-defined parameters 3 Easy Extend: simple retrofitting of optional machine components without the need for specialist CNC knowledge Together, these properties mean that the Sinumerik 828D is setting new standards in the category of compact CNC systems for the shopfloor. With Animated Elements, the user can keep precise track of the motion path motion world

8 Title Integrated CNC platform Without Advanced Surface (left) and with Advanced Surface (right): the difference is startling Advanced Surface produces surfaces that are as smooth as glass Sinumerik MDynamics milling expertise Sinumerik MDynamics is available in combination with the Sinumerik 840D sl NCU 710, 720 and 730 variants as a technology package for three-axis milling machines and a technology package for five-axis milling machines. The new Sinumerik 828D is available in a version that features integrated Sinumerik MDynamics software. The centerpiece of all versions is the new Advanced Surface intelligent path control. Highlights: 3 Optimized look ahead feature that ensures even greater speed and precision, enabling even higher surface quality 3 Optimized online compressor in the control system that guarantees exact contour accuracy and ensures optimized behavior for mixed CNC programs with G1 and G2/G3 commands New, intelligent jerk limitation feature that gently accelerates/brakes the axes with all dynamics, thereby protecting the machine s mechanics and lengthening its service life Torque pre-control system fitted to the new movement control system that responds according to acceleration. This ensures that the machining quality remains high or is improved even in critical production situations Automatic harmonization of the speed profiles on adjacent milling paths by the CNC, effective even in forward/backward line-by-line milling of contours and free-formed surfaces Conventional CNC, machining time: 48 mins with Advanced Surface, machining time: 33 mins Siemens AG Velocity Siemens AG 8 motion world

9 Additional innovative functions: 3 New tool and program management system for machine tool setup 3 New programming functions as well as ShopMill workstep programming, which make it even easier to program workpieces 3 Innovative technology cycles, such as the new integrated HighSpeed Setting Cycle832, designed for trochoidal milling or plunge milling, and the Cycle800 swivel cycle 3 Automatic measuring cycles, 3D simulation for programming and quotation costing support, plus efficient High-Speed Cutting (HSC) functions 3 Additional Compact Flash (CF) memory card for simple data and program handling 3 Spline interpolation and workpiece simulation for multilateral machining 3 Five-axis package: Cycle996 kinematic measurement cycle, 3D radius compensation and other advanced five-axis functions, such as integrated kinematics and Transformation Tool Center Point Programming (TRAORI) 3 Optional: Volumetric Compensation System (VCS) with the three-axis and five-axis technology package 3 The Milling specific system software version includes both the new Advanced Surface intelligent path control feature and also simple data and program handling thanks to an additional CF memory card. All other functions in the technological package for three-axis machining are available as options. grated HMI system with configurable functions, thus bringing together the entire suite of operating and programming functions. The modern Windows-style display is clearly laid out and intuitive in terms of operation, thereby guaranteeing absolute user-friendliness. ShopMill or ShopTurn workstep programming, Sinumerik high-level language with programguide or ISO code with cycle support whatever programming type the operator chooses, Sinumerik Operate offers unique advantages such as short programming, setup and machining times, maximum flexibility and ISO code compatibility. Unique system platform The new Sinumerik 828D from Siemens rounds off a unique, consistent system platform for machine tool automation, which can be used to implement costeffective solutions for all production-oriented industries. Sinumerik covers all production tasks, from made-to-order pieces to mass production, and from very simple parts to highly complex workpieces requiring a high degree of precision. p info NX CAM voucher Machine users purchasing the Sinumerik MDynamics technology package benefit from a complete, integrated CAD/CAM/CNC process chain with the NX CAM-Sinumerik Advantage Program software. Customers receive an NX CAM voucher with this program, entitling them to a free compatible NX CAM post-processor. This ensures perfect three- and five-axis machining from the blueprint to the finished part within the shortest time possible. motion world

10 Technology Milling p Daimler AG, Germany Perfectly Smooth Innovative High-Speed Cutting (HSC) functions on the Sinumerik 840D sl ensure high surface quality and improved economic efficiency. All Mercedes-Benz models are developed, tested and prepared for serial production at Daimler AG in Sindelfingen, Germany. The molds, models, dummies, prototypes, functional samples and wind tunnel models needed for this work are all produced on the shopfloor belonging to the Technical Molds, Rapid Prototyping, Rapid Tooling department. In order to meet the range of different requirements, such as the size of parts produced, the shopfloor operates several different machining centers. In a particularly challenging pilot project, Daimler used a five-axis Handtmann Gantry RS for HSC machining. The highlight of the machine is a Sinu merik 840D sl CNC equipped with the new Sinumerik MDynamics technology package for milling applications. Intelligent path control improves economic efficiency A key element of Sinumerik MDynamics is the new Advanced Surface path control feature. Achieving a good surface often depends on very precise coordination of all the production parameters in the 10 motion world

11 CAD/CAM system, the parts program and the machine data of the CNC. In the production of models and molds, the expenditure incurred by this coordination is fully included in unit costs. With Advanced Surface, this expenditure is completely eliminated as an innovative look-ahead capability, a new online compressor for NC data and harmonization of the speed profiles of adjacent milling paths, which works reliably even in line-by-line milling with alternating machining directions, all guarantee excellent surface quality even at high feed rates. According to the model and mold builders in Sindelfingen, these settings that are optimized just once in the post-processor. The CNC works fine with plastics, aluminum and CFRP, i.e. the machining quality is the same for all materials. This means that the machine dynamics is enhanced overall and can be focused on achieving maximum roughing-down performance, high-precision contour machining or optimum surface quality by activating the Cycle832 high-speed setting in the parts program. The efficiency of the business processes on the shopfloor is measured and monitored using the work orders stored in SAP and the number of parts delivered. In the Mercedes-Benz plant in Sindelfingen, models are milled for a broad range of body parts Handtmann Familiar operation In addition to this innovative functionality, operation of the new portal milling center also helps boost productivity. The machine operators confirm that the Handtmann machine and the Sinumerik CNC are very simple to operate: machine tool setup is supported by graphical tools with practical functions for measuring the tool and workpiece. In addition, the measuring cycles, such as Align Cavity, Bore and Level, speed up the process for setting or monitoring the zero point, thereby saving on setup time. The same measuring cycles can also be used to monitor the workpiece during the machining process. Versatile technological functions support the operator The Sinumerik 840D sl with its new technology package offers a particularly wide range of support tools for model and tool and mold making, for example in the form of simple data transfer via Ethernet, Compact Flash (CF) card or the USB port on the front panel from three-axis to five-axis machining. This means that even large-scale NC programs can be easily imported and processed directly by external data carriers. The machine operator is also supported by innovative cycles and milling strategies from the field of CAD/CAM, such as trochoidal milling of hard materials, plunge milling at high chip volumes (highperformance cutting or HPC), special cycles for multiaxis and/or multilateral machining and frames for implementing turned and swiveled coordinate systems. For the most accurate milling results, the cycle Measure Kinematics Cycle996 is used to control machine accuracy with this CNC. Cycle996 uses a measuring probe and measuring sphere to measure the entire kinematics of the rotational axes and, where applicable, to correct any erroneous axial vectors. The new machine also demonstrated that efficient production of models and molds is virtually unthinkable today without an integrated process chain from CAD-CAM level to CNC level. A CNC such as the Sinumerik 840D sl with Sinumerik MDynamics, which uses a single optimization procedure for all machining types and production tasks, offers decisive advantages in this respect. It ensures stable conditions at the end of the process chain, which greatly simplifies the work carried out in the CAM system, makes the results more reliable and maintains manufacturing productivity at a consistently high level. On the right path with the new Sinumerik After about six months of use in a full production environment, the Sindelfingen-based operators working with the Handtmann Gantry RS and the innovative functionality of the Sinumerik 840D sl feel very confident about the new technology. The standard CNC fulfills the requirements of the demanding model and mold-making process, and it offers the openness and flexibility required by modular tool making and special machinery construction. Together with Totally Integrated Automation, Safety Integrated and an integrated process chain, the solution yields very high benefits for machine tool makers and manufacturing companies alike. p info contact wolfgang.reichart@siemens.com motion world

12 Technology Milling p Wincor Nixdorf AG, Germany One for All The secret to the success of Wincor Nixdorf? Innovation and consistently optimized machinery with Sinumerik 840D sl. Wincor Nixdorf AG is of the world s leading and most successful providers of IT solutions for banks and commercial enterprises. Its clear commitment to innovation in all areas means that the company is also extremely well-equipped to cope with difficult economic periods. And as Michael Schönbeck, Head of Technology Lines, points out, the company uses only the best technology available. Over the past few years, he has restructured the tool shop, where 65 employees manufacture around 300 tools per year for in-house use. In addition, the company performs machining work for external customers and in return buys in the services of other mold manufacturers. This leads to a high degree of flexibility and optimum utilization. Uniform control architecture All pictures: Wincor Nixdorf Tool making at Wincor Nixdorf is focused on complex finish-machining. Prefabricated master dies are procured just-in-time and then have to be processed further with the same level of efficiency. More than 15 years ago, Schönbeck clearly saw that milling would become the most strategic production method in his tool shop. High-speed milling machines can be used to produce surfaces that only require a minimum of finishing work. So he asked himself: which control systems were capable of achieving the necessary speeds while also offering the functionality to process the required volumes of data? As Schönbeck explains, We used to deploy a variety of CNCs, so we were able compare different products objectively based on experience. And of course we also took a close look at the current and future generations of controllers at the time. Twelve years ago, the technology manager took the decision to equip a milling machine with Sinumerik 840D sl. He was extremely 12 motion world

13 pleased with the results and soon established a uniform control architecture throughout the entire tool shop, resulting in enormous benefits for the machine operators and logistics alike. The right machine tool for every task Standardization is an important goal for Wincor Nixdorf also in selecting machinery for the tool shop. Potential machine tool suppliers need to offer a wide range of products and provide a suitable solution for every machining task. The DMG Group, whose highquality HSC 75 linear machining center with direct drives is used in electrode production at Wincor Nixdorf, was selected to be the company s partner. After all, the best control system on the market is useless to us if the machine cannot achieve the required surface or is too slow, explains Schönbeck. He is delighted with both the machining times and the surface quality achieved on the graphite and copper electrodes. This machine virtually eliminates all finishing work, enabling us to achieve optimum productivity. Based on its positive experience with the HSC 75 linear, Wincor Nixdorf went on to purchase a larger, equally powerful machining center for its machining shop. The company opted for the HSC 105 linear from DMG, which is ideal for medium-sized five-axis parts. This machine has a very large working area in relation to its overall size, and not only does the fork head provide a high level of machining freedom, but the axes also achieve impressive acceleration and speeds. This is made possible among other things through the use of 1FN3 linear motors, which bring significant benefits in terms of precision, dynamics and acceleration. In order to provide optimum compensation for thermal influences and ensure clean swarf removal, Deckel Maho uses vibration-reducing material and intricately designed machine geometry. When working with short machining times, the interaction of linear motors, machine geometry and Sinumerik CNC ensures extremely high axis acceleration and speeds. gram, the more important these features are. For several years now, Siemens has provided an extremely user-friendly feature in the form of the Shop- Mill graphical user interface, which provides a quick and easy way of creating programs. Although this is only of limited importance at Wincor Nixdorf, where over 90 percent of the complex programs are created on external CAD/CAM workstations, it still provides valuable assistance to the machine operators: the setup and tool management functions it provides prove extremely useful when it comes to setting up workpiece setup. As Siemens consultant Ingo Bartsch says, Our interface software is intuitive and features graphical animations, making setup so simple that even untrained employees can pick it up within a few days. p The five-axis HSC 105 linear milling center with Sinumerik 840D sl is perfect for high-precision tasks and is also very easy to operate Powerful and user-friendly Michael Schönbeck is absolutely certain that the Sinu merik CNC makes a significant contribution to the results obtained; it is the fastest control system both in terms of batch processing and cycle times. Moreover, the configurable and programmable zero offsets known as frames are simple and flexible to set and can be transferred to the machine at the touch of a button. And the more elaborate the pro- info contact michael.pelz@siemens.com motion world

14 Rubrik Technology Unterrubrik Milling EiMa p EiMa Maschinenbau GmbH, Germany Improved Surface Quality in a Flash With Advanced Surface, it is no longer necessary to spend time adjusting machining parameters for piece production when making tools or molds. The surface quality of the workpiece is the most important quality feature in tool- and mold-making because it is immediately apparent. Up to now, however, detailed optimization of the machining parameters has been the only way to achieve a perfect surface; the parameters have to be adjusted for almost every single part in accordance with the requirements of the workpiece. Adjusting the milling parameters is a critical factor in terms of production planning costs and efficiency. If a part takes 3.5 hours to machine, the machine operator wants to be sure that the quality of the final product is exactly as required. After all, if he has to spend hours on polishing after the machining process, his previous cost calculations become void, emphasizes Markus Eisold, Managing Director of EiMa Maschinenbau. Perfect surface quality every time with Advanced Surface The Sinumerik MDynamics technology package with Advanced Surface addresses these issues. The new path control feature produces excellent surface qual- 14 motion world

15 ity even at higher feed speeds and without the need to optimize milling parameters for each individual part. Central to the success of this technology are the innovative Lookahead function and the NC data compressor, which has been revised and upgraded. Together, they ensure that neighboring milling paths have an identical speed profile, even during alternating line-by-line milling with different motion directions. The new Lookahead feature also minimizes position lag, guaranteeing high surface quality. The integrated jerk limitation feature and the COMPCAD online data compressor work together to ensure that the tool moves smoothly and fluidly. By centralizing ISO program data sets in splines, it is possible to guide the tool smoothly and continuously within the tolerance range, achieving a significant increase in contour accuracy at the edges. This all takes place without the need for the previously required expensive and time-consuming optimization. Innovative reference machine A Gamma T linear machine from the German-based company EiMa was among those selected as a pilot and reference machine for testing the path control. By this time, the company had further refined many of the features of the portal milling center, which made its debut at the EMO 2007 trade fair. For example, the addition of a gear rack drive has improved the rigidity and crash resistance of the Z axis, and the rigidity of the tool guide during 3+2-axis machining has also been further improved thanks to hydropneumatic fixed brakes in the five-axis head. In addition, higher-performance power units are now available for Sinumerik 840D sl CNCs, opening the door to a new generation of spindles. Some 24 kilowatts of power and speeds of up to 22,000 RPM also serve to improve processing performance for high-volume cutting applications. The new and convenient integrated Sinumerik user interface has also been installed in the machines as part of the pilot program for the new Sinumerik MDynamics technology package. The interface combines the best features of existing user interfaces in this CNC, including the integrated ShopMill functionality that has been expanded to support multi-channel machining, and builds on them with key features such as setup in JOG, simplified program data handling, convenient tool management, new innovative cycle technology and 3D simulation. compared with existing standard CNC functionality: A sample part was first machined using the old path control and without any further optimization of the milling parameters. The result demonstrated that, at critical points, there was room for improvement in terms of surface quality, contour accuracy and machining efficiency. The milling parameters were then optimized step-by-step in the CAD/CAM system, in the part program and in the CNC machine data until the required surface quality was achieved. We then activated the new path control, recalls Markus Eisold, and milled the workpiece for a third time, this time using the standard settings specified at the commissioning stage with the help of a sample part; in other words, without optimizing them to the With Advanced Surface and the new Sinumerik user interface, it s easier than before to apply our expertise and flexibility to tooland mold-making when constructing special machines. Markus Eisold, Managing Director of EiMa Maschinenbau GmbH individual part. The first try produced results that were better than, or at least as good as, individual optimization. The manager of the electrical department at EiMa, Jörg Diez, summarizes the results of the pilot project as follows: Machines like the Gamma T linear offer an increasingly interesting option for production of large-scale models and molds. The collaboration with Siemens in this area has therefore turned out to be really beneficial for us. It has allowed us as machine manufacturers to provide the best possible service to both special machine operators and tool- and mold-makers. We feel confident that with Siemens, we found the right partner, particularly in view of the new European machinery directive. p in a successful pilot program The performance improvements of the Sinumerik MDynamics technology package with the new Advanced Surface path control system are obvious when info contact peter.hofsaess@siemens.com motion world

16 Technology Product lifecycle management p CAD-CAM-CNC integration A Bridge Between Two Worlds The tight integration of the Sinumerik CNC product line, production networking, the postprocessor, the CAD/CAM environment and processing simulation ensures that no information is lost between the virtual world of process planning and the physical world of production operation. Publicis GmbH 16 motion world

17 The fundamental parts-manufacturing process involves two worlds: the virtual world of process planning (the design environment) and the physical world of production operation (the job shop). Until now, one hurdle on the way to increasing production efficiency was the fact that the virtual and physical worlds are normally only loosely connected. This creates a gap where knowledge and information obtained during programming in the CAM environment is often lost, while many functions in controller are not fully utilized because they are not addressed correctly by the programming system. Improvement of the CAM-CNC connection is therefore a key aspect in parts production. However, in order to achieve optimum interaction between the CAM environment and production, the systems involved need to be able to understand one another; that is, information from the one world needs to be available in the other in a form that can be understood by the programmer or worker and, in particular, the information must be preserved during the transition from the CAM environment to the shopfloor. Continuous information chain from product design to manufacturing Siemens is the only manufacturer able to offer a complete solution for the virtual and physical worlds of CNC production thanks to the combination of a powerful CAM environment NX CAM and an ultramodern NC system Sinumerik. Users benefit from the tight integration of expertise in the fields of both NC and CAM technology. For example, Siemens supports the programming of specific machining operations with best practice libraries, which already contain typical features as self-contained, optimized production operations. This ensures that the CAM software knows that a certain workpiece with freeformed surfaces can only be processed on a tool for simultaneous five-axis machining and therefore prepares the correct tools and milling strategies. Validation and optimization with control-based simulation Processing simulation plays a key role within CAM- CNC integration. The Siemens package provides a solution that enables a realistic simulation of the NC program and allows it to use complex Sinumerik functions, e.g. special processing cycles, to optimum effect. Following program creation, the program in the post-processor is converted into the relevant control format in NX CAM. Version 6 of NX CAM now contains special post-processor templates for the Sinumerik CNC. The programmer can enter parameters for the control directly in special dialog areas within NX CAM. These parameters are then automatically converted into the corresponding Sinumerik cycle and are preserved in the post-processor run. The corresponding Sinumerik parameters are correctly preset generally through best practice templates in corresponding libraries. This means, for example, that at the start of programming, the programmer can call up a special configuration for a machine in which the required parameters are already set, enabling him to focus solely on the programming of tool paths. In order to verify the final NC program in the Sinumerik dialect, Siemens has developed a virtual machine, both in NX CAM and in Tecnomatix RealNC, that can be used during production planning or on the shopfloor. This machine tool simulator is a digital fingerprint of the actual machine: the virtual NC kernel (VNCK) is tuned using the real machine tool s control parameters to make sure that the real and CAM/CNC integration: the benefits The close integration between the preparation of the NC programs in NX CAM and the use of these programs in the Sinumerik CNC system on the workshops leads to: Safe production start-up Improved machine utilization Quicker production start Standardization of the production materials Optimization of the production methods Compliance with product quality targets thanks to: A validated machining process using control-based simulation Improved tool path processing Optimized NX CAM performance that makes full use of the enhanced capabilities of the Sinumerik control systems motion world

18 Technology Product lifecycle management Demonstration in the Technology Application Center Siemens is hosting live demonstrations of the integration of the CAD-CAM and CNC environments for interested customers within the actual production environment at the new Technology and Application Center (TAC) in Erlangen, Germany. This will give visitors to the TAC direct insight into the interaction between NX CAD/CAM and the functions of the Sinumerik control system using real-world examples. Siemens AG virtual machines behave identically in terms of operation, dynamics, warning and error display. Optimized programming for Sinumerik Two aspects in particular are relevant for making optimum use of Sinumerik capabilities: programming of tool path processing and programming of the advanced functions of Sinumerik. In order to program the tool paths in NX CAM in such a way that they are automatically optimized, a CAM system is used that knows the geometric tool path data required and can distribute the points to suit the precise requirements of the CNC control system. One example: by synchronizing the data points in adjacent paths, the speed of the subsequent machining in the CNC control system can be controlled more evenly and the feed can be optimized. This increases the machining speed as well as improves surface quality. A further increase in efficiency in terms of quality and processing time can be achieved if the powerful Sinumerik control system functions are used consistently by the CAM system. Programming is essentially made up of the workpiece geometry, the machining step, the material of the part and the tool. This information is recorded in the NX CAM processing plan and is now used, for example, to set the correct High-Speed Cutting (HSC) technology parameters on the Sinumerik CNC. Using the highspeed cutting cycle CYCLE832, tolerance bands can be defined for machining, and functions such as smoothing, NC record compressor, pilot control or jerk limitation can be activated and deactivated independently of the processing step. Similarly, it is possible to activate the correct control parameters for rough machining, rough/smooth machining or smoothing. This establishes a balance between the different requirements precision, machining speed and surface quality for each machining step. As Sinumerik users on the shopfloor are familiar with these cycles, they can easily identify them in the Sinumerik HMI. They can understand sub-programs more easily as the system presents them with a clear overview of cycle commands rather than a vast array of machine-oriented G-code data. If required, the cycle parameters can also be adapted more easily to the control systems on the shopfloor. There is also the option to transfer information that the worker has changed back to the PLM process. This increases both the knowledge base in production planning and efficiency. p info contact torsten.beste@siemens.com jochen.bretschneider@siemens.com 18 motion world

19 Smoother transition from planning to production The integration of production planning and actual production not only affects the actual production information. If you look at the complete parts production process, typically there are a number of special technologies used in each step. These systems or software applications are not integrated into a common information platform. As a result, just answering the most basic of questions, such as Am I using the latest version of the parts program? Has the parts file been changed? Is this the right tool list? wastes considerable amounts of time. Siemens has now developed a solution that links the existing solutions for parts production planning and data management NX CAM and Teamcenter with the information management software for the shopfloor from the Sinumerik Manufacturing Excellence portfolio. This means that all the information used throughout the entire process can be synchronized from the definition and validation of the production plan right through to the use of this plan in the production process. Data along the entire parts production process is managed and organized uniformly in Teamcenter: for the part/product concerned, the production processes used, required resources and machines, system-specific or location information concerning the factory. This enables the user to significantly reduce the number of inefficient processes and potential errors. All of the information in one system In Teamcenter, all of the information concerning the parts production process is managed in a uniform way and is made available on the shopfloor. This includes: Integrated CAM data and resource management Integrated resource manager and tool inventory MCIS TDI tool management for the management and usage of tools NC program management with MCIS DNC MCIS DNC NC program management and transmission info contact matthias.doepfner@siemens.com NX TEAMCENTER MCIS TDI MCIS DNC CAD-CAM - NC programming Resource Management Part Planner Tool Management i.e. Receive Tool list, Tool Balancing NC-Program Management i.e. Receive NC Programs TEAMCENTER Tool Setup CNC Machine Tool motion world

20 Technology Energy efficiency IDENTIFY p Energy efficient drive technology INTERPRET AND DEFINE POTENTIAL Delivered with Energy Savings Siemens solutions for machine tools are designed with energy efficiency in mind. ENERGY EFFICIENCY CONSULTING DECIDE AND IMPLEMENT Energy efficiency is becoming an increasingly hot topic in the field of machine tool manufacturing and operation. Wasting energy not only costs money, but can cause thermal problems in the control cabinet and on the machine ultimately impacting productivity and precision. To save energy, we need to start at the machine itself. Measures to enhance efficiency here include dynamic optimization of the mechanics and drive technology assemblies and consumption-based optimization of the moving masses. Within any work cycle, there are enormous differences in the amount of electrical energy required during individual stages of the process, for example between machining times and non-productive times such as rapid feed or tool changeover. During rapid feed, the drives need to accelerate and brake sharply, with the result that power consumption during this phase is between one- and five-times higher than during actual machining. Striking an intelligent balance between speed and productivity in this phase can significantly cut power requirements. Drives need power The drive components have a massive impact on the overall power consumption of a machine. Electrical drive technology with intelligent, productive control algorithms and high efficiency ratings can play a key role in keeping energy costs to a minimum throughout the lifecycle of a machine. Furthermore, all types of infeeds for the Sinamics S120 drive system are available with an energy recovery feature, whereby the energy released during braking is fed back into the network for use by other electrical equipment. Another feature that helps improve overall machine energy efficiency is reactive power compensation. Sinamics infeeds with Active Line Modules (ALF) au- 20 motion world

21 tomatically compensate for the reactive power required by the line filter, thereby ensuring that no phase shift occurs between voltage and current. In the best-case scenario, this completely eliminates all additional costs for separate compensation systems. For maximum energy efficiency, the dimensions of the infeed/recovery unit and/or the braking resistors need to be tailored as closely as possible to the system concept. This is where dynamic energy management sets in: it acts on the acceleration/braking ramp and the torque set-point of the selected drives to ensure that the intermediate circuit values, voltage and maximum power remain within permitted values. This represents a safe way of harmonizing the infeed, recovery and braking modules with the machine and ensuring they are no larger than necessary. The application of this technology for emergency retraction and mains failure offers particular potential for machine tools. Siemens is available to offer customers all the support and guidance they need in designing such systems. New motors Main drives for belt-driven and coupled machine tool spindles The new 1PH8 motors are available in both synchronous and asynchronous versions. These motors boast impressive dynamics, minimal torque oscillations and high vibration quality, thereby enhancing the precision and productivity of machine tool spindles. Frequency converters and energy-efficient motors pay off Ancillary components on machine tools such as chip conveyors, pumps and compressors account for more than 50% of a machine s base load in standby mode alone. This high level consumption is due to the fact that many of the drives are uncontrolled, fixed-speed drives. Using frequency converters rather than conventional control methods can yield savings of up to 50%. No energy efficiency concept would be complete without energy-efficient motors. Turbo machines are a case in point: as these machines need to be run at a constant maximum speed at all times i.e. more than 2000 operating hours per year use of energy-saving motors in efficiency class EFF1 can result in massive savings in terms of energy and electricity costs. New linear motor The new 1FN6 linear motor features a magnet-free secondary section. The primary section is equipped with internal coils and magnets, is self-cooling and features separate plug connectors for pre-assembled signal and power cables. Intelligent approach to power Whether it be intelligent infeed technologies, use of frequency converters in ancillary components or energy-saving motors, energy-efficient automation and drive technology can provide a return on investment within a short period of time, significantly cut energy costs and, in turn, reduce unit costs, too. An effective energy management concept is also important. Simply keeping a record of individual power flows is not enough, as this will save neither power nor money. Companies need to identify and evaluate potential savings and then use this information to introduce energy-saving measures. Only by investing in energy-efficient machine tool automation systems will they then be able to minimize lifecycle costs and total cost of ownership. p info contact jochen.bretschneider@siemens.com High-inertia version for servomotors The proven 1FK7 servomotor series now has a new addition in the form of a high-inertia version. The higher intrinsic inertia on these versions results in an extremely robust control response, making them particularly suitable for applications with high and/or variable inertia loads. In conjunction with Sinumerik CNC, high-inertia motors can achieve outstanding contour precision without the time-consuming process of adapting the controller to the machine. All pictures: Siemens AG motion world

22 Technology Complete machining p Carl Benzinger GmbH, Germany Ideal for Delicate Parts Complete machining of parts for jewelry, medical products and the automotive industry using precision machines and Sinumerik 840D sl for top quality and maximum productivity. Manual work has largely disappeared from the jewelry sector nowadays high-tech machines are used to produce freely formed surfaces with a mirror finish and fit pieces with tiny diamonds. The requirements placed on the machine manufacturers are correspondingly high. Carl Benzinger GmbH of Pforzheim, Germany, makes precision machines that are accurate to less than a micrometer in terms of surface quality, roundness and positioning. The machines are used by all major companies in the watch and jewelry industry, as well as in other demanding sectors such as medical and dental part production, automotive technology, and the fittings and the aerospace industries. Customer proximity defines machine development The company with a staff of 140 people bases its success on its proximity to the customer. Benzinger offers a complete concept that includes process automation with robot and application technology, along with services such as After-Sales. In terms of the machines, the company sets great store by user-oriented development, as well as cost-effective production of high-precision workpieces from a batch size of 1 through to medium-sized series of around 5,000 units. The Take 5 combined turning/milling center fulfills these requirements effectively. The structure and arrangement of the axes on this machine series results in a particularly compact design, which requires about 50 percent less space than comparable turning/milling centers. The kinematics also has a positive effect on the machine s precision. As our customers often require simultaneous complete machining of complex components, we equipped the Take 5 with an additional milling spindle, explains electrical engineering manager Wolfgang Wiedemann. Sophisticated multi-channel technology for turning/milling concepts To ensure reliable control of the various axes and machining technologies, the Baden-based precision machine manufacturer is not prepared to accept any compromises when it comes to CNC technology. Several comparisons and tests revealed that the Sinumerik 840D sl is best suited to the turning/ milling concept on the Take 5. It is proficient in every machining technology, can control up to 31 axes, and has ten channels as standard. This is confirmed by Wiedemann, who reports that, The sophisticated multi-channel technology creates the perfect conditions for clear program structures, thus enabling simple programming for different technologies. The Take 5 uses five of these channels: turning on the main spindle, turning on the counter-spindle, milling, tool change and turning with the milling spindle. This enables milling and turning to be carried out simultaneously in different part programs. If necessary, a turning tool can also be fitted and clamped to the milling spindle so that various turning operations can then be carried out on the main and counter-spindles. Our customers can carry out all of these functions flexibly with the Sinumerik CNC. Many other control system manufacturers would have problems, adds Wiedemann. Moreover, with the Sinumerik 840D sl, it is possible to carry out turning and milling operations alternately in the same channel. As Siemens consultant Klaus Steinbrücker explains: Alternatively, the tool holder can be used sequentially across channels i.e. from different programs. This means that all necessary transformations can be used, such as Transmit for front milling, cylinder barrel transformation for surface-area milling, and five-axis milling with dynamic orientation of the milling tool on the workpiece. 22 motion world

23 All pictures: Benzinger We can perform all of the functions on our turning/milling center with the Sinumerik CNC. Many other control system manufacturers would have to use several control systems to achieve the same result. Wolfgang Wiedemann, electrical engineering manager Simple, safe operation The combined turning/milling center with two rotating spindles and a milling spindle is perfectly suited to simultaneous, complete machining of complex components In practice, the Take 5 s complex milling and turning programs are set-up for the most part at external workstations and transferred to the CNC via a network or USB stick. For simple programs and machine setup, users use the standard, clear control console, which is fixed to a dual-joint support arm and can be swiveled. Thanks to the user interfaces with cyclesupported screens, even technicians with little programming experience can get to grips with the system within the space of just a few days. If anything is unclear, an electronic wizard can be activated by means of the Help key to provide specific information. To ensure safe setup for the users, the Benzinger developers use the Safety Integrated function integrated in the Sinumerik 840D sl. This safety function provides reliable protection for the user, without the need for wiring mechanical and electronic circuit breakers. A further advantage is, for example, that if such a machine tool is fitted with a robot later on, it can be adapted quickly and easily. In just a few minutes, the user can create a part program that allows work to be carried out with the guard door open, that takes into account all necessary safety regulations, and that provides reliable protection against collisions. This saves on hardware, time and ultimately, costs. p info contact hubert.leibbrand@siemens.com motion world

24 Technology Turn-milling p Goratu Máquinas Herramienta, Spain Innovative Machining Strategy Machine tool manufacturer equips new multi-functional series for milling and turning with Sinumerik 840D sl control systems. Siemens AG Goratu Máquinas Herramienta, S.A. manufactures a complete range of CNC milling machines and CNC lathes under the Lagun and Geminis brand names. With almost 200 employees, the company is one of the largest Spanish machine tool builders and maintains global subsidiaries for sales and services. The wide product range responds to the needs of different industrial sectors addressed by the company, such as power generation (windmill shafts), aerospace, iron and steel, petrochemical, railway, and ship-building. Combined technologies in single machine tools With several thousand units installed globally, the company has long-standing experience in designing, engineering and manufacturing machine tools. Their newly-developed, multi-functional devices improve customer productivity in the manufacture of largesize components in different shapes, high quality and short time. Therefore turning and milling technologies are combined into one unique machine. Such a unit allows the machining processes without the reclamping of workpieces. Doing everything in one clamping, that is, turning, milling and drilling, saves both on machines and alignment, including set-up steps, thus reducing resulting errors and time spent. Basing on the two common manufacturing lines, Geminis for turning and Lagun for milling, Goratu offers a wide range of choices. Lagun CNC bed mills has been extended to customize the solutions according to individual production needs. For example, the GMM travelling column milling machines and the GCM travelling column milling machines with fixed tables that are giving increased capacities. For heavier or larger workpieces, milling offers a solid table, allowing component weights up to 3.5 ton/m². Powerful programming features To provide customers not only high quality machines with flexible milling and turning functionalities, but also with state-of-the-art control systems, the tool manufacturer decided to equip the new multifunctional machining centers with Sinumerik 840D sl. It provides functionality for the most varied technologies and make it as simple as possible to use and control complete machining on turn-milling machines. According to the Goratu management, Siemens controls are not only user-friendly, but they also offer powerful and versatile programming features. To get the best out of it, the company s training academy offers courses for new and advanced Sinumerik operators. Goratu s machines are modular in design and specifically developed to perform a full range of machining operations in a single setup, on a wide variety of materials. On the one hand, the latest developments on floor-type moving-column milling machines and on the other heavy CNC horizontal lathes, both in combination with Sinumerik controls. The machining centers demonstrate state-of-the-art technology for the processing of complex workpieces. Virtually unlimited capacity is combined with the ability to manage large parts profitably, delivering the versatility and flexibility for large part machining. p info contact klaus-juergen.birk@siemens.com 24 motion world

25 Functionality for turn-milling in all its variations With Sinumerik 840D sl, customers gain a variety of significant benefits, such as: 3 Multi-functionality with optional function packages for the Sinumerik 840D sl controller: users can configure solutions for almost any machining task in turning, milling, drilling, circular milling, turn-milling, crankpin milling, B-axis turning and five-axis machining with functions such as orientation interpolation, slotting, gear hobbing, curve table interpolation and cam milling. 3 Flexible programming for optimum processes in turn-milling (and other technologies): flexible and optimized processes can be achieved through synchronized motion actions that can be initiated synchronously with axis and spindle motions. Up to 256 such synchronized actions can be defined per part program. 3 Simple operation with advanced HMI functions: in addition to standardized or user-generated screen forms and help graphics, Sinumerik 840D sl offers further HMI functions that make complex machining processes more transparent and therefore more easily controllable. 3 Specific post-processors enable users to use the extensive possibilities of the multi-functional Sinumerik 840D sl fully and efficiently during turn-milling. 3 Safe retraction in case of error: with the drive-independent function extended drive stop and retract (ESR), Sinumerik offers a flexible response to various sources of error. Safe retraction is enabled by defined, time-delayed stopping, and by tool retraction from the machining plane into a position where it is protected from collision. 3 High precision for reliable production processes: innovative control/drive functions such as dynamic stiffness control (DSC), active vibration damping/advanced position control (APC) and auto servo tuning (AST) help achieve high precision and the greatest possible dimensional and geometrical accuracy during turn-milling. 3 Safety is ensured with a package of safety functions that are integrated into the control/drive system. This integration enables very short response times. Communication with the process is performed directly using safety-related input/output signals. 3 Virtual machining and prior simulation of machining tasks is recommended to achieve the greatest process certainty before the start of production with turn-milling. For these tasks, the Sinumerik virtual NC kernel (VNCK) solution can be integrated into simulation systems. For turn-milling of large workpieces, Goratu has developed the multi-tasking machining centers which are equipped with latest Sinumerik technology Goratu motion world

26 News Sinorix al-deco STD fire protection system at the TAC Fire-safe Machine Tools The potential fire risk of machine tools should be a serious concern. In many cases, a fire breakout would not just affect the machine itself, but it could also spread throughout the entire production facility. The intelligent Sinorix al-deco STD object protection system has now been installed on a turning machine at the Technology and Application Center (TAC) in Erlangen, Germany and can be used for live demonstrations. The key component of the fire extinguishing system is a tubular, patented linear fire sensor called Lifdes (Linear fire detection source), which is subject to a permanent pressure of approximately 15 bar and bursts as soon as its ambient temperature exceeds 110 C. The fire protection system does not require an external energy source to detect or extinguish the fire as both processes are pneumatic. The systems are highly resistant to all kinds of technical disturbances, resulting in negligible risk of false activation. The Sinorix system measures the volume of extinguishing agent online and monitors the pressure in the detection line, the operating status and the status of the network. All functions are displayed visually and acoustically via the interface, and there is a backup battery to ensure continuity of the interface functions in the event of a power failure. In addition, all safety-related and operating data is auto matically logged to a memory on a long-term basis and can be read via a USB interface. This enables clear statements to be made in the event of liability disputes. Siemens AG New manual for five-axis machining Milling with Sinumerik The Sinumerik 840D sl CNC offers a broad range of functions specifically for five-axis machining. The new manual on five-axis machining provides programmers and machine operators with an overview of all important control functions, how to use them effectively and requirements for the CAD/CAM environment. The topics covered by the manual include an explanation of the basic terminology and requirements of five-axis machining, a description of the fundamental Sinumerik control functions, such as measuring and tool and workpiece, as well as an overview of the higher-level control functions that should also be taken into consideration with regard to the CAM system s post-processor. The manual then concludes with industry-specific chapters on aerospace, structural components, engine and turbine components and complex free-formed surfaces all explained in detail with graphical and practical examples. A manual on tool- and mold-making with basic information on multi-axis machining is also available. This manual is particularly useful for three-axis machining and also serves as a basis for five-axis machining motion world

27 Dialog infos Do you want to find out more about automation and drive technology from Siemens Industry? Then find the contact person in charge for you: or visit us on the web: You will also find up-to-date newsletters as a free subscription; for example the Totally Integrated Automation Newsletter. Simply register your address at: service My Library Quick and Flexible to Configure Version 2.0 of the popular My Documentation Manager software application contains an innovative feature with enhanced usability for all Motion Control users: machine manufacturers and end-customers can not only compile customized technical documentation for a specific product or system on the Internet, but also create complete libraries with individually tailored content. These customized compilations can then be saved in RTF, PDF or XML format. As before, the creator of the compilation will be automatically notified if changes are made to the source documentation used. This notification can be included in the library. online Point your web browser to: and download the latest issue as a PDF file. The elec tro nic archive enables access to all previous issues. You can also send suggestions and comments about the overall issue and the individual articles by . You must be registered as a user before you can benefit from My Documentation Manager. This is a quick and easy process: simply complete the online registration form, submit it and you are ready to go. Imprint: motion world Publisher Siemens Aktiengesellschaft, Gleiwitzer Str. 555, Nuremberg, Germany Division Drive Technologies CEO Klaus Helmrich Editorial Responsibility in Accordance with the German Press Law Gerhard Bauer Responsible for Technical Contents Bernd Heuchemer Concept Christian Leifels Editorial committee Ivonne Luthardt Publishing House Publicis KommunikationsAgentur GmbH, GWA Corporate Publishing M1 P.O. Box 32 40, Erlangen, Germany Tel.: +49 (0) / Fax: +49 (0) / publishing-magazines@publicis-erlangen.de Editorial staff: Gabriele Stadlbauer Layout: Jürgen Streitenberger, Bettina Raunecker Copy editors: Sabine Zingelmann Job number: DTP: der Döss für Kommunikation, Nuremberg, Germany Printed by: Wünsch, Neumarkt, Germany Circulation: 10, by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher. This edition was printed on environmentallyfriendly chlorine-free paper. The following products are registered trademarks of Siemens AG: DriveCliq, MOBY, S7-300, ShopTurn, SIMATIC, SINAMICS, SINUMERIK, SINUMERIK 840, SINUTRAIN, SITRAIN, TOTALLY INTEGRATED AUTOMATION Wenn Markenzeichen, Handelsnamen, technische Lösungen oder dergleichen nicht besonders erwähnt sind, bedeutet dies nicht, dass sie keinen Schutz genießen. The information provided in this magazine contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. Order number: E20001-MC209-B100-X-7600 Printed in Germany motion world

28 SINUMERIK 828D for the shopfloor 1960 The firs t CNC-C integrated safety solut io n The world s first numerical control for the first time with CNC SINUMERIK Compact, strong and simple in the class of the compact CNC systems, the SINUMERIK 828D sets new standards with regard to ruggedness, performance and ease of operation. It is therefore ideally suitable for the use in the shopfloor environment, where it opens up unique options for higher productivity in the machining of turned and milled workpieces. Answers for industry.