working with ootb mach simulation examples

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DOCUMENTATIONABOUTTHEMACHSIMULATIONCONTENTNX9

1 Highlights - new with NX9 ....................................................................................................... 32 Overview ................................................................................................................................. 33 Load Options .......................................................................................................................... 34 CAM-Setup ............................................................................................................................. 45 MCS-Handling (Best practice for the OOTB examples) .......................................................... 5

5.1 General settings and rules .............................................................................................................................. 55.2 Special rules and settings for Mill-Turn machine tools. .................................................................................. 65.3 Library machine tool specific handling ............................................................................................................ 7

6 About Post Processors ........................................................................................................... 76.1 General supported features of the OOTB Posts ............................................................................................. 76.2 Creating file with tool and offset data .............................................................................................................. 86.3 MOM variable for MCS handling ..................................................................................................................... 96.4 Differences between pure template posts and OOTB posts (Sinumerik) ................................................... 106.5 About UDEs and OOTB ................................................................................................................................ 106.6 Post output for Coolant (Sinumerik, TNC, Fanuc) ........................................................................................ 106.7 About Special handling for 5 axis motions with Fanuc for table machine tool configuration ........................ 10

7 About CAM Programming ..................................................................................................... 118 Using the library tools ........................................................................................................... 129 About CSE Simulation Drivers .............................................................................................. 12

9.1 Handling of Offsets: ...................................................................................................................................... 129.2 Handling of the tool change .......................................................................................................................... 139.3 Handling the reference point (Fanuc) ........................................................................................................... 149.4 Handling of tool correction data .................................................................................................................... 14

10 About Sinumerik Cycles in the content ................................................................................. 1511 About swiveling cycles .......................................................................................................... 15

11.1 Swiveling on Heidenhain .............................................................................................................................. 1611.2 Swiveling in Sinumerik - CYCLE800 ............................................................................................................. 1711.3 Swiveling in Fanuc - G68.2 ........................................................................................................................... 18

12 Example specific considerations ........................................................................................... 1812.1 SIM01: ........................................................................................................................................................... 1812.2 SIM03: ........................................................................................................................................................... 1812.3 SIM05: ........................................................................................................................................................... 1912.4 SIM10: ........................................................................................................................................................... 2012.5 SIM11 SIM13 - Fanuc: ............................................................................................................................... 2012.6 SIM13: ........................................................................................................................................................... 20

13 The Mill-Turn Example sim15 ............................................................................................... 2013.1 Kinematics Configuration .............................................................................................................................. 2113.2 ONT Coordinate systems setup .................................................................................................................... 2213.3 Tool Change ................................................................................................................................................. 2313.4 About Spindles .............................................................................................................................................. 2413.5 TRANSMIT Operation and other milling motion types .................................................................................. 2413.6 TRAORI simultaneously 5-Axis milling ......................................................................................................... 2513.7 Handling of special features like part transfer, moving sub-spindle and jaws .............................................. 2513.8 Multiple Chains ............................................................................................................................................. 2813.9 Definition of Tools and related Settings (not specific for sim15) .................................................................. 28

14 The Head-Change Example SIM16 ...................................................................................... 3014.1 About the machine tool kinematics ............................................................................................................... 3014.2 About the head kinematics defined as devices ............................................................................................ 3114.3 About the Post and CAM setup .................................................................................................................... 3214.4 About the CSE Driver .................................................................................................................................... 33



14.5 Changes in the MCF for the head change .................................................................................................... 3415 Sim09 becomes a Turn-Mill machine Tool ............................................................................ 37

15.1 Kinematic Configuration ................................................................................................................................ 3715.2 Changes of the Post ..................................................................................................................................... 40

16 Creating your own CSE examples based on the OOTB mach examples ............................. 4117 Appendix ............................................................................................................................... 42

A. Example NC code TRAORI and circles ........................................................................................................ 42B. Detailed information about ini files ................................................................................................................ 42C. Example of a tool change subprogram ......................................................................................................... 43D. Post Processor features of the OOTB examples .......................................................................................... 44E. Example of an INI file .................................................................................................................................... 45F. Swiveling Cycles ........................................................................................................................................... 45G. PLANE SPATIAL .......................................................................................................................................... 45H. CYCLE800 .................................................................................................................................................... 47I. G68.2 ............................................................................................................................................................ 51J. Default controller settings inside the CCFs................................................................................................... 52K. OOTB MCS Handling output details ............................................................................................................. 54



1 Highlights - new with NX9 Update sim09 to have a turning table and act as turn-mill machine tool Sim15 is enhanced and comes with an updated CAM example and with improved

programming capabilities for the sub spindle plus movable jaws on chucks Clean-Up MTD drivers have separate folder for legacy reason Add for sim05 OKUMA with Post and Parser Add tomb-stone sim03 using new feature Paste with reference function and post outputs

subroutines Introduce level based CCF plus controller CCF Post: S840D postprocessor based on Sinumerik_840D_basic template post.

2 Overview This document explains the handling and usage of the simulation examples provided out-of-the-box (OOTB) with NX Version 9. The example data is mainly contained in two locations: one is for the library machine tool models in the $UGII_CAM_BASE_DIR/resource/library/machine/installed_machines folder, the other for the CAM examples utilizing the library machine tools. These CAM examples can be found under $UGII_CAM_BASE_DIR/samples/nc_simulation_samples. All of the machine tools in the library have preconfigured geometry, assembly and kinematics models as well as post processors and CSE controller models for the major controller types Siemens SINUMERIK 840D, Fanuc family and TNC Heidenhain Conversational; posts are available for metric and inch units. For all machine tools in the library there is at least one CAM setup example available. The intention of these examples is to show best practice and to demonstrate the features of the NX CAM built-in machine simulation. Another intended use of the examples is as seed parts for customer specific simulation.

NOTE: The examples cannot contain or show every possible feature of NX CAM, NX Post and ISV. In certain cases such as complex or multi-function machine tools, and in order to achieve advanced capabilities, specific customization of the provided posts and/or controller models will be necessary.

3 Load Options To ensure all related assembly component parts are loaded correctly it is recommended to use the "From Search Folder" load option with the following search paths. Be certain to include the three dots at the end of each path. Leave the Use Partial Loading - option unchecked'



4 CAM-Setup When creating a new CAM setup with the provided set of machine tools, the following best practice is suggested. It is assumed that the CAD geometry of the part to be machined already exists. Open the CAD part file in NX Select New and pick an appropriate entry in the Manufacturing tab.

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

Create a Wave link to the CAD geometry

Select the body of the CAD model for the Wave object and hide the CAD component in the assembly navigator

To prepare for material removal simulation it is recommended to have the blank geometry pre-defined as well. In the example shown it is a simple cylinder added to the assembly.

Starting with NX9 all CAM setups part files in the sample folder are pre-configured to be used as template or seed parts.



5 MCS-Handling (Best practice for the OOTB examples) In order to achieve a complete and reliable machine simulation, different modules need to play together. These are: CAM programming structure in the Operation Navigator (ONT), Internal Post Processor (MOM inside NX), TCL based post processor Simulation controller model.

A few rules need to be considered for NX CAM setup to support the assigned post processor creating a valid NC code which can be used at the physical machine tool as well as for simulation.

5.1 General settings and rules Each CAM setup example using one of our OOTB MACH machine tools must not include

more than one single MCS with the purpose Main

The Main MCS needs to be placed at the same location and orientation as the MACHINE_ZERO coordinate junction of the machine tool.

NOTE: This was used to tell the post processor the position of the machine zero position prior NX8.5. Starting with NX8.5 the post has access to the junctions in the kinematics model. For more details refer to Creating file with tool and offset data. The examples still include the MAIN MCS to represent the Machine Zero Position; this is due to planned future improvements and enhancements for a better usability.



All other used MCSs in the ONT need to be of purpose Local

If the Special Output of the local MCS is Fixture Offset, the post processor will output a fixture offset statement based on the number of the Fixture Offset. E.g. if Fixture Offset is 2: G55 -> SINUMERIK G55 -> Fanuc CYCL DEF 7.0 -> TNC (7.1/2/3 will include the offset values e.g. CYCLDEF 7.1 X 100) The Sinumerik Post will create an to_ini.ini file including the offset vector from the local MCS with fixture offset number to the Main MCS and output that like $P_UIFR[2]=CTRANS() It is not suggested to use fixture offset number 0, which will output a $P_UIFR[0] and that is mainly the machine zero system defined with the Main MCS object

If the Special Output of the local MCS is CSYS Rotation the postprocessor will output a special statement to indicate a translation and/or a rotation. The fixture offset number must always inherit its value from the parent MCS object. TRANS/ROT or CYCLE800 (based on UDE) -> SINUMERIK G68 -> Fanuc PLANE SPATIAL -> TNC

With these settings the example will look like: MCS Name Purpose Fixture Offset Special Output Post S840D Post Fanuc Post TNC MCS_MAIN Main 0 - | MCS_G54 Local 1 Fixture Offset G54 G54 CYCL DEF 7.0 | MCS_G55 Local 2 Fixture Offset G55 G55 CYCL DEF 7.0 | ROT Local 2 (inherit) CSYS Rotation CYCLE800 G68.2 PLANE SPATIAL More details and example are shown in Appendix: OOTB MCS Handling output details For the OOTB post, operations must not be placed under MCS objects with the special

output none or Use Main MCS. In such cases the post will not identify the correct offset for the operation and the offset creation in the to_ini.ini files will fail.

5.2 Special rules and settings for Mill-Turn machine tools. Working with Mill-Turn machines the work piece spindle object needs to be represented in the ONT. Therefore a MCS Spindle object is mandatory. That MCS object needs to be aligned with the work piece spindle and the X/Y or Z/X plane represents the lathe work plane. Also the Lathe axis needs to be aligned with the spindle axis. Working with multiple spindles e.g. Main and sub,



each spindle needs to be defined by an MCS Spindle object in the ONT. All operations and related offsets need to be located below that spindle object. Below a snapshot shows the configuration of the sim09 example:

The LATHE-SPINDLE object is a local MCS with special purpose None and fixture offset number 0, so that this MCS will be ignored by the post in regards to output offset information. The offsets G54 and G55 are located as child objects of the spindle. Also the sim15 is setup related that rules; details will be described in the sim15 chapter. Additional information about best practice to set up a multi-spindle Mill-Turn geometry view is available in the NX Help under CAMManufacturing TurningGeometry structure sample for a 2 spindle multifunction machine

5.3 Library machine tool specific handling SIM15 post rule for local MCS object with special output None

A local MCS with special purpose None located as child of a local MCS with special purpose Fixture Offset number will be used to output G59. See more in the chapter about sim15

6 About Post Processors All the OOTB delivered post processors are created with the Post Builder Version 9 based on the Sinumerik S840D basic template post. Some differences between pure template post and OOTB post are listed in the 3rd subchapter.

6.1 General supported features of the OOTB Posts All three major controllers support the basic functionality for 2 axis drilling, 3 axis, 3+2 axis and 5 axis milling and also some advanced functionality. 6.1.1 Basic functionality Addresses (X, Y, Z, A, B, C) Program control ( M30, M0...) Basic motion type: rapid, linear, circular Metric/Inch units Radius/diameter programming Fixture offset Coordinate system rotation(support Local CSYS and Auto3D way) (G68, TRANS/AROT) Tool radius compensation Tool length compensation Feed rate, feedrate unit Spindle mode and spindle speed Constant surface speed Tool change TCP (TRAORI, G43.4, M128)



Drilling cycle 6.1.2 Advanced functionality: Swiveling function (G68.2, CYCLE800, PLANE SPATIAL) Variable axis drilling (fully support cycle plane change) Turning cycle (CYCLE95, G71)

6.1.3 Sim15 Mill-turn (S840D and Fanuc) One mill-turn post Part transfer Polar mode Drilling XZC output

6.2 Creating file with tool and offset data The SINUMERIK 840D post processor creates a CAM setup specific initialization data file for offset values and the tool data. The post processor creates an additional ini file (to_ini.ini or to_ini_Channel.ini) in the SINUMERIK format. This file will be located in the cse_files/subprog subfolder of the CAM setup part:

MACH/samples/nc_simulation_samples/cse_files/subprog

This to_ini.ini file is handled as a subprogram and in the ini files of the machine tool in the library this file gets called (executed and loaded). When working with CSE controller models, the different ini files are loaded and executed before the simulation starts. The format and syntax of the files is controller specific and their purpose is to initialize certain settings upfront. For more details about ini files please see Appendix. Before the post create a new file to_ini.ini it will back up the existing ini file by renaming it to *.bck.

Note 1: New with NX85 is that the post query the kinematics model using the TCL query function MOM_ask_init_junction_xform and store the results in the variable mom_sim_result[9], mom_sim_result1[3] to get the data of the machine zero junction needed to calculate offset information for e.g. G54.

Note 2: With the Sinumerik template Post within PostBuilder Version 8 or newer you are able to configure the behavior of creating the ini file.

Note 3: The OOTB example machine tool ini files for Sinumerik (e.g. sim07_mill_5ax-Main.ini) have the entry TO_INI to call the post created file as a subprogram. If the creation of the file not work properly or the file gets deleted or the post does not have write access to create this file and the CSE Simulation starts it will give you a warning in the details window, that the related TO_INI file could not be found. The simulation will not stop in that case.



6.3 MOM variable for MCS handling For coordinate rotation NC codes output inside the post, the related coordinate matrix is changed. Reason for this is because the Main MCS is representing Machine zero and Local fixture offset representing machining coordinate G54, G55, but mom_csys_origin and mom_csys_matrix still map current local MCS to Main MCS. For CSYS rotation coordinate output, the value of linear offset (G68, CYCLE800 ) should be the offset between current local MCS to parent local MCS(e.g. G54,G55). Therefore, mom_parent_csys_matrix replaced mom_csys_matrix in postprocessor . MCS-Main (G53) |----MCS-Local-for-G54 mom_csys_matrix |-----MCS-for CSYS rotation or other-purpose mom_parent_csys_matrix



6.4 Differences between pure template posts and OOTB posts (Sinumerik) The OOTB posts are created based on the latest Sinumerik S840D basic template posts. Some settings and or features are slightly different, which are listed here. 6.4.1 Coolant Coolant output is different.

Posts of OOTB Examples Post from template post Coolant code always be M8 Coolant code depends on coolant status

6.4.2 Output of T0 M6 at end of program

Posts of OOTB Examples Post from template post Output T0 M6 at end of program No T0 M6 at end of program

6.5 About UDEs and OOTB The post shipped with the OOTB machine tools in the library are coming with their own UDEs (CDL file), which provides a series of UDE which all are supported.

6.6 Post output for Coolant (Sinumerik, TNC, Fanuc) OOTB post processors only support M8 (coolant on) and M9 (coolant off), to output other coolant codes, post processors need to be customized.

6.7 About Special handling for 5 axis motions with Fanuc for table machine tool configuration

The OOTB setting for Fanuc controller will not move the programming system together with the table when doing 5 axis motions like G43.X. The post takes care about that when outputting the X/Y/Z data. The CSE controller takes care about that by using a specific mode when activating the 5 axis transformation. This mode can be changed: In Post do the following: Change variable dpp_ge(sys_output_coord_mode) value to TCP_FIX_MACHINE in command PB_CMD_customize_output_mode In Simulation do the following: Change the setting of the variable #19696 in the INI file to =0 (default is 32 for non-rotating workpiece coordinate system)



7 About CAM Programming About Cutter Compensation for contact contour and circle statements in the NC code file hereby important information. Whenever the NC code contains statements which refer to a plane such as G02/G03 or G41/G42, the controller needs to have the related working plane defined. Therefore it is necessary to define the correct plane upfront. The initialization files provided with the machine tool examples define a default working plane. This is typically the XY-Plane (G17) for the milling machine tools and ZX-Plane (G18) for the turning machine tools. Important to understand are cases where the surfaces to be machined are not parallel to one of the orthogonal machine tool planes and the post processor has a specific transformation like TRAORI or using swivel cycles activated to achieve this operation. A typical example is shown with the external NC code listed in Appendix simulated with the machine tool example sim06_mill_5ax_cam_sinumerik_mm.prt. Activating cutter comp or circle output will only be correct if a related working plane is defined. This can be seen e.g. in the following picture for the green area and the operation PLANAR_PROFILE_TOP. It is taken from the example sim05 (head/head configuration). Here, the operation PLANAR_PROFILE_TOP includes circle statements for a plane which is not aligned with xy, yz, or zx. Circle records can correctly processed only because a ROT command was executed in a previous NC line and swivel the plane in the TRAORI mode. The latest used post in the example dont output TRAORI anymore, but use CYCLE800 to swivel the plane.

The example shown below (POCKET2_PLANAR_CUTCOMP, example sim05) is an alternative method when machining within a plane which is not aligned with xy, yz, or zx. Here, the working plane is not defined by a ROT statement; circular or cut comp output would not work and therefore are deactivated in the operation.



8 Using the library tools The CAM setup simulation examples use as many as possible tools available from the OOTB tool library (ASCII in NX native) as delivered with the actual NX version. It is not suggested to adding part files with the existing tool library entry names. (e.g. ugt010101_003.prt). It may happen that the added 3D tool does not match the geometry created based on the parameters.

9 About CSE Simulation Drivers

9.1 Handling of Offsets: Like any physical NC controller, CSE drivers can process offset information (activated e.g. through G55) only if the required data is provided, i.e. coordinate values between the actual chosen offset e.g. G55 and the machine tool zero position. There are two ways to achieve this with CSE and both are used in the OOTB examples. 9.1.1 Alternative 1 (Fanuc) In the case of Fanuc, the controller queries the information during simulation from the application (ISV NX). This is done internally by a command called LoadOffset during interpretation of an offset statement in the NC code like G55. The system searched in the ONT for an MCS object with the related fixture offset number. Example: In the NC code a G55 (2nd offset) is used. In this case the system cycles through all MCS objects and compares the value use in Fixture Offset with the given offset in the NC code.



9.1.2 Alternative 2 (Sinumerik and TNC) The SINUMERIK 840D CSE and the TNC controller doesnt use the LoadOffset mechanism as described above but follows an alternative implementation. On the physical controller in the shop floor, the offset values are typically measured by probing operations or are manually set in the controller. The controller stores these values in an offset table and in controller variables. The SINUMERIK OOTB post processors create an initialization file for the actual CAM setup including information about the offsets and tool data. This initialization file is loaded before the simulation starts. So the offset definition is achieved by the definition of the variables in the initialization file. Snapshot of the SINUMERIK ini file:

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

8 CYCL DEF 7.0 9 CYCL DEF 7.1 X -0.0000 10 CYCL DEF 7.2 Y -225.0000 11 CYCL DEF 7.3 Z -327.4470

Note: Working with CYCLE247 and/or is possible with CSE, but not part of the OOTB example.

9.2 Handling of the tool change Tool changes with CSE controller models in the existing examples are achieved by calling a tool change subprogram. This subprogram is located under the subprog folder for each CSE driver; its kept in the corresponding NC code syntax and basically positions the tool to the tool change location. Using one of these subprograms for a different machine tool will typically require an adjustment of the tool change position. Another section in the tool change subprogram is the Anycontroller (AC) part, which mimics the PLC portion of the tool change. This mainly takes care



of the mounting and un-mounting of the tool itself. Refer to NX Help for more details about the AC language. The OOTB examples demonstrate different kinds of tool change methods. The standard way is that one spindle is defined on the kinematics model of the milling

machine tool and the tools are mounted on the fly during simulation. This can be seen in sim02 to sim09 as well as sim14. sim08 is similar, but shows how an advanced tool change mechanism can be animated using the AC language to open and close doors.

In sim01, tools are already pre-mounted and visible in the CAM scenario on an eight pocket tool changer. During simulation, the system moves the spindle and the tool changer to mount and un-mount the tool.

The turning examples sim10 to sim13 dont mount tools during simulation. Here, all tools are already pre-mounted on the turret in the CAM scenario. The tool change subprogram takes care of the rotation of the turret and the activation of the selected tool.

An example of a tool change subprogram can be found in Appendix

Note: The machine tool view in the ONT reflects the definition of turrets and pockets in the kinematics model. Each time the machine tool is retrieved from library, the ONT is updated based on the kinematics model. It is strongly recommended not to add or remove turrets and pockets in the ONT machine tool view when working with machine tools.

9.3 Handling the reference point (Fanuc) In Fanuc NC code, the G command G28 is often used to move the reference point. The OOTB examples include this in the post and in the CSE controller models. This section describes how the position of the reference point is defined and stored to get correct simulation results. On physical machine tools, the reference point is stored inside of the controller. To mimic this in the CSE simulation, the position of the reference point is defined in the *.ini file along with the machine tool. The NC code to define reference points in Fanuc syntax is shown in the sim01 example (sim01_mill_3ax_fanuc-Main.ini) as:

(This part sets the position of the reference point G28) G54 G17 G90 G10L52 N1240P1R0000 -> X Position of the reference point related to machine zero N1240P2R225.425 -> Y Position of the reference point related to machine zero N1240P3R406.425 -> Z Position of the reference point related to machine zero G11

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

9.4 Handling of tool correction data Handling tool data CSE is able to get the data on different ways. One way is a direct connection to the application ISV and query the data through an API function during simulation e.g. when activating the tool correction e.g. Dxx or G43 Hxx). An alternative way is to rely on data predefined in controller variables e.g. in an ini file. The behavior can be triggered in the OOTB CCF by setting the global variable GV_bUseSetToolCorrection in the CSEInitializeChannel. Most controller use the first described way and get the tool correction data via the API during simulation form ISV. New with NX9 for the Sinumerik CCF (main purpose is for showcase) is, that these CCF relies completely on the provided data in the to_ini.ini file created by the OOTB post and doesnt query any tool correction data during simulation.



10 About Sinumerik Cycles in the content Since NX8 the OOTB library for Sinumerik supports list of cycles for simulation. The cycles are covered by an encrypted archive file (*.cyc) and placed in the subprog folder of the Sinumerik CSE simulation. Multiple versions are added to the system for Sinumerik Powerline and for Sinumerik Solutionline. The SolutionLine Version 4.4 used by default in the CSE simulation. The cycles of the Solutionline Version 4.4 are in the file: SinumerikSL_Cycles.cyc The cycles of the Solutionline Version 2.6 are in the file: SinumerikSL_Cycles.cycV26 The cycles of the Powerline are in the file SinumerikPL_Cycles.cyc_powerline

To use the cycle other than form the default rename the files so that the desired one has the extension *.cyc Here the list of cycles in the archives files: PowerLine CYCLE71 CYCLE81 CYCLE90 CYCLE801 HOLES1, HOLES2 LONGHOLE SLOT1, SLOT2 POCKET1, POCKET2, POCKET3, POCKET4 CYCLE800 (kinematic specific, customized per machine tool)

Solutionline CYCLE71 CYCLE81 CYCLE90 CYCLE801 HOLES1, HOLES2 LONGHOLE SLOT1, SLOT2 POCKET3, POCKET4 CYCLE95 CYCLE97 CYCLE800 (kinematic specific, customized per machine tool)

11 About swiveling cycles This will give an overview about what are swiveling cycles and how they are used. The main target is to machine on a plane not perpendicular to an existing linear axis. What it would take without swiveling: You have to create a rotated coordinate system Figure out how to move the rotary axis so that X, Y, Z can be used for the motions in the plane Solve the problem that your work piece coordinate system does not rotate with the rotary axis



Working with swiveling cycles will make the life easier and let the controller do the work. In the following subchapters it is explained in detail how the swiveling Cycle PLANE SPATIAL/AXIAL and CYCLE19 on Heidenhain, CYCLE800 on S840D and G68.2 on Fanuc controllers work and how this is implemented in the CSE and the OOTB examples. In addition you will see a section how this is configured and can be reused for a different machine tool. With NX85 all the five axis machine tools in OOTB support swiveling for all three controller type.

11.1 Swiveling on Heidenhain 11.1.1 How the ONT needs to be defined to achieve a proper Post output To achieve an output of PLANE SPATIAL by the Post the following prerequisites needs to be fulfilled. (PLANE SPATIAL is supported by OOTB post; PLANE AXIAL and CYCLE19 are supported in the CCF for simulation only) milling operations and drilling operations needs to be 3+2 axis operation The MCS need to be set to CSYS Rotation

11.1.2 How to customize the machine data to achieve correct simulation The settings are valid for all supported modes which are PLANE SPATIAL, PLANE AXIAL and CYCLE19. Inside the MCF global variable in Internal variables tab must be set related to the type of the machine tool and the axis vector directions. Name of the variables are: GV_strMachineType (T, M,P)

T for Tool Head/Head P for Part Table/Table M for Mixed Head/Table

GV_strSwivelingChainName The default name for the chain will be default

GV_strFourthAxisName GV_strFifthAxisName GV_dFourthAxisX (x component of fourth axis) GV_dFourthAxisY (y component of fourth axis) GV_dFourthAxisZ (z component of fourth axis) GV_dFifthAxisX (x component of fifth axis) GV_dFifthAxisY (y component of fifth axis) GV_dFifthAxisZ (z component of fifth axis)

And the soft min/max limit of the rotary axes should be set if you wish rotary axis solution can be selected based on axes limit.

More details about the cycle and the way how it is implemented in CSE can be found in the Appendix



11.2 Swiveling in Sinumerik - CYCLE800 The Sinumerik Solutionline version is implemented in this approach. Much more details about the cycle itself and the way how it is implemented in CSE can be found in the Appendix 11.2.1 Example and parameter

11.2.2 How the ONT needs to be defined to achieve a proper Post output To achieve an output of CYCLE800 by the Post the following prerequisites needs to be fulfilled. milling operations and drilling operations needs to be 3+2 axis operation Sinumerik 840 UDE should be added on the operations, Transformation option should

choose Swiveling as shown below:

11.2.3 Machine Tool dependent data customized ini files This is the list of variables defined for each machine tool in the ini file and others files to define data for the CYCEL800. These are the data, which need to match the related machine tool. Content of the OOTB INI file

SMAC; adopt the original DEF file from MC PGUD; need remove the line with REDEF TC_CARR; define tool holder data G40 D0 $MN_MM_NUM_TOOL_CARRIER=1 M17



Definition data of the TC variables: $TC_CARR7 ;x component of rotary axis v1 $TC_CARR8 ;y component of rotary axis v1 $TC_CARR9 ;z component of rotary axis v1 $TC_CARR10 ;x component of rotary axis v2 $TC_CARR11 ;y component of rotary axis v2 $TC_CARR12 ;z component of rotary axis v2 $TC_CARR23 ;kinematic type $TC_CARR24 ;Offset of rotary axis v1 $TC_CARR25 ;Offset of rotary axis v2 $TC_CARR30[1]=-90 ;software minimum limit of rotary axes v1 $TC_CARR31[1]=-9999999 ;software minimum limit of rotary axes v2 $TC_CARR32[1]=90 ;software maximum limit of rotary axes v1 $TC_CARR33[1]=9999999 ;software minimum limit of rotary axes v2 $TC_CARR34 ;tool holder name $TC_CARR35 ;Axis name 1 $TC_CARR36 ;Axis name 2 $TC_CARR37 ;Identifier $TC_CARR40 ;Z axis retract value

11.3 Swiveling in Fanuc - G68.2 11.3.1 How the ONT need to be defined to achieve a proper Post output To achieve an output of G68.2 by the Post the following prerequisites needs to be fulfilled. Milling operations and drilling operations needs to be 3+2 axis operation The MCS need to be set to CSYS Rotation

11.3.2 How to customize the machine data to achieve correct simulation The requirement for G68.2 is the same to the requirement for PLANE SPATIAL. Please refer to previous chapter More details about the cycle and the ay how it is implemented in CSE can be found in the Appendix

12 Example specific considerations

12.1 SIM01: This example has a special tool change mechanism including a real tool changer. Re-using this example for other machines without a similar tool changer can cause unexpected behavior. In this case, use sim02 as reference for a simple 3 axis milling machine tool.

12.2 SIM03: This metric Sinumerik example includes a cam setup, which handles operation using milling tool (T-Cutter and Step-Mill) dealing with multiple tracking points. New with NX9 an additional CAM Setup part file is included showing a tomb stone configuration. The CAM structure using the feature Paste with Reference and the OOTB post of this machine tool included one special UDE to activate/deactivate the feature to output the pure cutting area of the operation as separate subprograms.

Furthermore the post is enhanced to not outputting a ROT statement or a swivel cycle if the orientation of the used MCS programming coordinate system can be brought into synch with the



machine tool axis orientation by a simple B axis table rotation. This more following the real working on such machine tool configurations. If the post should output a ROT or swivel cycle it is needed to set up in CAM geometry view the fixture offset without any rotation and have a child MCS object defining the CSYS-Rotation (see also chapter 5.1)

12.3 SIM05: This machine includes post and Simulation for controller OKUMA. Here a list of the supported features. 12.3.1 Functionality list Okuma controller supports the basic functionality for 2 axis drilling, 3 axis, 3+2 axis and 5 axis milling and also some advanced functionality. 12.3.2 Basic functionality Addresses (X, Y, Z, A, B, C) Program control (M02, M0...) Basic motion type: rapid, linear, circular(G0/G1/G2/G3) Workplane selection (G17,G18,G19) Metric/Inch units(G20/G21) Absolute and incremental dimensioning mode(G90/G91) Fixture offset(G15 Hn/G16 Hn) Coordinate system rotation(support Local CSYS and Auto3D way) Tool radius compensation(G41/G42/G40) Tool length compensation(G54 H/G55 H/G56 H/G53 H/D) Feedrate, federate unit(G94/G95 F) Spindle speed and direction control (S, M3,M4,M5) Tool number and tool change(T M6) Coolant(M7/M8/M9) Home position(G30) Dwell(G4) Drilling cycle(G73/G74/G76/G81/G82/G83/G85/G86/G87/G8R9/G80)

12.3.3 Advanced functionality: Variable axis drilling (fully support cycle plane change) UDE-Set Tool Path Type to switch between 5 axis and 3 axis tool path.

12.3.4 Ssetting slope coordinate system (G69/G68) In sim05 Okuma kit, the coordinate conversion can be done up to three times. Firstly, the coordinate conversion is with respect to Z-axis, secondly it is with respect to X-axis, and finally it is with respect to Z-axis. The output format likes this: G69 X Y Z P G69 X Y Z R G69 X Y Z P G68 G68 G68 12.3.5 Switching between TCP G44 mode and G169 mode for 5 axis machine Set variable dpp_ge(tcp_output_type) to AXIS", and set dpp_ge(tcp_base_coord_type) to "TCP_FIX_MACHINE" in PB_CMD_dpp_ge_set_default_variable. It will output NC code G169. set variable dpp_ge(tcp_output_type) to VECTOR,and set dpp_ge(tcp_base_coord_type) to "TCP_FIX_TABLE" in PB_CMD_dpp_ge_set_default_variable. It will output NC code G44.



12.3.6 Define Set Tool Path Type via UDE

The UDE is used to set tool path type of a operation. Option (5 Axis Simultaneous Cutting): Yes: set the tool path type to 5 axis simultaneous cutting No: set the tool path type to 3 axis machining

In the sim05 Okuma kit, the post can automatically detect the tool path type, but if the post doesn't detect correctly, the users can use the UDE to reset the tool path type.

12.4 SIM10: This machine tool is only available with a Fanuc controller model. Material removal and/or tool path based TPB simulation are not supported. It doesnt support many different Mill-Turn features, mainly what the example includes. To see more Mill-Turn features like e.g. TRANSMIT/Polar mode refer to sim15 is suggested.

12.5 SIM11 SIM13 - Fanuc: The initial setting for these machine tools in the library changed to be type LATHE and run with G-Code System-A. That is done by using the variables in the ini file: #983=0 (specifies that this is a lathe) #3401=1 (specifies that G-Code system A should be used, where G99=feed per rev)

Doing so G99 will be interpreted as feed rate set per revolutions and G98 as feed per minute. And G90 G91 is not a valid code in that setting. For incremental motions U/V/W is used

12.6 SIM13: This machine tool is only available with a Fanuc controller model.

13 The Mill-Turn Example sim15 Since NX8 an OOTB Mill-Turn example with a Post Processor and Simulation Driver for Sinumerik S840D and since NX85 also with a Driver for Fanuc are supported. The machine tool is a two channel B-Axis head and lower turret configuration with a main and sub spindle. Additionally the kinematics includes a non-orthogonal X,Y,Z configuration and allows simultaneously 5-Axis milling on the main spindle (TRAORI). The CAM example includes different operations for milling and turning including TRANSMIT and Part Transfer. The goal of this example is to show the power of the CSE simulation capability.



Note: Due to the general complexity and variations of mill turn machine tools it could not expected that these example can be reused for any different mill turn machine tool type. For such complex manufacturing centers a customization for Post and Driver is always mandatory.

Note: This example does not support TPB and MTD

13.1 Kinematics Configuration Main Spindle and B-Axis Head Sub Spindle and Lower Turret

+ Z1

+ X1

+ C3

+ Y1+ B1

+ X2

+ Z2

+ C4

+ Z3

+ C2



13.2 ONT Coordinate systems setup

G59

ATRANS AND AROT based on G59

G54 Local 1

G53 MZJ

G55 Local 2

G59



MCS Description Picture

G53 The machine zero point is placed at the center of the main turning spindle MSC is main and fixture offset number is set to0

G54

The Offset G54 is placed at the center of the front face at the chuck. It is represented as a local MCS with Fixture Offset number set to1 This object defines the Spindle, so need to be of type MCS Spindle (!) (MAIN in the name refers to the main spindle not to the MCS purpose)

G59

At the front face of the work piece a MCS is placed. It is of type MCS Spindle to put turning and milling below. The G59 is an additional offset based on G54. The G59 is similar as a TRANS but will not be reset or overwritten by a new TRANS. Local, None and inherit the fixture offset number from the parent.

ATRANS AROT

For arbitrary/ rotated work planes. This will be indicated as an additional transformation ATRANS and AROT and is based on the G59 coordinate system.

G55

The Main Offset for the sub spindle G55 is placed at center of chuck face on sub spindle. This object defines the Spindle, so need to be of type MCS Spindle (!) It is represented as a local MCS with Fixture Offset number set to2

G59 Same as above, but for the part on the sub spindle

13.3 Tool Change The tool change on the B-Axis is done by calling a sub program TC.SPF. The parameter definition is defined as:

TC(tool number, B-Axis position, Spindle position ) Example:



13.4 About Spindles The machine tool has 4 spindles C1 Tool spindle in the B-Axis Head C2 The spindle for life tools on the lower turret C3 The work piece spindle of the sub spindle - right side C4 The work piece spindle of the main spindle - left side

The post outputs related code to activate (M3/M4) and stop (M5) them. At the beginning of an operation the related spindle will be set as main spindle with the SETMS command. At the beginning the main spindle C4 is assigned to the first channel (B-Axis Head) and the sub spindle C3 is assigned to the second channel (lower turret). If necessary to change this the post will output the command GETD(channel) to assigned the related spindle/axis to the channel which drive this spindle/axis

13.5 TRANSMIT Operation and other milling motion types The example includes the TRANSMIT option (CX Polar Mode) for one operation. To activate and deactivate a start and end UDE needs to be used.

N5520 ;Operation : PLANAR_MILL_ROUGH N5530 GETD(C4) N5540 ;Tool Change N5550 G17 N5560 DIAMOF TOWSTD N5570 TC(5,0.,0.) N5580 MSG("MILL_TRANSMIT") N5590 SETMS(1) N5600 ; N5610 ;Initial Move N5620 G0 B0.0 C4=0.0 N5630 TRANSMIT(1) N5640 G54 N5650 TRANS X0.0 Y0.0 Z300. N5660 G0 G90 X-42.544 Y-70.87 Z10. S1=2000 D1 M1=3 N5670 ;Approach Move N5680 Z-52. N5690 ;Engage Move N5700 G94 G1 Z-55. M8 F200. N5710 X-45.041 Y-66.538 N5720 ;Cutting



N5730 X-80.152 Y-5.636 N5740 ;Retract Move N5750 X-82.649 Y-1.304 N5760 Z-52. N5770 ;Departure Move N5780 G0 Z10. N5790 ;End of Path N5800 TRANS X0 Y0 Z0 N5810 TRAFOOF N5820 M1=5

For other milling modes like XYZ motions (example operation is FACE_MILLING_AREA) and for axial drilling XYC motion (example operation DRILL_IN_CENTER_S1H) the post figure out this automatically by the operation.

13.6 TRAORI simultaneously 5-Axis milling The example includes some multi axis operation, which simulated using the TRAORI function. As a show case one operation (CONTOUR_PROFILE_1) are created Vector output instead of Axis positioning. To achieve the vector output the following UDE is used.

13.7 Handling of special features like part transfer, moving sub-spindle and jaws New with NX9 are three user defined generic motion types to give the user full flexibility define special motions of the sub-spindle and the related jaws on the chucks. Doing these actions it is no longer needed to use special UDE, but more using these new sub operation types. The following sub-chapters describe the individual UI and related NC output of these operations.



13.7.1 Moving Sub-Spindle Z3

UI Setting Posted NC Code

Move to Home G90 G53 G0 Z3=0Move to Position (Move to) G90 G53 G0 Z3=value from Move to Start & End Point delta is difference in Z of selected points

G90 G53 G0 Z3=-delta

Clearance Mode (Distance) (before or after G0 motion)

G90 G53 G0 Z3=-value+clerancceDistance G90 G53 G1 Z3=-value F250

Travel to Fixed Stop G90 G53 G1 Z3=-value FXS[Z3]=1 F25 Fixed Stop Torque Add after FXS: FXST[Z3]=12.0 Fixed Stop Window Add after FXS: FXSW[Z3]=2.0 Feed (default is F250 on the G1) G90 G53 G1 Z3=-value FCustom Feed Rate



13.7.2 Handling of Chucks

UI Setting Posted NC Code Mainspindle Open M120Subspindle Open M130Mainspindle Close M121Subspindle Close M131Mainspindle Position G53 G0 CHUCK_MAIN=Jaw Position Subspindle Position G53 G0 CHUCK_SUB=Jaw Position 13.7.3 Handling work piece transfer

UI Setting Posted NC Code Main to Sub M140Sub to Main M141



13.8 Multiple Chains New with NX9 the kinematics model of sim15 has two kinematics chains of type milling defined in the MTB. At this point in time only the first one B-HEAD-MAIN-SPINDLE is used in the CAM setup and addressed by TRAORI. In the MCF it is prepared TRAORI(1) and TRAORI(2) for working on the main or sub spindle.

13.9 Definition of Tools and related Settings (not specific for sim15) This chapter explains the dependencies between tool angle data, the related orientation and mounting in to a machine tool. This will be used to created specific operations and achieve the desired orientation. Even if this is done based on one operation of the sim15 example, this is not specific but can be seen as some more general CAM tool related information. As the example we are using the operation ROUGH_BACK_TURN. Desired is the following manufacturing.

13.9.1 Settings in the tool



Selecting the tool in the ONT the tool will be displayed with the tracking point on the WCS in that orientation as it will be mounted into the pocket. In the case above this is the B-Axis head. To achieve the correct orientation the tool holder angle (OA), the insert position and the tool holder type can be changed accordantly. Usually the turning tool (if it is a parameter tool without tool assembly graphic) is mounted into the spindle with the tracking point. To change these values in the tab More section Simulation are used. In this example 100 / 0 will result in:

13.9.2 Settings in the Operation: To achieve the desired position for the operation the tool needs to be more orientated vertical instead of horizontal (B-Axis motion) this will be set into the operation. Here to achieve 80 degree. To achieve the rotation about 180 degree in the spindle of the B axis, so that the cutting edge is more on the right as on the left, the Flip Tool Holder is used.

100mm



14 The Head-Change Example SIM16 With NX8.5 we provide an OOTB example including a head change mechanism. This includes as usual Post Processor and Simulation Driver for Sinumerik S840D. The machine tool based on the gantry SIM05 example plus a head magazine (without extra geometry). Three different heads (devices) are added to the machine and used in the related CAM setup. The standard head to mount a tool vertical, a simple right angle head and a complete 5 axis head including two axes C and A. With the latter one the machine tool becomes similar as the SIM05. The main target of this example is to show how head change can be handled in NX CAM, in the post and in the CSE driver. The CAM example shows different operations placed on different heads. To handle the same tool on different heads the names of the tools must have post fix _headno. Simultaneously working with the rotary axes is not supported by this example (e.g. TRAORI). The prepositioning of the rotary axis must not be done direct inside the NC code e.g. C=30, but use the head change cycle, like the attached post did it. The head change cycle takes care about the positioning of the rotary axis and swiveling the plane internally. The post itself takes care about create coordinate system based on the working plane without the need to have separate MCS object for each face. This makes that example most easy to use for the user. One MCS to define a fixture offset like e.g. G54 is totally enough for such cases. At the end of that chapter is a section targeted mainly for CSE experts who want to customize other head change examples and need to understand how that one is working in detail.

Note: Due to the general complexity and some special assumptions made in that example it could not be expected that this example can be reused for a different head change machine tool without any customization on Post and Driver.

Note: This example is available in Sinumerik CSE and TPB. MTD is not supported.

14.1 About the machine tool kinematics This example is built in such a way that the base machine tool includes a head magazine, which gets filled by heads using the device mechanism. The head magazine pocket gets the holder type HEAD added, so that only heads and no tools can be placed in the pockets. The core machine tool includes the three linear axes and a pocket to mount the head on. This junction is classified as Tool Mount junction and is used later in simulation to mount the head.



Note1: To keep it simple, the orientation of the machine zero junction, the mount junctions on the machine and the junctions on the heads to mount them onto the machine are all identical.

Note2: The holding system is defined, so that only HEAD objects can be mounted to that pocket (_STATIC_HOLDER)

Note3: The Holder ID is not used today

14.2 About the head kinematics defined as devices The three heads are defined as devices with the related kinematics model and axes (if available). Here the example of the 2-axis head:



Note1: Must not assign an axis in the root component, but always create the junction which is used for an axis definition in the direct parent kinematics component of the axis.

The head objects are added into the device_database.dat file with the appropriate HEAD type so that they match the holding system into the 3 designed pockets of the core machine tool. It is important to mention that the description name will be used later when these objects get retrieved in NX CAM. Thus they are chosen simple.

14.3 About the Post and CAM setup 14.3.1 Tool name in NX CAM Today NX CAM allows different possibilities to setup head examples. This example is related to the Post and CSE Simulation and can be seen as best practice. Each tool and the related operation need to be placed under the related head device in the ONT. To allow placing the same tool under different heads, a workaround is used here by adding an extension to the name of the tool. The rule is:

Toolname_headnumber (e.g. MILL_2 for using tool MILL on head 2) The post will remove that additional post fix before output it into the NC code. The CSE driver again adds it to find the right tool inside the ONT.

Note1: These special workaround is needed because CAM does not support duplicate names of tools placed on different head either any other view to define and place heads and tools.

14.3.2 Rules for the geometry View There are no special rules, which apply to this example only. As usual the same rules as for other OOTB sample apply. If the tool axis of operation is not parallel to Z axis of machine, this operation could be put directly under G54 (G55, etc.) the post will take care of creating a temporarily MCS object related to the plane belonging to the operation and the driver will take care about automatic swiveling inside the HEADCHANGE cycle. 14.3.3 Post output For each head or tool change the post will output one cycle head change program. Doing it that way keeps the post structure simple. The output will look like:



HEADCHANGE (toolname, headnumber, C-axis_value, A-axis_value) The logic is done in the simulation of the head change machine tool (see next chapter for more details). In the case an operation use identical head and/or tool but a different head orientation the post outputs head change statement (HEADCHANGE). Due to coordinate rotation will be handled in HEADCHANGE subprogram, CYCLE800 will not be outputted.

14.4 About the CSE Driver The CSE driver handles that complete example mainly through the HEADCHANGE subprogram. All related controller logic is placed into that single subprogram, which calls other subprograms to mount/unmount the head and the tool. 14.4.1 Settings done in the ini file This example uses some global NC variables. Here a list and description of variables used and defined in the related ini file. DEF NCK INT $P_HEADNO

-> actual mounted head DEF NCK STRING[128] $P_HEADNAME

-> name of the mounted head DEF NCK STRING[128] SIM_TOOL_CARRIER

-> name of the tool carrier, depends on the pocket name DEF NCK INT HEAD_TRANS_PLUS_SWIVEL

-> switch to activate swivel together with the head NOT used today DEF NCK REAL POCKET_SWIVEL_ROTX/Y/Z

-> variable to describe the rotation needed to do the swiveling based on the initial position of the head after it is mounted

14.4.2 Head Change Program This subprogram is called for all head/tool change actions from the main program. This program is written in Sinumerik NC code language only. From the main program the other subprograms to mount and un-mount the tool and head are called. Name of the subprogram: HeadChange.spf Parameter description of program: No. Parameter Type Description 1 _TOOL STRING The name of the tool e.g. MILL 2 _HN INT The number of the head (1== vertical 2== RAH 3==AC-Head) 3 _CPOS REAL The axis values to position the C axis in the head (head 2 and 3 only) 4 _APOS REAL The axis values to position the A axis in the head (head 3 only)

14.4.3 Mount Head This subprogram represents the PLC action to mount the head and is implemented in Any-Controller language. The head is mounted in two steps: logically with the AC command mountHead and physically as usual with the grasp command. sHeadName = getVariable("$P_HEADNAME"); mountHead(sHeadName, "S"); grasp(sHeadName, getJunction("POCKET", "S")); The mountHead command registers the heads tool carriers and axes in CSE. Each tool carrier represents a pocket in the head. When retrieving a device from the library, it can happen that a head axis has to be renamed due to the fact that different heads come with the same axis name (in our example head 2 and head 3



both have a C axis defined). The head mount command takes care of the mapping between the logical and the physical axis name (e.g. C and C_1). All heads are mounted by grasp on the main pocket of the machine tool. 14.4.4 Mount Tool This subprogram represents the PLC action to mount the tool and is implemented in Any-Controller language. The correct tool carrier is specified in the head change subprogram by using the variable SIM_TOOL_CARRIER.

sCarrier = getVariable("SIM_TOOL_CARRIER"); The name is extended by the head number (see workaround in the post chapter)

sToolName = getArrayElement("$TC_TP2",nToolID)+"_"+getVariable("$P_HEADNO"); The creation of the tool itself is done as usual, but with the correct carrier object like:

generateTool (sToolName, sCarrier); The grasp command to physically mount the tool needs to use the pocket junction on the head.

grasp(getNextTool(sCarrier), getJunction(sCarrier, "S")); For the activation of the tool, the correct carrier object is required again:

activateNextTool (sCarrier);

14.4.5 Un-mount Tool This subprogram represents the PLC action to mount the head and is implemented in Any-Controller language. Un-mounting the tool is done as usual, with the hint that again the predefined carrier name needs to be used. sCarrier = getVariable("SIM_TOOL_CARRIER"); release ( getCurrentTool(sCarrier));

14.4.6 Un-mount Head This subprogram represents the PLC action to mount the head and is implemented in Any-Controller language. As for mount, also two steps are required: the physical un-mount using the grasp command and the logical un-mount using the AC command unmountHead. To position the head on the correct place in the magazine, the head name variable is used. nHeadID = getVariable("$P_HEADNO"); sHeadName = getVariable("$P_HEADNAME"); grasp(sHeadName, getJunction("HEAD-"+ITOS(nHeadID),"HMJ")); unmountHead("S");

14.5 Changes in the MCF for the head change This section is for experienced people who usually take care of customizing CSE simulation drivers only. It describes what is changed in the MCF on top of the OOTB CCF to implement the given head change example. 14.5.1 About head correction One important enhancement in NX8.5 is the capability to access the head correction matrix in CSE. With this information it is possible to activate a complete compensation calculation of the head including the actual position of the axes in the head. A new CSE kernel method was introduced to get the data from NX CAM.



The 2nd parameter of the kernel method getHeadCorrection needs to be the name of a registered tool carrier. When the head is mounted and logically assigned (mountHead), CSE registers a tool carrier for each pocket on the head. These names are currently based on the KIM-name like:

If this head gets mounted to the spindle S (main tool carrier of the machine tool) the parameters of getHeadCorrection look like:

getHeadCorrection("S","H"+getVariable("$P_HEADNO")+"_SPINDLE")

14.5.2 Axis and channel configuration in the MCF The mount head and un-mount head CSE kernel command register and unregister the axes on the head. To achieve the correct behavior in this example the base MCF does include the axes of the base machine only. These are X,Y,Z and the spindle S. 14.5.3 Changes done in meta Code D The length correction of both the tool and the head, are set in the transformation $TOOL. Below the main difference on top of the CCF is shown. The kernel command SetToolCorrection is used, but it is important here to use the correct tool carrier to get the compensation of the tool. The compensation of the head is determined by calling getHeadCorrection. To follow the common implementation, the overall handling is achieved in the D metacode, but the pure math and setting of the $TOOL transformation is done in a method called from the D metacode. That method is called GMe_ActivateHeadCorrection.

Note: In this implementation the update of the length compensation of the tool plus head is done only if the D meta code is called. To handle e.g. an update after each motion of a heads rotary axis it would be necessary to overwrite and change the meta code for C and A (calling the related



method from there). But due to the fact that this will be very uncommon behavior on real machine tools it is not implemented this way in the CSE sim16 example.

14.5.4 Method GMe_ActivateHeadCorrection In this method the correction values for the mounted head and possible axis position are calculated and the kernel commands provide a transformation matrix. That data is used to either only add the length compensation or and that is default compensate the length and swivel the working plane based on the actual orientation of the head. The mode can be controlled by the last parameter of the TOOLCHANGE subprogram, which internally sets the HEAD_TRANS_PLUS_SWIVEL variable. For deeper details about the math behind that please use the MC and check the related method.



15 Sim09 becomes a Turn-Mill machine Tool With NX9 the sim09 Sinumerik is enhanced with a turning table. Doing so that machine tool becomes a turn-mill machine tool. The following chapters explain in detail what is done to achieve this e.g. what is specific updated on top of the previous milling only sim09.

15.1 Kinematic Configuration 15.1.1 Machine Tool Builder The kinematic model contains two spindle objects. The First one is the main spindle with the tool mount junction S in head and the second one C with the part mount junction on the rotary table. Both components are classified as spindles-objects and can be driven with a NC command e.g. S1000 M3. For lathe spindles it is necessary to create two spindle components (C_Base, C_Rotary) beneath a parent object with a containing rotary junction (C_TABLE_ROT). The C_BASE-component contains the NC axis flag and is classified as _LATHE_SPINDLE without any graphics. The graphic elements are assigned in the C_ROTARY component

15.1.2 Machine Configurator For the CSE driver it is also necessary to assign these two spindle objects. The C component must be classified and assigned as a spindle as well as the S component. The default setup for main spindle is S.



15.1.3 Adapted CSE-controller functions SETMS The Sinumerik NC-command SETMS set the active main spindle. (1 for S; 2 for C)

Tool length correction The CSE driver for sim09 query tool correction data from ISV (using GV_bUseSetToolCorrection == TRUE). The method for the tool length correction is divided into three different cases: Case1 - 0 rotated B-Head (vertical) and G17 working plane for milling/drilling

Case2 - 0 rotated B-Head (vertical) and G18 working plane for turning considered the non-centered tool tip and the L-correction on first axis

Case3 - 180 rotated B-Head (horizontal) and G18 working plane for turning



The following picture illustrates the reason for the advanced customization in the third case of the tool length correction method. The head rotation from vertical (B0) into horizontal position (B180), causes an offset value (101,6mm) which must be considered in the tool length correction. The function calculateIKSLinears calculates this offset value.

15.1.4 Turning specific NC section Turning operations take place in the XZ-working plane (G18). Therefore its required to swivel (ROT) the coordinate system into the correct working plane. For asymmetric tools (e.g. turning tool) the tool tip must be orientated (SPOS) into the correct cutting direction.



15.2 Changes of the Post 15.2.1 Def-File Adresses S Change [S$spindle=] "S" M_spindle Change [M$spindle=] "M" spos Change "SPOS1=" "SPOS=" frame_rot_z Added ROT Z

15.2.2 PUI Limits Old New mom_kin_4th_axis_min_limit Change 0 -360 mom_kin_4th_axis_plane Change ZX Other mom_kin_4th_axis_vector(2) Change 0 1 mom_kin_5th_axis_max_limit Change 360 360000 mom_kin_5th_axis_plane Change 0 -360000 mom_kin_max_fpm Change 10000 15000

15.2.3 TCL MOM_initial_move: Removed Template set_spindle Added Custom

Command PB_CMD_TURN_reset_rotary

Added Template set_spindle (if TURN) Changed Parameter mom_siemens_5axis_mode = SWIVELING

in PB_CMD_set_Sinumerik_default_setting 15.2.4 Auto Tool Change Added Template Frame_z_rot Added Custom Commands: PB_CMD_TURN_reset_rotary

Changed Auto_Tool_Change to output ROT Z,90 to rotate coordinate system Compensate for the 180 position of the head SPOS to select the correct spindle for tool change/turning



16 Creating your own CSE examples based on the OOTB mach examples

It is possible to re-use the OOTB examples to build your own machine tool simulation by either selecting an alternative controller (SINUMERIK, Fanuc and TNC) or a comparable machine tool. If the target machine tool is too complex to be derived from one of our OOTB examples, please contact you Siemens PL service representative.



17 Appendix

A. Example NC code TRAORI and circles The used NC code example of TRAORI and circle handling

N90 G40 G17 G710 G94 G90 G60 G601 FNORM N340 T="UGT0203_005" N350 M6 G54 D6 G0 X0.0 Y0.0 Z0.0 ; This NC code example should explain and demonstrate how circle handling ; and TRAORI plays together. ; ; TEST A: ; Position to a point on the geometry G0 X26.750670246 Y42.242178464 Z0.0 ; make a circle F1000 G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464 ; ; TEST B: ; rotate the table including the part and do the motion again. G0 B-60 C0.0 G0 X26.750670246 Y42.242178464 Z0.0 G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464 ; For sure the motion is the same - no one tell the controller to do different ; ; TEST C: ; Activate TRAORI and try again ORIWKS TRAORI G0 X0.0 Y0.0 Z0.0 G0 X26.750670246 Y42.242178464 Z0.0 G3 X26.750670246 Y-42.242178464 I-26.750670246 J-42.242178464 ; TRAORI activates the compensation for the moved coordinate system. ; so the circle is done in the rotated plane. ; ; TEST D: ; There are cases where the machine should do the circle still in the XY-Plane ; of the machine tool, ; (not in the rotated plane defined by the rotation and TRAORI ; Deactivate output TRAORI, to have circle in the original (XY) plane TRAFOOF G0 X0.0 Y0.0 Z0.0 ; ; TRAORI is off ; so the NC code needs to have the offset of the rotation calculated (!). ; ; The values are based on the rotation -60 around B and 0 around C ; on the position of the original coordinate system in respect to the rotary ; NC axis (kinematics model) ; G0 X141.506583681 Y0.0 Z-254.902851038 G0 X=141.506583681+13.375335123 Y=0.0+42.242178464 Z=-254.902851038-23.166760002 G3 X=141.506583681+13.375335123 Y=0.0-42.242178464 I-26.750670246 J-42.242178464 ; Summary: ; The NC code examples shows, that the case 'D is general possible, ; but this not supported by the OOTB post processors. ; So the rule here is: ; Activate TRAORI and avoid outputting circle statements G2/G3 ; after activating TRAORI and have NC axes rotated M30

B. Detailed information about ini files A setup-specific INI file could contain, for example a list of setup-specific tools and tool count initial machine positions default fixture offset register inch or metric unit selection



Putting such INI files directly into the mach kit affects all setups that share the same machine. When creating your own copies of the OOTB machine tool examples, consider the following execution order for INI files: All INI files in the MACH library directory parallel to the place where the MCF file is

located All INI files in the CAM-Setup-part working directory (subfolder cse_files) All INI files in the directory specified by the UGII_CAM_CSE_USER_DIR environment

variable Within a directory, the execution order is specified by the optional last hyphen. If the order is omitted then execution order 0 is implied, and the ordering is further determined alphabetically by programName. Should programName be the same then the entire programName-Channel-executionOrder is compared.

C. Example of a tool change subprogram This example is taken from the sim05 Sinumerik. (ToolChange.SPF)

G0 G90 ; Set the tool change position values in metric X,Y,Z R501=800.000 R502=-1000.000 R503=700.000 ; check the active unit and change values if inch is in use IF ($P_GG[13] == 2) R501 = R501 / 25.4; R502 = R502 / 25.4; R503 = R503 / 25.4; ENDIF ; move to the tool change position G0 G53 X=R501 Y=R502 G0 G53 Z=R503 ;Activate AC and do the tool mount based on preselected tool data ##LANGUAGE AC INT nToolID; STRING sToolName; nToolID = getVariable("$P_TOOLP"); sToolName = getArrayElement("$TC_TP2",nToolID); IF (sToolName != ""); generateTool (sToolName, "S"); ELSE; IF (nToolID > 0); generateTool (getToolNameByNumber(nToolID), "S"); ELSE; // ERROR no Tool preselected - ?? Send error message ?? ENDIF; ENDIF; IF (exist(getCurrentTool("S"))); collision (OFF, getCurrentTool("S")); visibility ( getCurrentTool("S"), OFF, TRUE); release ( getCurrentTool("S")); ENDIF; IF (exist(getNextTool("S"))); grasp ( getNextTool("S"), getJunction("SPINDLE", "S")); position ( getNextTool("S"), 0.0, 0.0, 0.0, 0.0, 0.0, 0.0); visibility ( getNextTool("S"), ON, TRUE); collision (ON, getNextTool("S"), 2, -0.01); activateNextTool ("S"); ENDIF; ; switch back to Sinumerik syntax ##LANGUAGE NATIVE ; return t o main program RET



D. Post Processor features of the OOTB examples This chapter describes the supported functions of the example posts of the MACH library machine tools. All post processors are available as inch and metric versions. Milling Machine Posts Standard functions for 3-5 milling machines: Standard linear, circular and rapid motion (G0,G1, G2 and G3) Standard drilling cycles supported by NX. (G80-G89/CYCLE81-CYCLE89) Cutter compensation (G40, G41 and G42) Tool length compensation (G43/G43.1 for Fanuc) Work coordinate offsets (G53-G59 /G505/G54.1 P1 etc ) Spindle control (M03, M04, M05, S) Coolant (M08, M09) The five- axis posts support coordinate system output on machines that have two rotary

axes. This is commonly a G68/ROT/CYCLE SPATIAL. The posts will create a local coordinate system on the fly using the tool axis.

Five axis tool tip control G43.4/TRAORI/M128 Turning Machine Posts Standard functions for two axis lathes. Standard linear, circular and rapid motion (G0,G1, G2 and G3) Standard centerline drilling cycles supported by NX (G80-G85) Cutcom (G40, G41 and G42) Work coordinate offsets (G53-G59) Spindle control (M03, M04, M05) Coolant (M08, M09)

Specific Functions in Sample Posts Specific functions supported: ini file will be generated by post for SINUMERIK controller including fixture offset values

and tool information. Remove the tool at end of program for milling machine: example: T0 M06 For 4 or 5 axis machine, rotary axis limit setting in postprocessor should be same as the

machine model. For SINUMERIK machine, tool offset value D is decided by adjust register number in CAM

setup. Fixture offset registers range

SINUMERIK G54-G57 G505-G599 Fanuc G54-G59 G54.1 P1 G54.1 P2.

Fixture offset number in CAM setup will decide fixture offset output. For SINUMERIK machine, if number is between 1 and 4, corresponding output is G54-

G57, if number is 5 output will be G505 and so on. For Fanuc machines, if number is between 1 and 6, corresponding output is G54-G59, if

number is greater than 6, G54.1 Px will be output. X = number -6. Tool tip control TRAORI and M128 are similar function in Sinumerik and Heidenhain T530. They are both

kinematics independent, means mom_mcs_goto should be output instead of mom_pos for X Y Z position. But for OOTB Fanuc examples, G43.4 only has capability to compensate tool axis length in variable axes milling operations. G43.1 should be used in fixed axes milling with head rotation. G43 is used in all operations with Z orientation spindle.



E. Example of an INI file CHANDATA(1) ; define the offsets G54 is for $P_UIFR[1] ; define the offsets G55 is for $P_UIFR[2] ; define the offsets G...is for $P_UIFR[...] $P_UIFR[1]=CTRANS(X,100.0,Y,80.0,Z,110.0) ; ; What is needed to place tool data into this file without having alarms. ; This is related to the tool handling mechanism in the archive. ; 1. The used tool ID is needed to be assigned to a magazine ; Therfore use: ; TC_MPP6[1,2]=100 ; This places the tool with the number 100 to the second pocket ; on the first magazine ; ; Set the tool name or number used inside the NC code to the tool 100 ; $TC_TP1[100]=1 ; $TC_TP2[100]="1401631125" ; Tool identifier in the NC code ; $TC_TP7[1]=1 ; Magazin number for the tool ; $TC_TP8[1]=10 ; Release status of the tool ; set Bit 1 - release and bit 3 tool is measured. ; this is the default on the machine tool ; ; Set tool offset values for the related D number of the tool 100 ; $TC_DP1[100,1]=120 ; tool type 120->milling ; $TC_DP2[100,1]=133.00 ; flute length ; $TC_DP3[100,1]=133.00 ; length ; $TC_DP6[100,1]=68.500 ; radius ; $TC_DP7[100,1]=0 ; corner radius $TC_TP1[1]=1 $TC_TP2[1]="UGT0203_065" $TC_TP7[1]=1 $TC_TP8[1]=10 $TC_DP1[1,1]=120 $TC_DP2[1,1]=29.00 $TC_DP3[1,1]=109.00 $TC_DP6[1,1]=4.0 $TC_DP7[1,1]=4.0 $TC_MPP6[1,1]=1 ;$TX_TOOLCOUNT = 9 ; tool numbers M17

F. Swiveling Cycles All three CCFs for TNC, Sinumerik and Fanuc include one swivel cycle implementation for the related NC code PLANE SPATIAL, TCARR/PAROT and G68.2. The way how that is implemented is consolidate over the different controllers and follow one general workflow. Here the details of that workflow: Initialize the system/global variables to define chain kinematics. Apply work piece coordinate rotation (and translation) to transformation

(WPFRAME for Sinumerik, ROTATIONAL for Fanuc, PLANE for TNC). Calculate the tool vector after work piece coordinate rotation. Calculate tool angle and part rotating angle with rotated tool vector. Select the tool and part rotating angle based on the restriction (SEQ, limitation). Compensate the linear offset caused by tool and part rotating. Compensate the rotating offset caused by table rotating if applicable

(for HeadTable and TableTable machine). Move and rotate head and/or table.

G. PLANE SPATIAL Inside the used MCF global variable are set related to the type of the machine tool and the axis vector directions. Name of the variables are:



GV_strMachineType (T, M,P) GV_strFourthAxisName (fourth axis name) GV_strFifthAxisName

(fifth axis name is dependent on forth axis for T and P; for M it is the one near to the part)

GV_dFourthAxisX (x component of forth axis) GV_dFourthAxisY (y component of forth axis) GV_dFourthAxisZ (z component of forth axis) GV_dFifthAxisX (x component of fifth axis) GV_dFifthAxisY (y component of fifth axis) GV_dFifthAxisZ (z component of fifth axis) GV_dFourthAxisLimitMin (fourth axis limit min) GV_dFourthAxisLimitMax (fourth axis limit max) GV_dFifthAxisLimitMin (fifth axis limit min) GV_dFifthAxisLimitMax (fifth axis limit max)

Here an example how that will look like in the case of the complex DMU EVO machine tool GV_strMachineType: "P" GV_strFourthAxisName: "B" GV_strFifthAxisName: "C" GV_dFourthAxisX 0.584825 GV_dFourthAxisY -0.573576 GV_dFourthAxisZ 0.573576 GV_dFifthAxisX 0.0 GV_dFifthAxisY 0.0 GV_dFifthAxisZ -1.0 GV_dFourthAxisLimitMin -9999 GV_dFourthAxisLimitMax 9999 GV_dFifthAxisLimitMin -9999 GV_dFifthAxisLimitMax 9999

About SEQ+/- parameter in PLANE SPATIAL Choose the shortest way as the preferred solutions. Implement this in the CCF file. First check if both solutions are achievable due to limits of the axis. If neither solution is within traverse range, error message will be generated. This mechanism uses the axis limits set in the MCF file. About TABLE ROT/COORD ROT in PLANE SPATIAL Transformation mode is an optional parameter for Plane function and TABLE ROT. This takes effect only if the configuration is TABLE ROT, machine type head-head and SPC>0 (Q122=0) Workflow of internal PLANE SPATIAL implementation Apply SPA SPB SPC rotation to PLANE Calculate the tool vector with SPA SPB SPC rotation Generate possible tool and part angle solution using calculateIKSAngles Get valid tool and part angle solution via GMe_SwivelingGetRotateSolution Set Q120 Q121 Q122 accordingly Set linear compensation due to tool holder rotation via GMe_SwivelingCalculateLinears Align WCS on table rotation via GMe_SwivelingCompTableRotation Handle TABLE ROT exception Move rotary axis with meta code MOVE/TURN/STAY and ABST.



H. CYCLE800 Basic Workflow The CYCLE800.SPF consists of two subprograms, which are: On Powerline: TOOLCARR.SPF On Solutionline: CUST_800.SPF

In addition CYCLE800 makes use of lots of system-variables and machine data, e.g. TC_CARRxx[x] that holds the kinematic configuration and also needs some definition files like PGUD.DEF and SMAC.DEF so on Powerline even more.



Basic about TCARR and PAROT The command TCARR calculates rotational axis angle, and calculates the translation compensation based on current kinematics, and apply it to the according transformation. The command PAROT rotates the transformation PARTFRAME for the table. Depending on the mode of $P_GG[42] (TCOABS, TCOFR) the compensation is calculated in TCARR. With TCOABS

Based on the angles defined in TC_CARR13 and TC_CARR14 With TCOFR

Based on the current tool orientation the angles are calculated first IKS and picker required simCYCLE800 consists of two subprograms: CYCLE800.SPF(Siemens),

TOOLCARR.SPF(CUST_800 is the name used in current CYCLE800.SPF) It moves and rotates the tool or table according to the input mode. Currently it is implemented for M20 M40 M41 cases. M20 Rotate the tool or table according to $TC_CARR13 and $TC_CARR14 M40 The initiation behavior defined by the user M41 Tool retract Axis Z



Workflow of TCARR

0 >= Value

Reset transformation

TCOABS or TCOFR

Calculate IKS Angles

Assign TC_CARR13&14

to partAngle&toolAng

le

TCOFR TCOABS

YES NO

Start TCARR

End TCARR

Assign TCANG1&2 to

partAngle&toolAngle

CARR13==TCANG3 AND

CARR14==TCANG4AND

CARR13!=0AND CARR14!=0

Assign TCANG3&4 to

partAngle&toolAngle

YES

Gme_GetRotateSolution

$P_TCSOL>0

Gme_Caculatelinears

TRUE

Gme_Caculatelinears

NO

FALSE

Set $P_TCSOL & $P_TCANG value



Workflow of PAROT



How to set $TC_CARR37 The OOTB examples uses the Solutionline version 4.4 example: $TC_CARR37[1]=201003003

I. G68.2 Workflow of internal G68.2 implementation Apply XYZ translation and IJK rotation to ROTATIONAL Calculate the tool vector with IJK rotation Generate possible tool and part angle solution using calculateIKSAngles



Select the tool and part rotating angle based on the axis limitation by GMe_SwivelingGetRotateSolution.

Set GV_dFourthAxisAngle and GV_dFifthAxisAngle accordingly Set linear compensation due to tool holder rotation using GMe_SwivelingCalculateLinears Align WCS on table rotation via GMe_SwivelingCompTableRotation

About G53.1 If G68.2 specifies the relationship between the feature coordinate system and the work piece coordinate system, G53.1 will automatically specifies the +Z direction of the feature coordinate system as the tool axis direction even if no angle is specified for the rotary axis. G53.1 must be specified in a block after the block that contains G68.2 G53.1 must be specified in a block in which there is no other command.

J. Default controller settings inside the CCFs This section list the settings, which are take place when a CSE simulation is initialized based on the OOTB CCF. Thus the method CSEInitializeChannel is called, which sets these defaults. Afterwards possible ini files get registered, which add addition defaults or can overwrite the ones already set. Sinumerik: Defaults set in the CCF: G0 G17 G54 G60 G601 G710 G90 G94 CFC NORM G450 BRISK ORIMKS DIAMOF

TCOABS GV_bUseLoadOffset=FALSE to deactivate the LoadOffset functionality. GV_bUseSetToolCorrection=FALSE to not use SetToolCorrection in D-Metacode and use

data from ini file instead. $MC_FRAME_ADD_COMPONENTS=1. This means G58 and G59 can be used. Also

means that TRANS stores in $P_PFRAME[.., TR] and ATRANS stores in $P_PFRAME[.., FI]

Defaults from the ini File: TO_INI ; load a to_ini file including tool and offset dat

working with ootb mach simulation examples

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