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    Easy milling with ShopMill 7,___________________ 9,___________________ 17,___________________ 29,___________________ 43,___________________ 55,___________________ 77,___________________ 95,___________________ 125,___________________ 169,___________________ 201,___________________ 205,__________...

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    Legal information Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, no...

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 3 Table of contents 7,1 7,Introduction................................................................................................................................................ 7,7 9,2 9,Advantages of 9, ShopM...

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    Table of contents Easy milling with ShopMill 4 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 55,6 55,Example 1: Longitudinal g 55,uide................................................................................................................. 55,55 55,6.1 55,Overview ................

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    Table of contents Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 5 169,10 169,Example 5: Flange................................................................................................................................. 169,169 169,10.1 169, 169,Overview ....

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    Table of contents Easy milling with ShopMill 6 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 7 Introduction 1 Faster from the drawing to the workpiece - but how? The technological development of machine tools is highly dynamic. Particularly with the creation of NC programs, the range has extended from pure CAM sy...

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    Introduction Easy milling with ShopMill 8 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Please note that the technology data used here are only examples due to the wide variety of situations in the workshop. Just as ShopMill was created with the help of skilled workers, these Training Docum...

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 9 Advantages of ShopMill 2 This chapter shows you the special advantages of ShopMill. 2.1 You will save time for training.... ● ShopMill does not use any foreign-language terms you would otherwise have to learn. All req...

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    Advantages of ShopMill 2.1 You will save time for training.... Easy milling with ShopMill 10 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 ● When working with ShopMill, you are assisted optimally by colored help displays. ● You can also integrate DIN/ISO commands into the Process Plan o...

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    Advantages of ShopMill 2.1 You will save time for training.... Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 11 ● You may switch between the individual work step and the workpiece graphic at any time when creating a process plan. Figure 2-1 Work step in a process...

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    Advantages of ShopMill 2.2 You will save time for programming... Easy milling with ShopMill 12 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 2.2 You will save time for programming... ● ShopMill already assists you in entering the technological values: You will only have to enter the handboo...

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    Advantages of ShopMill 2.2 You will save time for programming... Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 13 ● The integrated contour calculator can process all standard dimensions (Cartesian, polar); it is nevertheless very easy to handle and understand - th...

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    Advantages of ShopMill 2.2 You will save time for programming... Easy milling with ShopMill 14 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 ● You may switch between the graphic view and parameter screenform with help display at any time. Figure 2-5 Parameter screen with help display ...

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    Advantages of ShopMill 2.3 You will save time for manufacturing... Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 15 2.3 You will save time for manufacturing... ● You need not take into account the pocket radii when selecting the milling cutter for removing the con...

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    Advantages of ShopMill 2.3 You will save time for manufacturing... Easy milling with ShopMill 16 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 ● You can optimize your machining sequence with a minimum of work - thanks to the compact structure of the process plan (in this case, by saving of ...

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 17 To make everything function smoothly... 3 In this chapter you will learn the basics of the ShopMill operation with the help of examples. 3.1 The use of ShopMill A powerful software is one thing, but it must also be ea...

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    To make everything function smoothly... 3.1 The use of ShopMill Easy milling with ShopMill 18 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The most important keys of the CNC full keyboard for navigation in ShopMill are listed in the following: Key Function <HELP> Calls the context-s...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 19 All main functions can be called using the horizontal softkeys. All subfunctions of ShopMill can be called using the vertical softkeys. The ma...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill 20 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 In this mode, the machine is set up; the tool is traversed in the MANUAL mode. It is also possible to gauge tools and to set workpiece zeros. ...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 21 Machine - AUTO Select the "Machine" softkey. Press the AUTO key. During manufacturing, the current work step is displayed. It...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill 22 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Tool lists No cutting without tools. The tools can be managed in a tool list. Figure 3-3 Tool list Magazine Tools can be organized into a mag...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 23 Work offsets Zero points are saved in a clearly laid-out zero-point table. Figure 3-5 Work offsets 3.2.3 Program Editing programs This key ...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill 24 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The contour to be machined is entered graphically as a machining step. Geometry and technology constitute a unit in programming. The subseque...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 25 Example for the dovetailing of geometry and technology: This geometrical-technological interrelation is represented very clearly in the graphi...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill 26 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 3-7 3D view Figure 3-8 Side view

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 27 3.2.4 Program Manager Managing programs With the Program Manager, you can create new programs at any time. You can similarly open exis...

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    To make everything function smoothly... 3.2 The contents of the main menu Easy milling with ShopMill 28 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Creating a new program If you create a new program, you can specify the type of programming using the following softkeys: ShopMill program G...

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 29 Basics for beginners 4 This chapter will explain the general basics of the geometry and technology for milling. No inputs for ShopMill are planned yet. 4.1 Geometrical basics 4.1.1 Tool axes and work planes On universa...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill 30 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 On modern machines, the tool mounting position is changed without any modification and in a few seconds by way of a universal swivel head. Figure 4-2 Horizontal spindle If ...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 31 4.1.2 Points in the work space Various important reference points are provided for a CNC - such as the SINUMERIK 828D with ShopMill - for orientation in the working space by...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill 32 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 4.1.3 Absolute and incremental dimensioning Absolute input The entered values refer to the workpiece zero. With absolute inputs, the absolute coordinate values of the end...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 33 A few examples for the absolute/incremental combination can be found below: 4.1.4 Linear motions Two specifications are required to define an end point unambiguously. These...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill 34 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 ● Polar Input of the length and an angle Angle 38.13° = angle with reference to the previous element or angle 53.13° = starting angle with reference to the positive X ax...

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    Basics for beginners 4.1 Geometrical basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 35 4.1.5 Circular motions In the case of arcs, X and Y specify the end point; the circle center is specified with I and J. In ShopMill, these four values can be entered separat...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill 36 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Display of all parameters ShopMill also allows to display all possible geometry values: A further advantage of absolute center-point dimensioning: You need not r...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 37 Special ceramic coatings, such as an Al2O3 layer, are the ideal choice for high cutting rates thanks to their heat resistance. The photos which were kindly provided by t...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill 38 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 4.2.2 The tools in use Facing cutter The facing cutter (also called facing head or milling head) is used to remove large amounts of material. Shell end mill The shell e...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 39 Slotting end mill The slotting end mill (also called drilling-groove cutter) cuts across the center and can therefore cut into the solid. Mostly, it possesses two or thre...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill 40 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Solid drill Solid drills are fitted with indexable inserts and are only available for drill holes with larger diameter. The drilling process must always be performed with...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 41 The speed for two tools is calculated in the following example: In NC coding, the speed is specified with the letter S (from 'speed"). Therefore, the inputs are: ...

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    Basics for beginners 4.2 Technological basics Easy milling with ShopMill 42 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The feedrate vf is calculated using the feed per tooth, the number of teeth and the known speed. The feedrate for two tools with different number of teeth is calculated i...

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 43 Well equipped 5 In this section you will learn how to create the tools required for the examples in the following sections. Furthermore, it is explained how to take into account the tool lengths and how to set the work...

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    Well equipped 5.1 Tool management Easy milling with ShopMill 44 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Meaning of the most important parameters in the tool list: Location Location number Type Tool type Tool name The tool is identified by the name and the replacement tool number. You m...

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    Well equipped 5.1 Tool management Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 45 5.1.2 The tool wear list The wearing data for the appropriate tools are defined here. Figure 5-3 Tool wear list The most important tool wearing parameters are: Δ Length Length wea...

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    Well equipped 5.2 Tools used Easy milling with ShopMill 46 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 5.1.3 Magazine list All tools that are assigned to one or several tool magazines are contained in the magazine list. This list displays the condition of each tool. Individual magazine loca...

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    Well equipped 5.2 Tools used Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 47 To create a new tool, call the tool list and search for a free location. Select the "New tool" softkey. Select the desired tool type from the tool catalog displayed. This tool...

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    Well equipped 5.3 Tools in the magazine Easy milling with ShopMill 48 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 5.3 Tools in the magazine In the following you will learn how to insert the tools into the magazine. Select a tool without location number from the tool list and select the &quo...

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    Well equipped 5.4 Gauging tools Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 49 The diameter of the tool is measured using the Diameter, manual function. The Length, autom. function can be used to measure the tool in the Z direction using a tool probe. The Di...

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    Well equipped 5.5 Setting the workpiece zero Easy milling with ShopMill 50 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The Fixed-point calibration function is used to determine the fixed point used as the reference point for measuring the tool length manually. 5.5 Setting the workpiece zer...

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    Well equipped 5.5 Setting the workpiece zero Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 51 The zero point of a workpiece edge will be set in the following example using an edge probe. 1) Selecting the edge Define the sampling direction for the probe: LH (+) or ...

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    Well equipped 5.5 Setting the workpiece zero Easy milling with ShopMill 52 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Example 1: Any corner If the workpiece is positioned as shown here, the position/corner of the workpiece can be determined by approaching four points. 3D probes are offere...

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    Well equipped 5.5 Setting the workpiece zero Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 53 Example 2: Calculating a drill hole Example 3: Calculating a circular spigot

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    Well equipped 5.5 Setting the workpiece zero Easy milling with ShopMill 54 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 If an electronic 3D probe from the tool magazine is inserted into the spindle, clamping tolerances will occur. This would lead to incorrect results in further measurements....

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 55 Example 1: Longitudinal guide 66.1 Overview Learning objectives This section will explain the first steps to create a workpiece in detail. You will learn how to... ● create and manage programs; ● call tools and per...

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    Example 1: Longitudinal guide 6.2 Program management / creating programs Easy milling with ShopMill 56 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Note ShopMill always saves the last setting selected with the toggle key. Therefore, make sure that all units, texts and symbols are specified...

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    Example 1: Longitudinal guide 6.2 Program management / creating programs Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 57 Open the main menu using the MENU SELECT key. In the main menu, you may call various areas of ShopMill. Figure 6-4 Main menu Select the Program...

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    Example 1: Longitudinal guide 6.2 Program management / creating programs Easy milling with ShopMill 58 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Confirm your input. The following dialog box is opened: Figure 6-7 Creating a step sequence program Select the input format using the ShopMill...

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    Example 1: Longitudinal guide 6.2 Program management / creating programs Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 59 Enter the following values: Field Value Selection via toggle key Notes Unit of measurement mm X Work offset G54 X Blank Cuboid X X0 -75 Y0...

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    Example 1: Longitudinal guide 6.2 Program management / creating programs Easy milling with ShopMill 60 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Retraction position pattern The position pattern can be set to "Optimized" ( = time-optimized traversing distances) or "Retractio...

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    Example 1: Longitudinal guide 6.3 Calling a tool and specifying cutter radius compensation Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 61 6.3 Calling a tool and specifying cutter radius compensation Operating sequences To call the required tool, proceed as follows...

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    Example 1: Longitudinal guide 6.4 Specifying the distance to be traversed Easy milling with ShopMill 62 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 6.4 Specifying the distance to be traversed Operating sequences Now enter the distances to be traversed: Select the "Straight line" s...

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    Example 1: Longitudinal guide 6.4 Specifying the distance to be traversed Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 63 Enter the following values in the interactive screenform: Field Value Selection via toggle key Notes Z -10 abs X Radius compensation Empty fi...

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    Example 1: Longitudinal guide 6.4 Specifying the distance to be traversed Easy milling with ShopMill 64 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 6-15 Specifying the distance to be traversed - First machining path "Apply" the set values. After acceptance, the list of wor...

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    Example 1: Longitudinal guide 6.4 Specifying the distance to be traversed Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 65 Start simulation. Figure 6-19 Simulation of the distance to be traversed You may end simulation by selecting either the Simulation softkey aga...

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    Example 1: Longitudinal guide 6.4 Specifying the distance to be traversed Easy milling with ShopMill 66 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Radius compensation Selection Result Radius compensation is disabled. The milling cutter traverses with its center point along the created ...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 67 6.5 Creating drill holes and position repetitions Operating sequences Now enter the values for the drill holes and position repetitions. ...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill 68 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 6-21 Centering "Apply" the set values. Proceed as follows to specify and link the drilling positions with the cutting...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 69 Enter the following values for the two individual drill holes: Field Value Selection via toggle key Notes Z0 -10 The starting depth is ...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill 70 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Position circle softkey. Figure 6-23 Position circle Enter the following values: Field Value Selection via toggle key Notes...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 71 "Apply" the set values. Select the Positions softkey. Select the Position pattern softkey. Figure 6-24 Positions - Matrix ...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill 72 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Accept the tool into your program. After accepting the tool, enter the following values: Field Value Selection via toggle key Notes F 1...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 73 Open the tool list. Use the cursor key to select the THREADCUTTER M10 tool. Accept the tool into your program. After accepting the tool,...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill 74 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 "Apply" the set values. After accepting the values, you will see the linking of the work steps in the work step editor. Figure...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 75 "Apply" the set values. Last, repeat the positions 001 and 002 for the 10mm drill. Figure 6-30 Repeat the positions 001 and 0...

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    Example 1: Longitudinal guide 6.5 Creating drill holes and position repetitions Easy milling with ShopMill 76 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 77 Example 2: Injection mold 77.1 Overview Learning objectives In this section you will learn the following new functions. You will learn how to... ● specify straight lines and circular paths using polar coordinates; ...

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    Example 2: Injection mold 7.1 Overview Easy milling with ShopMill 78 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Preparation Perform the following steps without help: 1. Create a new workpiece with the name 'EXAMPLE2'. 2. Create a new step sequence program with the name 'INJECTION_FORM' . ...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 79 7.2 Straight lines and circular paths by way of polar coordinates Operating sequences Before you start entering the contour, ...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill 80 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 7-5 Specifying the pole "Apply" the set values. Select the Straight line / polar softkey. Enter the follo...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 81 Figure 7-6 Specifying the straight line using polar coordinates "Apply" the set values. Select the Circle / pola...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill 82 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 7-8 Specifying the circular path "Apply" the set values. Select the Back softkey. Select the Straight li...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 83 Figure 7-9 Specifying a straight line "Apply" the set values. Select the Polar softkey. Select the Pole softkey....

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill 84 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 "Apply" the set values. Select the Circle / polar softkey. Enter the following value in the interactive screenform...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 85 Figure 7-12 Specifying a straight line "Apply" the set values. Select the Straight line softkey. The whole contou...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill 86 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Straight line softkey. Enter the following values in the interactive screenform: Field Value Selection via toggle...

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    Example 2: Injection mold 7.2 Straight lines and circular paths by way of polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 87 The following simulation shows the manufacturing sequence for you to check before manufacturing the workpiece. Figure 7-15 S...

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    Example 2: Injection mold 7.3 Rectangular pocket Easy milling with ShopMill 88 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 7.3 Rectangular pocket Operating sequences Proceed as follows to enter the rectangular pocket: Figure 7-17 Rectangular pocket - Example 2 Select the Milling softkey. ...

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    Example 2: Injection mold 7.3 Rectangular pocket Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 89 Field Value Selection via toggle key Notes DXY 80% X The max. infeed in the plane (DXY) specifies at which width the material is removed. This can be specified either a...

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    Example 2: Injection mold 7.3 Rectangular pocket Easy milling with ShopMill 90 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Pocket softkey. Enter the following values in the interactive screenform: Field Value Selection via toggle key Notes F 0.08 mm/tooth X V 150 m/min X Machi...

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    Example 2: Injection mold 7.4 Circular pockets on a position pattern Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 91 7.4 Circular pockets on a position pattern Operating sequences Proceed as follows to enter the rectangular pockets: Figure 7-20 Rectangular po...

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    Example 2: Injection mold 7.4 Circular pockets on a position pattern Easy milling with ShopMill 92 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Field Value Selection via toggle key Notes UZ 0.3 Insertion Helical X EP 2 mm/rev X ER 2 Solid machining Complete machining X Figure 7-21 R...

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    Example 2: Injection mold 7.4 Circular pockets on a position pattern Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 93 Figure 7-22 Finishing a circular pocket "Apply" the set values. Select the Drilling softkey. Select the Positions softkey. Select the...

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    Example 2: Injection mold 7.4 Circular pockets on a position pattern Easy milling with ShopMill 94 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 7-23 Positions of the circular pockets "Apply" the set values. Start simulation. Figure 7-24 Simulation - Cut active

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 95 Example 3: Mold plate 88.1 Overview Learning objectives In this section you will learn the following new functions, in particular the contour calculator. You will learn how to... ● mill open contours; ● remove cont...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill 96 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 8-2 Workpiece - Example 3: Preparation Perform the following steps without help: 1. Create a new workpiece with the name 'Example3'. 2. Create a new proc...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 97 Operating sequences Proceed as follows to enter the contour: Select the Contour milling softkey. Select the New contour softkey. Type the name MOLD_PLATE_Outsid...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill 98 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Note Here you only describe the workpiece contour; the approach and retraction travels will only be defined later. "Apply" the set values. Enter th...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 99 Enter the following values for the horizontal straight line in the interactive screenform: Field Value Selection via toggle key Notes X 35 abs X R 15 The radi...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill 100 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the vertical straight line in the interactive screenform: Field Value Selection via toggle key Notes Y -100 abs X Figure 8-7 ...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 101 Enter the following values for roughing in the interactive screenform: Field Value Selection via toggle key Notes F 0.15 mm/tooth X V 120 m/min X Machinin...

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    Example 3: Mold plate 8.2 Path milling of open contours Easy milling with ShopMill 102 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 8-8 Roughing the contour "Apply" the set values. Enter the following values for finishing in the interactive screenform: Field Value Select...

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    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 103 The two machining steps are linked in the work step editor. Figure 8-10 Linking of the work steps in the process plan Th...

  • Page 104

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill 104 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Contour milling softkey. Select the New contour softkey. Type the name 'MOLD_PLATE_Inside' for the contour. F...

  • Page 105

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 105 Enter the following values for the horizontal straight line in the interactive screenform: Field Value Selection via togg...

  • Page 106

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill 106 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the arc in the interactive screenform: Field Value Selection via toggle key Notes Directio...

  • Page 107

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 107 "Apply" the set values. Enter the following values for the straight line in the interactive screenform: Field ...

  • Page 108

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill 108 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the arc in the interactive screenform: Field Value Selection via toggle key Notes Directio...

  • Page 109

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 109 Enter the following values for the straight line in the interactive screenform: Field Value Selection via toggle key Note...

  • Page 110

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill 110 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Pocket softkey. Open the tool list and select CUTTER20. Accept the tool into your program. Note The manufac...

  • Page 111

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 111 Figure 8-22 Roughing a pocket "Apply" the set values. Select the Pocket Resid.mat. softkey. As the 20mm cutter...

  • Page 112

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill 112 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 8-23 Machining residual material of the pocket "Apply" the set values. Select the Pocket softkey. Ope...

  • Page 113

    Example 3: Mold plate 8.3 Solid machining and residual material; finishing of contour pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 113 Figure 8-24 Finishing a pocket "Apply" the set values. Select the Pocket softkey. In the interactive screenfor...

  • Page 114

    Example 3: Mold plate 8.4 Machining on several planes Easy milling with ShopMill 114 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 8.4 Machining on several planes Operating sequences Mill a 60mm circular pocket in two work steps as described in the example 'INJECTION_FORM' . Figure 8-26 Circ...

  • Page 115

    Example 3: Mold plate 8.4 Machining on several planes Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 115 2. In the second work step, the pocket is finished using the same tool. Figure 8-28 Finishing a circular pocket To specify how the inside circular pocket is mac...

  • Page 116

    Example 3: Mold plate 8.4 Machining on several planes Easy milling with ShopMill 116 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for machining of the circular pocket in the interactive screenform: Field Value Selection via toggle key Notes F 0.15 mm/tooth X V 12...

  • Page 117

    Example 3: Mold plate 8.4 Machining on several planes Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 117 Enter the following values for machining of the circular pocket in the interactive screenform: Field Value Selection via toggle key Notes F 0.08 mm/tooth X V 15...

  • Page 118

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill 118 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 8.5 Taking into account obstacles Operating sequences As you have already seen in example 1, different drill patterns can also be interlinked in the case of thi...

  • Page 119

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 119 Proceed as follows to enter the relevant drilling positions: Select the Positions softkey. First create the left line of holes in the sequence from bottom to t...

  • Page 120

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill 120 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Use the "Obstacle" function to specify a distance of 1 mm to be traversed, as the right-hand line of holes must also be drilled from bottom to top for...

  • Page 121

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 121 Figure 8-37 Specifying the line of holes "Apply" the set values. Select the Positions softkey. To get to the next drill pattern - the circle of hol...

  • Page 122

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill 122 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 8-38 Specifying the drill holes in the full circle "Apply" the set values. Select the Positions softkey. To make the last drill hole, anothe...

  • Page 123

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 123 Figure 8-39 Specifying the drilling positions "Apply" the set values. Note This programming example is intended to familiarize you with the "...

  • Page 124

    Example 3: Mold plate 8.5 Taking into account obstacles Easy milling with ShopMill 124 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

  • Page 125

    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 125 Example 4: Lever 99.1 Overview Learning objectives In this section you will learn the following new functions. You will learn how to... ● perform face milling; ● create edges (auxiliary pockets) for removing mater...

  • Page 126

    Example 4: Lever 9.1 Overview Easy milling with ShopMill 126 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 9-2 Workpiece - Example 4: Preparation Perform the following steps without help: 1. Create a new workpiece with the name 'Example4'. 2. Create a new process plan with the name 'L...

  • Page 127

    Example 4: Lever 9.2 Face milling Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 127 9.2 Face milling Operating sequences Select the Milling softkey. Select the Face milling softkey. Open the tool list and select FACEMILL63. Accept the tool into your program. Ente...

  • Page 128

    Example 4: Lever 9.2 Face milling Easy milling with ShopMill 128 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 "Apply" the set values. Select the Face milling softkey. Enter the following values for finishing in the interactive screenform: Field Value Selection via toggle key Not...

  • Page 129

    Example 4: Lever 9.3 Creating an edge for the lever island Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 129 9.3 Creating an edge for the lever island Operating sequences Note Islands are described - like pockets - as a contour in the graphical contour calculator....

  • Page 130

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 130 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Compare your contour with the screen below. Figure 9-8 Readily designed contour 9.4 Machining the lever Operating sequences Proceed as follows to enter the contour: Figure 9...

  • Page 131

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 131 In the interactive screenform, enter the following values for the starting point of the contour line: Field Value Selection via toggle key Notes X -24 abs Y 0 abs Figur...

  • Page 132

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 132 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the first arc in the interactive screenform: Field Value Selection via toggle key Notes Direction of rotation Clockwise X R 24 I 0 Radius an...

  • Page 133

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 133 Create the inclined straight line connected tangentially to the preceding element. Select the Tangent to prec.elem. softkey. Figure 9-13 Inclined straight line contour Press...

  • Page 134

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 134 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the arc connected tangentially. Select the Tangent to prec.elem. softkey. Enter the following values for the arc in the interactive screenform: Field Value Selection v...

  • Page 135

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 135 Enter the following values for the horizontal straight line up to end point X30 in the interactive screenform: Field Value Selection via toggle key Notes X 30 abs X R 40 En...

  • Page 136

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 136 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Observe the following note for the next inclined straight line: Note The tangential transition is always only referred to the main element, i.e. in this case, the straight i...

  • Page 137

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 137 Enter the arc connected tangentially. Select the Tangent to prec.elem. softkey. Select the All parameters softkey. Use the All parameters function to display detailed inform...

  • Page 138

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 138 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Specify the vertical straight line (automatically tangential) up to the end point Y-27. Select the Tangent to prec.elem. softkey. Enter the following values in the interactiv...

  • Page 139

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 139 Specify the inclined straight line. Figure 9-19 Inclined straight line contour Press ENTER to confirm your input.

  • Page 140

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 140 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Close the contour to the starting point with an arc. Select the Tangent to prec.elem. softkey. In the interactive screenform, enter the following values for the starting poin...

  • Page 141

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 141 Select the Pocket softkey. Open the tool list and select CUTTER20. Accept the tool into your program. Enter the following values for roughing in the interactive screenfor...

  • Page 142

    Example 4: Lever 9.4 Machining the lever Easy milling with ShopMill 142 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Pocket softkey. Enter the following values for finishing in the interactive screenform: Field Value Selection via toggle key Notes F 0.08 mm/tooth X V 150 m/min ...

  • Page 143

    Example 4: Lever 9.5 Creating an edge for the circular island Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 143 9.5 Creating an edge for the circular island Operating sequences Create an edge for boundary when milling without help. Mill down to a depth of -3. Figu...

  • Page 144

    Example 4: Lever 9.6 Creating a 30mm circular island Easy milling with ShopMill 144 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Design the boundary for the traversing paths around the workpiece contour as described above such that the 20mm milling cutter fits everywhere between the boundary...

  • Page 145

    Example 4: Lever 9.6 Creating a 30mm circular island Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 145 Select the Contour milling softkey. Create a new contour with the name 'LEVER_Circle_R15'. Figure 9-29 Creating the contour Create a circular contour without he...

  • Page 146

    Example 4: Lever 9.7 Creating a 10mm circular island Easy milling with ShopMill 146 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 9.7 Creating a 10mm circular island Operating sequences To create the 10mm circular island, proceed as follows: Figure 9-31 10mm circular island Select the Contou...

  • Page 147

    Example 4: Lever 9.8 Copying the 10mm circular island Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 147 After entering the circle, the broken-line graphics looks like this. Figure 9-34 Broken-line graphics 9.8 Copying the 10mm circular island Operating sequences ...

  • Page 148

    Example 4: Lever 9.8 Copying the 10mm circular island Easy milling with ShopMill 148 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Navigate and copy the 'LEVER_Circle_R5_A' contour. Figure 9-36 Copying the contour Paste the copied contour and give it the name 'LEVER_Circle_R5_B'. Figure 9-...

  • Page 149

    Example 4: Lever 9.8 Copying the 10mm circular island Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 149 After accepting the values, your process plan should look like this: Figure 9-38 Pasted contour in the work step editor Now you must only change the starting poi...

  • Page 150

    Example 4: Lever 9.9 Machining the circular island using the editor Easy milling with ShopMill 150 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 9.9 Machining the circular island using the editor Operating sequences To machine the three circular islands, proceed as follows: When machining the...

  • Page 151

    Example 4: Lever 9.9 Machining the circular island using the editor Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 151 Copy the highlighted work steps. Figure 9-42 Highlighted machining steps Paste the work steps beneath the contours. This will link the technologie...

  • Page 152

    Example 4: Lever 9.9 Machining the circular island using the editor Easy milling with ShopMill 152 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Open the work step for roughing. Enter the following values for roughing in the interactive screenform: Field Value Selection via toggle key Notes ...

  • Page 153

    Example 4: Lever 9.9 Machining the circular island using the editor Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 153 "Apply" the set values. The screenform above shows which geometries are used in finishing (process plan graphic). Figure 9-46 Broken-li...

  • Page 154

    Example 4: Lever 9.10 Deep hole drilling Easy milling with ShopMill 154 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Functions of the work step editor The following information provides you with an overview of the functions of the work step editor. Use this softkey to switch to the broken-...

  • Page 155

    Example 4: Lever 9.10 Deep hole drilling Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 155 Select the Drilling softkey. Select the Drilling Reaming softkey. Open the tool list and select PREDRILL30. Accept the tool into your program. Enter the following values...

  • Page 156

    Example 4: Lever 9.11 Milling a helix Easy milling with ShopMill 156 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the drilling position in the interactive screenform: Field Value Selection via toggle key Notes Positions Rectangular X Z0 -6 X0 70 Y0 -40 ...

  • Page 157

    Example 4: Lever 9.11 Milling a helix Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 157 Select the Straight line Circle softkey. Open the tool list and select CUTTER20 . Accept the tool into your program. Enter the following value in the interactive screenform: F...

  • Page 158

    Example 4: Lever 9.11 Milling a helix Easy milling with ShopMill 158 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Field Value Selection via toggle key Notes X 82 X Y -40 X Z -5 X Radius compensation off X Figure 9-53 Positioning "Apply" the set values. Select the Helix sof...

  • Page 159

    Example 4: Lever 9.12 Boring Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 159 Figure 9-54 Specifying the helix "Apply" the set values. 9.12 Boring Operating sequences Proceed as follows to machine the circular pocket to the required dimensions using a b...

  • Page 160

    Example 4: Lever 9.12 Boring Easy milling with ShopMill 160 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Enter the following values for the processing in the interactive screenform: Field Value Selection via toggle key Notes F 0.08 mm/rev X S 500 rpm X Z1 15 inc X DT 0 s X SPOS 45 Lif...

  • Page 161

    Example 4: Lever 9.13 Thread milling Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 161 Enter the following values for the position in the interactive screenform: Field Value Selection via toggle key Notes Z0 -6 X0 70 Y0 -40 Figure 9-57 Positioning "App...

  • Page 162

    Example 4: Lever 9.13 Thread milling Easy milling with ShopMill 162 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Open the tool list and select THREADCUTTER . Accept the tool into your program. Mill the thread from the top to the bottom. To this end, use the THREADCUTTER (F = 0.08 mm/tooth...

  • Page 163

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 163 Figure 9-60 Entering the position "Apply" the set values. 9.14 Programming a contour using polar coordinates Programming with polar coor...

  • Page 164

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill 164 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Operating sequences Move the cursor first to the arc to redimension its center (see screenform below). Figure 9-62 Positioning the cursor on the ar...

  • Page 165

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 165 Subsequently, change the values matching the arc: 1. In the arc dialog box, delete the values Y-58, I0 and J-58 which are no longer valid. Figure 9...

  • Page 166

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill 166 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The broken-line graphics shows that the auxiliary pocket LEVER_Lever_Area and the circular island LEVER_Circle_R5_B must also be adapted in the same...

  • Page 167

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 167 Figure 9-68 Adapting the circular island After successful adaptation, your broken-line graphics looks like this: Figure 9-69 Broken-line graphics

  • Page 168

    Example 4: Lever 9.14 Programming a contour using polar coordinates Easy milling with ShopMill 168 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

  • Page 169

    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 169 Example 5: Flange 1010.1 Overview Learning objectives In this chapter you will learn how to ... ● create a subroutine; ● mirror work steps; ● chamfer any contours, and ● create longitudinal and circular groove...

  • Page 170

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill 170 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Note All work steps were explained in the previous examples and nearly all softkeys / keys to be selected / pressed were indicated. In the following example, the whole s...

  • Page 171

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 171 Enter the following data for the program header. The blank dimensions will be specified later centrally in the main program. Figure 10-5 Entering the data for the subrout...

  • Page 172

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill 172 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Specify the starting point. The top right corner, for example, will be designed. Figure 10-7 Specifying the starting point "Apply" the set values. Create the ...

  • Page 173

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 173 The contour is to be roughed using an R20 milling cutter (F = 0.15 mm/tooth and v = 120 m/min). Figure 10-9 Roughing the contour The approach and retract paths are approa...

  • Page 174

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill 174 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 "Apply" the set values. In the next few steps, the corner of the blank cuboid is to be rounded using R5: Select the Contour milling softkey. Create a new con...

  • Page 175

    Example 5: Flange 10.2 Creating a subroutine Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 175 Subsequently, specify the contour and the relevant work steps: Figure 10-14 Specifying the geometry Figure 10-15 Roughing the contour

  • Page 176

    Example 5: Flange 10.3 Mirroring work steps Easy milling with ShopMill 176 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 10-16 Finishing the contour Figure 10-17 Complete subroutine in the work step editor 10.3 Mirroring work steps Task When you have finished the subroutine, create ...

  • Page 177

    Example 5: Flange 10.3 Mirroring work steps Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 177 The sequence of processing with the setting New is shown below in the form of drawings: 1. Processing (see subroutine) 2. Processing: Mirroring the X axis (the X values a...

  • Page 178

    Example 5: Flange 10.3 Mirroring work steps Easy milling with ShopMill 178 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 "Apply" the set values. Select the Miscellaneous softkey. Paste the subroutine into the main program. Note If you have created the subroutine in the same di...

  • Page 179

    Example 5: Flange 10.3 Mirroring work steps Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 179 Preparing the 2nd processing: Mirror the X values. Figure 10-22 Mirroring Press ENTER to confirm your input. To mirror the remaining processing operations, proceed as f...

  • Page 180

    Example 5: Flange 10.3 Mirroring work steps Easy milling with ShopMill 180 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 The help display illustrating this procedure will help you. After you have entered all 4 processing operations, disable mirroring for all three axes. Figure 10-24 Mirrorin...

  • Page 181

    Example 5: Flange 10.4 Holes Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 181 Check your work by now using the simulation. Figure 10-26 Simulation in 3D display 10.4 Holes Operating sequences With the next few work steps, you will create four drill holes in the c...

  • Page 182

    Example 5: Flange 10.4 Holes Easy milling with ShopMill 182 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 10-28 Centering Figure 10-29 Drilling

  • Page 183

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 183 Figure 10-30 Specifying the positions of the obstacles 10.5 Rotation of pockets Operating sequences To program the contour and the processing for the pocket highlighted yel...

  • Page 184

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill 184 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Specify the starting point. Figure 10-32 Specifying the starting point "Apply" the set values. Select the Arc softkey. Select the All parameters softkey. The a...

  • Page 185

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 185 "Apply" the set values. Select the Diagonal softkey. Select the All parameters softkey. Create the diagonal straight line. Figure 10-34 Specifying the diagona...

  • Page 186

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill 186 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Arc softkey. Select the All parameters softkey. Create the 2nd arc. Figure 10-35 Specifying the arc "Apply" the set values.

  • Page 187

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 187 Select the Diagonal softkey. Select the All parameters softkey. Create the 2nd diagonal straight line. Figure 10-36 Specifying the diagonal "Apply" the set va...

  • Page 188

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill 188 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Select the Arc softkey. Create the final arc. Figure 10-37 Specifying the final arc "Apply" the set values. Accept the contour pocket into your process plan. ...

  • Page 189

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 189 Figure 10-39 Finishing the pocket base Figure 10-40 Finishing the pocket edge To copy the created work step sequence for the machining of the three pockets, proceed as ...

  • Page 190

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill 190 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Copy the work step sequence to the clipboard. Figure 10-41 Copying the work steps Select the Miscellaneous softkey. Select the Transformations softkey. The coordinate sy...

  • Page 191

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 191 Paste the copied work steps. Figure 10-43 Pasting the copied work steps Select the Transformations softkey. Enter another rotation by 120°. Figure 10-44 Rotation around...

  • Page 192

    Example 5: Flange 10.5 Rotation of pockets Easy milling with ShopMill 192 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Paste the copied work steps. Figure 10-45 Pasting the copied work steps Select New and specify the value 0° to undo the rotation. Figure 10-46 Undoing the rotation Pres...

  • Page 193

    Example 5: Flange 10.6 Chamfering contours Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 193 10.6 Chamfering contours Operating sequences Chamfer the circular pocket last machined without help. For chamfering, you will need a tool type which allows entering of an a...

  • Page 194

    Example 5: Flange 10.6 Chamfering contours Easy milling with ShopMill 194 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Figure 10-49 Work step "Chamfering" in the work step editor Figure 10-50 Top view on the chamfered contour

  • Page 195

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 195 10.7 Longitudinal and circular grooves Operating sequences Finally, program the grooves. They will be positioned to the correct point by way of Position patter...

  • Page 196

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill 196 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Use the same tool (F = 0.05 mm/tooth and v = 150 m/min) for finishing. Figure 10-53 Finishing a longitudinal groove "Apply" the set values. Sele...

  • Page 197

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 197 Select the Milling softkey. Select the Groove softkey. Use the tool CUTTER6 (F = 0.08 mm/tooth, FZ = 0.08 mm/tooth and v = 120 m/min) for the roughing of th...

  • Page 198

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill 198 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Use the same tool (F = 0.05 mm/tooth, FZ = 0.05 mm/tooth and v = 150 m/min) for finishing. Figure 10-56 Finishing the circular groove "Apply" the s...

  • Page 199

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 199 Broken-line graphics Figure 10-58 Broken-line graphics Simulation in 3D display Figure 10-59 3D view

  • Page 200

    Example 5: Flange 10.7 Longitudinal and circular grooves Easy milling with ShopMill 200 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

  • Page 201

    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 201 And now you can start manufacturing! 11 After you have acquired well-founded knowledge of the creation of process plans in ShopMill by working with the examples, we will now machine workpieces. To machine a workpiece...

  • Page 202

    And now you can start manufacturing! Easy milling with ShopMill 202 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 . Note When working with the measuring devices and measuring cycles, observe the manufacturer specifications. Executing the process plan Now the machine is prepared, the work...

  • Page 203

    And now you can start manufacturing! Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 203 Select the NC selection softkey. Figure 11-3 Executing Due to the fact that the process plan has not yet been executed with control, turn the feedrate potentiometer to zero posi...

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    And now you can start manufacturing! Easy milling with ShopMill 204 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 205 How fit are you in ShopMill? 1212.1 Introduction The following four exercises are the basis for a personal test of your work with ShopMill. You will be assisted in all four exercises with an indication of one possible...

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    How fit are you in ShopMill? 12.2 Exercise 1 Easy milling with ShopMill 206 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Model Figure 12-2 Process plan Figure 12-3 Workpiece simulation

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    How fit are you in ShopMill? 12.3 Exercise 2 Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 207 12.3 Exercise 2 Will you manage this task using ShopMill within 20 minutes? Figure 12-4 Workshop drawing COMPLEX_POCKET Notes Even though it looks complex: This contour i...

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    How fit are you in ShopMill? 12.3 Exercise 2 Easy milling with ShopMill 208 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Model Figure 12-5 Process plan Figure 12-6 Workpiece simulation

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    How fit are you in ShopMill? 12.4 Exercise 3 Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 209 12.4 Exercise 3 Will you manage this task using ShopMill within 30 minutes? Figure 12-7 Workshop drawing PLATE Notes In this sample process plan, the area around the isla...

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    How fit are you in ShopMill? 12.4 Exercise 3 Easy milling with ShopMill 210 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Model Figure 12-8 Process plan Figure 12-9 Workpiece simulation

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    How fit are you in ShopMill? 12.5 Exercise 4 Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 211 12.5 Exercise 4 Will you manage this task using ShopMill within 30 minutes? Figure 12-10 Workshop drawing WING Notes In this sample process plan, the circular outside con...

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    How fit are you in ShopMill? 12.5 Exercise 4 Easy milling with ShopMill 212 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 Model Figure 12-11 Process plan Figure 12-12 Specifying engraving

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    How fit are you in ShopMill? 12.5 Exercise 4 Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 213 Figure 12-13 Workpiece simulation

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    How fit are you in ShopMill? 12.5 Exercise 4 Easy milling with ShopMill 214 Training Documents, 09/2011, 6FC5095-0AB50-1BP1

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    Easy milling with ShopMill Training Documents, 09/2011, 6FC5095-0AB50-1BP1 215 Index A Absolute 32,input, 32 Alarms 28,, 28 All parameter 137,s, 137 Apply dial 106,og, 106 Approach and retra 101,ction, 101, 173,173 Approach starting point, 78,78 Auxiliary 129,pocket, 129, 143,143 143, B B...

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    Index Easy milling with ShopMill 216 Training Documents, 09/2011, 6FC5095-0AB50-1BP1 N NC spotdrill, 39,39 O Obstacles, 120,120 P Past 16,e, 16 Points in the working space, 31,31 Polar angle, 79,79, 80,80 Polar coordinates, 163,163 79,Pole, 79 Position 12,pattern, 12 Posi 70,tioning, 7...

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