Belotti 5-Axis FLA, FLU and TRIM Models

SIEMENS 840D sl CNC Control

AlphaCAM 5-Axis Post-Processors User Manual

Rev. 1.1 - 04/07/2016

tmarkoski@stilesmachinery.com

Table of Contents

Disclaimer of Warranty ------------------------------------------------------------------------------------------------- 2

Required Files ------------------------------------------------------------------------------------------------------------- 3
NC Code Format ---------------------------------------------------------------------------------------------------------- 6
NC Code Output ---------------------------------------------------------------------------------------------------------- 7
Work Offsets --------------------------------------------------------------------------------------------------------------- 9
C-Axis Pre-Load ---------------------------------------------------------------------------------------------------------- 10
Machining Zones --------------------------------------------------------------------------------------------------------- 11
High Speed Machining ------------------------------------------------------------------------------------------------- 12
Safe Z Clearance Plane ------------------------------------------------------------------------------------------------ 15
Unwind C-Axis ------------------------------------------------------------------------------------------------------------ 16
CNC Programmer -------------------------------------------------------------------------------------------------------- 17
Send to AlphaEDIT ------------------------------------------------------------------------------------------------------ 18
Appendix -------------------------------------------------------------------------------------------------------------------- 21

DISCLAIMER OF WARRANTY:
This user manual and the accompanying files are sold or supplied "as is" and without warranties as to
performance of merchantability or any other Warranties whether expressed or implied.
While every effort has been made to verify the accuracy of the content provided, it is the responsibility
of those programming and operating Belotti 5-Axis CNC Machining Centers to abide by standards of safe programming,
setup and operation of any CNC Machine Tool.
Because the various machine configurations, programming methods, individual work pieces and
setup/operator skill levels all effect the actual operation of the machine,
NO WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS OFFERED.
The user must assume the entire risk of using the information provided in this manual and
accompanying files.
Any typographical errors should be brought to the attention of Stiles Machinery National Technical Support immediately.

Stiles Machinery Inc.

http://www.stilesmachinery.com/
Corporate Headquarters
3965 44th St. SE
Grand Rapids, MI 49512
p 616.698.7500
f 616.698.9411

Required Files
AlphaCAM Mill

SIEMENS_840D_sl_5X_CA.amp
This is the AlphaCAM Mill Post-Processor file for use with NC programs created in INCHES.
It should be placed in the AlphaCAM Mill Post-Processor folder.
The default AlphaCAM Mill Post-Processor folder is C:\Alphacam\LICOMDAT\MPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_mm.amp
This is the AlphaCAM Mill Post-Processor file for use with NC programs created in MILLIMETERS.
It should be placed in the AlphaCAM Mill Post-Processor folder.
The default AlphaCAM Mill Post-Processor folder is C:\Alphacam\LICOMDAT\MPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_ROTARY-CLAMPS.amp
This is the AlphaCAM Mill Post-Processor file for use with NC programs created in INCHES.
It has the additional function of supporting the rotary axis brakes.
It should be placed in the AlphaCAM Mill Post-Processor folder.
The default AlphaCAM Mill Post-Processor folder is C:\Alphacam\LICOMDAT\MPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_ROTARY-CLAMPS_mm.amp
This is the AlphaCAM Mill Post-Processor file for use with NC programs created in MILLIMETERS.
It has the additional function of supporting the rotary axis brakes.
It should be placed in the AlphaCAM Mill Post-Processor folder.
The default AlphaCAM Mill Post-Processor folder is C:\Alphacam\LICOMDAT\MPosts.Alp\ .

AlternateFileExtension.amb
This is the AlphaCAM Mill Add-In file that allows for the use of a file extension that differs from the standard
AlphaCAM *.anc file extension. This Add-In will read the Post-Processor file for the proper file extension (*.MPF).
It also provides the user with the ability to open the output file directly in AlphaEDIT.
This is an Add-In that is included with the AlphaCAM installation..
The default installation folder is
C:\Program Files (x86)\Vero Software\Alphacam 2016 R1\StartUp\File\AlternateFileExtension\ .
The Add-In must be explicitly enabled in order for it operate automatically.
From the main AlphaCAM Ribbon Bar, select Add-Ins/Macros | Add-Ins.
Enable the Add-In by placing a check mark next to the name of the Alternate File Extension Add-In in the list.

Required Files (continued)

AlphaCAM Router

SIEMENS_840D_sl_5X_CA.arp
This is the AlphaCAM Router Post-Processor file for use with NC programs created in INCHES.
It should be placed in the AlphaCAM Router Post-Processor folder.
The default AlphaCAM Router Post-Processor folder is C:\Alphacam\LICOMDAT\RPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_mm.arp
This is the AlphaCAM Router Post-Processor file for use with NC programs created in MILLIMETERS.
It should be placed in the AlphaCAM Mill Post-Processor folder.
The default AlphaCAM Router Post-Processor folder is C:\Alphacam\LICOMDAT\RPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_ROTARY-CLAMPS.arp
This is the AlphaCAM Router Post-Processor file for use with NC programs created in INCHES.
It has the additional function of supporting the rotary axis brakes.
It should be placed in the AlphaCAM Router Post-Processor folder.
The default AlphaCAM Router Post-Processor folder is C:\Alphacam\LICOMDAT\RPosts.Alp\ .

SIEMENS_840D_sl_5X_CA_ROTARY-CLAMPS_mm.arp
This is the AlphaCAM Router Post-Processor file for use with NC programs created in MILLIMETERS.
It has the additional function of supporting the rotary axis brakes.
It should be placed in the AlphaCAM Router Post-Processor folder.
The default AlphaCAM Router Post-Processor folder is C:\Alphacam\LICOMDAT\RPosts.Alp\ .

AlternateFileExtension.arb
This is the AlphaCAM Mill Add-In file that allows for the use of a file extension that differs from the standard
AlphaCAM *.anc file extension. This Add-In will read the Post-Processor file for the proper file extension (*.MPF).
It also provides the user with the ability to open the output file directly in AlphaEDIT.
This is an Add-In that is included with the AlphaCAM installation..
The default installation folder is
C:\Program Files (x86)\Vero Software\Alphacam 2016 R1\StartUp\File\AlternateFileExtension\ .
The Add-In must be explicitly enabled in order for it operate automatically.
From the main AlphaCAM Ribbon Bar, select Add-Ins/Macros | Add-Ins.
Enable the Add-In by placing a check mark next to the name of the Alternate File Extension Add-In in the list.

Required Files (continued)

AlphaEDIT

CleanComments.aab
This is an AlphaEDIT Add-In application that is required for the final formatting of the NC Program files (*.MPF)
output by the AlphaCAM Post-Processor. It should be placed AlphaEDIT Add-In folder.
The default AlphaEDIT Add-In folder is C:\Alphacam\LICOMDIR\VBMacros\Startup\ .
The Add-In must be explicitly enabled in order for it operate automatically.
From the main AlphaEDIT Ribbon Bar, select Utils | Add-Ins.
Enable the Add-In by placing a check mark next to the name of the CleanComments Add-In in the list.

NC Code Format
The post-processor will format the NC Code output with the following format options.

SIEMENS Vector format instead of explicit rotary axis angles.

SIEMENS CIP Arc format for all orientations.
Single Work Offset Part Datum Local Coordinate Systems are not supported.
All XYZ Coordinates are Global Coordinates, regardless of WorkPlane.
(SIEMENS CYCLE800 is not supported.)
Drill Cycles are must be configured in AlphaCAM as Global Linear.
(Drill Cycles will be output at Point-to-Point data in Global Coordinates.)
Rotary Axis Brakes via M-Code (SIEMENS_840D_sl_5X_CA_ROTARY-CLAMPS - INCH & MILLIMETER)

NC Code Output
As users may have multiple CNC Machines and post-processors, insure that the correct post-processor is selected.
From the main AlphaCAM Ribbon Bar, select Select Post and select either the inch or millimeter version of the
post-processor from the Open dialogue.

NC Code Output (continued)

To begin the NC code output process, from the main AlphaCAM Ribbon Bar, select Output NC

The Output NC dialogue will be displayed with the currently active post-processor.
Select the File option from the dialogue and click the OK button.

The Save As dialogue will be displayed with the current AlphaCAM file name and extension (*.MPF).
Select the proper output folder for the NC file and click the Save button.

NC Code Output (continued)

If the output file already exists in the output folder, the user will be asked if they wish to replace it.
Click Yes if you wish to overwrite the existing file or No if you wish to modify the output file name.

Work Offsets
At this point the user will be prompted for the Work Offset to be used for the NC Program.
The SIEMENS 840D sl CNC control supports G54-G57 and G505-G599.
Entering a value of 0- 3 will result in a Work Offset of G54-G57.
Entering a value of 4- 98 will result in a Work Offset of G505-G599.
The default value is 0 for a Work Offset of G54.
When the desired value has been entered in the field, click OK or press Enter on your keyboard.

NC Code Output (continued)

C-Axis Pre-Load
At this point the user will be prompted for Pre-Loading the C-Axis to a given value.
The Belotti FLA, FLU and TRIM Series use a C Primary/A-Secondary Rotary Axis configuration.
The C-Axis has a range limit of +90.0/-450.0 (540 Degrees of Total Travel).
The A-Axis has a range limit of +120.0/-120.0 .
If the user has any toolpaths that require 360 degrees of C-Axis travel in the CCW direction,
This option provides the user the option to Pre-Load the C-Axis with a value that helps
to maximize the available rotary axis travel without requiring a C-Axis unwinding sequence.
The setting used should be determined by the largest Pre-Load required among all the operations.
This option provides a C-Axis Pre-Load Sequence after each tool change.
If a user Pre-Loads the C-axis to C-180.0 prior to activating TRAORI and then using the SIEMENS Vector format
for our NC code, he will now have effectively changed the C-Axis to be symmetrical with +/-270 degrees of effective
travel.
The available values for entry are:
0= No Pre-Load
1=180.0 Degrees
2=270.0 Degrees
3=360.0 Degrees
4=450.0 Degrees
When the desired value has been entered in the field, click OK or press Enter on your keyboard.

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NC Code Output (continued)

Machining Zones
At this point the user will be prompted for the use of Machining Zones.
When a physical partition is installed, the machine is divided into a Left and Right Zone.
M201 establishes the left zone.
M202 establishes the right zone.
If the partition is not present, the machine is considered to be in using the left zone for the entire machine envelope.
M201 would still be required to establish a left zone without the partition.
When the desired value has been entered in the field, click OK or press Enter on your keyboard.

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NC Code Output (continued)

High Speed Machining
At this point the user will be prompted for the use of SIEMENS High Speed Machining Mode.

A value of 1 in the input field indicates to the post-processor to get the HSM settings directly from Operation Note #5 for
the HSM command. When the desired value has been entered in the field, click OK or press Enter on your keyboard.
The SIEMENS High-Speed Mode will be output for all Non-Drilling Ops.
A value of 0 in the input field indicates to the post-processor to ignore HSM settings completely.
None will be included in the output NC code file.
The individual arguments of a CYCLE832 HSM command should be entered in Operation Note #5.
Each argument should be entered in order and separated by a comma.
The post will construct the complete CYCLE832 command and output it at the appropriate point in the NC code.
IMPORTANT!
Keep in mind that Roughing and Semi-Finish operations should always have sufficient
excess material as to not violate the finished part dimensions, tolerance and surface finish.
Example:
HSM ON
3-Axis: CYCLE832(0.0025,1,1)
5-Axis: CYCLE832(0.0025,_ORI_FINISH,0.5)
HSM OFF
CYCLE832()

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NC Code Output (continued)

CYCLE832 Format for Standard 3-Axis Machining
CYCLE832(Tolerance, Mode, Version)
The tolerance will depend upon the mode.
Finishing will have the smallest value and Roughing the largest.
Typical tolerance values are:
Finishing = 0.0025
Semi-Finishing = 0.005
Roughing = 0.01
The available modes are:
0=Deselect (Not Used)
1 = Finish
2 = Semi-Finish
3 = Rough
The Version should always be set to 1.
The three values should be entered in Operation Note (5) as comma delimited values.

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NC Code Output (continued)

CYCLE832 Format for Standard 5-Axis Simultaneous Machining (Includes 4-Axis)
CYCLE832(HSM Tolerance, 5-Axis Smoothing Mode, Angular Tolerance)
The HSM Tolerance will depend upon the 5-Axis Smoothing mode.
Finishing will have the smallest value and Roughing the largest.
Typical tolerance values are:
Finishing = 0.0025
Semi-Finishing = 0.005
Roughing = 0.01
The available 5-Axis Smoothing modes are:
_ORI_FINISH = Finish
_ORI_SEMIFIN = Semi-Finish
_ORI_ROUGH = Rough
The Angular Tolerance is entered as a value in Degrees.
The Angular Tolerance is similar to the HSM tolerance in that the smaller values should be sued for finishing.
The larger values should be used for roughing.
The finishing value should be between 0.25 to 0.5 degrees.
The semi-finish value should be 0.5 degrees.
The roughing value should be between 0.5 - 1.0 degrees.
The three values should be entered in Operation Note (5) as comma delimited values.

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NC Code Output (continued)

Safe Z Clearance Plane
At this point the user will be prompted for the use of a Safe Z Clearance Plane between operations on different
WorkPlanes. If the user enters 1 in the input field, they will then be prompted for a Safe Z Clearance Value.
This value is referenced from the part Work Offset in the G17(XY Plane).
When the desired values have been entered in the fields, click OK or press Enter on your keyboard.

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NC Code Output (continued)

IMPORTANT!
The user prompt for a Safe Z-Value only applies to Milling Operations!
Use the Advanced Toolpath Editor and modify 'Safe Rapid' to set Safe Z-Value for 5-Axis Drilling Operations.

Unwind C-Axis
At this point the user will be prompted for the use of an Unwind/Pre-Load sequence, for the C-Axis, between operations
on different WorkPlanes. If the user enters 1 in the input field, the Unwind/Pre-Load sequence will be output AFTER a
Move to the Safe Z Clearance Plane if the user has selected the Safe Z option at the prompt.
This option is only necessary if the order of the tilted workplane operations progresses in a counter clockwise direction
about the part. This option is also useful when working on completely vertical workplanes at opposing ends of a part.
This option will change the tool orientation to vertical (Tool Vector of 0,0,1), cancel TRAORI, Unwind/Pre-Load the C-Axis,
re-enable TRAORI and continue on.
When the desired value has been entered in the field, click OK or press Enter on your keyboard.

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NC Code Output (continued)

CNC Programmer
At this point the user will be prompted for the name of the CNC Programmer who created the AlphaCAM file.
When the CNC Programmers name has been entered in the field, click OK or press Enter on your keyboard.
The post-processor will the begin creating the NC code file.

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NC Code Output (continued)

Send to AlphaEDIT
At this point the NC Code output process is almost complete.
The user will be presented with a final dialogue that allows a review of the NC code as well as the ability of the user
to open the NC Code file directly in AlphaEDIT.
IMPORTANT!
What the user sees in this dialogue is NOT the final formatted NC Code file!
The user MUST click the Send to AlphaEDIT button to complete the entire process and get the final NC code file.

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NC Code Output (continued)

Once the user clicks the Send to AlphaEDIT button, the dialogue will close and the file will be opened in AlphaEDIT.
The AlphaEDIT Add-In CleanComments will execute automatically.
The Add-In strips the NC code file of the Operations List and creates an ASCII Text file with that data.

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NC Code Output (continued)

The CleanComments Add-In will then finish the final formatting of the NC code file and the process is complete.

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Appendix

Belotti SIEMENS Settings and Parameters

SIEMENS TRAORI / TRAFOOF Commands

SIEMENS Vector Programming for 5-Axis

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Belotti 5-Axis Machining Center w/SIEMENS 840D sl

The following settings should be verified during installation of all Belotti 5-Axis Machine Centers equipped with SIEMENS
840D sl CNC Controls.

L6 Tool Change Manufacturer Cycle

1.
2.
3.
4.

Press MENU SELECT | Setup | System data.

Press the Open Soft Key to open the file.
Locate the G710 command near the beginning of the file.
Insert a G94 (Unit Per Minute Feed) command on the line immediately following the G710.
This command is required to insure that an automatic tool change sequence in an
NC program will not cause an alarm because of the spindle having 0 RPM and also being
in a modal G95 (Unit Per Revolution Feed) Mode.

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Orientation Commands with G-Code

Press MENU SELECT | Setup | Mach. Data | Channel MD.
Parameters #21102, #21103 and #21104 should all be set to a value of 1.
These parameter changes require an NCK Power On Reset (Warm Restart).
These settings control the ability to use the ORIVECT, ORIAXES and ORIPLANE function
commands directly in the NC code file. If these parameters are not set to a value of 1,
the following alarm will be generated.
Sinumerik Alarm 14134 Channel %1 block %2 G code for orientation interpolation not allowed

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3D Tool Radius Compensation

Press MENU SELECT | Setup | Right Soft Key Arrow | Licenses | All Options.
Check the Set Box for the option.
3D Tool Radius Compensation is an option for enhanced 5-Axis operations.
If the option is not licensed, setting this option will result in a warning and any attempt
to use the command in an NC program will fail.
The SIEMENS part number for the option is listed below the description.

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3D Machining Simulation
Basic Orthogonal Views for Machine Simulation are standard.
In order to view Machine Simulation in an Isometric, Trimetric or Axonometric view,
the following options are required to be set. This enables the 3D View Soft Key.
If the options are not licensed, the 3D View Soft Key will not be visible and a warning
will be displayed. The SIEMENS part numbers for the options are listed below the descriptions.
Press MENU SELECT | Setup | Right Soft Key Arrow | Licenses | All Options.
Check the Set Box for each option.

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SIEMENS TRAORI / TRAFOOF Commands

Never use a TRAFOOF command in an NC program unless TRAORI has been explicitly called and is active. Doing so will
definitely cause problems for machines with Offset Heads. This can and will be a problem even when CYCLE800 is called
properly. The only exception is the initialization at the header of an NC file.
Double-check the commissioning of the machine!
There are orientation codes instantiated at startup.
ORIWKS, ORIVECT, ORIAXES, ORIROTA can all be effected by TRAFOOF if a TRAORI command isnt active. (The
commands highlighted in blue are specifically related to HSM operation.)
This problem showed up with a customer recently and it resulted from a Mastercam Post where the user simply put
TRAFOOF in all tool change sequences and prior to all CYCLE800 calls, regardless of whether or not TRAORI was
activated. The user was going from 3-Axis to 3+2 Tilted Work Plane and the tool tip was out of position.
Please refer to the document in Sharepoint at the link below for detailed CAM System Post-Processor formatting for the
SIEMENS 840D sl CNC Control.

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SIEMENS Vector Programming for 5-Axis

Tim Markoski: Posted on Monday, July 20, 2015 10:41 AM

5-Axis machining has become more prevalent with the advent of newer machine tool technology and the increased power
of CAM systems for programming. When programming a 5-Axis CNC Machine Tool, the issue always boils down to
getting the post-processor of a given CAM system to properly support the kinematics of the machine tool.
The CAM system must be able to provide the necessary angular values for the rotary axes. This issue can become
complex when dealing with the issues of analyzing and choosing the proper rotary solution for a given toolpath.
For example, a C/A Gantry Head has two solutions for every position other than A0. C0.0. Meaning, for the same position
and orientation, two sets of axis data can be evaluated. That is, C=45, A=30 is the same orientation as
C= -135 , A= -30.
Many CAM systems do not have the inherent 'intelligence' in their post-processors to make this choice. This can become
a problem if the intended CNC Control is not capable of being set to bias for the solution with the smallest actual motion.
CAM systems will also have issues the closer any given rotary axis comes to a singularity.
For the purposes of CNC Machining, a singularity occurs when there is an infinite number of solutions for a given tool
vector orientation. For example, when we have A0.0 C0.0, our tool vector has an infinite number of C-Axis positions that
will satisfy the orientation.
Mathematically, a Tool Vector is represented by its component values that are relative to the linear X, Y and Z axes.
These component values typically use the addresses I, J and K. The relationship of the vector component is defined as
the directional cosine. The directional cosines of a vector are the cosines of the angles between the vector and the three
coordinate axes.

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Normally, CAM system post-processors use the tool vector data to calculate the required rotary axis angle. However, as
previously stated, this calculation can become problematic for certain CAM systems.
To deal with these problems, CNC controls are becoming more 'intelligent'. The SIEMENS 840D sl is one such control
that has some unique abilities when it comes to the actual NC code syntax.
The SIEMENS 840D sl is capable of processing the tool vectors directly instead of explicit rotary axis angles. The
SIEMENS format for using the tool vector in the NC code is A3= xxxx B3=xxxx C3=xxxx . A3, B3 & C3 are simply the
SIEMENS designation of the typical I,J & K vector designation.
When coupled with the use of the SIEMENS TRAORI function (RTCP), an NC program can be created that actually takes
advantage of singularities and machine kinematics.
For certain types of 5-axis machines, the physical rotary axis limits can also be problematic for a CAM post-processor. It is
quite typical to find 5-Axis heads where the spindle axis is actually offset from the C-axis centerline. It is common to see
the rotary axis limits for a C/A Gantry Head of C+90.0/C-450.0 on a CNC Router. Whenever any angle would go beyond
the limits, an unwind sequence would need to be generated before that over-travel occurs.
By using the SIEMENS Vector format, it is possible to effectively eliminate the need for an unwinding sequence. Using our
C/A Gantry Head with limits of C+90.0/C-450.0 we can see we have a total rotary axis travel of 540 degrees. If we preposition our C-axis to C-180.0 prior to activating TRAORI and then using the SIEMENS Vector format for our NC code, we
now have effectively changed our C-Axis to be symmetrical with +/-270 degrees of effective travel. However, depending
on the nature of the toolpath required, pre-positioning to a different C-Axis position may be required.

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In the above example, we have pre-positioned the C-Axis to C-360.0, activated TRAORI and then positioned to an X,Y,Z
location with a Tool Vector of 0,0,1 .
If we had our CAM system generate rotary axis angle instead of vectors, we would normally expect to see A0.0 C0.0 for a
vector of 0,0,1 . However, by using the SIEMENS Vector format, we have actually taken advantage of the C-Axis
singularity.
We can now generate a 5-axis toolpath with a complete sweep of 360 degrees of travel in the C-axis, in the CCW
direction, without generating an over-travel and an unwind sequence.

An additional benefit to the SIEMENS Vector format is that it is not limited to 5-Axis and it will support arcs. The vector
data is also modal. Meaning that if a tool vector doesn't change, no additional vector address output is required.
However, there is an important rule regarding the modality of the vector values. The vectors must all be output together.
Mathematically, all three vector components are related. That relationship is defined by the following equation. SQRT (A3
+ B3 + C3) = 1 .
Other things to consider when using the SIEMENS Vector format is the resolution of the vector data. SIEMENS
recommends that a minimum resolution when programming in INCH units for X,Y,Z and CR should be 5 decimal places. A
minimum resolution for the vectors themselves should be 6 decimal places.
The extra decimal for XYZ and CR in an INCH unit program insures the most accurate and smooth High Speed motion
while using TRAORI. Additionally, while we are using vectors in our NC program, the CNC Control is still calculating the
rotary axis angles, monitoring and displaying them during operation and simulation. By allowing the CNC control to make
its calculations using the most accurate vector data will result in a more accurate calculation of an angular addresses and
more accurate positioning.

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To sum up, the Vector format of the SIEMENS 840D sl is an advanced tool that provides a great deal of programming
flexibility in addition to solving problems with machine kinematics encountered by CAM systems.
It is worth considering configuring your CAM Post-Processor to use SIEMENS Vector Programming to take advantage of
the benefits provided.
Useful Links
NAS 979 Test Part programmed using SIEMENS 840D Vector Format and CIP Arc Format.
https://www.youtube.com/watch?v=1Gbd026klGE
NAS 979 Test Part program
https://www.dropbox.com/s/1o9jt99cnkw6jbp/NAS_979_5X.MPF?dl=0

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