Multi-Axis Flank Contouring Recap Exercise 1 15 min
In this exercise you will create a Multi- Axis Flank Contouring operation to machine back wall of part with:
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Tanto Fan Strategy (1) Combin Tanto Strategy (2) Combin Parelm Strategy (3)
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Advanced Part Machining
Tanto Fan Strategy (1/2)
Student Notes:
Open Flank_RecapEx1_Start.CATProcess Create a Multi-Axis Flank Operation Define geometry (as shown): Select Part surface Select drive surface Select Start & End elements (surfaces) Define limit condition (On)
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Define strategy Machining tab: Max distance between steps = 5mm Stepover tab: Number of paths =1 Number of levels =1
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Advanced Part Machining
Tanto Fan Strategy (2/2)
Student Notes:
Tool Axis tab: Guidance = Tanto Fan Contact height = 0mm Define tool End Mill ball end T2 End Mill D 16 Rc8 D=16mm, L=100mm, Lc=50mm Feeds and Speeds: Use default parameters.
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Replay Operation:
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Advanced Part Machining
Combin Tanto Strategy
Student Notes:
Use previous exercise result
Copy/Paste previous Multi-Axis Flank Contouring Operation (with Tanto Fan Strategy) Modify strategy Tool Axis: Guidance = Combin Tanto Replay Operation Modify Leave and Approach fanning distance Tool Axis: Leave and Approach fanning distance = 15mm
Replay the operation again Save the result See result in Flank_RecapEx1_End.CATProcess
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Advanced Part Machining
Multi-Axis Flank Contouring
Student Notes:
Recap Exercise 2 5 min
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In this exercise you will create a Multi- Axis Flank Contouring operation to machine pocket walls with: Mixed Combin Strategy
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Advanced Part Machining
Mixed Combin Strategy
Student Notes:
Open Flank_RecapEx2_Start.CATProcess Create a Multi-Axis Flank Operation Define geometry (as shown) Select Part surface Select drive surface Select Start & End points (zx plane) Define limit conditions (On)
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Define strategy Machining: Max distance between steps = 5mm Activate : Close tool path Tool Axis: Guidance = Mixed Combin
Replay Operation
See result in Flank_RecapEx2_End.CATProcess
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Advanced Part Machining Student Notes:
Multi-Axis Flank Contouring Recap Exercise 3 45 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:
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Flank Finishing (1) Start\End in the Closed Pocket (2) Joggle Management (3) Thickness On Tool Path (4) Curves As Part (5) Local Modifications (6)
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6
4
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5
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Advanced Part Machining
Flank Finishing
Student Notes:
Open Flank_RecapEx3_Start.CATProcess Do a video replay of ‘Rough Part’ Manufacturing Program and store video result. (options video must be ‘Part Operation level’) Insert a Multi-Axis Flank Contouring Operation in ‘finish left pocket’ Manufacturing Program. Define operation Geometry as shown to finish walls of left open pocket. Tool path style: Zig zag Tool Axis Guidance: Tanto Fan Deactivate all macros Replay the operation.
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Error message will appear: check that « close tool path » option is deactivated.
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Advanced Part Machining
Start\End in closed Pocket
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in “start/end closed pocket” Manufacturing Program. Define operation Geometry as shown to finish closed pocket. Use top edge of Drive.1 as start and stop element. Close tool path Stepover (as shown): Tool Axis Guidance: Tanto Fan
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Replay the operation.
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Advanced Part Machining
Joggle Management
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in “joggle management” Manufacturing Program. Copy/paste previous operation Reset Geometry and select new Geometry as shown to finish closed pocket with joggle. Select top of the joggle as part element.
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Replay the operation.
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Advanced Part Machining
Thickness on Tool Path
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in “Thickness on toolpath” Manufacturing Program to finish external wall. Define operation Geometry as shown. Select full bottom as Part element. Start element (curve) Select tapered fsur as Stop element. Stepover definition shown as Axial Strategy ‘One way’ tool path style ‘Combin Tanto’ strategy
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Disable fanning ‘On Stop’ element Define Macros to obtain following result Replay the operation.
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Advanced Part Machining Student Notes:
Curves as Part Insert a Multi-Axis Flank Contouring Operation in “Curve as part” Manufacturing Program to finish the external walls in one operation.
Curve (red) as part element
Define operation Geometry as shown. Select bottom curve as Part element. Start & Stop curve elements.
Make sure that ‘Close tool path’ is deactivated. Combin Tanto strategy
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Replay the operation.
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Advanced Part Machining
Local Modifications
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in “local modifications” Manufacturing Program to finish both open pockets.
Define operation Geometry as shown. Select bottom of any pocket out of two as a Part element.
Stepover No of levels = 01
Tanto Fan strategy
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Replay the operation.
See result in Flank_RecapEx3_End.CATProcess
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Advanced Part Machining Student Notes:
Multi-Axis Flank Contouring Recap Exercise 4 15 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options: Non-contiguous drives surfaces (1) Non-contiguous drives surfaces in the same plane (2)
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Advanced Part Machining Student Notes:
Non- contiguous Drives Surfaces Open Flank_RecapEx4_Start.CATProcess Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation.
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Define operation Geometry as shown. Bottom as part surface Start and Stop surfaces. Set Tool Axis I,J,K as 0,0,1 Use Local Modifications as shown.
Start surface
Stop surface
Replay the operation.
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Advanced Part Machining
Non- contiguous Drives Surfaces in Same Plane
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation. Define operation Geometry as shown. Bottom as part surface Start curve and Stop surface. Tool Axis Guidance: Tanto Fan Use Local Modifications as shown.
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Replay the operation. Non- contiguous Drives BUT located in same plane. Hence a loft surface is defined. Then it is to be selected as a drive and local modifications are to be applied.
See result in Flank_RecapEx4_End.CATProcess
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Advanced Part Machining
Multi-Axis Flank Contouring
Student Notes:
Recap Exercise 5 20 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:
Non- contiguous Drives Surfaces Open Flank_RecapEx5_Start.CATProcess Insert a Multi-Axis Flank Contouring Operation to machine blade1 extrado & blade2 intrado in one operation.
Top
Define operation Geometry as shown. Select Drives: Blade1 extrado, top of the blisk, blade2 intrados Select Part: blisk external surface Select stop and start: bottom of the blisk Define Tool Axis Guidance: Combin Tanto Bottom
Modify locally Stopping condition, restarting direction & tool side as following.
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Drive element 2 Restart = LEFT Stop = TO Tool side = SWAP
Define Ref point and tool axis (0,0,-1) Define Macros: Approach = Axial 10 mm Retract = Axial 170 mm Replay the operation.
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Drive element 3 Restart = LEFT Tool side = Same as first
Drive 1 element 1 Stop = PAST
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Advanced Part Machining
Auxiliary Guide Curve (1/2)
Student Notes:
Insert a Multi-Axis Flank Contouring Operation in Tool Change.3 T1 End Mill D 32 to perform a roughing between blades. Define operation Geometry as shown. Select Drive: blade2 intrados Select Part: blisk external surface Select start: top of the blisk Select stop: bottom of the blisk Offset on drive: 8 mm
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Define Strategy Stepover as shown
Define Macros as given below: Return in a Level Retract: Axial 10 mm Return in a Level Approach: Axial 100 mm Return between levels Retract: Axial 100 mm Return between levels Approach: Axial 10 mm Replay the operation.
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Advanced Part Machining Student Notes:
Auxiliary Guide Curve (2/2) Insert a Multi-Axis Flank Contouring Operation to perform a finishing on blade using auxiliary guide curve. Copy/ paste previous roughing operation. Define operation Geometry as shown. Offset on drive: 0 mm All other parameters are same as previous roughing operation. Define Strategy Select curve as Auxiliary Guide Stepover as shown Define Tool T1 End Mill D16 Rc2
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Define Macros as given below: Return between levels Retract & Approach: Add Axial motion up to a plane with offset = 50 mm. Replay the operation.
Multi-Axis Helix Machining Recap Exercise 1 15 min
In this exercise you will create a Multi- Axis Helix Machining by using following options: Rough Body Blade (1) Rough Foot Blade (2)
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Advanced Part Machining
Rough Body Blade
Student Notes:
Open Helix_RecapEx1_Start.CATProcess Create a Multi Axis Helix Machining operation Define Geometry as shown. Select Part surface ( 4 adjacent surfaces between Upper & Lower contours) Select leading & trailing edges Select Upper and Lower contours Define Strategy as shown Select start element On upper contour Radial: Define 10 turns Tool Axis: Lead & Tilt Fixed lead (10deg) and tilt (0deg)
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Define Tool Default End Mill tool Define Approach and retract macro as shown Circular R=5mm, 90deg, 90deg Replay Operation
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Advanced Part Machining Student Notes:
Rough Foot Blade Copy/Paste previous operation Modify Geometry as shown: Select Upper and lower contours Modify strategy as shown: Modify starting point On upper contour Modify Tool Axis: 4 axis Tilt Tilt (35deg) and Lead (10deg) Define 4X plane Select Foot plane Modify Radial: Define 4 turns
4X Plane
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Change tool to conical mill T2 Conical Mill D 25 Replay the operation See result in Helix_RecapEx1_End.CATProcess
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Advanced Part Machining
Multi-Axis Helix Machining
Student Notes:
Recap Exercise 2 20 min
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In this exercise you will create a Multi-Axis Helix operation to finish blade without collision with other blades by using Interpol axis strategy with pre-defined axis.
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Advanced Part Machining
Interpolation (1/3)
Student Notes:
Open Helix_RecapEx2_Start.CATProcess Define Geometry as shown: Select Part surface (4 adjacent surfaces between Upper & Lower contours) Select Leading & Trailing edges Select Upper and Lower contours
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Define Strategy as shown: Machining Machining tolerance = 1mm (for quick computation) Select starting point On Lower contour Radial: Define 50 turns or use scallop height value Tool Axis: Lead and tilt Fixed lead (10deg) and Tilt (45deg) Define Tool: End Mill tool T3 End Mill D 15 Replay Operation: Display tools in replay Collisions with the other blade as shown. Wrong Strategy
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Advanced Part Machining Student Notes:
Interpolation (2/3) Copy/paste previous Multi-Axis Helix Machining. Rename it as “with collision => check ON ”. Define check elements Select surface of other blades. Add 2 mm offset on check. Activate Collision Checking with ‘On tool assembly’. Replay the operation. Too many jumps as shown. Wrong strategy
check
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check
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Advanced Part Machining
Interpolation (3/3)
Student Notes:
Copy/paste previous Multi-Axis Helix Machining. Rename it as “interpol without collision”.
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Modify Strategy as shown Tool Axis: Interpolation Select axis geometries Edit: Change the directions of the default axes (I.1,I.2,I.3 & I.4) Add other axes: Select point + direction x time Validate Remove the check. Collision Checking with ‘On cutting part of tool’. Replay the operation.
In this exercise you will learn how to create Cavities Roughing Operations using following options:
1
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Basic Rough Top (1) Basic Rough Part (2) Basic Rework (3)
2 3
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Advanced Part Machining
Basic Rough Top
Student Notes:
Open Cavity_RecapEx1_Start.CATProcess
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Create a Cavity Roughing operation Define geometry as shown Select Part: full part Select Stock (not necessary as already defined in the PO) Select Top plane: top of the stock (optional) Select bottom plane: top of the part + 0.1mm offset by MB3 on Bottom in Geometry tab. Define strategy as shown Machining Back and forth Outer Part and Pockets Radial Max distance between pass = 31mm HSM Corner radius = 3mm Zone Activate pocket filter Machining direction Select optimized Define tool Select T4 End Mill D40 Rc4 Replay Operation
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Advanced Part Machining
Basic Rough Part
Student Notes:
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Use previous exercise result. Create a Cavity Roughing operation Define Geometry as shown Select Part: full part Stock selection is not required Select bottom plane: bottom of the pocket + offset = 0mm Select imposed planes: select Z15 & Z5 reachable plane Define Strategy as shown Machining Helical Outward Pockets only Always stay on bottom Forced cutting mode on part contour Radial Max distance between pass = 11mm Define Tool Select T4 End Mill D 20 Rc4 Replay Operation
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Advanced Part Machining
Basic Rough Part
Student Notes:
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Use result of Basic Rough Top exercise Create a Cavity Roughing operation Define Geometry as shown Select Part: full part Select Stock (do not select stock) Select bottom plane: bottom of the pocket + offset = 0.1mm Select imposed planes: select Z15 reachable plane Define Strategy as shown Machining Helical Outward Pockets only Always stay on bottom Forced cutting mode on part contour Radial Max distance between pass = 11mm Define Tool T4 End Mill D 20 Rc4 Replay Operation
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Advanced Part Machining Student Notes:
Basic Rough Part Analyze Result Make a photo simulation Pick point on horizontal area Check offsets as shown
+0.1
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+0.1
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+0
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Advanced Part Machining Student Notes:
Basic Rough Part Modify part offset parameter: Add part offset = 0.5mm Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm Max Depth of cut = 5mm
Z=19.02
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Z=05 Z=00
+5.05
Stock Z=35.1
Z=35
Z=15
+0.1
Z=10.05
Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1
+4.02
Depth of cut computation From stock to imposed plane: No of level = (35.1-15)/5= 4.02 5 depth of cut = (35.1-15.5)/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= 1.98 2 depth of cut = (15-5.1)/2= 4.95 mm
The critical value is Part offset. We always must have at least, this value on the part.
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Advanced Part Machining Student Notes:
Basic Rough Part Modify Strategy: Activate Machine horizontal area until minimum thickness Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm Max Depth of cut = 5mm
Stock Z=35.1
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Z=15 Z=05 Z=00
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Z=10.05
Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1
+0.1 +0.5
+0.5
Depth of cut computation From stock to imposed plane: No of level = (35.1-15)/5= 4.02 5 depth of cut = (35.1-15.5)/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= 1.98 2 depth of cut = (15-5.1)/2= 4.95 mm Two Additional planes have been created to respect offset value on horizontal area.
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Advanced Part Machining Student Notes:
Basic Rough Part Modify Strategy: Add 1mm minimum thickness on horizontal area (MTHA) Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm MTHA = 1 mm Max Depth of cut = 5mm
Stock Z=35.1
Z=35 Z=19.02 Copyright DASSAULT SYSTEMES
Z=15 Z=05 Z=00
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Z=10.05
Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1
+0.1 +1.5
+1.5
Depth of cut computation From stock to imposed plane: No of level = (35.1-15)/5= 4.02 5 depth of cut = (35.1-15.5)/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= 1.98 2 depth of cut = (15-5.1)/2= 4.95 mm The 2 Additional planes have been translated to the value of MTHA to respect offset value on horizontal area: part offset+ MTHA offset
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Advanced Part Machining
Basic Rough Part
Student Notes:
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Modify Strategy: You can make again all the previous test with a offset on imposed plane > part offset Example: Add offset = 1mm on imposed plane
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Advanced Part Machining
Basic Rework
Student Notes:
Use previous exercise result without part offset & horizontal area parameters.
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Copy/paste previous cavity roughing operation Modify the tool T4 End Mill D 16 Rc4 Replay & Video simulation of the full program Modify offset on part to 0mm Replay and video again
See result in Cavity_RecapEx1_End.CATProcess
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Advanced Part Machining
Cavities Roughing
Student Notes:
Recap Exercise 2 15 min
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In this exercise you will learn how to create Cavities Roughing Operation to rough frame part.
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Advanced Part Machining Student Notes:
Rough Frame (1/2) Open Cavity_RecapEx2_Start.CATProcess
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Define geometry as shown Select Part: Full part + Mask(in No Show) Select Stock in No Show (not necessary as it is already defined in the PO) Offset on part: 3 mm Select bottom plane + offset 3 mm Select imposed plane by using search/view planes to impose Z=60mm (top of the wall) + offset 3 mm
Part
Mask
Use mask methodology (mask is already defined in Stock CATPart).
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Advanced Part Machining Student Notes:
Rough Frame (2/2) Define Strategy as shown Remaining thickness for sides: 3 mm Radial tab: Stepover length= 32 mm Axial tab: Maximum cut depth= 10 mm HSM: Corner radius= 2 mm Zone: Activate Pocket filter Define Tool T2 End Mill D 40 Rc4
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Do not forget to add 3mm offset on each plane.
3mm
6mm
Replay the operation.
See result in Cavity_RecapEx2_End.CATProcess
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3mm
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Advanced Part Machining
Master Exercise: Aerospace Part
Student Notes:
In this exercise, you will machine a Aerospace Part using the Advanced Part Machining workbench.
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60 min
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Advanced Part Machining
Pocketing Operation
Student Notes:
Open MasterExercise_AMG_Start.CATProcess Hide Machine elements Create a Pocketing Operation in Tool Change.4 Define Geometry: Select bottom: Top of the part Select inner contour of stock as guiding element. Offset on contour = 20 mm Define Strategy Machining Tolerance = 0.3 mm Number of levels = 1
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Replay the operation
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Advanced Part Machining
Roughing.1 Operation
Student Notes:
Create a Roughing.1 Operation after Pocketing Operation Define Geometry: Select Part, Bottom (on round emboss) and Limiting Contour (red ) No Offsets Define Strategy Tool path style: Spiral Maximum cut depth = 30mm Deactivate Part Contouring Deactivate Automatic horizontal areas detection Deactivate High speed milling
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Replay the operation
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Advanced Part Machining
Roughing.2 Operation
Student Notes:
Create a Roughing.2 Operation in Tool Change.6 Define Geometry: Select bottom: bottom of the part. Select stock as Check. Offset on Part & Bottom = 2 mm Define Strategy Deactivate Automatic horizontal areas detection
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Replay the operation
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Advanced Part Machining
Cavities Roughing Operation
Student Notes:
Create a Cavities Roughing Operation in Tool Change.3 Define Geometry: Select Bottom of the part and Limiting Contour. Offset on bottom = - 8 mm Select Imposed plane as shown. Define Strategy Activate Machine horizontal area until minimum thickness Machining Tolerance = 0.1 mm Pockets only Activate High speed milling and Corner radius on part contouring
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Replay the operation
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Advanced Part Machining
Profile Contouring Operation
Student Notes:
Create a Profile Contouring Operation after Cavities Roughing Operation Define Geometry: Select Top and Bottom of the part. Select Guide, Relimiting points at ends Offset on Bottom = - 5mm Define Strategy Distance between paths= 1 mm No of levels = 3 mm
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Replay the operation
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Advanced Part Machining
Multi-Axis Flank Contouring Operation
Student Notes:
Create a Multi-Axis Flank Contouring Operation after Profile Contouring Operation Define Geometry: Select bottom as Parts. Select drive elements (Drive1 & Drive2) Select Start & Stop elements (curves) Offset on part = - 5mm Define Strategy Tool Axis: Tanto Fan Replay the operation
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Do Machine Simulation Show Machine elements (Refer next foil for details)
See Result in MasterExercise_AMG_End.CATProcess
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Advanced Part Machining
Customization
Student Notes:
Before to run the demonstration based on the BULKHEAD part on the Zimmermann machine-tool, you have the following customization to do: Copy the following files to the location given as follows ZIMMERMANN_FZ30_S840D.pp into the directory intel_a\startup\Manufacturing\PPPar ZIMMERMANN_FZ30_S840D.ce into the directory intel_a\startup\Manufacturing\CENITCE CPOST_MILL.pptable into the directory intel_a\startup\Manufacturing\PPTABLES Launch CATIA and select in Tools\Options\Machining\Output CENIT as Post Processor and Controller Emulator.
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From Manufacturing Program, activate the option ' NC Code Based Simulation'and select the ISO Code (ProcessBulkhead.CATNCCode) saved (or regenerate it interactively) to start the simulation of the ISO Code for Machine-Tool simulation and Material Removal simulation.
machining passes, for the last motion of each approach macro, and for the first .... NC programmer will just have to select it in PPR Tree or in CATIA window ...
IWT - Main Department Manufacturing Technologies and the ECO-Center for low pollution manufacturing ... workpiece, and to transport the cutting chips out of the contact zone and out of the machine tool. ..... of the generated hole. The effect of ...
Jan 19, 2009 - CATIA Training. COPYRIGHT DASSAULT ...... Click on âCompute tool gage on assemblyâ icon ... You will see in the PPR tree that CATIA has.
Jan 19, 2009 - tool path definition, including support of High Speed Milling technology. Automated .... Generates HTML documentation for shopfloor. Generate.
Jan 19, 2009 - Define Prismatic Machining operations (2.5 Axis Milling) in CATIA V5 .... A Master Exercise provides a project where an industry scenario part is used to ... Added Exercises are provided after execution of Master Exercise for.
Jan 19, 2009 - CATIA Training. COPYRIGHT DASSAULT .... Select the tool assembly tab page ..... Close all your CATIA models: CATProduct and CATProcess ...
Introduction to Manufacturing Processes by J. A. Schey (2nd edn, 1987, New York: ... in the final manuscript being less late than it otherwise would have been. ...... typical high temperature hardnesses of the main classes of cutting tool ...... chip
CATIA V5 Training. Exercises. Version 5 Release 19. January 2009 ..... Macros for Approach and Retract. Use a circular Horizontal Axial Macro with the ...
performance: cutting tool, cutting parameters and mainly the cutting strategy used ... objective of the formation of a wide nucleus of work teams that guaranty the.
Jan 19, 2009 - Students attending this course should have knowledge of CATIA V5 .... Master Exercises provides a project where an industry type parts are used to assist .... report. Applies all the machining processes of a catalog on a set of selecte
Jan 19, 2009 - Students attending this course must have knowledge of CATIA V5. Fundamentals, NC ... Multi Spindle, Multi Turret Assembly. 38. Counter ...
9.5 Model-based systems for simulation and control of machining .... 70 to 95% of their time inactive on the shop floor. ..... runs â for example as might occur in converting sheet metal, steel bar, ...... chip and the tool; and experimental result
Fig. 16 is a cross-section view of the wing spar prior to seam welding. A British designer, Mr. Duncanson, had a similar design. The spar he designed was of ...
Jan 19, 2009 - CATIA Training. COPYRIGHT .... Define the following parameter for this macro: ... Then create your Retract macro with predefined axial mode:.
Jan 19, 2009 - Machining. CATIA V5 Training. Foils ... NC programmer knowing how to work with CATIA V5 Parts and already skilled in .... holder assembly.
Jan 19, 2009 - CATIA V5 Training. Exercises. Version 5 Release 19 ..... Select Compute tool gage on assembly icon. Select in the dialog box select all.
Jan 19, 2009 - CATIA Training. COPYRIGHT .... The PPR Tree is displayed in the left of the CATIA Window ... Select the Tool Assembly tab page in Insert tab:.
Jan 19, 2009 - CATIA V5 Training. Exercises. Version 5 Release 19. January .... Tool: drill diameter 3.5mm. Edit the tool assembly to fix the tool (power fixed).
