Advanced Part Machining - Freeyvonet.florent.free.fr/SERVEUR/COURS CATIA/CATIA Machining/AMG… ·...

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Advanced Part Machining��

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Advanced Part Machining

CATIA V5 TrainingExercises

Version 5 Release 19January 2009

EDU_CAT_EN_AMG_FX_V5R19

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Table of Contents (1/2)

Exercise Presentation 4CATIA Settings 5

Multi-Axis Flank Contouring: Recap Exercises 7Multi-Axis Flank Contouring: Recap Exercise 1 8Multi-Axis Flank Contouring: Recap Exercise 2 13Multi-Axis Flank Contouring: Recap Exercise 3 15Multi-Axis Flank Contouring: Recap Exercise 4 22Multi-Axis Flank Contouring: Recap Exercise 5 25

Multi-Axis Helix Machining: Recap Exercises 29Multi-Axis Helix Machining: Recap Exercise 1 30Multi-Axis Helix Machining: Recap Exercise 2 33

Cavities Roughing: Recap Exercises 37Cavities Roughing: Recap Exercise 1 38Cavities Roughing: Recap Exercise 2 48

Master Exercise: Aerospace Part 51Pocketing Operation 52Roughing Operations 53Cavities Roughing Operation 55

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Table of Contents (2/2)

Profile Contouring Operation 56Multi-Axis Flank Contouring 57

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Aerospace PartExercise Presentation

180 min

Recap Exercises are provided at the end of each lesson to reinforce the concepts learnt.

Multi-Axis Flank Contouring

Multi-Axis Helix MachiningCavities Roughing Operation

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CATIA Settings (1/2)

Select Tools + Options.In the General view, select the Document tab.

12

In the Linked Document Localization field, select the line Other Folders then click the button Up until this line is on top of the list.

3

Click the button Configure... ; the Other Folders window is displayed.4

Search for the folder in which your data is located and select it.

5

Click OK twice to accept the new folder location.

6

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CATIA Settings (2/2)

Display Isoparametric CurvesTools/Option/ General/Display/Performances

Restart CATIASelect following option

OR

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Multi-Axis Flank Contouring: Recap ExercisesFollowing recap exercises are provided:

Multi-Axis Flank Contouring: Recap Exercise 1Multi-Axis Flank Contouring: Recap Exercise 2Multi-Axis Flank Contouring: Recap Exercise 3Multi-Axis Flank Contouring: Recap Exercise 4Multi-Axis Flank Contouring: Recap Exercise 5

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Multi-Axis Flank ContouringRecap Exercise 1

15 min

Tanto Fan Strategy (1)Combin Tanto Strategy (2)Combin Parelm Strategy (3)

In this exercise you will create a Multi- Axis Flank Contouring operation to machine back wall of part with:

1

2

3

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Tanto Fan Strategy (1/2)

Open Flank_RecapEx1_Start.CATProcess

Create a Multi-Axis Flank Operation

Define geometry (as shown):Select Part surfaceSelect drive surfaceSelect Start & End elements (surfaces)Define limit condition (On)

Define strategyMachining tab:� Max distance between

steps = 5mmStepover tab: � Number of paths =1� Number of levels =1

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Tanto Fan Strategy (2/2)

Define toolEnd Mill ball end T2 End Mill D 16 Rc8D=16mm, L=100mm, Lc=50mm

Feeds and Speeds:Use default parameters.

Replay Operation:

Tool Axis tab:� Guidance = Tanto Fan� Contact height = 0mm

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Combin Tanto Strategy

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 distanceTool Axis:�Leave and Approach fanning distance = 15mm

Replay the operation again

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Combin Parelm Strategy

Copy/Paste Previous Multi-Axis Flank Contouring Operation (with Combin Tanto Strategy)

Modify strategy Tool Axis:�Guidance = Combin Parelm

Replay Operation

Modify Leave and Approach fanning distanceTool Axis:�Leave and Approach fanning distance = 5mm

Replay the operation again

Save the result

See result in Flank_RecapEx1_End.CATProcess

Use previous exercise result

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5 min

In this exercise you will create a Multi- Axis Flank Contouring operation to machine pocket walls with:

Mixed Combin Strategy

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Mixed Combin Strategy


Create a Multi-Axis Flank Operation

Define geometry (as shown)Select Part surfaceSelect drive surfaceSelect Start & End points (zx plane)Define limit conditions (On)

Define strategyMachining:

�Max distance between steps = 5mm�Activate : Close tool path

Tool Axis:�Guidance = Mixed Combin

Replay Operation


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45 min

In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:

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)

52

3

6 41

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Flank Finishing


Do a video replay of ‘Rough Part’ Manufacturing Program and store video result. (options video must be ‘Part Operation level’)

Error message will appear: check that « close tool path »option is deactivated.

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 zagTool Axis Guidance: Tanto FanDeactivate all macrosReplay the operation.

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Start\End in closed Pocket

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

Replay the operation.

Insert a Multi-Axis Flank Contouring Operation in “start/end closed pocket”Manufacturing Program.

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Joggle Management

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.


Insert a Multi-Axis Flank Contouring Operation in “joggle management”Manufacturing Program.

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Thickness on Tool Path

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

Disable fanning ‘On Stop’ element

Define Macros to obtain following result


Insert a Multi-Axis Flank Contouring Operation in “Thickness on toolpath”Manufacturing Program to finish external wall.

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Curves as Part

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


Curve (red) as part element

Insert a Multi-Axis Flank Contouring Operation in “Curve as part”Manufacturing Program to finish the external walls in one operation.

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Local Modifications

Define operation Geometry as shown.Select bottom of any pocket out of two as a Part element.

StepoverNo of levels = 01

Tanto Fan strategy



Insert a Multi-Axis Flank Contouring Operation in “local modifications”Manufacturing Program to finish both open pockets.

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15 min


Non-contiguous drives surfaces (1)Non-contiguous drives surfaces in the same plane (2)

1

2

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Define operation Geometry as shown.Bottom as part surfaceStart and Stop surfaces.

Set Tool Axis I,J,K as 0,0,1Use Local Modifications as shown.


Non- contiguous Drives Surfaces


Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation.

Start surface

Stop surface

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Non- contiguous Drives Surfaces in Same Plane

Define operation Geometry as shown.Bottom as part surfaceStart curve and Stop surface.

Tool Axis Guidance: Tanto FanUse Local Modifications as shown.


Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing 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.

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20 min


Non- Contiguous Drives SurfacesAuxiliary Guide Curve

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Non- contiguous Drives Surfaces


Define operation Geometry as shown.Select Drives: Blade1 extrado, top of the blisk, blade2 intradosSelect Part: blisk external surfaceSelect stop and start: bottom of the blisk

Define Tool Axis Guidance: Combin Tanto

Modify locally Stopping condition, restarting direction & tool side as following.

Define Ref point and tool axis (0,0,-1)Define Macros:

Approach = Axial 10 mmRetract = Axial 170 mm


Insert a Multi-Axis Flank Contouring Operation to machine blade1 extrado & blade2 intrado in one operation.

Drive 1 element 1Stop = PAST

Drive element 2Restart = LEFTStop = TOTool side = SWAP

Drive element 3Restart = LEFTTool side = Same as first

Bottom

Top

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Auxiliary Guide Curve (1/2)

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 intradosSelect Part: blisk external surfaceSelect start: top of the bliskSelect stop: bottom of the bliskOffset on drive: 8 mm

Define Strategy Stepover as shown

Define Macros as given below:Return in a Level Retract: Axial 10 mmReturn in a Level Approach: Axial 100 mmReturn between levels Retract: Axial 100 mmReturn between levels Approach: Axial 10 mm


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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 mmAll 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

Define Macros as given below:Return between levels Retract & Approach:Add Axial motion up to a plane with offset = 50 mm.


See result in Flank_RecapEx5_End.CATProcessWithout Aux. Guide With Aux. Guide

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Multi-Axis Helix Machining: Recap ExercisesFollowing recap exercises are provided:

Multi-Axis Helix Machining: Recap Exercise 1Multi-Axis Helix Machining: Recap Exercise 2

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Multi-Axis Helix MachiningRecap 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)

1

2

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Rough Body Blade

Open Helix_RecapEx1_Start.CATProcess

Create a Multi Axis Helix Machining operationDefine Geometry as shown.

Select Part surface ( 4 adjacent surfaces between Upper & Lower contours) Select leading & trailing edgesSelect Upper and Lower contours

Define Strategy as shownSelect start element� On upper contour

Radial:� Define 10 turns

Tool Axis:� Lead & Tilt� Fixed lead (10deg) and tilt (0deg)

Define ToolDefault End Mill tool

Define Approach and retract macro as shownCircular R=5mm, 90deg, 90deg

Replay Operation

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Rough Foot Blade

See result in Helix_RecapEx1_End.CATProcess

4X Plane

Copy/Paste previous operation

Modify Geometry as shown:Select Upper and lower contours

Modify strategy as shown:Modify starting point

� On upper contourModify Tool Axis:

� 4 axis Tilt� Tilt (35deg) and Lead (10deg)

Define 4X plane� Select Foot plane

Modify Radial:� Define 4 turns

Change tool to conical mill T2 Conical Mill D 25

Replay the operation

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Multi-Axis Helix MachiningRecap Exercise 2

20 min

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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Interpolation (1/3)

Open Helix_RecapEx2_Start.CATProcess

Define Geometry as shown:Select Part surface (4 adjacent surfaces between Upper & Lower contours) Select Leading & Trailing edgesSelect Upper and Lower contours

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 valueTool 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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Interpolation (2/3)

Define check elementsSelect surface of other blades.Add 2 mm offset on check.

Activate Collision Checking with ‘On tool assembly’.


Too many jumps as shown.�� Wrong strategy

check

Copy/paste previous Multi-Axis Helix Machining. Rename it as “with collision => check ON ”.

check

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Interpolation (3/3)

Copy/paste previous Multi-Axis Helix Machining. Rename it as “interpol without collision”.

Modify Strategy as shownTool 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.

Copy/paste previous Multi-Axis Helix Machining. Rename it as “interpol without collision => check ON”.

Define check elements as done before.Activate Collision Checking with ‘On tool assembly’.Replay the operation.

�� Good Strategy

See result in Helix_RecapEx2_Start.CATProcess

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Cavities Roughing: Recap ExercisesFollowing recap exercises are provided:

Cavities Roughing: Recap Exercise 1Cavities Roughing: Recap Exercise 2

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Cavities RoughingRecap Exercise 1

30 min

In this exercise you will learn how to create Cavities Roughing Operations using following options:

Basic Rough Top (1)Basic Rough Part (2)Basic Rework (3)

1

2

3

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Basic Rough Top

Open Cavity_RecapEx1_Start.CATProcess

Create a Cavity Roughing operation Define geometry as shown

Select Part: full partSelect 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 shownMachining

� 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 toolSelect T4 End Mill D40 Rc4

Replay Operation

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Basic Rough Part

Use previous exercise result.

Create a Cavity Roughing operationDefine Geometry as shown

Select Part: full partStock selection is not requiredSelect bottom plane: bottom of the pocket + offset = 0mmSelect imposed planes: select Z15 & Z5 reachable plane

Define Strategy as shownMachining� Helical� Outward� Pockets only� Always stay on bottom� Forced cutting mode on part

contourRadial� Max distance between

pass = 11mmDefine Tool

Select T4 End Mill D 20 Rc4

Replay Operation

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Basic Rough Part

Use result of Basic Rough Top exercise

Create a Cavity Roughing operationDefine Geometry as shown

Select Part: full partSelect Stock (do not select stock) Select bottom plane: bottom of the pocket + offset = 0.1mmSelect imposed planes: select Z15 reachable plane

Define Strategy as shownMachining� Helical� Outward� Pockets only� Always stay on bottom� Forced cutting mode on part

contourRadial� Max distance between

pass = 11mmDefine Tool

T4 End Mill D 20 Rc4

Replay Operation

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Basic Rough Part

Analyze ResultMake a photo simulationPick point on horizontal area� Check offsets as shown

+0.1

+0.1

+0

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Bottom Z=5+0.1=5.1

Basic Rough Part

The critical value is Part offset. We always must have at least, this value on the part.

+5.05

+0.1

+4.02

Z=35

Z=15

Z=05Z=00

Stock Z=35.1

Part Z=15+0.5=15.5Imposed Z=15

Part Z=5+0.5=5.5

Z=19.02

Z=10.05

Modify part offset parameter:Add part offset = 0.5mmReplay by planeAnalyze

Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm

Max Depth of cut = 5mm

Depth of cut computationFrom 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

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Basic Rough Part

Bottom Z=5+0.1=5.1

Z=35

Z=15

Z=05Z=00

Stock Z=35.1


Part Z=5+0.5=5.5

Z=19.02

Z=10.05

Modify Strategy:Activate Machine horizontal area until minimum thicknessReplay by planeAnalyze

Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm




Two Additional planes have been created to respect offset value on horizontal area.

+0.5

+0.1

+0.5

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Basic Rough Part

Bottom Z=5+0.1=5.1

Z=35

Z=15

Z=05Z=00

Stock Z=35.1


Part Z=5+0.5=5.5

Z=19.02

Z=10.05

Modify Strategy:Add 1mm minimum thickness onhorizontal area (MTHA)Replay by planeAnalyze

Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm� MTHA = 1 mm




The 2 Additional planes have been translated to the value of MTHA to respect offset value on horizontal area: part offset+ MTHA offset

+1.5

+0.1

+1.5

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Basic Rough Part

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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Basic Rework

Copy/paste previous cavity roughing operation Modify the tool

T4 End Mill D 16 Rc4Replay & Video simulation of the full programModify offset on part to 0mmReplay and video again

See result in Cavity_RecapEx1_End.CATProcess

Use previous exercise result without part offset & horizontal area parameters.

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Cavities RoughingRecap Exercise 2

15 min

In this exercise you will learn how to create Cavities Roughing Operation to rough frame part.

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Rough Frame (1/2)

Open Cavity_RecapEx2_Start.CATProcess

Define geometry as shownSelect 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 mmSelect 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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Rough Frame (2/2)

Define Strategy as shownRemaining thickness for sides: 3 mmRadial tab: Stepover length= 32 mmAxial tab: Maximum cut depth= 10 mmHSM: Corner radius= 2 mmZone: Activate Pocket filter

Define ToolT2 End Mill D 40 Rc4


Do not forget to add 3mm offset on each plane.

3mm

3mm 6mm

See result in Cavity_RecapEx2_End.CATProcess

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Master Exercise: Aerospace PartIn this exercise, you will machine a Aerospace Part using the Advanced Part Machining workbench.

60 min

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Pocketing Operation

Open MasterExercise_AMG_Start.CATProcess

Hide Machine elements

Create a Pocketing Operation in Tool Change.4

Define Geometry:Select bottom: Top of the partSelect inner contour of stock as guiding element. Offset on contour = 20 mm

Define StrategyMachining Tolerance = 0.3 mmNumber of levels = 1


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Roughing.1 Operation

Create a Roughing.1 Operation after Pocketing Operation

Define Geometry:Select Part, Bottom (on round emboss) and Limiting Contour (red )No Offsets

Define StrategyTool path style: SpiralMaximum cut depth = 30mmDeactivate Part ContouringDeactivate Automatic horizontal areas detectionDeactivate High speed milling


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Roughing.2 Operation

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 StrategyDeactivate Automatic horizontal areas detection


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Cavities Roughing Operation

Create a Cavities Roughing Operation in Tool Change.3

Define Geometry:Select Bottom of the part and Limiting Contour.Offset on bottom = - 8 mmSelect Imposed plane as shown.

Define StrategyActivate Machine horizontal area until minimum thicknessMachining Tolerance = 0.1 mmPockets onlyActivate High speed milling and Corner radius on part contouring


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Profile Contouring Operation

Create a Profile Contouring Operation after Cavities Roughing Operation

Define Geometry:Select Top and Bottom of the part.Select Guide, Relimiting points at endsOffset on Bottom = - 5mm

Define StrategyDistance between paths= 1 mmNo of levels = 3 mm


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Multi-Axis Flank Contouring Operation

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 StrategyTool Axis: Tanto Fan


Do Machine SimulationShow Machine elements(Refer next foil for details)

See Result in MasterExercise_AMG_End.CATProcess

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Customization

Copy the following files to the location given as followsZIMMERMANN_FZ30_S840D.pp into the directory intel_a\startup\Manufacturing\PPParZIMMERMANN_FZ30_S840D.ce into the directory intel_a\startup\Manufacturing\CENITCECPOST_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.

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.

Before to run the demonstration based on the BULKHEAD part on the Zimmermann machine-tool, you have the following customization to do:

Advanced Part Machining - Freeyvonet.florent.free.fr/SERVEUR/COURS CATIA/CATIA Machining/AMG… ·...

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