Edu Cat en Mmg Fx v5r19 Toprint

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Multi-Axis Surface Machining��

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Multi-Axis Surface Machining

CATIA V5 TrainingExercises

Version 5 Release 19January 2009

EDU_CAT_EN_MMG_FX_V5R19

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Table of Contents

Master Exercise: Fender (Wing) 3Design Process: Fender 4

Master Exercise: Step 1 5Create a new Part Operation 6

Master Exercise: Step 2 7Create Multi-Axis Sweeping Operations 8

Master Exercise: Step 3 16Create a Multi-Axis Contour Driven Operation 17

Master Exercise: Step 4 20Create a Multi-Axis Curve Machining Operation 21

Exercises 24Exercise 1: Hood 25Exercise 2: Pocket 32Exercise 3: Isoparametric and Drill 36Exercise 4: Multi-Axis Curve Machining 41Exercise 5: Tube Machining 45Exercise 6: Multi-Axis Spiral Machining 53

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Master Exercise: Fender (Wing)Exercise Presentation

70 min

In this exercise, you will learn 5-Axis Surface Machining fundamental concepts by machining a part from the 3D.

You will define parameters within the Part Operation and use provided tools within a tool catalog. You will see also how to define a geometry and a strategy.

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Design Process: Fender

Creation of the Part OperationMulti-Axis Contour

Driven Operation

Multi-Axis Curve Machining Operation

Multi-Axis Sweeping Operation

1

3

4

2

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Master Exercise: Fender Step 1: Create a new Part Operation

5 min

In this step you will learn how to define a new Part Operation.

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Create a New Part Operation

Access to SMG Workbench (with MMG license)Set the Part Operation Parameters

Select a 5-Axis machine, a tool catalogToolSamples_MMGSelect the Design Part and Stock for simulationDefine a Tool Change Point ( 0,-1200,600)

Save the CATProcess as Step1 result

Open Wing_Step1.CATPart

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Master Exercise: FenderStep 2: Create Multi-Axis Sweeping Operations

35 min

In this step you will learn how to perform a 5-Axis Sweeping Operation.You will see a Multi-Axis Sweeping Operation with:

Fixed lead and tilt Tool Axis Guidance,Fixed lead and variable tilt Tool Axis Guidance,Fixed Tool axis mode,Thru a Point Tool axis mode,Normal to line Tool axis mode,4-axis lead/lag Tool axis mode,Optimized Lead Tool axis mode.

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Multi-Axis Sweeping

Select a geometry as shown

Define a Strategy

� Fixed lead and tilt Tool Axis Guidance ( 0º, 0º )

Radial Stepover: distance on part 10mm

Select a tool (BullNose_32_R08)

View direction: Make 3 different tests

Test 1: K = 1

Test 2: J = -1

Test 3: J = -1 K = 1

Create Multi-Axis Sweeping Operations (1/8)

Test 1

Test 2

Test 3

Use Step 1 result

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Multi-Axis Sweeping The choice of the view direction is very importantIt will drive the ability of the tool to reach or not all the areas you expect to machine.

See Multi-Axis Sweeping.1Multi-Axis Sweeping.2

and Multi-Axis Sweeping.3

Refer Wing_Sweeping_Tests.CATProcess

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Multi-Axis Sweeping Select a geometry: part & check surface

Define a Strategy� Fixed lead and variable tilt Tool Axis Guidance

Select a toolTool path computation


Wing_Step2_Start.CATProcess

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Multi-Axis Sweeping Select a geometryDefine a Strategy� Fixed Axis Tool axis mode



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Multi-Axis Sweeping Select a geometryDefine a Strategy� Thru a Point Tool axis mode



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Multi-Axis SweepingSelect a geometryDefine a Strategy� Normal to line Tool axis mode


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Multi-Axis Sweeping Select a geometry

Define a Strategy� 4-Axis lead/lag Tool axis mode


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Multi-Axis SweepingSelect a geometryDefine a Strategy� Optimized Lead Tool axis mode


Refer result in Wing_Step2_End.CATProcess

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Master Exercise: FenderStep 3: Create a Multi-Axis Contour Driven Operation

15 min

In this step you will learn how to perform a 5-Axis Contour Driven Operation. You will see a Multi-Axis Contour Driven Operation with:

Case1 Between Contours guiding strategy,Case2 With Parallel Contour guiding strategy,Case3 With Spine Contour guiding strategy.

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Multi-Axis Contour Driven (Multi-Axis Contour Driven.1)Select a geometryDefine a Strategy� Between contours Guiding Strategy

Select a tool BallNose D20mmTool path computation

Create a Multi-Axis Contour Driven Operation (1/3)

Select two curves as shown

Open Wing_Step3_Start.CATProcess(make sure that the MMG incense is available)

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Multi-Axis Contour Driven (Multi-Axis Contour Driven.2)Select a geometryDefine a Strategy� Parallel contour Guiding Strategy


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Multi-Axis Contour Driven (Multi-Axis Contour Driven.3)Select a geometryDefine a Strategy� Spine contour Guiding Strategy




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Master Exercise: FenderStep 4: Create a Multi-Axis Curve Machining Operation

15 min

In this step you will learn how to perform a Multi-Axis Curve Machining Operation. You will see how to create this operation using:

Between 2 Curves mode,Contact mode,Between curve and part mode

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Multi-Axis Curve MachiningSelect a geometryDefine a Strategy� Between 2 curves mode

Select a tool EndMillD10mmTool path computation

Create a Multi-Axis Curve Machining Operation (1/3)

Open Wing_Step4_Start.CATProcess(make sure that the MMG incense is available)

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We want to follow the red curve linked to the blue areaMulti-Axis Curve Machining

Select a geometryDefine a Strategy� Contact mode



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Multi-Axis Curve MachiningSelect a geometryDefine a Strategy� Between curve and part mode



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ExercisesYou will perform following exercises to reinforce the knowledge learnt in the course.

Exercise 1: HoodExercise 2: PocketExercise 3: Isoparametric and DrillExercise 4: Multi-Axis Curve MachiningExercise 5: Tube MachiningExercise 6: Multi-Axis Spiral Machining

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Exercise 1: HoodExercise Presentation

40 min

In this exercise, you will practice 5-Axis Machining on a Hood.

You will have the chance to try out various tools and various modes to create 5-axis tool paths.

You will again learn how to prepare a geometry, define macros and start a machining process.

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Design Process: Hood

1

3

4

2

Perform a Sweep Roughing in 3-Axis

Perform a Multi-Axis contour Driven Operation

Perform a Multi-Axis Curve Machining Operation

Perform a Multi-Axis Sweeping Operation

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Do It Yourself (1/5)

Sweep Roughing in 3-AxisZProgressive Roughing TypeGeometry: select the hood and the bottom face of the stockOffset on Part 2mm

Open Hood_Start.CATProcess(make sure that the SMG workbench is active)

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Change Workbench => MMGSweep Roughing in 3-Axis

Select Tool Taurus D48R6Stepover 20mmCut Depth 4mm (or more to speed up)Offset on Part 2mm

The result is used as a stock for further operationsMake a video if possible and store the resultMultiple video available within one manufacturing program using the tool options


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Multi-Axis Sweeping OperationVariable lead and fixed tilt Tool Axis GuidanceSelect Tool BallNose D18Macros for Approach and RetractUse a circular Horizontal Axial Macrowith the displayed values.Manage locally the parameter angular

orientation to make sure you have the right arc direction for both macros.

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Multi-Axis contour Driven OperationBetween contours Guiding StrategySelect the two contours as shown in redFixed Lead and tilt ( 0deg, 0deg) tool axis modeMacros for Approach and Retractbuilt by user ( one circular and one axial motion)Radius around 50mm and axial move 200mm

Select Tool BallNose D14mm


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Perform a Multi-Axis Curve Machining OperationBetween 2 curves Curve Machining ModeSelect the external boundary as guiding elementLead and tilt Tool Axis Guidance ( 0deg,0deg)Select the brown surfaces as driving elementsSet some approach and retract macros


Refer result in Hood_End.CATProcess

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Exercise 2: PocketExercise Presentation

15 min

In this exercise, you will see how to create a Multi-Axis Operation with:

Between curve and part Curve Machining ModeTangent Axis Mode Strategy

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Design Process: Pocket

Tangent Axis with Infinite Fanning

Tangent Axis with Small Fanning

1

2

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Multi-Axis Curve MachiningBetween curve and part Curve Machining Mode

Select 3 red curves as guide, bottom surface as partand brown surfaces as drive

With Tangent Axis Mode StrategyAlong Ruling Directionwith Infinite Fanning Distance ( 1000mm)


Open Pocket_Start.CATProcess(make sure that the MMG license is available)

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Multi-Axis Curve MachiningBetween curve and part Curve Machining Mode

Select 3 red curves as guide, bottom surface as partand brown surfaces as drive

With Tangent Axis Mode Strategy,Along Ruling Directionwith Small Fanning Distance ( 25mm)


Refer result in Pocket_End.CATProcess

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Exercise 3: Isoparametric and DrillExercise Presentation

15 min

In this exercise, you will see how to create a Multi-Axis Isoparametric Operations and Drilling Operations:

Isoparametric using Interpolation Mode AxisMulti-Axis Drilling Operations

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Design Process: Isoparametric and Drill

Isoparametric with Interpolation axis mode

Multi-Axis Drilling Operation

2

1

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Create a Multi-Axis Isoparametric OperationSelect geometry ( 3 faces as shown )Select corner points (1,2,3 & 4)

Strategy tab: pick the arrow to defineInterpolation vectorsUse compass to set the vectors direction Pick one arrow (turned to red ) then snap the compass to another white arrow, you will tune the red one. Click once to go outand change arrow


Open Isoparametric_Drilling_Start.CATProcess(make sure that the MMG license is available)

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Create a Multi-Axis Isoparametric OperationGeometry: set the part offset to -1mmTool Default oneMacros approach and retract � Use Circular Horizontal Axial

Check the result of first operation as shown ��

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Refer result in Isoparametric_Drilling_End.CATProcess


Create Multi-Axis Drilling Operations2 holes with Drill diameter 10mmUse Normal to PS Axis, jump distance > 43mm3 holes with Drill diameter 22mmUse Normal to PS Axis, jump distance =54 mm

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Exercise 4: Multi-Axis Curve MachiningExercise Presentation

15 min

In this exercise, you will see the difference between the Submodavailable in Multi Axis Curve Machining With Tangent Axis Mode:

Along isoparametric LineNormal to drive curve

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Design Process: Multi Axis Curve Machining Mod

Tangent Axis with mode along isoline

Tangent Axis with mode Normal to drive curve

Load CATProcess and enter in Multi axis Curve machining

2

1

2

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Load Piece_of_fender.CATPartCreate a Multi-Axis Curve Machining

Geometry tab ( Between two curves option )Use Tangent Axis mode for strategyPick the wall surfaces as driving elementsBe sure all arrows ( guide and drive ) are well externally set

Display of Information concerning the maximum and minimum overcut computed

Open TangentAxis_Start.CATProcess(make sure that the MMG license is available)

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DO IT YOURSELF WITH ANOTHER PROVIDED FILE NAMED:

Second OptionGeometry tab ( Between two curves option )Strategy Tab Tangent axis, Mod: Normal to drive curvePick the wall surfaces as driving elementsBe sure all arrows ( guide and drive ) are well externally set


The visualization mode allows you to check exactly where the overcut occur

Ruled_Surface.CATPart

Refer result in TangentAxis_End.CATProcess

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Exercise 5: Tube MachiningExercise Presentation

40 min

In this exercise, you will see how to create fundamental Multi-Axis Tube Machining Operations:

Use Along Guide StrategyUse of different Tool Axis Mode Along Guide with tilt Angle 32deg for OusideprocessThru Point strategy for Inside wall process

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Design Process: Tube Machining Outside and Inside

Tube Machining Guide, Outside,Conic tool etc

TM Guide, Inside with Lollipop Tool, Thru Point axis mode,

2

1

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Exercise 5A (1/5)

Guide

Tube Machining Guide, Outside,Conic tool etc

Open TubeMachining_Start.CATProcess (make sure that the MMG license is available)

1

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Exercise 5A (2/5)

Tool definition:T4 Conical MillD25

Axial Tab:Stepover = Distance on Part 2mm

Tool Axis Mode:Along Guide with - 32 deg Tilt Angle

Compute

Part and Check definition:

Check

Part

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Exercise 5A (3/5)

Guide

Thru A point Tool Axis Mode

Limit 1

Tube Machining Guide, Inside,Lollipop tool2

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Exercise 5A (4/5)

Tool definitionT3 Lollipop D12

Axial Tab:Stepover = Distance on Part 2mm

Tool Axis Mode:Thru a point

Part Definition:Select internal faces

Compute

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Exercise 5A (5/5)

Additional information:

STRATEGY: You may use the contextual menu on Guide definition to switch from Guide to Axis definition for testing.

Open TubeMachining_End.CATProcess

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Exercise 5B

Do It Yourself:

Open Port_Machining_Start.CATProcess

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Exercise 6: Multi-Axis Spiral MachiningExercise Presentation

10 min

In this exercise, you will learn how to create a Multi-Axis Spiral Machining Operation.

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Design Process: Multi-Axis Spiral Machining

Load CATProcess and enter in Multi axis Spiral machining

1

2 Perform a Multi-Axis Spiral Machining Operation

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GeometrySelect Part and Guide facesKeep default offset values


Open MultiAxis_SpiralMachining_Start.CATProcess

Multi-Axis Spiral Machining

Part

Guide face (Drive1)Guide face (Drive2)

StrategyAxial

� Number of levels = 2

Tool Axis� Mode = Normal to part

HSM� Select ‘High Speed Milling’

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Refer result in MultiAxis_SpiralMachining_End.CATProcess

Tool: Ball end T1 End Mill D 15

Macro:Axial approachAxial retract

Replay the tool path

Edu Cat en Mmg Fx v5r19 Toprint

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