ESPRIT Milling Tutorial 04

Project 5: Mill 5-axis parts | 111

PRO

JECT

Mill 5-axis parts

Func�ons on the SolidMill Mold 5-Axis toolbar deliver

fast, safe, and reliable programming for a variety of 5-axis

applica�ons.

In this project, you will:

Use 5-axis swarf milling opera�ons to cut the �lted walls •

on the inside and outside of a part by u�lizing the side of

the tool

Create a 5-axis contouring opera�on to cut a profile on a •

formed piece of sheet metal while keeping the tool axis

perpendicular to the model surfaces at all �mes

Create five different 5-axis milling opera�ons with the •

Composite cycle by u�lizing a variety of machining pa#erns

and tool orienta�ons

Like other ESPRIT cycles, the SolidMill Mold 5-Axis cycles are

feature-based. All Mold 5-Axis cycles must be applied on a

FreeForm feature. The FreeForm feature defines WHAT is cut,

while the cycle defines HOW it will be cut.

5

Create 5-axis swarf operations ..112

Create a 5-axis contouring operation ..............................................123

Create 5-axis composite operations .......................................... 127

The files for this project are available for download from

ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT

CD.

All dimensions in this tutorial are in millimeters. Make sure

System Unit on the Tools menu is set to Metric.

Before you start this lesson, you can review and simulate the

completed files in the following folder:

Milling - 5-Axis

112 | Get Started with ESPRIT 2009

Create 5-axis swarf operationsIn this lesson, you will start by crea�ng two FreeForm features that define the area to be

machined.

Then you will create two Ruled features that will guide the orienta�on of the tool during the cut.

The upper and lower profiles of the Ruled feature set the limits of the wall to be cut while the

match lines between the two profiles are used for the tool orienta�on.

The 5-Axis Swarf cycle u�lizes the side of the tool to cut �lted walls. While the flank of the tool is

removing material along a wall, the bo#om of the tool can be in the air or moving along the “floor”

of the part.

Open the part f i le

Open the file 1. SwarfOpera�on.esp

Two chain features have already been created on the wireframe geometry. You will use these

chains to create a Ruled feature. But first, you will create two FreeForm features that define the

area to be machined.


Create a FreeForm feature on the inside of the part

Click the Layers icon and select 5 ‘Solid’ to display the solid 1.

model. Close the Layers dialog.

On the Smart toolbar, click SolidMill FreeForm.2.

Click FreeForm Feature.3.

Click Grouping Proper�es and set Face to Tangent Faces. Click 4.

the Proper�es icon and set Maximum Tangent Angle Between

Faces to 2 and click OK.

Hold down the Shi% key and select any face on the inside of the 5.

part. All the inner tangent faces are added to the Part list in the

Project Manager.

In the Project Manager, click inside the Check list to ac�vate it.6.

Select the solid model to add it as the check element.7.

Click OK to create the feature.8.


Create a FreeForm feature on the outside of the part

Click FreeForm Feature again.1.

Hold down the Shi% key and select a ver�cal edge on the outer wall of the part. All the outside 2.

faces are grouped and added to the Part list.

Click inside the Check list and then select the solid model.3.


Close the Grouping Proper�es dialog.5.


Create a Ruled feature from wireframe geometry

Click Ruled Feature.1.

Set “Recognize From” to “Wire Frame Geometry”.2.

Click inside “Upper Chain” to ac�vate it, then select the chain called “UpperProfile”.3.

Click inside “Lower Chain” and then select the chain called “LowerProfile”.4.

Click inside “Match Lines” and select all the segments that link the upper profile to the lower 5.

profile.

Change “Name” to Inside1.6.

Set “Cu&ng Side” to Le% and click OK.7.


Create a Ruled feature from solid faces

Again, click Ruled Feature.1.

Set “Recognize From” to “Solid Faces”.2.

Click inside “Faces” to ac�vate it and then hold down the Shi% key and select a ver�cal edge 3.

on the outside of the part to propagate all the outer faces.

Click inside “Lower Edge” and select one of the edges at the bo#om of the outer wall of the 4.

part.

Change “Name” to “Outside2”.5.

Set “Cu&ng Side” to Le% and click OK.6.


Create a 5-Axis Swarf operation with f loor sur faces

In the Feature Manager, select the feature “1. 1 FreeForm”.

Click 5-Axis Swarf Milling.2.

On the General tab, select the tool 3. EM6.

Click the Tool Path tab.4.


Set the tool path parameters

Set Tolerance to 0.1 and Stock Allowance to 0.1.

Click the selec�on arrow next to Ruled Feature and select the feature “2. Inside1”.

Set the following parameters:3.

Cu&ng Side = Le%•

Offset Tool Radius = Yes•

Stop At Floor = • Yes

Stock Allowance Floors = 0•

Single Cut = Yes•

Invert Tool Direc�on = No•

Loop Around Corners = No•


Set the approach type

Click the Retract tab.1.

In the Approaches list, click Add New 2.

Approach.

Add a Radius approach to the list.3.

Set Arc Angle to 45.4.

Set Arc Radius to 5.5.

Click OK to calculate the tool path.6.

Simulate

Simulate to verify the tool path.


Modify the tool path parameters

Double-click on the Swarf opera�on in the Opera�on Manager and change the following 1.

parameters:

Single Cut = No•

Incremental Depth = 2•

Alternate Cut Direc�on = Yes•

Click OK and simulate the new tool path.2.


Create a 5-Axis Swarf operation without f loor sur faces

In the Feature Manager, select the feature “1. 2 FreeForm”.

Click 5-Axis Swarf Milling.2.




Click the selec�on arrow next to Ruled Feature and select the feature “6. Outside2”.


Cu&ng Side = Le%•

Offset Tool Radius = Yes•

Stop At Floor = • No

Bo#om Wall Extension = • 2

Single Cut = No•

Incremental Depth = • 2

Alternate Cut Direc�on = No•

Adapt Orienta�on to Curvature = No•

Invert Tool Direc�on = No•

Loop Around Corners = Yes•


Set the approach type


Add a Radius approach to the Approaches list.2.

Set Arc Angle to 90.3.

Set Arc Radius to 8.4.



Create a 5-axis contouring operationIn this lesson, you will create a con�nuous 5-axis contouring opera�on along a selected profile.

The profile must lie en�rely on the surface to be machined (it must belong to the surface at least

within the machining tolerance). As the tool follows the profile, the tool axis is kept parallel with

the surface normal on the model.

For this lesson, you will use a chain feature as the drive profile for the tool. However, you can also

use a solid edge, solid loop, curve, segment, arc, line, or circle as a drive profile.


Open the file 1. ContourOpera�on.esp

This file already contains a chain feature that you will use as the drive profile for the tool.


Create a 5-Axis Contour operation

Click 1. 5-Axis Contour Milling on the Mold 5-Axis toolbar.

Because a FreeForm feature was not selected first, ESPRIT starts the crea�on of a new 2.

FreeForm feature.

Select the en�re solid body and click OK.3.


Click the Tool Path tab5.


Define the tool path parameters


Click the selec�on arrow next to Drive Profile and select the feature “2. 2 Chain”.


Drive Feature on Edge = No•

Reverse Tool Direc�on = No•

Cu&ng Side = Le%•

Drive Profile Offset = 1 (equal to the tool radius)•

Penetra�on Distance = 1.5 (a distance bigger than the thickness of the sheet metal)•

Max Angle From Normal = 0•


Define the l inks


Add a Lateral approach to the Approaches 2.

list.

Set Lateral Distance to 10.3.

Set Tool Length to 100.4.


Simulate.6.


Create 5-axis composite operationsThe concept of the 5-Axis Composite cycle is that any 5-axis machining func�on, no ma#er

how complex, can be defined with a few simple steps. Instead of fragmen�ng advanced 5-axis

func�onality into a dozen or more separate dedicated func�ons with a limited set of op�ons, the

5-Axis Composite Milling cycle combines every possible way to machine a complex 5-axis part

while presen�ng the op�ons in the logical steps for machining any type of part.

The 5-Axis Composite Milling func�on separates the desired shape of the tool path on the area

to be machined from the rules that govern the orienta�on of the tool axis during machining. In

this way, users can create their own customized tool path as a combina�on of available choices.

In other words, by choosing from the five different machining pa#erns and the four different tool

orienta�on strategies, you have twenty different ways to machine the part.

The tool path pa#ern defines the tool path flow along the part; the tool axis orienta�on defines

the orienta�on of the tool while machining. Users also have the ability to limit a 5-axis cycle to

4-axis mo�on by locking an axis.

In the following lessons you will learn to use each type of machining pa#ern on both milling and

mill/turn machines.


Create a composite operation from parallel planes

The Parallel Planes Intersec�on pa#ern creates curves by intersec�on of the part with a set of

parallel planes. The tool is then driven along those curves. The plane direc�on is set from an

exis�ng work plane that must be previously saved. This work plane is used to control the direc�on

of the set of planes. The planes will be created in the direc�on of the W axis.

The posi�on of the first plane in the set is defined by selec�ng a point or by entering X, Y, Z

coordinate values. The posi�on of the last plane is set by a user-defined distance. The distance is

measured along the posi�ve direc�on of the W axis. The user then enters the incremental distance

between each plane in the set. The step over of the calculated tool path depends on the distance

between the planes.


Open the file 1. Composite_ParallelPlanes.esp

Start by crea�ng a point at: X = 20, Y = 0, Z = 0.2.

This point will be used for the tool orienta�on.


Create a FreeForm feature

Click 1. FreeForm Feature on the Mold 5-Axis toolbar.

Use the Shi% key and grouping proper�es to group all the internal tangent faces of the part.2.

Select the solid model as the check element.3.



Create a 5-Axis Composite operation

Select the FreeForm feature and click 1. 5-Axis Composite on the Mold 5-Axis toolbar.

Select the tool 2. UN10.




Set Machining Pa#ern to 2. Parallel Planes Intersec�on.


Tool Posi�on = Contact Point On Curve•


Work Plane = • YZX (this is an exis�ng work plane in the document)

Start Point X, Y, Z = 0,0,0•

Ending Distance = • -80 (a nega�ve ending distance will go in the opposite direc�on of the W

axis of the selected work plane)

Pass Movement = One Way•

Change Pass Start Posi�on = Yes•

Step Increment = • 3


Define the tool axis orientat ion

Set Orienta�on Strategy to 1. Through Point.

Click the selec�on arrow next to Through Point X, Y, Z and select the point in the work area.2.


Toward Through Point = No•

In-Line Angle = 0•

Cross Angle = 0•

Angle Limita�on = No Limit•


Simulate

Simulate to verify the tool path.

Define the l inks


Add a Ver�cal approach with a 60mm Ver�cal 2.

Distance.

Add an Adap�ve Cubic feed link and set the 3.

Maximum Link Distance to 20mm.



Create a composite operation from planes along a curve

The Planes Intersec�on With Spine Curve pa#ern is similar to the Parallel Planes Intersec�on

pa#ern except that the set of planes are created perpendicular to a spine curve.

The spine profile can be a chain feature, an edge, a face loop, a curve, a segment, an arc or a

circle. The first plane in the set is located at a point along the curve. The point should belong to

the selected curve, but it does not necessarily need to be the ini�al point of the curve itself. The

last plane in the set is also located at a a point along the curve. Like the start point, the end point

should belong to the selected curve, but it does not necessarily need to be the ending point of the

curve itself.


Open the file 1. Composite_PlanesWithSpineCurve.esp.

In the Feature Manager, select “2. 1 FreeForm”.

Click 3. 5-Axis Composite.

Select the tool 4. BM20.


Define the toolpath parameters

On the Tool Path tab, set Tolerance to 0.1 and Stock Allowance to 0.1.

Set Machining Pa#ern to 2. Planes Intersec�on With Spine Curve.


Tool Posi�on = Contact Point On Curve•


Spine Profile = • 1 Chain

Start Point X, Y, Z = click the selec�on arrow and digi�ze the start point of 1 Chain. Then •

change the X value to 2.

End Point X, Y, Z = digi�ze the end point of 1 Chain•

Pass Movement = Op�mized Direc�on•

Change Pass Start Posi�on = No•




Set Orienta�on Strategy to 1. Perpendicular to

Drive Surface.



Cross Angle = 0•

Angle Limita�on = • Fixed Angle With

Reference Axis = • X-Axis

Fixed Angle = • 75

The Angle Limita�on se&ng is used to lock the

B-axis at -15 degrees. The Reference Axis is set to

X-Axis because the reference axis is in the global

XYZ system.

Define the l inks


Add a Ver�cal approach with a Ver�cal Distance 2.

of 10mm.

Add a Fluent Cubic feed link with:3.

Maximum Link Distance = 10•

Start Arc Angle = 30•

Start Arc Radius = 5•

End Arc Angle = 30•

End Arc Radius = 5•



Create a composite operation from a drive sur face

Parametric Pa#ern generates the tool path from the parametric curve of a selected drive surface.

When more than one surface is being cut, the curves are propagated side by side to the next

surfaces. The propaga�on tries to keep a fluid flow to the tool path. The drive surface must belong

to the model being cut.

A%er the drive surface is selected, the U and V cu&ng direc�ons are displayed on the selected

drive surface. A white arrow shows the normal direc�on of the drive surface. The U direc�on is

displayed with a red arrow and the V direc�on is displayed with a green arrow.

The direc�on of the cut can be set to either the U direc�on or the V direc�on of the drive surface.

By default, the tool moves in the same direc�on as the arrow but an op�on is provided that lets

the user cut in the opposite direc�on.


Open the file 1. Composite_ParametricPa!ern.esp.

Select the FreeForm feature.2.


On the General tab, select the tool 4. BM20.




Set Machining Pa#ern to 2. Parametric Pa!ern.


Tool Posi�on = Tool Center on Curve•

Drive Surface = click the selec�on arrow and digi�ze the face shown on the solid•

Cu&ng Direc�on = V Direc�on•

Reverse Cu&ng Direc�on = Yes•

Reverse Step Over Direc�on = Yes•

Pass Movement = Op�mized Direc�on•






Drive Surface.



Cross Angle = 0•


Define the l inks


Add a Bridge feed link with:2.

Maximum Link Distance =5•

Ver�cal Distance = 2•



Create a composite operation from a projected surface

Project Parametric Pa#ern is similar to Parametric Pa#ern except that an auxiliary surface that

does not belong to the model is used. The shape of the tool path is created by projec�on of the

parametric lines of the drive surface onto the model. The projec�on is normal to the drive surface.

A%er the drive surface is selected, the U and V cu&ng direc�ons are displayed on the selected

drive surface as red and green arrows respec�vely. A white arrow shows the normal direc�on of

the drive surface.

The direc�on of projec�on is, by default, the opposite direc�on of the natural Normal direc�on of

the drive surface. That means that if the normal of the drive surface is poin�ng towards the model,

points will be projected in the opposite direc�on.

If the Normal direc�on arrow is poin�ng towards the model, check Reverse Projec�on Side to

make sure points are projected onto the model. The projec�on distance controls the maximum

distance that points are projected from the drive surface onto the model. The projec�on distance

can be used to prevent points from being projected onto undesired surfaces behind the target

surfaces.


Open the file 1. Composite_ProjectParametric.esp.







Set Machining Pa#ern to 2. Project Parametric Pa!ern.


Tool Posi�on = Contact Point on Curve•


Drive Surface = click the selec�on arrow and digi�ze • 2 Nurb Surface

Cu&ng Direc�on = • V Direc�on

Reverse Cu&ng Direc�on = Yes•

Reverse Step Over Direc�on = Yes•

Reverse Projec�on Side = • Yes

Projec�on Distance = • 10

Pass Movement = • Zigzag




Calculate the toolpath


Simulate.2.

No�ce how the tool stays perpendicular to the drive surface and not to the model.



Drive Surface.



Cross Angle = 0•



Create a composite operation with a constant of fset

The Contour Offset pa#ern uses a progressive offset of the boundary of the surfaces to be

machined. This produces a somewhat concentric tool path. The progressive offset can start on the

inside of the area to be machined, proceeding outward toward the external border, or it can start

at the external boundary and proceed inward toward the center of the area to be machined. If the

area to be machined contains islands, the offset can be calculated in an alterna�ng inner-outer

order.


Open the file 1. Composite_ContourOffset.esp.







Set Machining Pa#ern to 2. Contour Offset.


Tool Posi�on = Contact Point on Curve•


Use Approach Point = No•

Pass Movement = • Inside Out



Set the following tool axis orienta�on parameters:4.

Orienta�on Strategy = • Perpendicular to Drive Surface

In-Line Angle =0•

Cross Angle =0•


ESPRIT Milling Tutorial 04

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