Programing a 3 Axis Machining Centre With Topsolid - Part i - Modelling of Pieces

8/3/2019 Programing a 3 Axis Machining Centre With Topsolid - Part i - Modelling of Pieces

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PROGRAMING A 3 AXIS MACHINING CENTRE WITHTOPSOLID - PART I - MODELLING OF PIECES

STANIMIR Alexandru*, PANDURU Dumitru*, VADUVA Catalin*,TLULiviu*, STANIMIR Marius**

*University of Craiova Romania, **University of Medicine and Pharmacy, Craiova Romania

Abstract:In these papers, part I and II, we present some results obtained onComputer Aided Programming of machine tools acquired by a group of

students that followed an introductory course in TopSolid 2009 at the Faculty ofMechanics from Craiova and a traineeship in a factory that uses this softwarein production. Since the using of this software in our area is relatively recent, inthe part I of these papers, we have found useful a short presentation of TopSolid

software, in order to start focusing on the CAD module. The chosen case studyin this paper refers to the modeling of a part that requires the use of the main

features of this module and also the use of the main manufacturing processesthat usually may be meet on a three-axis machining center.

Key words: TopSolid, CAD, learning, case study

1. INTRODUCTIONDesigning products that can be easily manufactured is one of the key challenges of

companies nowadays. As result, a large game of computer-aided design and computer-aided

manufacturing software (CAD/CAM) was developed and is used in mechanical, electrical, and

electronic design; simulation, drafting, and engineering; and design analysis and manufacturing.

Typically, CAD and CAM software run on mainframe computers, general-purpose workstations

and personal computers [5, 6].

Computer Aided Design involves the use of computer hardware and graphics software

to generate design drawings. Modern CAD equipment enables the designer to quickly produce

very accurate and realistic images of products to be manufactured. There are several types of

CAD/CAM software that are listed as CAD programs. Often, capabilities differ by application.

For example, two-dimensional CAD or 2D CAD software is suitable for drafting services andgeneral-purpose applications. By contrast, three-dimensional CAD or 3D CAD software is well-

suited for machine shops, product designers, reverse engineering, and complex surfacing [1, 3,

11, 12].

It is common to compare CAD-systems before deciding which to choose, or sometimes

just out of curiosity. But there is no CAD-system that is best for everyone. They differ in price,

functionality and sometimes also in their philosophy, like SpaceClaim is very different from

Pro/ENGINEER. To illustrate some of the advantages of using TopSolid, can be mentioned

Daniel Forsman [13] that has been teacher of CAD and Product Development for more than ten

years at the University of Gvle and who recently started his own consultancy company,

focusing on CAD and CAE using TopSolid 7 (the new improved software of TopSolid 2009)

and NASTRAN. For him, being a startup, the price/performance-ratio was important. At this


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point he founded TopSolid very hard to beat! Some of the things that made him a TopSolid

convert were:

Price/performance - cheaper than most of the well-known-programs, but at least the same level

of useful functionality.

It is working much faster in TopSolid 7 than either SolidWorks or Pro/ENGINEER.

The new ribbon bar in TopSolid is much better that SolidWorks or Inventor use. It doesnt

take up much space; it is really slick and easy to understand.

The sheet metal-module is easily the best he has ever tried. Although very powerful it is but

still easy to use.

Amazingly fast graphics, beautiful realistic rendering (also real-time rendering) and the fastest

drawing views.

Mechanism-functionality is included from the beginning, making dynamic calculations of

mechanisms possible.

Very intelligent libraries of standard parts included.

For working with wood, sheet metal manufacturing or CNC, TopSolid is very hard to beat. It

is really intended for integrated CAD/CAM in those areas.

For the beginner, the structure of the model tree could be very confusing. TopSolid is verydifferent here than SolidWorks for example, using operations instead of plain features.

TopSolid is not primarily intended as a CAE-platform. It has dynamic calculations of

mechanisms and a basic FEA-module available.

The user base of TopSolid is a lot smaller and it is not so easy to find information in forums or

blogs. But these things can get better.

The role of the typical university engineering program is to produce graduate

engineers prepared to enter engineering practice, and to conduct applied and fundamental

research in the engineering disciplines. Because of the rapid development of certain

technologies by industrial research organizations and software developers, the engineering

program may find itself lagging in the integration of current engineering practice and

technology. Solid modeling is an example of a technology that found widespread acceptance in

practice before it was adopted and integrated into most mechanical and manufacturingengineering programs.

Two technologies that have been integrated into most of the mechanical and

manufacturing engineering programs are finite element analysis (FEA), and numerically

controlled machining (NC machining). Both of these technologies are widely practiced in

industry. In the CAM application, details on lines and surfaces joining properly in the solid

model are critical to creation of the NC code. Thus, model preparation is critical [4, 2, 14].

In this paper are evaluated some results obtained on Computer Aided

Programming of machine tools acquired by a group of students that followed an

introductory course in TopSolidDesign at the Faculty of Mechanics of the University of

Craiova and a traineeship of two weeks at DiCo Romania, a factory that uses this

software.

2. TOPSOLID 2009 MODULES AND INTERFACE

TopSolid is a contemporary CAD product that runs in the Windows environment, core

product of a family of integrated software solutions developed by Missler Software that offer a

global and integrated general mechanical solution for both design and manufacturing (fig.1).

The family of solutions includes: TopSolidDesign: 3D design and surface modeling;

TopSolidDraft: drawing features and 2D design; TopSolid'Castor: FEA analysis of structures in

terms of volume beams and hulls; TopSolid'Pdm: connection to database; TopSolid'Mold: mold

and tooling design; TopSolid'Progress: progression and stamping tool design; TopSolid'Sheet

Metal: design of sheet metal applications; TopSolid'Cam: 2 to 5 axis 2D/3D milling and

turning; TopSolid'Electrode: design of electrodes; TopSolid'Wood and WoodCam: integrated


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design, manufacturing and management software for wood processing; TopSolid'Wire: Cam

solutions for wire EDM; TopSolid'Erp: supply chain requirements from commercial to

production management administration [7].

Fig. 1 Main view of TopSolid 2009

These products share the same user interface and associative database. For each module,

Missler Software offers a product with real associative CAD/CAM, thus avoiding duplication of

information transfer between the engineering and manufacturing departments. The result is an

impressive gain in productivity. To make all this possible, TopSolid implements a method of

design using functions and components that already contain the information needed forassembling and manufacturing [8, 9, 10].

In this paper have been used the modules Design and Draft, the selection of each of this

can be seen in fig. 2 and fig. 3

Fig. 2 Selection of Design module Fig. 3 Selection of Draft module

The TopSolid 2009 interface, presented in the figure 4, contains:title bars (software anddocument) 1, drop down menus 2, integrated system icon bar 3, work icon bar 4, prompt line

bar with neutral point functions 5, context icon bar 6, symbolic tree or construction tree 7, status

bar 8, alpha bar or message window 9, graphic area (work space) 10, current coordinate system

11, compass 12, quick layers bar 13, quick line styles bar 14 and symbolic tree indexes 15. The


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drop down menus in the bar 2, allows the following functions: file management, print,

document properties (File), element edition (curve, shape, operation etc) such as Duplicate,

Repeat,

Fig. 4 Main view of TopSolid 2009 [7]

Replace, Extract, Insert etc (Edit), parameter and values management of the document

(Parameter), creation and modification of 2D element separated by a horizontal line (Curve),

creation and modification of 3D element with the same organization as Curve (Shape),

assembly functions and component creation (Assembly), movement management defined withkinematic joints between elements (Kinematics), movement management of elements

assembled with constraints of forces and gravity (Dynamics), creation of coordinate system,

point, dimension, constraint and options (Tools), information management related to an element

as color, transparency, layer etc (Attribute), measure of distance, mass, inertia etc in the alpha

bar (Analyze), piping functions (Piping), sheet metal design tools (Sheet metal), realistic

rendering functions (Image), wood design functions (for TopSolidWood module), view

creation tools as section, detail, auxiliary, along direction etc (View), dimension tools and

modification of dimension format height, text, extremities etc (Dimension), bill of material

creation and management as well as indexes (Bill of material), complete drawing with texts,

geometrical tolerances and other symbols (Detailing), window management, i.e. Tile vertically

(Window), online help, about TopSolid, modules version of TopSolid, codes etc (Help).

3. BRIEF PRESENTATION OF DESIGN MODULE

TopSolid'Design is a fully integrated and associative 3D design software

enabling the operator to draft and design products more efficiently. Kinematics,

structural calculation, sheet metal processing and mechanical components form an

integral part of TopSolids 3D design capabilities to improve efficiency in the 3D

design process.TopSolids 3D design functions have no limits in terms of modeling and

create the most complex surface and solid models. With TopSolidDesign, drafting and

pre-dimensioning is easy and the management of assemblies with thousands of parts is

no problem. One of the strengths ofTopSolidDesign is the fact that operators can
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draw in 2D or 3D by defining the design parameters, geometric parameters (spatial

requirements, support surfaces etc) and dimensional parameters (length, diameter, etc).

Usually, to create a 3 D model, first have to begin with a sketch or a contour

over existing sketch lines, or on the grid of the active coordinate system. Closed

contours are automatically created when the start point is re-selected.For finalizing a sketch or a contour in a proper way, it has to be dimensioned and

constrained using the icons form the work icon bar (fig. 5 and fig. 6).

Fig. 5 Work icon bar for a contour creation

Fig. 6 Work icon bar for a sketch creation

In order to create a 3D surface or a solid, from the context icon bar 6 (fig. 4), have to

select Surface or Shape icons. Generally, if the profile is open a surface is created and if it is

closed a solid is created. The work icon bar for each of this context icons are shown in figures 7

and 8. Using the icons from the work icon bar the surfaces or the solids can be dimensioned and

customized as required.

Fig. 7 Work icon bar for a shape creation


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Fig. 8 Work icon bar for a surface creation

4. CASE STUDY

The chosen case study in this paper refers to the modeling of a part that require s the useof the main features of Design module like points, circles, sketch lines, curves, offset contours,

axis and coordinate system in the sketch mode and extrude, boss, drilling, pocket, propagate

operation in shapes mode.

Also the shape of chosen part assumes the use of the main manufacturing processes that

usually may be met on a three-axis machining center.

The part of which 3 D model has to be completed is shown in the figure 9. That design

was realized in the Draft module of Top Solid, after the 3D solid creation.

Fig. 9 The part

In order to create a new Design document it follows the next steps: Open TopSolid

New doccument Design, afted that, the interface of TopSolid Design it is open and ready to

work (fig. 10).


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Fig. 10 The TopSolid Design interface with the work coordinate system

Creating the sketch:

- generate two orthogonal sketch lines in the origin of coordinate system using the sequence:

Curves Create sketch line Line type (dotline) and the option CHANGE TO

VERTICAL/HORIZONTAL and clicking on the origin point ESC Key;

- create the origins of circles using the sequences: Tools Points Basic point Position

-50,40 enter key Position 50,40 enter key Position 10,-64Enter keyESC Key;

- circles creation using the sequences:

CurvesCreate circleRadius=10enter keyselect the points with the cursor

Radius=60enter keyselect the origin point with the cursor ESC Key;

- dimensioning using the sequence: Curves dimension and the element to dimension is

selected with the cursor ESC Key (like in the picture 11) ;

Fig. 11 Create sketch lines and circles Fig. 12 Create contour

- contour creation using the sequence (fig. 12):

CurvesCreate contourLine type (continous line)left mouse buton click on top of R60

circle and create contour with the cursor selecting the appropriate Link (line or circle with Arc

Radius 10mm)close contour selecting the start point of contour creation ESC Key;

- pocket creation (fig. 13) following the steps 1...5:

1. circle R50 mm creation using the sequence:

CurvesCreate circleRadius=50enter key select the origin point with the cursor ESC

Key;

2. one side offset creation on the horizontal sketch line using the sequence:


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CurvesCreate offset contour Line type (dotline) Reference curve: left mouse button click

on the horizontal sketch lineDistance=3mmenter keyDimension location: select with the

left mouse button the dimension locationMode=ONE SIDEThru point: change if necessary

with the left mouse button the direction of red arrow ESC Key;

3. 60 and 120 oriented sketch line creation using the sequences:

Curves Create sketch line Line type (dotline) Angle=60 (or 120) Enter key select

the origin point with the cursor ESC Key;

4. one side offset creation on the 60 oriented sketch line (using a sequence similar to step 2);

5. both side offset creation on the 120 oriented sketch line using the sequence:

CurvesCreate offset contour Line type (dotline) Reference curve: left mouse button click

on the 120 oriented sketch lineMode=BOTH SIDESDistance=6mmEnter

keyDimension location: select with the left mouse button the dimension location ESC Key;

6. creation of a sketch line perpendicular on the 120 oriented sketch line using the sequences:

Curves Create sketch line Line type (dotline)DIRECTION OF REFERENCE select

120 oriented sketch line with the cursor OK CHANGE TO VERTICAL select the

origin point with the cursor ESC Key;

7. one side offset creation at 45 mm distance of the sketch line created at the previous step;8. contour pocket creation using a Arc radius of 10mm.

Fig. 13 Create pocket contour Fig. 14 Repeat pocket

- creation of the three pockets with the repeat command, using the sequence (fig. 14):

Curves Edit Repeat Template elements to repeate: left mouse button click on the pocket

contour CIRCULAR Propagation axis: left mouse button click on the R50 circle OK

Total angle: 360 Enter key Total number: 3 ESC Key.

Creating the solid:

- extrusion of external contour using the sequence (fig. 15):

Shapes Create extruded shape Section curves or text: left mouse button click on the

external contour Height: 9mm Enter key ESC Key;- boss creation using the sequences (fig. 16):

CurvesCreate circleRadius=55Enter key Line type (dotline) Center: left mouse

button click on the origin of the coordinate system ESC Key;

Shapes Boss Referance face: left mouse button click on the top surface Curve(s): left

mouse button click on the circle R=55 Boss parameters Height: 7mm (fig. 17) OK

ESC Key;


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Fig. 15 Extrusion of external contour Fig. 16 Boss creation

- pockets creation on 7mm deep using the sequence (fig. 20):

Shapes Pocket Referance face: left mouse button click on the top face of the boss

Curve(s): left mouse button click on the pocket contour Pocket parameters (fig. 18) Depth:

7mm OK ESC Key;- creating three 8mm holes by repeating the sequence for each R10mm round edge (fig. 21):

Shapes Drilling Face to drill: left mouse button click on the face of extruded shape First

alignment face or edge: left mouse button click on the round edge R10mm Drilling models:

hole OK Diameter: 8mm (fig. 19) OK ESC Key;

- creating six M8mm tapered holes (fig. 21) following next 1-4 steps:

1. recuperate the sketch lines:

Curves Driving element Element or opperation to treat: left mouse button click on a

pocket ESC Key;

2. create a point on the intersection between R50 circle and 120 sketch line:

Curves Tools Points Curve-curve intersection pointFirst curve: left mouse button click

on the 120 sketch lineSecond curve: left mouse button click on the R50 circle ESC Key;

3. create a coordonate system on a point:Curves Tools Coordinate systems Coordinate system on point Origin point: left mouse

button click on just created point OK ESC Key;

4. create hols+tapping:

Shapes Drilling Face to drill: left mouse button click on the top face of boss First

alignment face or edge: left mouse button click on origin coordinate system just created

Drilling models: hole+tapping OK hole+tapping Denomination: M8, Depth: 7mm (fig.

22) OKPropagate CIRCULARPropagation axis: left mouse button click on the R50

circleOK360Total number:6Enter key ESC Key;

Fig. 17 Boss parameters Fig. 18 Pocket parameters Fig. 19 Hole parameters


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Fig. 20 Create pocket Fig. 21 Create holes and tapered holes

- extracting one tapered hole using the sequence (fig. 23):

Shapes Edit Modify Element to modify: left mouse button click on the M8 hole

Operation to modify: circular propagation EXCLUDE INSTANCE Instance to exclude:left mouse button click on the M8 hole OK ESC Key;

- delete upper right pocket using the sequence (fig. 22 and 23):

Shapes Edit Break associativity left mouse button click on pocket contour, when all

three are red colored left mouse button click on margin of context icon bar to open the three

entities (fig. 22) select composite curve and Delete ESC Key;

Fig. 22 Pocket deleting Fig. 23 The final part model

5. CONCLUSIONS

Based on the students results analyze concerning the programming of machine tools with

Top solid software, we can conclude:- The TopSolid interface is friendly, easy to use and well accepted by students due to itssuggestive icons;- Although the amount of information necessary for the proper use of the TopSolid Designmodule is large compared to the time that was provided for study, each student who attended thecourse, proved to be able to model the parts under current production of the DiCo company;- Using Draft module, in association with the module Design is useful to achieve the necessarydatabases, considering the periodic repetition of the same parts.

6. REFERENCES


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[1] Chaves-Jacob. J., Poulachon. G., Duc. E., New approach to 5-axis flank milling of free-form surfaces:

Computation of adapted tool shape, Computer-Aided Design v.41, 2009, p. 918-929

[2] Lin.T., Ullah. S., Harib.K.,On the Effective Teaching of CAD/CAM at the Undergraduate Level,

Computer-Aided Design & Applications, Vol. 3, No. 1-4, 2006, pp 331-339

[3] Lrinc. E., Computer Aided Program Creation for CNC Production Machines based on Group

Technology Theory, The International Conference of the Carpatian Euro-Region Specialists in IndustrialSystems 7th Edition http://www.nordtech.ubm.ro/issues/2008/2008.01.47.pdf

[4]. Reiter. W.jr., Collaborative engineering in the digital enterprise, International Journal of Computer

Integrated Manufacturing, 2003, VOL. 16, NO. 78, 586589

[5] Rosso. R. Jr., Newman. A., Newman. S., Future Issues for CAD/CAM and Intelligent CNC

Manufacture, Proceedings of the 19th International Manufacturing Conference IMC-19 / 2002-Queens

University Belfast N. Ireland

[6]Yang. M., Kim. C., A CAD/CAM System for Precision Cams with Three CNC Interpolation Methods,

lnt J Adv Manuf Technol (1994)9:87-92

[7] TopSolid Quick references, Missler software

[8] TopSolidDesign 2006 - Training Guide, Missler software

[9] Top Tool, Missler software

[10] TopSolidDesign 2007, 2008, 2009 Whats New, Missler software

[11]http://www.globalspec.com/learnmore/industrial_engineering_software/engineering_scientific_software/computer_aided_design_computer_aided_manufacturing_software_cad_cam

[12]http://www.topsolid.com/news/press/viewpressrelease.asp?id=378

[13]http://www.topsolidblog.com/weekend-reading-topsolid-7-3-vs-the-rest/

[14]http://www.cadcamrecruiters.com.
http://www.globalspec.com/learnmore/industrial_engineering_software/engineering_scientific_software/computer_aided_design_computer_aided_manufacturing_software_cad_camhttp://www.globalspec.com/learnmore/industrial_engineering_software/engineering_scientific_software/computer_aided_design_computer_aided_manufacturing_software_cad_camhttp://www.topsolid.com/news/press/viewpressrelease.asp?id=378http://www.topsolidblog.com/weekend-reading-topsolid-7-3-vs-the-rest/http://www.globalspec.com/learnmore/industrial_engineering_software/engineering_scientific_software/computer_aided_design_computer_aided_manufacturing_software_cad_camhttp://www.globalspec.com/learnmore/industrial_engineering_software/engineering_scientific_software/computer_aided_design_computer_aided_manufacturing_software_cad_camhttp://www.topsolid.com/news/press/viewpressrelease.asp?id=378http://www.topsolidblog.com/weekend-reading-topsolid-7-3-vs-the-rest/

Programing a 3 Axis Machining Centre With Topsolid - Part i - Modelling of Pieces

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