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3 Axis Surface Machining

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3 Axis Surface Machining

Preface

Using this Guide More Information Conventions

What's New

Getting Started

More Information Conventions What's New Getting Started Operation-oriented Machining Entering the Workbench Rough

Operation-oriented Machining Entering the Workbench Rough Machining the Part Zlevel Machining of the Outside of a Part ZLevel Machining of the Inside Walls of a Part Machining with parallel contours Checking the results Creating a Rework Area Reworking Generating an NC Output File Generating an NC Output File Generating NC Shopfloor Documentation Area-oriented Machining Entering the workbench Defining the areas to machine Defining the tools to use Rough machining the part Sweeping the top surface Sweeping the side areas ZLevel on vertical walls Reworking between contours Generating an output file Generating workshop documentation

User Tasks

Recommendations Selecting Geometry Using Geometrical Zones Changing the Tool Axis Computing the Tool Gage Roughing operations Sweep roughing Roughing Roughing - Ordering Zones

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Roughing - Automatic Rough Stock Roughing - Offset on Part Finishing and Semi-finishing Operations Sweeping ZLevel machining Contour-driven machining Contour-driven - Stepover Strategy Contour Driven View and Options Strategy Isoparametric Machining Spiral milling Contouring Points and Lines Wizards Reworking Operations Pencil operations Roughing rework Machining features Defining an area to machine Defining an area to rework Offset Groups Tool path Editor Editing a point Editing an area Split on Collision Points Transformations Connecting toolpaths Reversing a toolpath Approaches and Retracts in tool paths Packing a tool path Checking tool holder collision Importing Files STL Files Importing Files

Workbench Description

Menu bar description Toolbar description Machining Operations Toolbar Tool Path Editor Toolbar Machining Features Toolbar Geometry Management Geometry Management Specification Tree

Reference Information

Sweep Roughing Parameters Roughing Parameters Sweeping Parameters ZLevel Parameters Spiral Milling Parameters Contour-driven Parameters Pencil Parameters

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Isoparametric Machining Parameters Tool Path Editor Parameters Machining/Slope Areas Parameters Macros Parameters

Glossary

Index

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Preface

3 Axis Surface Machining is a new generation product that defines and manages NC programs. 3 Axis Surface

Machining is dedicated to the machining of 3D geometry work parts with 3-axis machining techniques. It is particularly adapted to the needs of mold, die and tool makers and prototype manufacturers in all branches and at all levels of industry.

3 Axis Surface Machining offers easy-to-learn and easy-to-use shopfloor-oriented tool path definition for 3-axis

manufacturing. 3 Axis Surface Machining is based on industry-recognized, leading-edge technologies which offer the tightest integration between tool path definition, verification and instant cycle updates.

3

Axis Surface Machining covers full design-to-manufacture processes offering functions for:

defining the areas you want to machine,

rough machining either by vertical or horizontal planes,

roughing rework,

sweeping,

ZLevel machining,

pencil operations,

contour-driven operations,

profile contouring,

drilling,

detecting residual material,

defining areas to rework,

visualization of the result of the machining program,

the production of shopfloor documentation.

3

Axis Surface Machining gives you the freedom to choose the working methods that best suit your needs.

Using this Guide More Information Conventions

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Using this Guide

Surface Machining is a versatile application, fully adapted to your needs and your working methods whether they are machining area-oriented or operation-oriented . You can either define the machining areas on your part and area-oriented or operation-oriented. You can either define the machining areas on your part and then assign an operation to each of them or you can define your machining process as a series of operations with an area to machine for each operation. A machining area can be:

the whole part (for example, in roughing),

a subset of the faces on the part,

a subset of faces on the part with a limiting contour.

The Getting Started chapter contains two sections, one which demonstrates operation-oriented machining and another which demonstrates area-oriented machining.

Before starting work with Surface Machining, please ensure that you have an open file (CATPart or CATProduct) and that you are in the Surface Machining workbench (Start > NC Manufacturing > Surface Machining).and another which demonstrates area-oriented machining. Here is a suggested order for operations in a machining

Here is a suggested order for operations in a machining program:(Start > NC Manufacturing > Surface Machining). ● rough machining operations, ● ● ● ●

rough machining operations,

(semi-)finishing operations,

detection of unmachined areas,

reworking of unmachined areas,

generation and output of documentation.

Area-oriented

Area-oriented methodology is useful when you have a complex part to machine and you know in advance what kind of operation you are going to apply to each separate area.

This approach is of great use when, for example, you are going to machine a "family" of similar parts and when you have dedicated machines for mass production.

You define the areas on one part, you assign an operation to each area, and then you machine. At the end you have a program that you can apply to all of the "members" of the "family" at least working cost because:

the machining strategy has already been defined (chosen operations),

the tool has already been defined,

only the area need be redefined,

you know exactly what kind of output you require,

and as a result the computation can be run in batch to further reduce time loss.

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1. Define all of the separate areas to machine on your work piece.

2. Select the area or areas you want to machine with a particular operation.

3. Click the appropriate icon (for example, sweeping).

4. Change the parameters in that operation (if required).

The only mandatory data for a operation is the area to machine (with the exception of roughing which requires a rough stock too) and all of the other parameters have default values.

We recommend that you use the default parameters first unless you are sure of the values you wish to enter.

5. Compute the operation. If the results are satisfactory, repeat steps 2, 3, and 4 for all of the other areas to machine.

Operation-oriented

Use operation-oriented machining when you want to progressively define your machining program operation-by-operation sequentially. Each operation has the area it deals with defined as part of its data.

This approach is useful for single or limited part production because it allows you to define your requirements step-by-step.

1. Choose the operation you want to use.

2. Click the "part" area in the geometric components of the operation.

3. Select the area(s) to machine either as the whole part with the contextual menu or as a face or group of faces with the face selection wizard.

4. Change the other parameters in the operation (if required).

The only mandatory data for a operation is the area to machine (with the exception of roughing which requires a rough stock too) and all of the other parameters have default values.

We recommend that you use the default parameters first unless you are sure of the values you wish to enter.

5. Compute the operation. If the results are satisfactory, continue defining the remaining operations for your machining program.

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Where to Find More Information

Prior to reading this book, we recommend that you read the Version 5 Manufacturing Infrastructure User's Guide.

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Conventions

Certain conventions are used in CATIA, ENOVIA & DELMIA documentation to help you recognize and understand important concepts and specifications. The following text conventions may be used:

The titles of CATIA documents appear in this manner throughout the text. appear in this manner throughout the text.

File -> New identifies the commands to be used. -> New identifies the commands to be used.

The use of the mouse differs according to the type of action you need to perform.

Use this

mouse button,

whenever you read

Double-click Shift-click Ctrl-click Check (check boxes) Drag Drag and drop (icons onto objects, objects onto objects)need to perform. Use this mouse button, whenever you read Select (menus, commands, geometry in graphics

Select (menus, commands, geometry in graphics area,

)

Click (icons, dialog box buttons, tabs, selection of a location in the document window,

Movetabs, selection of a location in the document window, Drag Right-click (to select contextual menu) Graphic

Drag

Right-click (to select contextual menu)selection of a location in the document window, Move Drag Graphic conventions are denoted as follows:

Graphic conventions are denoted as follows:

)

indicates the estimated time to accomplish a task.menu) Graphic conventions are denoted as follows: ) indicates a target of a task. indicates the

indicates a target of a task.) indicates the estimated time to accomplish a task. indicates the prerequisites. indicates the scenario of

indicates the prerequisites.time to accomplish a task. indicates a target of a task. indicates the scenario of a

indicates the scenario of a task.indicates a target of a task. indicates the prerequisites. indicates tips indicates a warning. indicates information.

indicates tipsthe prerequisites. indicates the scenario of a task. indicates a warning. indicates information. indicates basic

indicates a warning.the prerequisites. indicates the scenario of a task. indicates tips indicates information. indicates basic concepts.

indicates information.the prerequisites. indicates the scenario of a task. indicates tips indicates a warning. indicates basic concepts.

indicates basic concepts.indicates the prerequisites. indicates the scenario of a task. indicates tips indicates a warning. indicates information.

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indicates methodological information.3 Axis Surface Machining Version 5 Release 13 Page 9 indicates reference information. indicates information regarding

indicates reference information.5 Release 13 Page 9 indicates methodological information. indicates information regarding settings, customization,

indicates information regarding settings, customization, etc.methodological information. indicates reference information. indicates the end of a task. indicates functionalities that

indicates the end of a task.information regarding settings, customization, etc. indicates functionalities that are new or enhanced with this

indicates functionalities that are new or enhanced with this Release. Enhancements can also be identified by a blue-colored background in the left-hand margin or on the text itself.settings, customization, etc. indicates the end of a task. indicates functionalities that are P1-specific. indicates

indicates functionalities that are P1-specific.background in the left-hand margin or on the text itself. indicates functionalities that are P2-specific. indicates

indicates functionalities that are P2-specific.text itself. indicates functionalities that are P1-specific. indicates functionalities that are P3-specific. allows you

indicates functionalities that are P3-specific.P1-specific. indicates functionalities that are P2-specific. allows you to switch back the full-window viewing mode.

allows you to switch back the full-window viewing mode.P2-specific. indicates functionalities that are P3-specific. These icons in the table of contents correspond to the

These icons in the table of contents correspond to the entries or mode.

"Site Map".in the table of contents correspond to the entries or mode. "Split View" mode. "What's New".

"Split View" mode.correspond to the entries or mode. "Site Map". "What's New". "Preface". "Getting

"What's New".or mode. "Site Map". "Split View" mode. "Preface". "Getting Started". "Basic

"Preface"."Split View" mode. "What's New". "Getting Started". "Basic Tasks". "User

"Getting Started".View" mode. "What's New". "Preface". "Basic Tasks". "User Tasks" or the

"Basic Tasks".New". "Preface". "Getting Started". "User Tasks" or the "Advanced Tasks".

"User Tasks" or the "Advanced Tasks"."Getting Started". "Basic Tasks". "Workbench Description". "Customizing".

"Workbench Description"."User Tasks" or the "Advanced Tasks". "Customizing". "Reference".

"Customizing".Tasks" or the "Advanced Tasks". "Workbench Description". "Reference". "Methodology".

"Reference".Tasks" or the "Advanced Tasks". "Workbench Description". "Customizing". "Methodology".

"Methodology".Tasks" or the "Advanced Tasks". "Workbench Description". "Customizing". "Reference".

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"Glossary".3 Axis Surface Machining Version 5 Release 13 Page 10 "Index".

"Index".3 Axis Surface Machining Version 5 Release 13 Page 10 "Glossary".

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What's New?

New Functionalities

Tool Gage Compute Tool Gage on Assembly computes the minimum tool gage. The information generated can be saved as a .txt file. Tool path editor With the Split on collision points command, you can select a new tool and generate a new operation applied on the points in collision.

Enhanced Functionalities

Enhancements brought to the NC Manufacturing Infrastructure This product benefits from enhancements to the infrastructure's general functions (NC resources, design changes, simulation, NC data output, 3D PLM integration, and so on). Please refer to the NC Manufacturing Infrastructure User's Guide for more information. User interface (Roughing, Sweep Roughing, Sweeping, Pencil, ZLevel, Contour Driven, Spiral Milling) In the Strategy tab, you can choose to display the parameters strictly necessary to obtain a tool path (<<Less button) or all the parameters to optimize the tool path (More >> button) Invalid faces You can choose to ignore an invalid face during the tool path computation (Roughing, Sweep Roughing, Sweeping, Pencil, ZLevel, Contour Driven, Spiral Milling). Tool path editor The tool path editor is available for all milling operations, with more selection capabilities and an improved user interface of Approach/Retract changes. Roughing Pre and Post macro: You can define a dedicated motion before the engagement and one after the retract. Optimize retract: during the tool path computation, you can check the collisions between the tool and the residual stock on each point. Between contour Allows offset on guides in Between Contour mode. Allows to faster determine the area to be machined without building additional geometries.

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Getting Started

Before getting to grips with all of the Surface Machining capacities, here are two short step-by step tutorials that will help guide you through the key functionalities.

You will learn how to use the functions listed below and learn how to define areas on the part to machine, use specific machining operations on the part and output data.

There are two ways of defining your machining program, you can either base it on operation definition or on area definition. Try both tutorials to see which method suits your working techniques best.

to see which method suits your working techniques best. The tutorials should take you 30 minutes

The tutorials should take you 30 minutes each to complete.

Operation-oriented Machining Area-oriented Machining

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Operation-oriented Machining

Operation-oriented machining is a method where you define each operation one-by-one. When you define an operation you decide (using the geometry tab) which areas of the part you want to machine with that particular operation. This tutorial teaches you how to:

define the operations necessary for the machining of the part below,

run the program to create the tool paths,

check for residual material,

rework the unmachined areas,

and produce an APT file and a workshop document.

areas, ● and produce an APT file and a workshop document. Entering the Workbench Rough Machining

Entering the Workbench Rough Machining the Part Zlevel Machining of the Outside of a Part ZLevel Machining of the Inside Walls of a Part Machining with parallel contours Checking the results Creating a Rework Area Reworking Generating an NC Output File Generating an NC Output File Generating NC Shopfloor Documentation

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Entering the Workbench

This task shows you how to open a part and enter the Surface Machining workbench.Version 5 Release 13 Page 14 Entering the Workbench Open the SurfaceMachining3.CATProduct file in the samples

Open the SurfaceMachining3.CATProduct file in the samples directory. SurfaceMachining3.CATProduct file in the samples directory.

1.

Open the SurfaceMachining3.CATProduct file in the samples directory. 1.

2.

Select NC Manufacturing > Surface Machining from the Start menu.

The Surface Machining workbench is displayed.

The part surrounded by the rough stock is displayed in the Set Up Editor window along with the manufacturing specifications.

part surrounded by the rough stock is displayed in the Set Up Editor window along with

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3. Select Product1 containing the shape to machine and the rough stock in the specifications tree and display

them in wireframe mode using this icon

.
.
tree and display them in wireframe mode using this icon . Double click Part Operation.1 in

Double click Part Operation.1 in the tree. In the dialog box that is displayed and click the design part icon.

Select Open-body.1 in Shape to Machine in the tree and double click in the viewer to validate your selection and redisplay the dialog box.

in Shape to Machine in the tree and double click in the viewer to validate your

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Then click the stock icon, select PartBody in Rough Stock in the tree and double click in the viewer to redisplay the dialog box.

and double click in the viewer to redisplay the dialog box. Click OK to confirm. The

Click OK to confirm.

The design part defines the reference part that will be used by the application to compute the residual material. viewer to redisplay the dialog box. Click OK to confirm. The rough stock is the rough

The rough stock is the rough stock for the overall part. Each successive operation works on the residual material that

is

left by the operation before it in the manufacturing program.

4. Select Manufacturing Program.1 (under PartOperation.1) in the specifications tree to make it the current

entity.

commands.) in the specifications tree to make it the current entity. A program must be current

A

program must be current before you can insert program entities such as machining operations, tools and auxiliary

A program must be current before you can insert program entities such as machining operations, tools

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Rough Machining the Part

This task shows you how to insert a rough machining operation in the program.

This task shows you how to insert a rough machining operation in the program.

As this operation will use the default tool and options proposed by the program, you just specify the geometry to be machined.

1. Select the Roughing icon .

1.

Select the Roughing icon

.
.

A Roughing.1 entity and a default tool are added to the program.

The Roughing dialog box is displayed.

to the program. The Roughing dialog box is displayed. The status light on the Geometric components
to the program. The Roughing dialog box is displayed. The status light on the Geometric components

The status light on the Geometric components tab is red ( must select the part geometry in order to create the operation.

2. Click the red area that represents the part.

) which means that you

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3 Axis Surface Machining Version 5 Release 13 Page 18 The dialog box shrinks to allow

The dialog box shrinks to allow you to select the part in the viewer.

3. In the viewer, click the part. Double click anywhere in the viewer to confirm your selection and to

redisplay the dialog box. The red area in the geometric area is now green to indicate that the

geometry has been selected.

4. Click the sensitive area that represents the rough stock. The dialog box shrinks to allow you to

select the rough stock in the viewer.

5. In the viewer, click the geometry that defines the rough stock. The red area in the geometric

components tab is now green to indicate that the geometry has been selected.

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3 Axis Surface Machining Version 5 Release 13 Page 19 6. Click Replay . The tool

6. Click Replay. The tool path is displayed and the display and analysis dialog box is called up.

7. Click OK. The tool path is erased from the viewer and you come back to the operation dialog box.

8. Click OK to close the dialog box.

Now we are going to use ZLevel machining on the walls of the pocket and the outside of the part.

close the dialog box. Now we are going to use ZLevel machining on the walls of

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ZLevel Machining of the Outside of a Part

13 Page 20 ZLevel Machining of the Outside of a Part This task shows you how

This task shows you how to use ZLevel machining for finishing the outside of the part.

To simplify the selection of faces in this task, select Rough Stock in the ProductList and, using the Hide/Show option in the contextual menu, make it invisible. Then select Shape to Machine in the

ProductList and display it in shading with edges mode (

the ProductList and display it in shading with edges mode ( ). Make sure that Roughing.1

).

ProductList and display it in shading with edges mode ( ). Make sure that Roughing.1 is

Make sure that Roughing.1 is the current entity so that the ZLevel operation will be inserted after it.

1. Select the ZLevel icon Select the ZLevel icon

.
.

A Zlevel.1 entity is added to the program.

The Zlevel dialog box is displayed.

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3 Axis Surface Machining Version 5 Release 13 Page 21 2. Call the contextual menu of

2. Call the contextual menu of the sensitive red area that represents the part and choose Select

faces

The dialog box shrinks and the face selection toolbar is displayed.

Select all of the walls that form a belt around the part. Click OK.

The dialog box is redisplayed and the red area is now green.

In the viewer, the edges around the selected faces are highlighted.

box is redisplayed and the red area is now green. In the viewer, the edges around

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3. Click the check element in the sensitive icon to select the upper face of the part.

4. Go to the Machining strategy tab (

Clik Replay.

) and choose Outer part for the Machining mode . Outer part for the Machining mode.

5. The tool path is displayed and the display and analysis dialog box is called up. Click OK.

6. The tool path is erased from the viewer and you come back to the operation dialog box. Click OK

to close the dialog box.

The operation you have just created should still be the current entity. Now we are going to define the ZLevel machining of the pocket.

you have just created should still be the current entity. Now we are going to define

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ZLevel Machining of the Inside Walls of a Part

13 Page 23 ZLevel Machining of the Inside Walls of a Part This task shows you

This task shows you how to use ZLevel machining for finishing the inside walls of the pocket.

Make sure that ZLevel.1 is the current entity so that this operation will be inserted after it.

1. Select the ZLevel icon

.
.

A Zlevel.2 entity is added to the program.

The Zlevel dialog box is displayed.

it. 1. Select the ZLevel icon . A Zlevel.2 entity is added to the program. The

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2. Call the contextual menu of the sensitive red area that represents the part and choose Select

faces

The dialog box shrinks and the face selection toolbar is displayed.

Select all of the faces that form the inside wall of the pocket. Clik OK.

The dialog box is redisplayed and the red area is now green.

In the viewer, the edges around the selected faces are highlighted.

viewer, the edges around the selected faces are highlighted. 3. Go to the Machining strategy tab

3. Go to the Machining strategy tab (

4. Click Replay.

3. Go to the Machining strategy tab ( 4. Click Replay . ) and choose Pockets

) and choose Pockets only for the Machining mode.

5. The tool path is displayed and the display and analysis dialog box is called up.

Click OK.

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6. The tool path is erased from the viewer and you come back to the operation dialog box.

Click to close the dialog box.

The operation you have just created should still be the current entity.

Now we are going to define a sweeping operation for the top surface of the part and the bottom of the pocket.

entity. Now we are going to define a sweeping operation for the top surface of the

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Sweeping

This task shows you how to use sweeping for finishing the part.Surface Machining Version 5 Release 13 Page 26 Sweeping You are going to define two separate

task shows you how to use sweeping for finishing the part. You are going to define

You are going to define two separate operations one for the top surface and another for the bottom of the pocket. Make sure that ZLevel2 is the current entity so that the sweeping operation will be inserted after it.

1. Select the Sweeping icon

.
.

A Sweeping.1 entity is added to the program.

The Sweeping dialog box is displayed.

1. Select the Sweeping icon . A Sweeping.1 entity is added to the program. The Sweeping

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2. Call the contextual menu of the sensitive red area that represents the part and choose Select

faces

The dialog box shrinks and the face selection toolbar is displayed.

Select the top surface of the part. Click OK.

The dialog box is redisplayed and the red area is now green.

In the viewer, the edges around the top surface are now highlighted.

the edges around the top surface are now highlighted. 3. Click Replay . 4. The tool

3. Click Replay.

4. The tool path is displayed and the display and analysis dialog box is called up. Click OK.

The operation you have just created should still be the current entity.

5. Repeat all of the above steps for the bottom surface of the pocket.

just created should still be the current entity. 5. Repeat all of the above steps for

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Checking the Results

Your specification tree should look like this. 1. Select Manufacturing Program.1.
Your specification tree should look like this.
1. Select Manufacturing Program.1.

This task shows you how to visually check the machined part resulting from the tool paths for the operations you defined in your machining program.

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2. In the contextual menu, choose Manufacturing Program.1 object > Tool Path Replay.

The Display and Analysis dialog box is displayed.

Replay . The Display and Analysis dialog box is displayed. Click this icon path after each
Replay . The Display and Analysis dialog box is displayed. Click this icon path after each

Click this icon

path after each operation. If any of the operations were not computed with Replay, they

will be computed at this stage.

to go from one operation to the next displaying the computed tool

You can display a photo of how the finished part would look with

.
.

Press OK to close the dialog box.

the computed tool You can display a photo of how the finished part would look with

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Creating a Rework Area

This task shows you how to define an area to rework from the areas of the part that were not machined with the tool used in the operations.Version 5 Release 13 Page 30 Creating a Rework Area You must compute the tool paths

You must compute the tool paths for your machining program first. compute the tool paths for your machining program first.

Click the Rework Area icon Rework Area icon

1.

.
.

2.

Click the red area that represents the part. The dialog box shrinks to allow you to select the part

2. Click the red area that represents the part. The dialog box shrinks to allow you

in the viewer. Select the part. Double click anywhere in the viewer to confirm your selection and

to redisplay the dialog box.

to confirm your selection and to redisplay the dialog box. 3. Enter a value of 10mm

3. Enter a value of 10mm for the Entry diameter and 2mm for the Corner radius (values used in

the machining operations).

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3 Axis Surface Machining Version 5 Release 13 Page 31 Be careful not to hit Return
3 Axis Surface Machining Version 5 Release 13 Page 31 Be careful not to hit Return

Be careful not to hit Return while entering this data as that will close the dialog box.

4. Click Compute. This creates a Rework Area which remains the current entity. The areas that we

are going to rework are displayed.

remains the current entity. The areas that we are going to rework are displayed. 5. Click

5. Click OK to close the dialog box.

remains the current entity. The areas that we are going to rework are displayed. 5. Click

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3 Axis Surface Machining Version 5 Release 13 Page 32 Reworking This task shows you how

Reworking

This task shows you how to rework the areas of the part that have not been machined and were there is residual material.

You must have created a rework area. A rework area is an area that cannot be machined with a given tool.

The rework area must be the current entity. If you have doubts about whether the rework area you just defined is still the current entity or not (i.e. if

you performed another action since), click the Manufacturing Features icon area from the list.

1. Click the ZLevel icon
1. Click the ZLevel icon

and click OK.

area from the list. 1. Click the ZLevel icon and click OK . and select the

and select the rework

2. In the Manufacturing Features window (

third ZLevel operation.

Manufacturing Features window ( third ZLevel operation. 3. Double click the tool diameter. ), double click

3. Double click the tool diameter.

window ( third ZLevel operation. 3. Double click the tool diameter. ), double click the tool

), double click the tool that is associated with the

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3 Axis Surface Machining Version 5 Release 13 Page 33 Enter a value of 5. Press

Enter a value of 5.

Press OK to confirm the tool diameter and then OK to close the tool definition dialog box.

4. Still in the Machining Features window, double click ZLevel.3 to display the ZLevel dialog box.

5. Go to the Strategy tab

.
.

In the Machining tab, choose Outer part for the Machining mode.

6. Press Replay. The new tool path is displayed.

7. Click OK to close the operation dialog box and Close to close the manufacturing view.

Now we are going to generate an NC data file.

close the operation dialog box and Close to close the manufacturing view. Now we are going

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Generating an NC Output File

Version 5 Release 13 Page 34 Generating an NC Output File This task explains how to

This task explains how to interactively generate NC code from the program you have just created.

1. Save your program with File/Save as

called models)

in the directory of your choice (here we have a directory

in the directory of your choice (here we have a directory and call your program MySurfaceMachining

and call your program MySurfaceMachining.

Press Save.

2. Select Manufacturing Program.1 in the specifications tree and select Generate NC Code

Interactively in the contextual menu.

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3 Axis Surface Machining Version 5 Release 13 Page 35 In the dialog box that is

In the dialog box that is displayed, call your file SurfaceMachining (the aptsource suffix is automatic). Browse to the directory where you want to save it (here we have chosen to put it in the same directory as the CATProcess but this is not obligatory).

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3 Axis Surface Machining Version 5 Release 13 Page 36 Click Save to create the APT

Click Save to create the APT file.

The APT file can be read with any kind of text editor.

Version 5 Release 13 Page 36 Click Save to create the APT file. The APT file

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Generating One File Per Operation

This task explains how to generate one file per operation in the machining program .

This task explains how to generate one file per operation in the machining program .

Step 1. is only necessary if you have not already saved your CATProcess.

1. Save your program with File/Save as in the directory of your choice (here we

1.

Save your program with File/Save as

in the directory of your choice (here we have a directory

called models)

of your choice (here we have a directory called models) and call your program MySurfaceMachining .

and call your program MySurfaceMachining. Press Save.

2. Select Manufacturing Program.1 in the specifications tree and click the Generate NC Code in

Batch Mode icon

.
.

Enter the following data in the dialog box that is displayed:

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3 Axis Surface Machining Version 5 Release 13 Page 38 Call your file SurfaceMachiningOperations and store

Call your file SurfaceMachiningOperations and store it in the same directory as your CATProcess (the choice of directory is not obligatory, you can store your files in the directory of your choice).

Make sure that the Split files by operation is selected. Click Save to create the APT file.

The APT file can be read with any kind of text editor.

3. Press Execute.

One file is created per operation.

APT file. The APT file can be read with any kind of text editor. 3. Press

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Generating NC Shopfloor Documentation

5 Release 13 Page 39 Generating NC Shopfloor Documentation This task explains how to interactively generate

This task explains how to interactively generate shopfloor NC documentation in HTML format from the program you have just created.

1. Select the Generate documentation icon

displayed.

1. Select the Generate documentation icon displayed. . The process documentation dialog box is 2. Select

. The process documentation dialog box is

icon displayed. . The process documentation dialog box is 2. Select the SurfaceMachinist4.CATScript file from the

2. Select the SurfaceMachinist4.CATScript file from the samples directory. Leave "Process" as the

process name.

Choose the directory where you want to store your new file (we have chosen MyFiles, but this is

not obligatory). Enter "Process" in the Main File Name field.

3. Press OK. Your NC document has been created. Press Close to close the dialog box.

in the Main File Name field. 3. Press OK . Your NC document has been created.

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Area-oriented Machining

Area-oriented machining is a method where you define all of the separate areas you want to machine on the part before assigning an operation to each one.

In this tutorial you are going to learn how to:

define areas (including a rework area) on the part below,

define tools to use on the areas,

use a safety plane,

change a tool axis,

create an APT file and a workshop document.

tool axis, ● create an APT file and a workshop document. Entering the workbench Defining the

Entering the workbench Defining the areas to machine Defining the tools to use Rough machining the part Sweeping the top surface Sweeping the side areas ZLevel on vertical walls Reworking between contours Generating an output file Generating workshop documentation

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Entering the Workbench

This task shows you how to open a part and enter the Surface Machining workbench.
This task shows you how to open a part and enter the Surface Machining workbench.

This task shows you how to open a part and enter the Surface Machining workbench.

1. Open the Gets2.CATPart in the samples directory.

2. Select NC Manufacturing > Surface Machining from the Start menu.

The Surface Machining workbench is displayed. The part is displayed in the viewer along with the manufacturing specifications.

3. Press MB2 and MB3 at the same time and turn the part round so that it looks like this:

manufacturing specifications. 3. Press MB2 and MB3 at the same time and turn the part round

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4. Double click Part Operation.1 in the tree. In the dialog box that is displayed, click the design

part icon and click the part in the viewer. Then double click anywhere in the viewer and press OK.

This step is necessary for the visualization and analysis part of the process.

for the visualization and analysis part of the process. You might find it easier to select

You might find it easier to select the surfaces if you hide the planes and the machining axis system.

Select the planes in the tree and use the Hide/Show option in the contextual menu:

tree and use the Hide/Show option in the contextual menu: ● Select the machining axis system

Select the machining axis system in the viewer:

option in the contextual menu: ● Select the machining axis system in the viewer: ● and

and hide it in the same manner.

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3 Axis Surface Machining Version 5 Release 13 Page 43
3 Axis Surface Machining Version 5 Release 13 Page 43

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Defining the Areas to Machine

This task teaches you how to define the specific areas on the part that you are going to machine. You are going to define:Version 5 Release 13 Page 44 Defining the Areas to Machine ● the whole part as

the whole part as a machining area for rough machining purposes

four other areas for use with different cycle types

and a rework area.

Click the Machining/Slope Area icon Machining/Slope Area icon

1.

.
.

2.

Click the red, sensitive area in the dialog box.

The dialog box shrinks to allow you to select the part in the viewer.

box shrinks to allow you to select the part in the viewer. 3. Click the part

3. Click the part in the view. The whole part is selected. Double click anywhere in the viewer to

redisplay the dialog box.

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4. Give the machining area a name. Replace the text in the name box by Whole.

area a name. Replace the text in the name box by Whole . Click OK .

Click OK. You have just created your first machining area.

5. Now create an area on the top of the part. Select the Machining area icon. Call the contextual

menu of the sensitive red area that represents the part and choose Select faces

The dialog box

shrinks and the face selection toolbar is displayed. Now select the areas that you see selected in

the picture below.

select the areas that you see selected in the picture below. Click OK in the face

Click OK in the face selection toolbar.

Call this area Top.

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6. Now do the same for the left side of the part with these faces:

do the same for the left side of the part with these faces: Call this area

Call this area Left.

7. Define a third area with these faces and call it Right.

side of the part with these faces: Call this area Left . 7. Define a third

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8. Finally, create the last machining area with the 3 faces below and call it Bottom.

machining area with the 3 faces below and call it Bottom . 9. Check the areas

9. Check the areas that you have just created in the Manufacturing view look like this:

just created in the Manufacturing view look like this: . The view should 10. Now you
just created in the Manufacturing view look like this: . The view should 10. Now you

. The view should

10. Now you are going to create a rework area to use when removing residual material. Select Whole

in the manufacturing view.

11. Click the Rework area icon

.
.

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12. In the dialog box that is displayed, change the Entry diameter to 10 mm, the Corner radius to

5 mm and the name to Rework.

dialog box that is displayed, change the Entry diameter to 10 mm, the Corner radius to

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13. Press Compute to compute the area. The rework area should look like this on the part:

the area. The rework area should look like this on the part: 14. Press OK to

14. Press OK to close the dialog box.

Press Close to close the manufacturing view.

The next step is to define the tools that you will need to machine the areas you have just defined.

manufacturing view. The next step is to define the tools that you will need to machine

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Defining the Tools to Use

Version 5 Release 13 Page 50 Defining the Tools to Use This task defines the three

This task defines the three tools that you are going to need to machine the part.

1. Click Manufacturing Program.1 in the PPR and then click the End mill tool change icon

.
.

If you cannot see this icon, use View > Toolbars and activate Auxiliary Operations.

View > Toolbars and activate Auxiliary Operations . 2. In the dialog box that is displayed,

2. In the dialog box that is displayed, click the box to select a ball-end tool confirm with OK.

3. Click the End mill tool change icon again.

4. Activate the ball-end tool box.

5. Double click the diameter.

. 3. Click the End mill tool change icon again. 4. Activate the ball-end tool box.

and

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3 Axis Surface Machining Version 5 Release 13 Page 51 6. Enter a value of 20

6. Enter a value of 20 in the dialog box that is displayed.

Click OK

a value of 20 in the dialog box that is displayed. Click OK 7. Change the

7. Change the tool name to T2 End Mill D 20

8. Now define a third tool that:

is ball end,

has a diameter of 4 mm,

and is called T3 End Mill D 04.

a third tool that: ● is ball end, ● has a diameter of 4 mm, ●

. Click OK.

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9. You now have the three tools that you will need to machine the part.

Your PPR should look like this:

We are now going to move on to the next step where you will rough machine the part.

part. Your PPR should look like this: We are now going to move on to the
part. Your PPR should look like this: We are now going to move on to the

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Sweep Roughing the Part

Version 5 Release 13 Page 53 Sweep Roughing the Part This task will show you how

This task will show you how to rough machine the whole part using a sweep roughing operation.

1. Open the Manufacturing View by clicking this icon

.
.

2. Select Whole from the list of areas.

this icon . 2. Select Whole from the list of areas. 3. Click the Sweep Roughing

3. Click the Sweep Roughing icon

.
.

4. Go to the tool tab and choose tool T2 End Mill D20.

from the list of areas. 3. Click the Sweep Roughing icon . 4. Go to the

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5. Press Replay to compute the operation. The toolpath is displayed on the part. Press OK to close

the small dialog box that is displayed (bottom right).

6. Press OK to close the operation dialog box.

7. Now you are going to machine the Top surface.

(bottom right). 6. Press OK to close the operation dialog box. 7. Now you are going

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Sweeping the Top Surface

Version 5 Release 13 Page 55 Sweeping the Top Surface This task will show you how

This task will show you how to sweep the top surface of the part and how to change a tool.

1. In the manufacturing view, select the machining area called Top from the list of areas.

2. Click the Sweeping icon

.
.

3. In the Strategy tab, give a stepover distance value of 1mm.

the Strategy tab, give a stepover distance value of 1mm. 4. Go to the Geometry tab

4. Go to the Geometry tab and make sure that Part autolimit is turned on

.
.

5. Go to the Tool tab and choose tool T1 End Mill D 10.

5. Go to the Tool tab and choose tool T1 End Mill D 10 . 6.

6. Press Replay to compute the tool path.

7. Press OK to close the operation dialog box.

Now you are going to machine the sides of the part.

the tool path. 7. Press OK to close the operation dialog box. Now you are going

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Sweeping the Side Areas

This task is going to teach you how to:

sweep machining areas Left and Right and Left and Right and

change the orientation of the tool axis.

In the Manufacturing view , select the machining area called Left . Manufacturing view, select the machining area called Left.

1.

2.

Click the Sweeping icon

.
.

3.

In the Strategy tab, define a new tool axis like this:

Left . 1. 2. Click the Sweeping icon . 3. In the Strategy tab, define a

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4. Go to the Tool tab and select T1 End Mill D 10.

5. Press Replay to compute the tool path.

6. Press OK to close the operation dialog box.

7. Now you are going to machine the area called Right. Select it in the manufacturing view.

8. Click the Sweeping icon

.
.

9. Change the tool axis like this:

the Sweeping icon . 9. Change the tool axis like this: 10. Define the same tool

10. Define the same tool as for area Left.

11. Press Replay to compute the tool path.

12. Press OK to close the operation dialog box.

The next step is to machine the area called Bottom.

the tool path. 12. Press OK to close the operation dialog box. The next step is

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ZLevel on the Vertical Walls

This task teaches you how to:Version 5 Release 13 Page 58 ZLevel on the Vertical Walls ● use ZLevel milling ●

use ZLevel milling

change a tool axis

use the safety plane.

In the Manufacturing view, select the machining area called Bottom . Manufacturing view, select the machining area called Bottom.

1.

2.

Click the ZLevel icon

.
.

3.

In the Strategy tab, define a new tool axis like this:

Click here:

In the Strategy tab, define a new tool axis like this: ● Click here: ● Define

Define the tool axis with these settings:

In the Strategy tab, define a new tool axis like this: ● Click here: ● Define

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4. Go to the Macro tab and deactivate the Optimize retracts option.

Macro tab and deactivate the Optimize retracts option. The purpose of this is to ensure that

The purpose of this is to ensure that the tool rises high enough over the area to avoid gouging the rest of the part.

5. Press Replay to compute the tool path.

6. Press OK to close the operation dialog box.

the rest of the part. 5. Press Replay to compute the tool path. 6. Press OK

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Reworking Between Contours

Version 5 Release 13 Page 60 Reworking Between Contours This task shows you how to take

This task shows you how to take an area that has not been machined because the tool used was too big and rework it with a smaller tool.

1. Select Rework in the manufacturing view.

2. Click the Contour-driven icon

.
.

3. Go to the Radial tab in the Machining Strategy tab and choose Constant on part in the

Stepover list.

tab and choose Constant on part in the Stepover list. 4. Now go to the tool

4. Now go to the tool tab and select tool T3 End Mill D 04.

5. Press Replay to compute the tool path.

6. Press OK to close the operation dialog box.

Now, you are going to create an APT file.

to compute the tool path. 6. Press OK to close the operation dialog box. Now, you

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Generating an NC Output File

Version 5 Release 13 Page 61 Generating an NC Output File This task explains how to

This task explains how to interactively generate NC code from the program you have just created.

1. Save your program with File/Save as

called models)

in the directory of your choice (here we have a directory

models) in the directory of your choice (here we have a directory Call your program MyGettingStarted

Call your program MyGettingStarted.

Press Save.

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2. Select Manufacturing Program.1 in the specifications tree then select the Generate NC Code

Interactively icon

.
.
tree then select the Generate NC Code Interactively icon . Call your file SurfaceMachining (the aptsource

Call your file SurfaceMachining (the aptsource suffix is automatic). Browse to the directory where you want to save it (here we have chosen to put it in the same directory as the CATPRocess but this is not obligatory).

Click Save to create the APT file.

The APT file can be read with any kind of editor.

Next you are going to generate workshop documentation in HTML format.

The APT file can be read with any kind of editor. Next you are going to

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Generating NC Workshop Documentation

5 Release 13 Page 63 Generating NC Workshop Documentation This task explains how to interactively generate

This task explains how to interactively generate shopfloor NC documentation in HTML format from the program you have just created.

1. Select the Generate Documentation icon

.
.

The process documentation dialog box is displayed.

icon . The process documentation dialog box is displayed. 2. Select the SurfaceMachinist4.CATScript file from the

2. Select the SurfaceMachinist4.CATScript file from the samples directory.

Leave "Process" as the process name.

Choose the directory where you want to store your new file (we have chosen MyFiles, but this is not obligatory).

Enter "Process" in the Main File Name field.

3. Press OK.

Your NC document has been created.

Press Close to close the dialog box.

in the Main File Name field. 3. Press OK . Your NC document has been created.

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User Tasks

The basic tasks in this section involve creating, editing and managing machining operations and other entities of the manufacturing process.

The first basic tasks are general ones:

Recommendations.

Selecting geometry shows you how to use the sensitive icon in the geometry tab.

Using geometrical zones shows you how to define and use geometrical areas.

Changing the tool axis shows you how to change a tool axis from the sensitive icon.

Set Up and Part Positioning

Design Changes.

The following chapters are more specific and deal with:

Roughing operations

Finishing and semi-finishing operations

Reworking operations

Axial machining operations

Machining features

Tool path editor

Importing files

Auxiliary operations

Part operation and manufacturing program

Managing manufacturing entities

Verification, simulation and program output

MfgBatch Utility for Generating NC Data

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Recommendations

If you intend to create complementary geometry, before you start 3 Axis Surface Machining go to Tools/Options and, in the Display tab of the NC Manufacturing options, tick the box that allows you to create a CATPart to store necessary geometry. If you are not going to modify the geometry, then make sure that this box is not ticked.

Before starting 3 Axis Surface Machining, go to Tools/Options and in the Operation tab of the NC Manufacturing option and tick the Use default values of the current program box. This will ensure that when a new operation is created its parameters will be initialized with default values that are appropriate to that operation and not with the values from the operation just before it.

You should save your CATProcess before generating HTML workshop documentation.

If you have defined a safety plane, you should deactivate the Optimize retracts option. If you do not, the safety plane will be ignored.

In an operation, if you cannot see the whole dialog box (particularly the OK, Apply and Cancel buttons), exit your CATIA session and use Settings > Control Panel > Display > Settings to:

give a higher value for your screen resolution,

or, if you are using large fonts, use small fonts.

Depending on your screen size, you may have to use both of the solutions.

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Selecting Geometry

Either:Version 5 Release 13 Page 66 Selecting Geometry ● ● make the Manufacturing Program current in

make the Manufacturing Program current in the specification tree if you want to define an operation and the part/area to machine at the same time,

or select a machining feature from the list if you have already defined the area to machine and now you want to define the operation to apply to it.

When you use a boundary of faces to define a limiting contour, if the faces are not perfectly connected then only the first face will be selected.and now you want to define the operation to apply to it. ● ● ● ●

In the face selection wizard, the Polygon trap option does not always select all of the faces inside the polygon and sometimes selects extra ones, i.e. it goes through the surface and selects faces from the other side of the model.

Occasionally, when selecting a complex area on a tool path using either a polygon or a contour, the area outside the boundary is selected rather than the area inside.

When using a polygon to select an area on a tool path, display of the polygon before confirmation may be erratic (it may rise to a point that is not on the tool path itself), particularly around areas where the polygon intersects itself.

1. Select a Machining Operation icon.

2. The dialog box opens at the Geometry tab page

.
.

This page includes a sensitive icon to help you specify the geometry to be machined. The red status light on

the tab indicates that you must select the geometry in order to create the operation

Each machining operation offers its own sensitive icon. In addition, the icon is slightly different if you are using a rework area or a slope area and will have fewer parameters.machined. The red status light on the tab indicates that you must select the geometry in

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3 Axis Surface Machining Version 5 Release 13 Page 67 Example: initial sensitive icon for Sweeping

Example: initial sensitive icon for Sweeping

13 Page 67 Example: initial sensitive icon for Sweeping the same icon with a rework area

the same icon with a rework area

If you are editing a rework or a slope area, an additional information is displayed, indicating which type of subset you are working on. This field is not editable (you can not go from one subset to another).

is not editable (you can not go from one subset to another). ● There is also

There is also an Info button that, when pressed, gives the details on the parameters that were defined with the rework area.

In the Geometric component tab you can define the part to machine (obligatory, the corresponding portion of the icon turns from red to green once you have defined it).

The other geometric components that you can select in the view (but that are not obligatory) are:

the check element,

an area to avoid,

the safety plane,

a top plane,

a bottom plane,

a start plane,

an end plane,

inner points,

the limiting contour,

the offset on the part (double-click on

contour, ● the offset on the part (double-click on ), ● the offset on the check

),

the offset on the check element (double-click on

on ), ● the offset on the check element (double-click on ). Please refer to the

).

Please refer to the Reference information of each machining operation for more details.

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3. Select a part to machine:

by clicking the part definition area: the dialog box shrinks to let you select one or several bodies. Double-click anywhere in the viewer to revert to the dialog box.

by using the contextual menu of the part definition area:

choose Select faces

to select zones of a body with the face selection toolbar,

to select zones of a body with the face selection toolbar , 4. Select another geometry

4. Select another geometry

by clicking on a face definition area and using the face selection toolbar,

by clicking on a contour definition area and using the edge selection toolbar.

by passing the mouse over an element definition area:

choose Body(ies) in the contextual menu if you wish to machine a whole part and not just an area on it, or Select zones if you wish to select zones.

not just an area on it, or Select zones if you wish to select zones. ●

or by choosing a pre-defined area like this:

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3 Axis Surface Machining Version 5 Release 13 Page 69 You can use Offset Groups and

You can use Offset Groups and Features when defining geometry.

can use Offset Groups and Features when defining geometry. ● The types of selection by default

The types of selection by default (reached by clicking a sensitive zone) are adapted to the types of the elements to select (bodies for a part to machine, but faces for check elements, for instance).

The contextual menus vary also with the type of elements to select.

All of the above planes can be defined by selecting a point or a plane in the viewer.

You can also set an offset on all of the planes using the contextual menu over each plane. The offset can be either positive or negative and is previewed in the viewer before it is validated.

and is previewed in the viewer before it is validated. Press OK in the dialog box

Press OK in the dialog box to confirm.

In the case of imposed planes, the offset value will be applied to all of the planes you have imposed. The tool will pass through all of the planes defined by the offset and not through the planes that are imposed. One advantage of this is that if the top surface of the part is flat and you have defined an Offset on part of, for example of 1mm, you can define the same offset on the imposed planes so as to ensure that there will be no residual material remaining on the top surface.

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5. Use Part autolimit and the limiting contour individually or together to define the area you want to

machine:

In the pictures, the blue outline is the part edge, the yellow part is the area that will be machined,

the black line is the limiting contour:

If you use Part autolimit, the whole part is machined. I f you activate Part autolimit, the tool will not go beyond the edge of the part.

, the tool will not go beyond the edge of the part. ● If you use

If you use a Limiting contour, only the area inside the limiting contour is machined.

, only the area inside the limiting contour is machined. ● If you wish to machine

If you wish to machine the area outside the limiting contour, choose Outside as the Side to machine.

is machined. ● If you wish to machine the area outside the limiting contour, choose Outside

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6. Once the limiting contour is defined, you can also define the following parameters:

Stop position defines where the tool stops:

Outside stops the tool outside the limit line,

Inside stops inside the limit line,

On stops the tool on the limit line.

Stop mode defines which part of the tool is considered at the Stop position, whether it is the contact point or the tool tip.

Offset is the distance that the tool that the tool will be either inside or outside the limit line depending on the Stop mode that you chose.

You can now either run the operation on the part, store the operation that you have just defined or define other parameters in the machining strategy, tool data, speeds and rates, or macro data tabs first.

just defined or define other parameters in the machining strategy, tool data, speeds and rates, or

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Using Geometrical Zones

This task shows you how to define and use geometrical areas.

This task shows you how to define and use geometrical areas.

1. Open file DemoRASA.CATPart in the samples directory.

1. Open file DemoRASA.CATPart in the samples directory.

2. Click the Geometrical Zone icon

.
.

3. Select the Line button, call the contour you are about to select "MyContour" and click the

orange outline in the sensitive icon.

button, call the contour you are about to select " MyContour " and click the orange

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4. Select this contour:

Version 5 Release 13 Page 73 4. Select this contour: Press OK 5. Create a sweeping

Press OK

5. Create a sweeping operation in the tree and select the whole body for the part.

in the tree and select the whole body for the part. 6. Choose Select zones in
6. Choose Select zones in the limiting contour contextual menu. In the dialog box that
6.
Choose Select zones in the limiting contour contextual menu. In the dialog box that is displayed,
choose MyContour and select it with the arrow. Press OK.
7.

Press Replay.

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3 Axis Surface Machining Version 5 Release 13 Page 74 7. You can also define geometrical

7. You can also define geometrical zones in an operation dialog box.

Open the sweeping operation you have just defined. Select this face as an area to avoid:

you have just defined. Select this face as an area to avoid: Select Export in the

Select Export in the Area to avoid contextual menu and call it MyPlane.

in the Area to avoid contextual menu and call it MyPlane . Press OK . You

Press OK. You can now use this surface in the same way as you used the contour above.

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3 Axis Surface Machining Version 5 Release 13 Page 75 ● All geometrical zones that you

All geometrical zones that you create can be used in any number of operations.

The Hide/Show item in the contextual menu does not work for geometrical zones .

be used in any number of operations. ● The Hide/Show item in the contextual menu does

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Changing the Tool Axis

Version 5 Release 13 Page 76 Changing the Tool Axis This task will show you how

This task will show you how to change the Tool Axis to define a machining operation, or a machining/slope area or a rework area.

Please note that the Display tool and position options are not available for the definition of a machining/slope area or a rework area.

To change the tool axis click the Tool axis represented in the sensitive icon (depending on the machining operation, the representation may change), or use Select in its contextual menu.

operation, the representation may change), or use Select in its contextual menu. The Tool Axis dialog

The Tool Axis dialog box is displayed.

operation, the representation may change), or use Select in its contextual menu. The Tool Axis dialog

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Selection has the following options:

5 Release 13 Page 77 Selection has the following options: You can choose between selection by

You can choose between selection by Coordinates (X, Y, Z) or by Angles. Angles lets you choose the tool axis by rotation around a main axis. Angle 1 and Angle 2 are used to define the location of the tool axis around the main axis that you select.

Feature-defined: you select a 3D element such as a plane that will serve to automatically define the best tool axis.

Selection: you select a 2D element such as a line or a straight edge that will serve to define the tool axis.

Manual

Points in the view: click two points anywhere in the view to define the tool axis.

There is also a button that lets you reverse the direction of the axis with respect to the coordinate system origin.

When available, you can also choose to display the tool and select the position of the tool (default or user- defined).

When available, you can also choose to display the tool and select the position of the

3 Axis Surface Machining

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Compute Tool Gage on Assembly

Version 5 Release 13 Page 78 Compute Tool Gage on Assembly This task will show you

This task will show you how to compute tool gage on assembly and save the associated report.

Open the Block.CATProcess from the samples directory.

In this CATProcess, there are two machining operations, Spiral milling.1, that is not computed, and Sweeping.1 that is computed. Note that Computed refers to the computation of the tool path, not to that of the tool gage.

computation of the tool path, not to that of the tool gage. 1. Click on the

1. Click on the Compute Tool Gage on Assembly icon

path, not to that of the tool gage. 1. Click on the Compute Tool Gage on

. The dialog box is displayed:

path, not to that of the tool gage. 1. Click on the Compute Tool Gage on

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2. Push the Select All button:

5 Release 13 Page 79 2. Push the Select All button: The Selection field is updated,

The Selection field is updated,

The Operations field is updated with the available information:

Name of the operation,

Activate status: by default it is set to No. This means that the minimum tool gage will be computed from the current tool path but will not be automatically recomputed if the tool path is modified. If you set Activate to Yes, the minimum tool gage will be automatically recomputed when you recompute the tool path.

Current Length of the tool,

Minimum Tool Gage if one has already been computed.

● Minimum Tool Gage if one has already been computed. ● When an operation is active,

When an operation is active, it is automatically selected and displayed in the dialog box when you open it.

Use the Reset button to erase the whole selection.

You can pick operations in the specification tree to add them to the list in the dialog box.

3. Define the Activate status if necessary:

Use the Activate All or Deactivate All buttons to set the Activate status for all the operations or

Select an operation in the list and use the contextual menu to set the Activate status for one operation:

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3 Axis Surface Machining Version 5 Release 13 4. Start the computation: Page 80 ● Use

4. Start the computation:

Page 80

Use the Compute All button to compute the minimum tool gage for all operations or

Select an operation in the list and use the contextual menu to compute the minimum tool gage for one operation:

menu to compute the minimum tool gage for one operation: 5. The following message appears because

5. The following message appears because no tool path has been computed yet for Spiral milling.1

no tool path has been computed yet for Spiral milling.1 6. Click OK, exit the dialog

6. Click OK, exit the dialog box, compute the tool path.

7. Reopen the dialog box, the previous selection is still active. You can restart the computation of the minimum tool gage. The value of the

minimum tool gage is displayed.

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3 Axis Surface Machining Version 5 Release 13 Page 81 8. The Report button let you

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8. The Report button let you save the information displayed in the dialog box in a .txt file

5 Release 13 Page 81 8. The Report button let you save the information displayed in

3 Axis Surface Machining

3 Axis Surface Machining In this example, Version 5 Release 13 ● Sweeping.1 Activate status is

In this example,

Version 5 Release 13

Axis Surface Machining In this example, Version 5 Release 13 ● Sweeping.1 Activate status is No

Sweeping.1 Activate status is No.

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If you modify the parameters of this operation and recompute the tool path, the Minimum Tool Gage will not be recomputed. You will have to

restart this computation manually.

Spiral milling.1 Activate status is Yes.

If you modify the parameters of this operation and recompute the tool path, the Minimum Tool Gage will be recomputed too. If you reopen the

Minimum Tool Gage on Assembly dialog box, the Minimum Tool Gage value will be updated to the new value.

Use this capacity to save time when you are working on operations that require long computation times:

select the operations you will be working on,

set their Activate status to Yes,

make all the modifications you require,

when you are finished, start the computation of the tool paths, the computation of the Minimum Tool Gage will be done at the same time.

If the following message appearsof the Minimum Tool Gage will be done at the same time. ● exit the dialog

be done at the same time. If the following message appears ● exit the dialog box,

exit the dialog box, double-click Part Operation.1 in the specification tree.

enter the part in the first line of the Geometry tab. Click OK and reopen the Minimum Tool Gage On Assembly dialog box. Restart the computation.

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Rough Machining Operations

These are the tasks that you will use for rough machining the part.

Create a sweep roughing operation:the tasks that you will use for rough machining the part. ● ● ● Select the

Select the sweep roughing icon,

Choose a part to machine,

Specify the tool to be used.

You can also specify machining parameters, feedrates and spindle speeds and macro data.

Create a roughing operation:parameters , feedrates and spindle speeds and macro data. ● ● ● ● Select the roughing

Select the roughing icon,

Choose a part to machine

Specify the tool to be used,

Specify the type of roughing.

You can also specify machining parameters, feedrates and spindle speeds and macro data.

Basic tasks illustrate:

a sweep roughing operation,

a roughing operation,

ordering zones in a roughing operation,

the creation of an automatic rough stock,

the creation of an offset on part.

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Sweep Roughing

This task shows you how to insert a sweep roughing operation into the program. Sweep roughing is an operation which allows you to rough machine parts by vertical planes.Machining Version 5 Release 13 Page 85 Sweep Roughing To create the operation you define: ●

To create the operation you define:

the geometry of the part to machine

,
,

the parameters of the machining strategy

the tool to use

parameters of the machining strategy ● the tool to use ;only end mill tools ● the

;only end mill tools

the feedrates and spindle speeds

the macros.

.
.
,
,
,
,
the feedrates and spindle speeds ● the macros. . , , are available for this operation,

are available for this operation,

Only the geometry is obligatory, all of the other requirements have a default value.

Either:all of the other requirements have a default value. ● ● make the Manufacturing Program current

make the Manufacturing Program current in the specification tree if you want to define an operation and the part/area to machine at the same time,

or select a machining feature from the list if you have already defined the area to machine and now you want to define the operation to apply to it.

Below we are going to see how to do the first of these.

Open file Basic1.CATPart then select NC Manufacturing > Surface Machining in the Start menu.

1. Select the Sweep Roughing icon Select the Sweep Roughing icon

.
.

A SweepRoughing entity and a default tool are added to the program. The dialog box

and a default tool are added to the program. The dialog box opens at the geometry

opens at the geometry tab page specify the geometry to be machined.

. This page includes a sensitive icon to help you

The area that represents the part geometry is colored red indicating that the geometry is required for defining the area to machine. All of the other geometry parameters are optional.box opens at the geometry tab page specify the geometry to be machined. . This page

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2. Click the red area in the sensitive icon and select the part in the viewer.

Then double click anywhere in the viewer to confirm your selection and redisplay the dialog box.

3. Press Replay. You will see that the top area of the part has been rough machined.

see that the top area of the part has been rough machined. A progress indicator is

A progress indicator is displayed. You can cancel the tool path computation at any moment before 100% completion.

tool path computation at any moment before 100% completion. If a tool path cannot be computed

If a tool path cannot be computed because of invalid faces, an explicit warning message like this one will appear:

an explicit warning message like this one will appear: Each invalid face is highlighted in red,

Each invalid face is highlighted in red, with an arrow pointing on it.

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3 Axis Surface Machining Version 5 Release 13 Page 87 This visualization is removed when you

This visualization is removed when you close the main dialog box or when you select Remove in the contextual menu.

box or when you select Remove in the contextual menu. Click OK in the Warning box

Click OK in the Warning box to revert to the main dialog box.

In the Geometry tab, a message Ignore invalid faces: No is displayed:

revert to the main dialog box. In the Geometry tab, a message Ignore invalid faces: No

You can either:

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close the dialog box. When you reopen it, the Ignore invalid faces: No will not be displayed.

heal the defective geometry and restart the computation. If it is successful the message Ignore

 

invalid faces: No will disappear.

 

ignore the invalid faces. Pick the text Ignore invalid faces: No. It will turn to Ignore invalid faces:

Yes and the computation will continue. The message remains displayed as a warning.

 
Be very careful when you choose to ignore invalid faces. We recommend that you ignore
Be very careful when you choose to ignore invalid faces. We recommend that you ignore only faces that
will not affect the tool path. Otherwise this may lead to defective tool paths.
recommend that you ignore only faces that will not affect the tool path. Otherwise this may

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Roughing

This task shows you how to insert a roughing operation into the program. Roughing is an operation which allows you to rough machine parts by horizontal planes.Surface Machining Version 5 Release 13 Page 89 Roughing To create the geometry you define: ●

To create the geometry you define:

geometric components

,
,

machining strategy

,
,

tool data

components , ● machining strategy , ● tool data ;only end mill tools ● speeds and

;only end mill tools

speeds and rates

,
,

macro data

.
.
end mill tools ● speeds and rates , ● macro data . are available for this

are available for this operation,

Only the geometry is obligatory, all of the other requirements have a default value.

Either:all of the other requirements have a default value. ● ● make the Manufacturing Program current

make the Manufacturing Program current in the specification tree if you want to define an operation and the part/area to machine at the same time,

or select a machining feature or an offset group from the list if you have already defined the area to machine and now you want to define the operation to apply to it.

Below we are going to see how to do the first of these.

Open file SurfaceMachining3.CATProduct, then select NC Manufacturing > Surface Machining in the Start menu.

Then display the model in wireframe mode with this icon

.
.

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1. Select the Roughing icon .

1.

Select the Roughing icon

.
.
 

A

roughing entity and a default tool area added to the program. The dialog box opens at

the geometry tab page geometry to be machined. . This page includes a sensitive icon

the geometry tab page geometry to be machined.

. This page includes a sensitive icon to help you specify the

The red area in the sensitive icon represents the part geometry. It is obligatory, as

The red area in the sensitive icon represents the part geometry. It is obligatory, as is the rough stock. All of the other parameters are optional.

2. Click the red area in the sensitive icon and select the part in the viewer. Then double click

 

anywhere in the viewer to confirm your selection and redisplay the dialog box.

 

3. Click the rough stock in the sensitive icon.

 

Select the stock in the viewer.

 

4. Press Replay to compute the operation. You will see that the part has been rough machined.

 

A

progress indicator is displayed. You can cancel the tool path computation at any moment

before 100% completion.

If a tool path cannot be computed because of invalid faces, an explicit warning message

If a tool path cannot be computed because of invalid faces, an explicit warning message like this one will appear:

an explicit warning message like this one will appear: Each invalid face is highlighted in red,

Each invalid face is highlighted in red, with an arrow pointing on it.

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3 Axis Surface Machining Version 5 Release 13 Page 91 This visualization is removed when you

This visualization is removed when you close the main dialog box or when you select Remove in the contextual menu.

dialog box or when you select Remove in the contextual menu. Click OK in the Warning
dialog box or when you select Remove in the contextual menu. Click OK in the Warning

Click OK in the Warning box to revert to the main dialog box.

In the Geometry tab, a message Ignore invalid faces: No is displayed:

Warning box to revert to the main dialog box. In the Geometry tab, a message Ignore

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close the dialog box. When you reopen it, the Ignore invalid faces: No will not be displayed.

heal the defective geometry and restart the computation. If it is successful the message Ignore

 

invalid faces: No will disappear.

 

ignore the invalid faces. Pick the text Ignore invalid faces: No. It will turn to Ignore invalid faces:

Yes and the computation will continue. The message remains displayed as a warning.

 
Be very careful when you choose to ignore invalid faces. We recommend that you ignore
Be very careful when you choose to ignore invalid faces. We recommend that you ignore only faces that
will not affect the tool path. Otherwise this may lead to defective tool paths.

5. If you want to perform another roughing operation, you can use the result of the above operation

as the rough stock for the next:

Click the Full Video icon (

rough stock for the next: ● Click the Full Video icon ( ) and running the

) and running the animation,

Click the Save Video Result in cgr icon (

Call the file Roughing

icon ( ) and running the animation, ● Click the Save Video Result in cgr icon

),

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3 Axis Surface Machining Version 5 Release 13 Page 93 and press Save . ● Close

and press Save.

Close all of the dialog boxes.

Double click Product 1 in the tree and, using the contextual menu, choose

Components > Existing Component

,

Browse to the right directory and choose Roughing.cgr.

Double click Part Operation in the tree.

● Double click Part Operation in the tree. You can now select Roughing in the tree

You can now select Roughing in the tree as your rough stock for the next operation.

click Part Operation in the tree. You can now select Roughing in the tree as your

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Roughing - Ordering Zones

Version 5 Release 13 Page 94 Roughing - Ordering Zones This task will show you how

This task will show you how to set the order in which the zones on a part are machined. Zones can be either pockets or the outer part.

You must have a part that has a point or a plane defined in the each of the zones you want to select.

1. Open ZoneOrder.CATProcess from the samples directory.

2. Click the Roughing icon

.
.

3. Click the red sensitive area and select the whole part to be machined.

red sensitive area and select the whole part to be machined. 4. Click Zone order and

4. Click Zone order

select the whole part to be machined. 4. Click Zone order and select the zones to

and select the zones to machine by clicking on the point in each as shown below:

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3 Axis Surface Machining Version 5 Release 13 Page 95 Press Replay . The zones will

Press Replay.

The zones will be machined in the order they were selected.

The zones will be machined in the order they were selected. Use the Video from last

Use the Video from last saved function ( the right order.

they were selected. Use the Video from last saved function ( the right order. ) to

) to check that the zones were machined in

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5. Now create another Roughing cycle with the same ordered zones and, in Zone order contextual

menu, deactivate the Machine only ordered areas option.

menu, deactivate the Machine only ordered areas option. Press Replay . ● If a tool path

Press Replay.

the Machine only ordered areas option. Press Replay . ● If a tool path cannot be

If a tool path cannot be computed because of invalid faces, an explicit error message like this one will appear:

faces, an explicit error message like this one will appear: ● Notice that the whole part

Notice that the whole part is machined (including the outside of the part) and not only the zones you ordered.

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3 Axis Surface Machining Version 5 Release 13 Page 97
3 Axis Surface Machining Version 5 Release 13 Page 97

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Automatic Rough Stock

Version 5 Release 13 Page 98 Automatic Rough Stock This task explains how to create an

This task explains how to create an automatic rough stock for a roughing operation.

You must have a part to machine in your workbench.

1. Open file AutoRoughStock.CATPart in the samples directory.

Open file AutoRoughStock.CATPart in the samples directory. 2. Select the Creates rough stock icon 3. Select

2. Select the Creates rough stock icon

samples directory. 2. Select the Creates rough stock icon 3. Select the part. A dialog box

3. Select the part. A dialog box is displayed that contains the minimum and maximum values that are required in X, Y and Z to create a box

that would surround the part. The default box is displayed in bold dark lines.

are required in X, Y and Z to create a box that would surround the part.

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4. You can modify the X,Y,Z values if you choose.

Page 99 4. You can modify the X,Y,Z values if you choose. 5. You can also

5. You can also change the axis system used to define the rough stock by clicking on Select an axis and then choosing either:

an axis in one of the other axis systems,

a plane

or a planar surface.

an axis and then choosing either: ● an axis in one of the other axis systems,

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6. Press OK to create the rough stock.

3 Axis Surface Machining Version 5 Release 13 Page 100 6. Press OK to create the

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3 Axis Surface Machining Version 5 Release 13 Page 101 Offset on Part This task explains

Offset on Part

This task explains how to create a stock as an offset of the part, for a roughing operation or a simulation .

Open the gets2.CATPart from the samples directory then select NC Manufacturing > Surface Machining in the Start menu.

1. Click the Creates a stock by offset icon displayed:

1. Click the Creates a stock by offset icon displayed: in the Geometry management toolbar. The
1. Click the Creates a stock by offset icon displayed: in the Geometry management toolbar. The

in the Geometry management toolbar. The dialog box is

1. Destination: select a part in which the result will be stored.

2. Part body: select the part on which the offset is computed.

3. Enter the value of the Offset.

4. Enter an offset direction,

either by its coordinates,

or with the Select button: select a line to take its orientation, or a plane to take its normal,

use reverse in reverse a given direction.

The direction is displayed as a red arrow.

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Two other parameters are available:

Level of detail: this coefficient represents the accuracy level of the computed rough stock. The higher the

value, the higher the precision (but also the higher data size).

Number of points: displays the number of points of the computed rough stock, for information.

6. Click apply to visualize the result and OK to validate the offset: An element OffsetPolygon.X is created in the

the offset: An element OffsetPolygon.X is created in the specification tree. ● The output is not

specification tree.

OffsetPolygon.X is created in the specification tree. ● The output is not an exact offset of
OffsetPolygon.X is created in the specification tree. ● The output is not an exact offset of

The output is not an exact offset of the part: details not seen in the offset direction may be omitted.

The bottom of the result is always flat and situated in a plane above the lowest point of the part at a distance equal to the offset value.

The result is not associative.

in a plane above the lowest point of the part at a distance equal to the

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Finishing and Semi-finishing Operations

These are the operations that you will need to finish or semi-finish the machining of the part.

Create a Sweeping operation:need to finish or semi-finish the machining of the part. ● ● ● Select the sweeping

Select the sweeping icon,

Choose a part to machine,

Specify the tool to be used.

You can also specify machining parameters, feedrates and spindle speeds and macro data.

Create a ZLevel operation:parameters , feedrates and spindle speeds and macro data. ● ● ● Select the ZLevel icon,

Select the ZLevel icon,

Choose a part to machine,

Specify the tool to be used.

You can also specify machining parameters, feedrates and spindle speeds and macro data.

Create a Contour-driven operation:parameters , feedrates and spindle speeds and macro data. ● ● ● ● Select the contour-driven

Select the contour-driven icon,

Choose a part to machine and the type of contour,

Choose a stepover mode,

Specify the tool to be used.

You can also specify machining parameters, feedrates and spindle speeds and macro data.

Create a Profile contouring operation:parameters , feedrates and spindle speeds and macro data. ● ● ● Select the Profile contouring

Select the Profile contouring icon,

Choose a part to machine,

Choose the contouring mode,

Specify the tool to be used.

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