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Get Started with ESPRIT 2009
Copyright © 2008 DP Technology Corp. All rights reserved. U.S. Patent No. 6,907,313. Other
U.S. patents pending.
Information is subject to change without notice.
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information storage or retrieval system, without written permission from DP Technology Corp.
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or otherwise operate the software without the security programs and/or modules installed. Any
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Contents
ESPRIT has all the power you need to machine any part... Installing ESPRIT................................ 2
ESPRIT is a high-performance computer-aided manufacturing
(CAM) system for a full range of machine tool applications. Getting Help.......................................... 5
ESPRIT delivers powerful full-spectrum programming for 2-5 ESPRIT Support................................... 7
axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking
mill-turn machining, and B-axis machine tools.
ESPRIT’s high-performance capabilities include machining
any part geometry (solid, surface, or wireframe), universal
post processing to format G-code for virtually any machine
tool, and solid simulation and verification with dry runs
rendered in dynamic solids for optimal part quality and
consistency.
ESPRIT’s multitasking component provides powerful
capabilities for driving mill-turn machines, multi-axis
lathes, and Swiss-style machine tools. ESPRIT provides
synchronization of simultaneous cutting cycles using any
combination of turrets and spindles for milling or turning,
factory-certified post processors for all the leading
multitasking machine tools, and dynamic solid simulations
for dry run verification of the machining processes.
Get Started with ESPRIT will teach you all the basics of how
to machine your parts, plus show you advanced techniques
to help you get the most out of ESPRIT 2009.
Securit y Module
Plug your Security Module into the appropriate port on your computer. If you have a parallel
Module, plug it into the primary parallel port (LPT1) at the back of your computer. Do not plug it
into a serial port. ESPRIT is not fully functional if the Module is not inserted correctly. Without the
Module, ESPRIT runs in “demonstration mode”. You can use ESPRIT, but you will not be able to
create NC code or store any files.
Take special care to protect your security module from loss or damage. It is an integral component
of the software and your license.
The only device you may attach to the back of a parallel Security Module is a parallel printer.
Or,
From the Windows Start menu, select All ProgramsESPRIT 2009ESPRIT.
To print any topic, select the Print button at the top of the Help window. To return to the main
topic window (displayed above), select the Home button. Use the Forward and Back buttons to
move back and forth through the topics you’ve already viewed.
There are four tabs in the navigation pane of the Help window that help you find the information
you need. If you do not want to view the tabs, select the Hide button. To display them again, select
Show.
• Contents. Displays information in a chapter format. Help topics are grouped logically by subject
area. Each time you select a topic in the list, it opens automatically in the right pane of the Help
window.
• Index. Displays topic information in alphabetical order. You can scroll through the list or type
the first few letters of the keyword you are looking for. To open a highlighted entry in the index,
simply press Enter or select the Display button. Or, you can double-click on an entry to open that
topic.
• Search. Lets you search through every topic in the help file for a specific word or phrase. Type a
word or phrase (enclose the phrase in quotes to find that exact phrase), then select List Topics or
simply press Enter. Every help topic that contains that word or phrase is listed.
Phone Suppor t
Contact your reseller first. Resellers of ESPRIT give specialized information related to the custom
solution they provided to you. This is the best place to start.
If you don’t have a reseller, contact the nearest DP Technology office.
Corporate Office Midwest USA Eastern USA
DP Technology Corp. DP Technology Corp. DP Technology Corp.
1150 Avenida Acaso 1001 E. Touhy Avenue 8535 Cliff Cameron Drive
Camarillo, CA 93012 Suite 300 Suite 112
Des Plaines, IL 60018 Charlotte, NC 28269
Toll Free: 800.627.8479 Toll Free: 800.627.8479 Toll Free: 800.627.8479
Tel: 805.388.6000 Tel: 847.297.8100 Tel: 704.594.9551
Fax: 805.388.3085 Fax: 847.297.8107 Fax: 704.594.9802
dptechnology.com
DP Japan DP China
Level 28, Shinagawa InterCity 458 North Fu Te Road
Tower A Building No. 36, 1F
2-15-1 Konan, Minato-ku Waigaiqiao F. T. Z.
Tokyo 108-6028 Shanghai 200131
Japan China
Tel: +81 3 5485 1884 Tel: +86 21 5868 3696
Fax: +81 3 5469 1885 Fax: +86 21 5868 2803
dptechnology.jp dptechnology.cn
Before you begin the projects in this guide, you should The ESPRIT Work Environment.10
familiarize yourself with how to work with part files in
ESPRIT. As a native Windows-based application, the ESPRIT Opening and Storing Files in
interface and its menus and toolbars should look familiar to ESPRIT....................................................... 12
you.
Selecting Elements.......................... 14
This chapter explains how to work with ESPRIT part files as
well as how to open files from other CAD systems. You will Controlling the Display of
also learn about the ESPRIT work environment and how to Elements.................................................. 17
customize it to the way you work. In addition, you will gain
a working knowledge of how the ESPRIT KnowledgeBase Using Features.................................. 20
works.
ESPRIT Machining Technology.24
Note: Before beginning to use ESPRIT, you should have a
working knowledge of your computer’s operating system ESPRIT KnowledgeBase............... 26
and its conventions. You should know how to use a mouse
and standard menus and commands. To review these
techniques, refer to the documentation for Microsoft®
Windows®.
ESPRIT Fundamentals | 9
The ESPRIT Work Environment
Let’s take a quick look at the ESPRIT screen. Status Area
This window is displayed when you create a
The Status area, at the bottom of the ESPRIT
new file or open an existing one.
screen, provides dynamic information about
The ESPRIT window contains menus and the current work environment. As you select
default toolbars along the top of the screen, commands or move the cursor, the information
a graphic work area where you can view your is constantly updated.
work, and a status area along the bottom of
the screen that displays dynamic information Specialized Windows
about your part environment and the current
ESPRIT also provides two specialized windows
command or action.
that provide additional information about
the parts you are working on and provide an
Menus and Toolbars excellent way to manage your work.
You can select commands from the menus or
from toolbars. Use the Smart toolbar to quickly Project Manager
display and hide ESPRIT toolbars based on the The Project Manager consists of a set of
type of work you want to do. windows that list every operation, feature, and
cutting tool in the current session and lets you
manage, sort, and reorder these items. The
Tools window does not display for wire EDM
For example, if you want to create features, files. To view the Project Manager, press the
just activate the Features group of toolbars. F2 key or click Project Manager on the View
All other toolbars are automatically hidden. menu.
All visible toolbars activated from the Smart
toolbar will always be shown in the same Property Browser
position so you never have to hunt for a The Property Browser displays information
command. about any item selected in the graphic work
area or the Project Manager. You can view and
Graphic Work Area change individual properties for the selected
By default, the initial view orientation is set to item. To view the Property Browser, click
the Top view with the XYZ axes displayed. The Properties on the View menu or hold down the
X-axis is horizontal, Y is vertical, and Z points Alt key as you press Enter.
out towards you. To change to a different
view, use the View pulldown near the upper
right of the screen. To show or hide the XYZ
coordinates, select XYZ Axis on the View menu.
Prompt Area
The Prompt area is perhaps the most
important area on the ESPRIT screen. The
prompts tell you what to do next. Always pay
attention to what the prompt is telling you.
Property
Browser
ESPRIT Fundamentals | 11
Opening and Storing Files in ESPRIT
When you start a new session in ESPRIT or familiar with ESPRIT, you can create templates
create a new file, you are given the choice of that make it easier and faster to work on similar
starting with a blank file or basing your new types of jobs.
work session on a predefined template. As a new user, select <Blank Document> and
click OK.
The display of the template dialog is controlled
by the “Display Template Dialog” option on the
Input page of the Options dialog, available on
the Tools menu. By default, the template dialog
displays.
For more information about how to create and
use template files, please refer to the ESPRIT
online help.
Saving Files
After working in ESPRIT, you’ll want to save your work so you can retrieve it later.
The Save command stores the current file as a native ESPRIT file or as another type of CAD format.
ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file
format, select the “Save as type” pulldown and then select a file extension.
ESPRIT Fundamentals | 13
Selecting Elements
One of the most important tasks in any CAD/CAM system is the
ability to select a variety of elements in the part file. A single
part file may include one or more solid models, wireframe
geometry, surfaces, and toolpath,
In addition, you must have the ability to select individual
components of an element, such as edges on a solid model or
the endpoint of a line.
Group Dialog
ESPRIT Fundamentals | 15
SNAP Mode select Options and then the Input tab). This
When SNAP mode is enabled, the cursor lets you select from a defined invisible array
recognizes the midpoints and endpoints of lines of screen locations in response to prompts for
and segments and the centerpoints of circles points, angles, distances, and so on.
and arcs as valid point selections. You may want to set the grid spacing to match
With SNAP enabled, the cursor changes to: your part drawing values.
when you hover over the end of a
segment or arc
Deselect ing Elements
To deselect all items simply click anywhere in a
when you hover near the midpoint of a
blank area of the work area.
segment or arc
when you hover over the centerpoint of Select ing Items in the
a circle or arc
Project Manager
SUB-ELEMENTS mode Features and machining operations can be
When SUB-ELEMENTS mode is enabled, you selected directly in the Project Manager. Most
can select the individual sub-elements of solid of the time, this is much easier than selecting
models or EDM features in the work area. For these items in the work area.
example, you can select the faces, faces loops, When a feature or operation is selected within
or edges of a solid model. You can also select the Project Manager, the same item highlights
the sub-elements of draft conic features. in the work area.
The selection of sub-elements is extremely
useful for selecting the individual faces on a
solid model that you want to machine. The
Grouping Properties command relies on the
selection of sub-elements to automatically
group faces for several types of features: Holes,
Draft Feature Recognition, Turning Profiles, and
FreeForm features.
INT Mode
When INT mode is enabled, the cursor
recognizes the intersections of segments, lines,
arcs, and circles as valid point selections.
With INT set on, the cursor changes
immediately to and remains as the INT
cursor until an intersection is chosen. The
cursor exits INT mode immediately after an
intersection is chosen.
GRID Mode
ESPRIT uses the grid configuration settings from
the Options dialog box (from the Tools menu,
Views
ESPRIT provides several standard view
orientations.
ESPRIT Fundamentals | 17
Storing a View Zoom Previous: Zooms out to a smaller view
1. Click View Planes from the Layers and or jumps back to the previous view after using
Planes toolbar. Zoom.
2. Click the New... button. Zoom Dynamic: Dynamically zooms the view in
3. Type a name and click OK. or out depending on the direction of the mouse
movement. Moving the mouse forward causes
the view to zoom in; move the mouse back to
zoom out.
Rotate: To dynamically rotate your drawing
view in three dimensions about a selected
element, select Rotate View then hold down
the left mouse button over any line (including
the x, y, and z axes), segment, circle, arc, or
point and drag the mouse in the direction you
want to rotate the view.
Or, you can hold down the left mouse button
on an open space in the work area and drag the
mouse to freely rotate the view.
Pan: Shifts the view. Select Pan, then drag your
mouse in the direction you want to move the
view.
You can then choose that view at any time from
the pulldown list.
Press Ctrl+M to display the dialog and uncheck any items you want to hide. All elements of that
type will be hidden in the work area. To display the elements again, check the item in the dialog.
Layers
Layers are very useful for controlling the display of different types of elements in a complex part
file. For example, you can set up different layers for machine components, the initial part stock
or casting, the finished part, roughing toolpaths and finishing toolpaths, or any other type of
geometry.
Once an item is placed on a particular layer, you can turn the layer on or off to hide or show the
different aspects of your part. Place elements of any type in a named layer, then turn that layer off
to hide all items in that layer. The elements are not deleted, just temporarily hidden. You can turn a
layer back on at any time.
ESPRIT Fundamentals | 19
Using Features
Features serve several purposes in ESPRIT. First, they describe the shape of the parts you want to
machine. ESPRIT uses standard manufacturing terms for features such as pocket, hole, profile, face,
and so on. In this way, a set of features can describe the shape of an entire part.
Features also contain machining properties that control where material removal should occur.
These properties include cutting depths, draft angles, cut direction, entry and exit points, and lead-
in/lead-out points to name a few.
When NC operations are created, ESPRIT typically prompts you to select a feature. You can select a
feature before or after the operation technology is defined. It is recommended that you select the
feature first because then the machining operation automatically adopts the machining properties
from the selected feature.
Features are created using the commands on the Features toolbar. To display the toolbar, click
Features on the Smart toolbar. A feature can be created from wireframe geometry, solid models,
surfaces, or NURB curves.
When a feature is created, it is classified as one of the following:
Chain Feature
An individual feature is considered to be a chain feature. A chain feature could be the boundary
around a part, a simple pocket, or a path constructed of wireframe geometry. A chain feature
defines the start location, direction, and end location for a cutting path.
Chain features are quite simple and are used when you want the cutter to follow a defined path.
Typically, these are contouring or profiling operations. In most cases, the tool can be centered on
the chain feature or offset to the right or left.
PTOP
A PTOP (point-to-point) feature defines a path connecting a series of holes or points.
PTOP features are typically used for drilling operations and can also be used for manual milling.
The tool will follow this path to drill each hole. PTOP features contain information about the depth
and diameter of holes along the path as well as information about chamfers and counterbores.
Feature
A collection of individual features that comprise an area to be machined is considered a feature.
Features are represented by a folder in the Feature Manager. A feature is typically a pocket
containing sub-pockets or islands or a part feature containing all features found within a part
boundary.
ESPRIT Fundamentals | 21
Default Par t Types
The ESPRIT KnowledgeBase includes several standard part types - milled, turned, mill/turn, or wire
EDM.
The KnowledgeBase can then be used to apply a specific type of machining based on which type
of part you are working on. For example, milling operations can be automatically applied to milled
features and EDM operations can be specified for specific wire EDM features.
Feature Manager
ESPRIT provides two very useful tools to help you manage
features: the Feature Manager and the Property Browser,
The Feature Manager lists every feature in the open part
file along with any associated machining operations.
The Feature Manager is a component of the Project
Manager. To display the Project Manager, press the F2 key
or select Project Manager from the View menu. The Project
Manager includes the Operations Manager, the Feature
Manager and the Tools Manager.
To view the Feature Manager, click on the Features tab.
Each time a feature is created, it is added to the Feature
Manager. When a feature is selected in the list, the
same feature highlights in the work area. As you create
machining operations, it is much easier to select a feature
from this list than in the work area, especially when a part
file contains multiple features.
Several operations can be associated with a single feature
and operations can be copied from one feature to another.
To edit a feature property, click on the property’s value in the right column and make your change.
In this way, you can create a feature from 2D geometry and quickly give it 3D properties by adding
depth and draft angles.
ESPRIT Fundamentals | 23
ESPRIT Machining Technology
Use ESPRIT to create a wide variety of machining operations for milling, turning, mill/turn and wire
EDM.
Machining Modes
On the Machining menu, individual cutting operations are organized into three primary modes:
SolidMill, SolidTurn, and SolidWire. Selecting a command on one of these menus places you in that
mode. You can be in only one mode at a time. For example, if you have the SolidMill FreeForm
toolbar displayed and then open the SolidTurn toolbar, the SolidTurn toolbar replaces the SolidMill
FreeForm toolbar. Once a part has been programmed with a machining cycle, the mode in ESPRIT
is locked. Only one machining mode is allowed per file.
The current machining mode is displayed in the status area.
Technology Pages
When you select a machining command, the technology pages for that command are displayed.
Each technology page lets you choose the machining settings that control how that operation will
be performed.
You can save the technology settings for a particular operation by right-clicking inside the
technology page and selecting Save. To retrieve those stored settings later, right-click inside the
technology page and select Open.
Post Processing
After you create an operation, it is added to the Operations Manager in the Project Manager. You
can convert any or all of those operations to NC code.
To convert selected operations, open the Project Manager (press F2). Hold down the Ctrl key to
select individual operations or hold down the Shift key and then select the first and last of a block
of operations.
You can access the NC Code command in a number of ways:
• On the Common Machining toolbar, click NC Code
• Press the F9 key
• On the File menu, click NC Code
• Right-click inside the Operations page of the Project Manager and select NC Code from the menu
Important: To generate NC code, your security module must be attached to your computer and
you must have a valid license. You cannot save files or generate NC code if you are running ESPRIT
in “demo” mode.
Right-click to
save, open or
reset technology
defaults
ESPRIT Fundamentals | 25
ESPRIT KnowledgeBase
The ESPRIT KnowledgeBase includes a
comprehensive database that lets you store
information about feeds, speeds, material,
cutting tools and standard machining
processes, providing you with optimum • KnowledgeBase Document Settings
feedrates and tools for machining your parts. • KnowledgeBase Settings
The information stored in the KnowledgeBase • Rebuild
can be accessed by anyone in the shop during • Rebuild Options
an ESPRIT session. • Process Manager
This guide primarily focuses on the following • KnowledgeBase Manager
KnowledgeBase commands on the Common
The KnowledgeBase Manager includes:
Machining toolbar:
• Cutting Tools Manager
• Speeds Feeds Manager
• Default part types
• KnowledgeBase Document Settings • Default technology
• KnowledgeBase Settings The separate KnowledgeBase Development
• Process Manager Environment includes:
For detailed information about the ESPRIT • All base options
KnowledgeBase, please read the ESPRIT online • Process Technology Manager
help. • Default Technology Manager
Important: To access the ESPRIT
KnowledgeBase, your security module must be
attached to your computer and you must have
a valid license. KnowledgeBase commands are
disabled if you are running ESPRIT in “demo”
mode.
The KnowledgeBase greatly expands the
productivity and automation capabilities
of ESPRIT. Use the KnowledgeBase to set
up and store your most commonly used
tools, materials, and parameter settings for
operation and tool pages. The KnowledgeBase
also offers dramatic improvements in the
efficiency, consistency and quality of machining
operations. Classify features by part type and
then use feature recognition to automatically
associate machining processes to a part.
As part of the base license of ESPRIT, the
following KnowledgeBase components are
included:
ESPRIT Fundamentals | 27
KnowledgeBase Set t ings
The KnowledgeBase Settings command is used to configure the colors displayed on technology
pages and for items linked to the KnowlegeBase in dialogs and the Property Browser. You can also
set up options for the Process Manager and global KnowledgeBase settings.
The option “Apply selected processes to all features” controls how a machining process is applied
to features when you use the Process Manager.
When this option is checked, the same process is applied to all the selected features. This is useful
when you want to machine several similar features at one time.
When “Apply selected processes to all features” is unchecked, you can select several features at
once and apply a separate machining process to each one.
The Reset Technology Last User Defaults button lets you reset all the technology page defaults to
the ESPRIT system defaults.
You can learn more about KnowledgeBase Options in the ESPRIT online help.
KnowledgeBase Settings
Process Manager
ESPRIT Fundamentals | 29
30 | Get Started with ESPRIT
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Create Features
Features provide the basis for most machining operations in Create Milling Features...............32
ESPRIT. The machining properties contained within a feature
provide a single source of information about how to cut Create Turning Features.............39
the part regardless of which type or how many operations
Create Wire EDM Features....... 50
are associated with the feature. This allows for better
automation capabilities because the associated toolpaths are
automatically updated whenever a feature is modified.
In summary, features:
• Describe the shape of the part you want to cut
• Contain machining properties that control how the shape
is cut
• Allow you to automate machining processes
This project shows you how to create features for use with
milling, turning, and wire EDM operations.
Before you begin, please review how to select elements
using SNAP mode and HI mode in the “ESPRIT Fundamentals”
chapter.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Face Profiles
The Face Profiles command lets you create a feature by selecting a face or individual face edges
on a solid model. The feature recognition capabilities in the Face Profiles command will create a
feature for the face boundary and additional features for any pockets, holes, or bosses associated
with the selected face.
Holes associated with the selected face are processed using the settings in the Feature Parameters
command. Face Profiles can handle compound holes such as chamfered, counterbored, and
countersunk. For complex holes you must use the Holes command on the Features toolbar. To
learn more about Hole features, please review the online help in ESPRIT.
Feature Parameters
The Feature Parameters command lets you define the parameters for how holes and pockets are
created when the Face Profiles or Pocket commands are used.
When the diameter of a hole lies within the minimum and maximum range, a Hole feature is
created. Drilling operations are typically applied to hole features. You can also choose to create a
single PTOP feature that connects all the holes when ESPRIT recognizes the features.
Otherwise, a pocket or a profile feature is created for any hole with a diameter outside the defined
range. Face Profiles will create a profile. Pocket will create a pocket. You can then apply a pocketing
or spiraling operation to mill these types of holes.
To learn how to machine the features in this lesson, complete the project called “Mill a Standard
Part”.
Press F2
to display
Project
Manager
Press
Alt+Enter
to display
Property
Browser
Enable HI Mode
Step 1 Step 2
Click Features Click Feature Parameters
Step 3
Click Selection
Arrow
Step 4
Select the edge of
one of the larger
corner holes
Step 5
Click OK
When you click a selection arrow in any dialog, you can select an element in the work area and
ESPRIT will read the data directly from the part.
Step 1
Click Face Profiles
Step 2
Select the top
face of the part
Step 3
Click OK
Step 1
In the Features list, select to
highlight the slot feature
Step 2
Right-click on the feature,
then click Rename on the
menu
Step 3
Type Slot and press Enter
to rename the feature
Step 4
In the Feature Manager, find the
highlighted feature shown and
rename it ‘Face Island’
Step 5
Optionally, rename the other
features as shown
Step 1
Click Holes
Step 2
Set the Max and Min
Diameter to 42
Step 3
Select the top face of
Step 4 the part
Click OK
You can now adjust the diameter of the hole feature to match your drill and the depth to match
the full depth of the part.
1. In the Feature Manager, select the new Hole feature.
2. In the Property Browser, change the Depth value from 23.1 to 38.1.
3. Change the Diameter value from 42 to 30.
Turning Profiles
The Turning Profile command analyzes the shape of a selected solid model, surface, surface
composite, or STL model to find internal and external profiles. ESPRIT rotates the part around the
x-axis to find the OD profile, ID profile or projections of the front face or back face. The calculated
profile can be created as a chain feature or as individual geometric elements.
Chain Features
ESPRIT provides two general ways to create chain features. The Auto Chain command will create a
chain feature automatically from existing geometry. All of the geometry between the start and end
locations you select are added to the chain feature.
The Manual Chain command lets you create a chain feature by manually selecting existing
elements and, if SNAP mode is on, you can also select SNAP locations.
Chain features can also be created from surface curves, surface edges and text, but that does not
apply to this lesson.
To learn how to machine the features in this lesson, complete the project called “Turn an Advanced
Part”.
Set Up t he K nowledgeBase
1. On the Smart toolbar, click Common Machining and then click KnowledgeBase Document
Settings.
2. Set Part Type to MillTurn Part - Std Metric.
3. Click OK.
Step 1
Set the layer to
Geometry
Step 2 Step 3
Click Features Click Turning
Profiles
Step 4
Step 5 Select the solid
Set Profile Type to Full model
Set Create to Geometry
Set Profile Location to Top
Click OK
You now have geometry that defines a complete profile of the part. Now you will create a chain
feature that passes over the groove area. First you need to turn off the ‘Part’ layer to make it easier
to see the geometry.
Step 7
Uncheck ‘Part’
Select ‘Chain Features’
Click Current
Close the Layers dialog
Step 8
Click Auto Chain
Step 9
Select the start
point of the feature
as shown
Step 11 Step 10
Select the end point of Select the segment to
the long segment the left to indicate the
feature direction
Step 14
Click Auto Chain
Step 15 Step 16
Create a chain on the ID Click Cycle Stop
profile as shown
Step 17
Click Layers, then check ‘Part’ to
display the solid model again
Step 1
In the Status area, make sure
SUB-ELEMENTS is active
Step 2
Click Turning Profiles
Step 3
Zoom in on the groove
Step 5
Select the other chamfer face and the
face between them
Step 6
Set Profile Type to OD
Set Create to Feature
Set Profile Location to Bottom
Click OK
5. Click OK.
8. Use the Rotate command on the View toolbar to rotate the part and then select the third
edge as shown.
9. Click OK.
Notice that you do not need to select a closed loop of edges to create a face profile feature. You
have now created an open feature that can be milled with a contouring operation.
Because this feature is not parallel to the current work plane, ESPRIT has created a new work
plane and assigned it to the feature. You can see the new work plane on the work planes drop
down list.
7. Click OK.
Step 4
Check ‘Connect all
holes with one Ptop’
Step 5
Check ‘Manual
Selection’
Step 6
Select the OD face that
contains the holes
Step 7
Click OK
Step 8
Click Manual PTOP
Step 9
Select the point at the
origin
Step 10
Click Cycle Stop
Step 3
Click Draft Features
Step 4
Set Part Type to Punch
Set Approach Type to Middle
Set the UV plane height to 15
Approach Type is used to locate the element where the feature will start based on the location of
the thread point. In this example, the start point will be created at the midpoint of the element
closest to the thread point.
The lower edge of this profile is actually comprised of two separate line segments. ESPRIT gives
you the option to retain them as separate elements when the feature is created or combine them
into a single element.
In this project, a different draft angle will be applied to each segment so you will not want to
combine them.
Step 7
Click OK to create the feature
Step 8
In the Feature Manager, select the new
feature
Step 9
In the Property Browser, click on the value
for Draft, change it to 10 and press Enter
The Sub-Element forward and back arrow buttons let you quickly move through and select
sub-elements in an EDM feature. The feature in this lesson has 10 sub-elements, which include
segments and arcs. As each sub-element is selected, the start and end locations are highlighted
in the work area.
Step 1
In the Feature Manager, select the draft
conic feature
Step 2
Use the sub-element arrow buttons to
select the upper right corner of the feature
Step 3
Change the Corner Radius Mode to
Isometric and press Enter to confirm
Step 5
Change Corner Radius Mode to
Programmable and press Enter
Step 6
Change Program Radius to 2.0 and press
Enter
Step 7
Use the same techniques to update
the rest of the feature
3. On the View menu, click Mask and then uncheck Geometry. This will hide the display of all
geometry so that you won’t accidentally select geometry instead of feature subelements.
4. Make sure HI mode is active.
Note: When you use HI mode, ESPRIT will first highlight the entire feature. Right-click to respond
No, then respond Yes with a left-click when the sub-element highlights.
Step 7
While holding down the Ctrl and
Shift keys simultaneously, select
any sub-element between the
first and last
Step 8
Click Taper Change
Step 9
Set Starting Taper and
Ending Taper to 5, then
click OK
When a taper is applied to sub-elements, the feature direction determines the location of the
starting taper. The selection of the first sub-element in a group has no effect. This becomes
apparent when a gradual taper is applied as you can see below.
Tip: Draft Conic features are always created in a counter-clockwise direction.
Step 1
Hold down the Shift key and
use HI mode to select an
edge
Step 2
Hold down the Ctrl key and
select the thread point
Step 4
Set Part Type to Punch
Set Priority to Ruled Only
Set Approach Type to Single Direction
Set Angle to 60
Set the UV plane height to 30
Click OK
As you can see in the Property Browser, the ruled feature has properties for the XY profile, the UV
profile, and the match lines between them.
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Mill a Standard Part
ESPRIT has very strong capabilities in 2.5D milling, providing Remove Excess Material............ 62
both ease-of-use and a high level of control over every
aspect of a milling operation. Cut the Pockets and Slot.......... 70
The intent of this project is to teach you the process for Mill and Drill Holes........................77
creating standard milling operations using ESPRIT’s SolidMill
Traditional machining technology. Create a Shop Floor Report.... 82
ESPRIT gives you several options for accessing standard
milling commands.
• Menus and Toolbars. Traditional milling commands are
located on the SolidMill Traditional submenu on the
Machining menu. You can also use the SolidMill toolbar.
• Process Manager. You can also select SolidMill commands
from a single menu within the Process Manager. The
Process Manager lets you apply several machining
operations to a single feature at one time.
For this project, you will learn how to use the commands on
the SolidMill Traditional toolbar to create standard milling
operations and how to create a machining process using the
Process Manager.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Milling - Standard\standard_milling_complete.esp.
Step 2
Right-click inside the
technology page and click
Open
Step 3
Open the file:
Milling - Standard\Technology\1-Facing.prc
Step 4
Click OK
Step 5
In the work area, select the
Stock Profile feature
Step 7
This is the only island to
avoid, so right-click to
continue to the next step
Step 8
When prompted to select non-cross
pockets, right-click to answer No.
A non-cross pocket designates an open
area where the tool cannot rapid across.
Step 9
When prompted to select cross pockets,
right-click to answer No.
A cross pocket designates an open area
where the tool can rapid across.
Step 1
Click Wire Frame
Milling
Step 2
Open the file:
2-Wire Frame Milling.prc
Step 3
Click OK
Step 5
Select the Wireframe Drive Curve
feature located on the island wall
Step 1 Step 2
Select the External Click Contouring
Profile feature
Step 3
Open the file:
3-Contouring Rough.prc
Step 4
Click OK
Step 6
Open the file:
4-Contouring Finish.prc
Step 7
Click OK
Step 1 Step 2
Select the Medium Pocket A process already exists in the
feature and then click KnowledgeBase. Click New Process
Process Manager to create your own process.
Step 3
Select SolidMill Traditional -
Trochoidal Pocketing
Step 5
Select SolidMill Traditional -
Traditional Pocketing
Step 6
Open the file:
6-Pocket1 Finish Pocketing.prc
and click OK
Step 8
Open the file:
7-Pocket1 Rest Machining.prc
and click OK
Step 9
Click Apply
Do not click Exit yet
Step 1 Step 2
Select the Small Click New
Pocket feature Process
Step 3
Select SolidMill Traditional -
Trochoidal Pocketing
Step 4
Open the file:
8-Pocket2 Trochoidal Pocketing.prc
and click OK
Step 6
Open the file:
9-Pocket2 Finish Pocketing.prc
and click OK
Step 7
Click Apply
Step 8
Click Exit
Step 1
Select the Slot
feature
Step 2 Step 3
Click SolidMill Click Pocketing
Traditional
Step 4
Open the file:
10-Slot with Ramping.prc
and click OK
Drilling
The Drilling command is applied to hole features or point-to-point (PTOP) features. The drilling
order is defined by the path of the PTOP feature. SolidMill Drilling supports several types of
drilling, including drill, tap, peck, and bore. The operation drills to a specified depth and you have
the option to include the length of the tool tip in the total depth value. You can also use SolidMill
Drilling to spot drill holes to the correct depth based on the diameter of the tool and the chamfer
diameter.
Spiraling
The Spiraling command creates spiral or helical cutting passes based on the selection of a circle
or a feature in the shape of a circle. A spiraling operation is typically used when you want to mill a
hole that is too large to drill.
Step 3
Open the file:
11-Milled Hole Drilling.prc
and click OK
Step 4 Step 5
Select the Milled Click Spiraling
Hole Upper feature
Step 6
Open the file:
12-Milled Hole Spiraling.prc
and click OK
Step 9
Open the file:
13-Milled Hole Bottom Up Spiraling.prc
and click OK
Step 4 Step 5
Hold down the Ctrl key and select Click Process
the Countersink and Counterbore Manager
features
Step 6
Click Apply
Step 7
Click Exit
Summar y Repor t
Basic information about the machining process is provided on a single summary page. The
summary report contains a header with general information about the program and an operation
list with one row per operation. Each row displays the main information about the operation like
the operation name, the tool name, the tool ID, feeds and speed, and so on.
Detailed Repor t
This report provides the same summary page along with detailed pages for each operation and a
complete tool list. Click on an operation hyperlink in the summary page to access the operation
details. Click on a tool hyperlink to access the tool details. Operation report pages provide detailed
operation-specific information such as the tool details and available cutting parameters.
Step 2
Select Milling-Detailed, then click
Create Reports
It will take several moments to generate a detailed report of all the operations and tools used in
this part file. After the report is generated, Windows Explorer will launch and open to the folder
where the report files were generated.
Step 3
Right-click on OpSummary.htm
and click Open
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Mill on a Rotary Axis
ESPRIT’s 4-axis wrap milling is used for cutting while the NC Cut Along a Contour..................... 86
machine axis rotates. Wrap milling is designed to be used
with a barrel stock rotating about an axis. For a standard Rough and Finish the Pocket...91
milling machine, the rotation axis can be parallel to the
Copy and Rotate Operations....94
x-axis (A-axis), y-axis (B-axis) or z-axis (C-axis). For a mill/turn
machine, the rotation axis is typically the C-axis.
Wrap milling should not be confused with index milling.
Indexing, or 4/5-axis milling, refers to the situation where the
NC machine axis (or axes) rotates to a new orientation, then
cuts after the NC machine stops rotating.
This project will show you how to set up rotary axes in
ESPRIT and create rotary milling operations to contour and
pocket the OD of a part. Wrap milling operations can also be
performed on the ID and the face of a part.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Milling - Rotary\rotary_milling_complete.esp.
Wrap Contouring
The Wrap Contouring command lets you easily cut solids and 3-dimensional geometry while the
stock rotates on the NC machine. You can create as many contouring passes as needed — a single
finishing pass along the outline of the feature or multiple roughing passes offset incrementally
from the feature. You can also define separate stock allowance values for the walls and floors.
Entry and exit moves can be created while the stock is rotating or the tool can approach and exit
the part without rotary motion.
Wrap Contouring is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face
Contouring is used.
If you click on the X, Y, or Z axis you will see that they all have linear motion and that each has
its own axis vector that defines the direction of the axis.
4. Open the assembly tree for Table and then open Axes.
The order of the axes listed in Machine Setup is important. The first axis in the list is the
primary axis. The second axis is the secondary axis and so on. In this case, the C-axis is
mounted on the A-axis. Movement will first occur on the A-axis, followed by movement on the
C-axis.
Notice that the maximum rotation allowed for the A-axis is 90 degrees.
The maximum rotation allowed for the C-axis is a full 360 degrees.
5. Click OK to close the Machine Setup dialog.
Step 1
Select the chain feature
around the contoured
shoulder
Step 2 Step 3
Click SolidMill Click Wrap
Traditional - Contouring
SolidMill Production
Step 5
Open the file:
Milling - Rotary\Technology\1-WrapContouring.prc
Step 6
Click OK to create the
operation
Rough t he Pocket
You will first create an operation to rough the pocket using concentric cutting passes that start in
the middle of the pocket and move outward. A rough stock of 0.20 mm will remain on the walls
only. A second Wrap Pocketing operation will be used to finish the walls.
The roughing tool is defined in the General technology page and the cutting strategy is defined
on the Rough page.
Step 1 Step 2
Select the chain feature Click Wrap
around the pocket Pocketing
Step 4
Click OK
Step 1
With the chain feature
still selected, click Wrap
Pocketing
Step 3
Click OK
Step 1 Step 2
Hold down the Ctrl key On the Edit menu,
and select the two Wrap click Copy
Pocketing operations
Step 3
Set Transformation Type to
Rotate and click Copy
Step 4
Set Number of Copies to 3
and press the Tab key
Step 5
Check Use Origin for
Rotation Axis
Step 6
Click OK
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Mill a Mold Core
The mold insert in this project is part of a mold assembly Remove Excess Material............ 98
used to manufacture a 2-button computer mouse. This
Pre-Finish All Surfaces............. 102
part will give you a good overview of surface roughing
and finishing techniques in ESPRIT. Not all surfaces of this Finish Near-Flat Surfaces.......106
sample part will be machined completely.
The intent of this project is to teach you the process for Finish the Blend Fillet..............108
milling complex surfaces. By the end of this lesson you will
know how to use the more advanced milling techniques
offered by ESPRIT that let you optimize your toolpaths and
cut your parts the way you want to.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Milling - Surfaces\mold_core_complete.esp.
Variable-Z Roughing
Typical surface roughing operations use a standard cutting pattern, such as a back and forth
motion, to remove material at specified incremental depths. This can cause multiple tool
repositioning moves and a tool motion that does not follow the curves of the part.
The Variable-Z Roughing command creates an optimized roughing operation with cutting passes
that adapt to the shape of the part. At each incremental depth of the operation, ESPRIT calculates
the part boundaries so the tool follows a more intelligent pattern with fewer repositioning moves.
Search Factor
Complex surfaces require complex toolpath. The Search Factor setting in ESPRIT lets you increase
the analysis of the part geometry to improve the accuracy of the toolpath.
Search Factor is applied to a part based on a grid calculated from the tool size, the tolerance, and
the step over specified on the operation technology page. The default value for Search Factor is
1. The operation searches for cutting passes based on the original calculated grid. Setting Search
Factor to 2 divides each grid in half (in effect doubling the number of grids), setting it to 3 divides
each grid in thirds, and so on.
For surfaces that require high precision machining, use a higher Search Factor value to allow for a
more precise scanning of your part.
Hiding Operations
When you program surfaces, the complexity of the different toolpaths can make it difficult to see
what you are doing on the screen. ESPRIT lets you hide the display of existing operations while
you are working and then display them again later. This makes it faster and easier to program your
parts by displaying only the operations you are currently working on.
In the Operations Manager, you can right-click on any operation and click Hide to hide the toolpath
or click Show to display a hidden toolpath. Hidden operations simulate and post like visible
operations.
Step 2
Right-click inside the
technology page and
click Open
Step 3
Open the file:
Milling - Surfaces\Technology\1-Variable-Z.prc
Step 4
Click OK
Step 5 Step 6
Select the solid model Click Cycle Stop to create the
operation
Step 8
Right-click on the roughing
operation and click Hide
Z-Level Finishing
The Z-Level Finishing command combines two types of machining strategies into a single operation
for the best possible surface finish on complex surfaces. Separate machining options are available
for vertical and horizontal cutting passes. The appropriate machining strategy is selected based
on a user-defined slope angle that indicates whether a surface should be considered vertical or
horizontal.
When you create a Z-Level Finishing operation, you have the option to machine the entire part or
you can selectively machine vertical or horizontal areas only. When you machine the entire part,
you can choose to cut the vertical and horizontal areas with different tools. Options for machining
vertical areas are located on the Z-Level Finish technology page, while options for machining
horizontal areas are located on the Floor Finish page. Feeds and speeds and entry/exit moves can
be defined independently for z-level and horizontal cutting passes.
Step 2
Open the file:
2-Z-Level_Vertical.prc
Step 3
Click OK
Step 4
Answer Yes when prompted
to use the previously selected
surfaces
Step 5
Click Cycle Stop
Step 1
Click Z-Level Finishing
Step 2
Open the file:
3-Z-Level_Horizontal.prc
Step 3
Click OK
Step 5
Click Cycle Stop
Step 6
Hide the display of the
two Z-Level Finishing
operations
Finishing
The SolidMill Finishing command creates finishing passes using either a specified step over distance
or an allowable scallop height from the tool you are using. When scallop height is specified, ESPRIT
calculates the distance of the step over between each cutting pass. Finishing offers a wide variety
of tool motion patterns that give you full control over how your toolpath is created.
Slope Machining
Several options are available that let you optimize the machining of localized areas within a part
based on a user-defined slope angle. There is no need to create additional toolpath boundaries.
In addition to creating a finishing operation for an entire part, individual areas of that part can be
defined as flat or steep based on the slope of the surface. Once these areas are identified, separate
operations can be created using different milling strategies.
Step 2
Open the file:
4-AreaFinish.prc
Step 3
Click OK
Step 4
Use the default
surfaces
Step 5
Click Cycle Stop
Step 2
Open the file:
5-FilletFinish.prc
Step 3
Click OK
Step 4
Select the chain feature for
the outer boundary
Step 6
Use the default surfaces and
click Cycle Stop
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Mill 5-axis parts
Functions on the SolidMill Mold 5-Axis toolbar deliver Create 5-axis swarf operations...
fast, safe, and reliable programming for a variety of 5-axis 112
applications.
Create a 5-axis contouring
In this project, you will:
operation...............................................123
• Use 5-axis swarf milling operations to cut the tilted walls
on the inside and outside of a part by utilizing the side of Create 5-axis composite
the tool operations........................................... 127
• Create a 5-axis contouring operation to cut a profile on a
formed piece of sheet metal while keeping the tool axis
perpendicular to the model surfaces at all times
• Create five different 5-axis milling operations with the
Composite cycle by utilizing a variety of machining patterns
and tool orientations
Like other ESPRIT cycles, the SolidMill Mold 5-Axis cycles are
feature-based. All Mold 5-Axis cycles must be applied on a
FreeForm feature. The FreeForm feature defines WHAT is cut,
while the cycle defines HOW it will be cut.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
completed files in the following folder:
Milling - 5-Axis
S imulate
Simulate to verify the tool path.
S imulate
Simulate to verify the tool path.
Define t he links
1. Click the Retract tab.
2. Add a Vertical approach with a Vertical Distance
of 10mm.
3. Add a Fluent Cubic feed link with:
• Maximum Link Distance = 10
• Start Arc Angle = 30
• Start Arc Radius = 5
• End Arc Angle = 30
• End Arc Radius = 5
4. Click OK to calculate the tool path.
Define t he links
1. Click the Retract tab.
2. Add a Bridge feed link with:
• Maximum Link Distance =5
• Vertical Distance = 2
3. Click OK to calculate the tool path.
Calculate t he toolpat h
1. Click OK to calculate the tool path.
2. Simulate.
Notice how the tool stays perpendicular to the drive surface and not to the model.
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Turn a Standard Part
A basic lathe permits movement within a single plane defined Remove Excess Material........... 146
by the Z and X axes—the Z axis being parallel to the stock and
the X axis perpendicular. In order for ESPRIT to accommodate Finish and Groove the OD....... 154
both standard milling and turning operations, the global axis
Finish and Thread the ID......... 157
labeled “X” is the spindle axis (the Z axis). The global axis
labeled “Y” is the lathe X axis. Perform the Cutoff........................ 161
The intent of this project is to teach you the process for
creating basic lathe operations using ESPRIT’s SolidTurn
machining technology.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Turning - Standard\turned_part_complete.esp.
Step 4
Hold down the Ctrl key as you
select the following features in
the Feature Manager:
1 Chain
2 Chain Step 5
7 Chain Click Process
1 PTOP Manager
Step 6
Select ‘1 Chain’ in the feature
list
Step 7
Select SolidTurn - Roughing
Step 9
Open the following technology file:
Turning - Standard\Technology\1-Face Rough.prc
Notice that Type of Work is set to Face and Stock Type is set to Automation. Click the Rough tab
and observe the settings for Rough Passes. This operation uses a 2mm depth of cut with a uniform
amount of rough stock set to 0.2mm. The setting for Pullout Mode controls the direction of the
clearance cuts. In this case, the clearance cut will take place in the same direction as the cutting
pass for a distance of 2mm. On the Finish tab, notice that a finish pass will not be performed. The
OD will be finished later with a contouring operation.
Step 11
Select ‘2 Chain’ in the
feature list, then select
SolidTurn - Roughing
Step 12
Right-click in the technology page and click Open
In the same Technology folder, open the file:
2-OD Rough.prc
Step 13
Click OK to create the OD
Rough process step
Step 14
Select ‘7 Chain’ in the
feature list, then select
SolidTurn - Roughing
This operation will be used to rough the undercut area on the OD using a constant depth of cut.
Notice on the Advanced tab that Undercutting Mode is set to Below. ESPRIT will recognize and cut
any undercut areas located below the tool while undercut areas in front of the tool will be ignored.
Step 16
Select the PTOP feature
in the list, then select
SolidTurn - Drilling
Step 17
Open the file:
4-ID Center Drill.prc
Step 18
Click OK to create the
Center Drill process
step
Step 20
Click Exit to close the
Process Manager
You have now removed most of the excess material from this part.
If you click on the Operations tab in the Project Manager, you will see another view of the four
operations you just created. You do not need to be overly concerned about the order in which you
create operations, because they can be reordered easily in the Operations Manager with a simple
drag and drop.
Contouring
The SolidTurn Contouring command lets you create a finish pass along the face, OD or ID of a
part. You can choose to skip undercut areas where a material violation may occur or cut as much
material as possible with consideration for the size of the cavity and the side relief of the tool.
Grooving
The SolidTurn Grooving command gives you multiple options that let you control exactly how you
want to cut your grooves. A grooving operation can be applied to the face, OD or ID of a part.
You can create only roughing passes, only finishing passes, or both. When roughing and finishing
passes are combined, ESPRIT lets you define exactly when and where the finishing passes will be
created in relation to the roughing passes.
Step 1
Select the following
features: Step 2
3 Chain Click Process
8 Chain Manager
Step 3
Select ‘3 Chain’ in the
features list
Step 4
Select SolidTurn - Grooving
Step 6
Click OK to create
the OD Groove
process step
Step 8
Open the file:
6-OD Finish.prc
Step 9
Click OK
Step 10
Click Apply
Do not click Exit yet
Threading
The SolidTurn Threading command lets you create a threading operation on the face, OD or ID of a
part.
During simulation, the actual thread channels can be simulated by setting Simulate Threads to Full
Thread in the Simulation Parameters dialog.
Step 1
With the Process
Manager still open,
Select the feature:
4 Chain
Step 2
Select SolidTurn - Roughing
Step 4
Click OK
Step 5
Click Apply
Step 7
Open the file:
8-ID Groove
Step 8
Click OK
Step 9
Click Apply
Step 10
Click Exit
Step 12 Step 13
Select ‘10 Chain’ Click Threading
Step 14
Open the file:
9-ID Thread
Step 15
Click OK
Step 1 Step 2
Select the feature Click Cutoff
‘9 Chain’
Step 3
Select the Cutoff Tool
Step 4
Set Stock Type to
Automation
Step 6
Set the Entry and
Exit settings as
shown
Step 7
Click the Rough tab
Step 8
Set the Rough
Passes settings as
shown
Step 9
Click OK
Stop
Run
Speed
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Turn an Advanced Part
In the previous project, you learned how to turn a part on a Create a Balanced Rough.........166
basic lathe. Now, you will learn how to mill/turn a part on a
multi-axis lathe with two spindles and two turrets. Drill and Groove Simultaneously
169
A basic lathe permits movement within a single plane defined
by the Z and X axes. However, to perform livetool milling Mill/Turn a Face Profile........... 172
operations, additional axis combinations are required.
The first addition is a rotational axis along the stock, often Transfer the Part to a Sub-
referred to as the C axis. The next step is to add an axis Spindle....................................................174
normal to the ZX machining plane, often referred to as
Drill on a Rotary Axis................. 177
the Y axis. A rotational axis along the Y axis is called the B
axis. A specific machine tool manufacturer may refer to an Mill with the B-Axis..................... 178
additional axis by another name, but all mill/turn machines
support these axis combinations in one form or another.
The intent of this project is to teach you the process for
creating multi-axis lathe operations. You will perform several
operations on the main spindle, then transfer the part to the
sub-spindle where you will complete the machining.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Turning - Advanced\advanced_turning_complete.esp.
Step 1 Step 2
Open the Layers Press Ctrl+M and
dialog and turn off the check Lathe Stock on
Part layer the Details tab
Step 3 Step 4
Select the chain Click Balanced
feature for the Roughing
OD profile
Step 5
Right-click inside the
technology page and
click Open
Step 6
Open the file:
Turning - Advanced\Technology\1-Balanced Rough.prc
Step 7
Click OK
Add a S y nc Code
Next, you will add a sync code after these roughing operations to make sure that these
operations are completely finished before machining can begin on the next operation.
There are two methods for syncing operations. You can use the sync commands located at the
top of the Operations Manager or you can use drag and drop. For these operations, you will use
the sync commands. For the next set of operations, you will learn to use drag and drop. Then you
can decide which method you prefer.
Step 1 Step 3
Click the Operations tab to view the Click ‘Create Sync Below Selected
Operations Manager Operations’
Step 2
Select either of the Balanced
Roughing operations, then hold
down the Shift key as you select
the other operation
Step 1 Step 2
Select the PTOP feature on Click Drilling
the face of the part
Step 3
Open the file:
2-Face Drilling.prc
Step 4
Click OK
Step 1 Step 2
Select the chain Click Grooving
feature for the lower
groove
Step 3
Open the file:
3-OD Groove.prc
Step 4
Click OK
Step 2
Click Spindle Priority
Step 3
Select near the bottom of the Drilling
operation
Step 4
Hold down the mouse button as you
drag the cursor to the bottom of the
Grooving operation. You should see a
bright red line below both operations.
Step 5
Release the mouse to create a sync
code below the selected operations
Note: Selecting above or below an operation has an affect on where the sync code is created.
When you select above an operation, the sync code is added above that operation. A bright red
line above or below the selected operation highlights where the sync code will be located.
Set a negative axis limit in X to position the tool below the center line. A positive limit positions the
tool above the center line. Machine Setup is available on the Common Machining menu.
Step 2 Step 3
Select the profile Click Rotary Face
feature on the face of Contouring
the part
Step 4
Open the file:
4-Wrap Face Contouring.prc
Step 5
Click OK
Step 6
Add a sync code after the milling
operation and the last sync code
Step 3
Open the file:
5-Pickup.prc
Click OK
Step 4
Select the reference
point on the face of the
part
Step 1
Click Bar Feed
Step 2
Open the file:
6-Barfeed by Spindle.prc
Click OK
Step 3
Select the reference point
on the face of the part
Step 1 Step 2
Select the chain Click Cutoff
feature at the
back of the part
Step 3
Open the file: 7-Cutoff.prc
Click OK
Step 4
Add a sync code after
the Cut Off Cycle
Step 1
Click SolidMillTurn
Step 2
Select the PTOP feature Step 3
for the holes on the OD of Click Wrap
the part Drilling
Step 4
Open the file:
8-Wrap Drilling.prc
and click OK
Step 1
Select the profile
feature on the OD Step 2
of the part Click Contouring
Step 3
Open the file:
9-Baxis Milling.prc
Click OK
A sync must be added after the wrap drilling operation and before the B-axis contouring operation.
Wrap Drilling rotates the part as it drills. The B-axis contouring operation requires that the part
remain stationary while only the tool moves.
Adding a sync code after a tool change saves time because the tool for the contouring operation
will be loaded on the top turret while the drilling operation is being performed on the lower turret.
Step 5
Change the view orientation to
‘Right’
Step 6
Select the B-axis Milling
Operation
Step 7
Press Ctrl+C
Step 8
Set the dialog as shown and
click OK to copy and rotate the
operation
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Wire EDM a Die Plate
ESPRIT offers a complete tool set for your make/model Create Draft Conic Features..182
of EDM machine. Each manufacturer’s unique cutting
technology and methodologies are integrated into specialized Contour the Die Openings........ 191
technology pages. This gives you full control over the
Sort EDM Operations..................198
advanced features and unique functionality of the leading
machines on the market. Simulate the Slug Removal..... 201
Before creating SolidWire operations, you must first let
ESPRIT know which type of wire EDM machine you are using.
The machine type you choose determines the options that
are available on the operation technology pages.
The intent of this project is to teach you the process for
creating 2-axis wire EDM operations using ESPRIT’s SolidWire
Gold machining technology.
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Wire EDM\die_plate_complete.esp.
Feature Groups
Although you can create wire EDM operations one at a time, it is much faster and easier to select a
group of similar features and apply the same operation to the entire group at one time.
When several features are selected first and then a technology applied, ESPRIT will automatically
create a folder in the Feature Manager that contains all the selected features, a ‘parent’ operation,
and a ‘child’ operation for each feature.
Each child operation has the exact same technology settings as the parent operation. If you change
the parent operation, the child operations will be updated automatically.
You can also treat the child operations as independent operations by changing some of the
technology settings. However, if any of those settings are updated later in the parent operation,
the parent will override the children.
Step 4
Click Draft Features
Step 5
Set Part Type to Hole
Step 6
Click the selection arrow next to
Maximum Diameter
Step 7
Select an edge of one of the holes to
automatically load the value on the
technology page
Step 9
Set Group to Folder to Yes
Step 10
Click OK
Note: Full descriptions of the draft feature dialog settings are available in ESPRIT Help (press F1).
The Feature Recognition Report dialog displays a message that the positions of the thread points
was calculated by ESPRIT. The display of this dialog is controlled on the Rules page with the ‘Display
Error Messages’ setting.
Step 11
Click OK
Step 1 Step 2
Click Grouping Set Face to
Properties Tangent Faces
Step 3
Hold down the Shift key and
the Ctrl key as you select a face
from each opening
Next you will select all the thread points. These points will be used to define the lead-in/lead-out
and start points for each feature.
Step 5
Hold down the Ctrl key as you
draw a selection box around all
the points
Step 6
Click Draft Features
Step 7
Set Part Type to Die
Set Approach Type to Normal
Set UV to 20
Step 8
Click the Rules tab
Step 9
Set Group to Folder to Yes
Step 10
Click OK
Step 11
Set the Selection Filter
back to All
Step 1
Click SolidWire
Step 2 Step 3
Select all the Click Contouring
features in the Hole
Group
Since most of the machining information is extracted directly from the selected features, you only
need to define the cutting strategy on the Contour page and how many cutting passes to create on
the Contour page.
Step 5
Click the Contour tab and set Strategy to Rough
and 1 Skim, then click OK
Step 1
Drag the feature for the triangular
opening to the XYZ coordinate to
move it out of the Die Group
Step 4
Set Strategy to [Rough][Skim]
Step 6
Set the Primary Cut Strategy to
Rough
Step 7
Set the Land Cut Strategy to
Rough and 2 Skims
Step 8
Click OK
Step 11
Make sure Strategy is set to [Rough][Skim]
Notice that this time there is no reference plane for the
land height
You will use Advanced Operations Sorting to sort the operations by type so that all the roughs are
performed first, the cutoffs second and the skims last. Then you will practice optimizing the cutting
path using different optimization methods.
Note: You can also manually reorder individual SolidWire operations by dragging and dropping
them anywhere in the Operations Manager.
Step 2
Set Sort By to [Rough][Cut-Off][Skim]
Step 3
Set the Path Optimization Routine to Shortest
Path, then click the selection arrow and select
the lower left feature as shown
Step 4
Click Apply to see the results
Step 6
Set Band Width to 10 and then click Apply to
see the results
Step 7
Click OK
Step 1
Hold down the Shift key and select a
segment in the outer profile
Step 4 Step 5
Click Simulation Click Simulation
Parameters
Step 6
Uncheck Automatic Slug
Removal
Step 8
Set Type to Stock
Set Create From to Extrusion
Step 9
Set Z+ to 0 and Z- to 20
Click the Selection Arrow and
then select the chain feature
Step 10
Click Add
Step 11
Click OK
Step 1
Click Run to simulate all the
cutting operations
Step 2
Click Slug Removal
Step 3
Select different stock items in the list and click
Move Down or Move Up
ESPRIT will prevent you from moving the tapered Step 4
stock above the block because this is not possible Click Stop to exit the
simulation
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Wire EDM a 4-Axis Part
The files for this project are available for download from
ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT
CD.
All dimensions in this tutorial are in millimeters. Make sure
System Unit on the Tools menu is set to Metric.
Before you start this lesson, you can review and simulate the
cutting operations in the following file:
Wire EDM\advanced_4axis_complete.esp
4 -A xis Contouring
The 4-Axis Contouring command on the SolidWire Platinum menu is very similar to the Contouring
command on the SolidWire Gold menu, except that you will be cutting separate UV and XY profiles.
The biggest difference between 2-axis and 4-axis contouring in ESPRIT is that you cannot use chain
features for 4-axis cutting operations. ESPRIT provides a specialized EDM feature called a Ruled
feature for 4-axis wire EDM operations. Ruled features are described in greater detail in Project 1:
Create Features.
Cut O f fs
ESPRIT lets you perform a cut-off in two steps. When cutting a punch, a large cut-off distance
is sometimes necessary in order to retain rigidity and stability of the punch while roughing
and skimming. However, a smaller glue distance is required to allow the operator to make
arrangements for the punch that will fall free. Using a secondary cut off frees the operator from
standing at the machine while a large glue stop is being cut.
Step 3
Set Direction to CW
Set Strategy to
[Rough] [Skim] [Cut-Off]
Step 4
Set Retract Length to 2.0
Step 5
Click the Contour tab
Step 6
Set Strategy to Rough and 2 Skims
Step 7
Set the offsets as follows:
Rough: 0.19
Skim 1: 0.125
Skim 2: 0.106
Step 9
Set the Cut-Off settings as
shown
Step 10
Click OK