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3 T C E J O R P Mill on a Rotary Axis ESPRIT’s 4-axis
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Mill on a Rotary Axis

ESPRIT’s 4-axis wrap milling is used for cu ng while the NC machine axis rotates. Wrap milling is designed to be used with a barrel stock rota ng about an axis. For a standard milling machine, the rota on axis can be parallel to the x-axis (A-axis), y-axis (B-axis) or z-axis (C-axis). For a mill/turn machine, the rota on axis is typically the C-axis.

Wrap milling should not be confused with index milling. Indexing, or 4/5-axis milling, refers to the situa on where the NC machine axis (or axes) rotates to a new orienta on, then cuts a er the NC machine stops rota ng.

This project will show you how to set up rotary axes in ESPRIT and create rotary milling opera ons to contour and pocket the OD of a part. Wrap milling opera ons 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 cu ng opera ons in the following file:

Milling - Rotary\rotary_milling_complete.esp.

Cut Along a Contour

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Rough and Finish the Pocket 91

Copy and Rotate Operations

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Cut Along a Contour 86 Rough and Finish the Pocket 91 Copy and Rotate Operations 94
Cut Along a Contour 86 Rough and Finish the Pocket 91 Copy and Rotate Operations 94
Cut Along a Contour 86 Rough and Finish the Pocket 91 Copy and Rotate Operations 94

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Cut Along a Contour

You will begin this project by crea ng a contouring pass on the OD of the part.

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 mul ple 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 rota ng or the tool can approach and exit the part without rotary mo on.

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.

Machine Setup for Rotary Milling

To enable rotary milling, you need to define at least one rotary axis and set the angle limits for the NC machine. Wrap milling opera ons can be defined on any rotary axis or combina on of two rotary axes. If available, the secondary axis will be used as the rotary axis. Otherwise, the primary axis is used.

Crea ng a new rotary axis in ESPRIT is quite simple using the Machine Setup command on the Common Machining menu.

Machine Setup lets you configure any type of 2-axis through 5-axis milling machine. You can define separate linear mo on in X, Y, and Z for your machine components as well as rotary movement in A, B, and C. This allows you to customize the configura on of the machine in ESPRIT to match your milling machine exactly and provide an accurate display of all machine mo on, including rotary and index milling, during simula on.

Open the Part File

1. On the File menu, click Open.

2. Locate and open the following file: Milling - Rotary\rotary_milling.esp This file contains all the features, cu ng tools and machine parameters needed for this project.

3. On the Smart toolbar, click Common Machining to display the toolbar.

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Define Rotary Axes in Machine Setup The NC machine for this project uses standard X,

Define Rotary Axes in Machine Setup

The NC machine for this project uses standard X, Y, and Z linear mo on on the machine head. The table has a rotary C-axis mounted on the A-axis.

head. The table has a rotary C-axis mounted on the A-axis. Let’s take a look at

Let’s take a look at the machine parameters in ESPRIT.

1. On the Common Machining toolbar, click Machine Setup.

2. Click the Assembly tab.

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3. Open the assembly tree for Head and then open the tree for Axes. (Click the plus sign to open a tree)

the tree for Axes . (Click the plus sign to open a tree) If you click

If you click on the X, Y, or Z axis you will see that they all have linear mo on and that each has its own axis vector that defines the direc on of the axis.

4. Open the assembly tree for Table and then open Axes.

4. Open the assembly tree for Table and then open Axes . The order of the

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. No ce that the maximum rota on allowed for the A-axis is 90 degrees.

the maximum rota on allowed for the A-axis is 90 degrees. The maximum rota on allowed

The maximum rota on allowed for the C-axis is a full 360 degrees.

5. Click OK to close the Machine Setup dialog.

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Create a Wrap Contouring Operation

This opera on will cut the contoured shoulder on the OD of the part with a single pass using a 25mm end mill. The diameter of the stock is 25mm. The entry and exit moves are performed while the part is sta onary. The lead-in and lead-out distances are both set to 20mm. The Move Type se ng on the Wrap Contouring technology page controls the posi on of the tool during the cu ng moves. In this case, the tool axis is posi oned on the radial axis. Since the wall you are cu ng is parallel to the radial axis, you do not need to use the Preserve Radial Wall op on to prevent any possible gouging.

Step 1 Select the chain feature around the contoured shoulder

Step 2 Click SolidMill Tradi onal - SolidMill Produc on

Step 3

Click Wrap

Contouring

SolidMill Tradi onal - SolidMill Produc on Step 3 Click Wrap Contouring Project 3: Mill on

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Step 4 Right-click inside the technology page and click Open

Step 5 Open the file: Milling - Rotary\Technology\1-WrapContouring.prc Step 6 Click OK to create the
Step 5
Open the file:
Milling - Rotary\Technology\1-WrapContouring.prc
Step 6
Click OK to create the
opera on
- Rotary\Technology\1-WrapContouring.prc Step 6 Click OK to create the opera on 90 | Get Started with

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Get Started with ESPRIT 2009

Rough and Finish the Pocket

This part has four pockets on the OD. To save me, you will create opera ons to rough and finish one of the pockets then simply copy those opera ons to the other three pockets.

Wrap Pocketing

Wrap Pocke ng lets you easily cut solids and 3-dimensional geometry while the stock rotates on the NC machine. Roughing passes, wall finish passes and floor finish passes can be combined in a single opera on and each type of cu ng pass allows the selec on of a different tool. Tool path can be produced on the OD or the ID of cylindrical stock and all tool paths are drawn in 3D for be er visualiza on.

With the excep on of specific rotary op ons, the se ngs for Wrap Pocke ng are iden cal to the SolidMill Pocke ng technology pages.

Wrap Pocke ng is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face Pocke ng is used.

Rough the Pocket

You will first create an opera on to rough the pocket using concentric cu ng 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 Pocke ng opera on will be used to finish the walls. The roughing tool is defined in the General technology page and the cu ng strategy is defined on the Rough page.

Step 1 Select the chain feature around the pocket Step 2 Click Wrap Pocke ng
Step 1
Select the chain feature
around the pocket
Step 2
Click Wrap
Pocke ng

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Step 3 Open the file: 2-WrapPocke ng_Rough.prc Step 4 Click OK
Step 3
Open the file:
2-WrapPocke ng_Rough.prc
Step 4
Click OK

Finish the Pocket Walls

Next, you will create an opera on that only outputs a single wall finish pass using a 10mm finishing tool. The tool and cu ng strategy are defined on the Wall Finish technology page.

Step 1 With the chain feature s ll selected, click Wrap Pocke ng
Step 1
With the chain feature
s ll selected, click Wrap
Pocke ng

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Step 2 Open the file: 3-WrapPocke ng_Finish.prc Step 3 Click OK
Step 2
Open the file:
3-WrapPocke ng_Finish.prc
Step 3
Click OK
Step 2 Open the file: 3-WrapPocke ng_Finish.prc Step 3 Click OK Project 3: Mill on a

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Copy and Rotate Operations

You now have rough and finish opera ons for one pocket. You will quickly copy those opera ons to the other three pockets. In this case, the default UVW axis will be used as the rota on axis.

Step 1 Hold down the Ctrl key and select the two Wrap Pocke ng opera

Step 1 Hold down the Ctrl key and select the two Wrap Pocke ng opera ons

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Step 2 On the Edit menu, click Copy

Step 3 Set Transforma on Type to Rotate and click Copy Step 4 Set Number
Step 3
Set Transforma on 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
Rota on Axis
Step 6
Click OK
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Simulate

Simulate Project 3: Mill on a Rotary Axis | 95

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