CATIA Training
Surface Machining Detailed Steps
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Version 5 Release 19 January 2009 EDU-CAT-EN-SMG-FS-V5R19
Surface Machining
Detailed Steps
Table of Contents Master Exercise: Renfort......................................................................................................................... 3 Step 1: Create a new Part Operation (PO) and A Machining Feature ................................................ 3 Recap Exercise: Create a Roughing Operation...................................................................................... 8 1. Pocket Ordering............................................................................................................................... 8 2. Imposed Plane definition in Roughing........................................................................................... 10 Step 2A: Create a Sweep Roughing Operation ................................................................................ 13 Step 2B: Create a Roughing Operation............................................................................................. 17 Step 3: Create a Slope Area, a Sweeping, Zlevel and a Pencil Operation ....................................... 22 Step 4: Create a Rework area, ZLevel and Contour-driven Operations ........................................... 28 Recap Exercise: Create an Isoparametric Machining Operation.......................................................... 32 Recap Exercise: Create a Spiral Milling Operation............................................................................... 35 Recap Exercise: Create NC Geometrical Element, Slope Area and Rework Area (Machining Feature) .............................................................................................................................................................. 36 1. Stock Creation ............................................................................................................................... 36 2. Geometrical Zone Creation ........................................................................................................... 36 3. Roughing Operation Creation........................................................................................................ 36 4. Slope Area Creation ...................................................................................................................... 37 5. Rework Area Definition:................................................................................................................. 39 Recap Exercise: Create a Profile Contouring Operation ...................................................................... 42 1. Contouring the part........................................................................................................................ 42 2. Contouring Pocket 1 ...................................................................................................................... 44 Recap Exercise: Analyze and Modify a Computed Tool Path .............................................................. 47 1. Computing the Minimum Tool Gage.............................................................................................. 47 2. Split on collision points .................................................................................................................. 50 3. Create geometries ......................................................................................................................... 56
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Master Exercise: Renfort Step 1: Create a new Part Operation (PO) and A Machining Feature 1.1 •
Create a new Part operation Reset all options in Tool menu, select Option Click on Select Reset all options
• •
Click Yes Deactivate Automatic backup in General folder. Select Machining
Activate option ‘Create a CATPart to store geometry’ for Manufacturing Click OK to close the dialog-box 1.2 -
Open the part to machine
• •
Menu File, Open … Open the Renfort.CATPart
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1.3 -
Launch the Surface Machining workbench
In the Start menu, select Machining, then Surface Machining.
1.4 •
Define Part Operation parameters In the PPR tree, double-click on Part Operation.1 :
The following (Part Operation or “PO”) window appears:
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To select the machine: Click on the Machine icon: In the machine editor, click on the 3-axis icon, Click OK to accept the 3-axis_default_machine.
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To select the part to machine: Click on the “No design part selected (for simulation only) icon”, Double click on the Part in the 3D View to assign it. Click OK to accept and close the PO window (we will come back to this later).
•
To define and create the stock: Click on the Creates Rough Stock icon located on the SMG workbench Click in the area of the Destination field
Then expand the Part1 in the PPR tree and select Part1 Click on “Yes” in the Warning that pops up. Select the part in the screen, the stock to be created is previewed according to the contentment box of the part.
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Change the Z min coordinate from –88.011mm to –100mm. Change the Z max coordinate from 63.348mm to 70mm. Click OK in the dialog-box to accept and create the stock. •
In the PPR tree, double-click on Part Operation.1 to reopen the PO. Click on the “No stock selected” icon, Double click on the Stock in the 3D View to assign it.
• •
1.5 • • •
Click OK to accept and close the Part Operation Hide the stock by right clicking (Mouse Button 3 or MB3) on it in the view and selecting “Hide/Show” Create a Machining Feature Click Machining/Slope Area icon: Next, you will define a Machining Area comprised of the whole part Type in “Whole part” in the name field.
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• •
In the Machining Area window, select the “Part” symbol. Then select the part in the 3D viewer by single clicking on it.
• •
Double-click in an empty part of the screen to stop and accept the selection. Click OK to accept the definition of the current Machining Area
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Recap Exercise: Create a Roughing Operation 1. Pocket Ordering • • •
Close all open files. Open the Start_Pocket_Ordering_in_Roughing.CATProcess Click once on Manufacturing Program.1 in the PPR tree to make it active. It will turn orange.
• •
Click on Roughing icon In Geometry tab select the Part symbol and then select the part in the viewer. Double click on an empty area to end selection and accept.
• •
Set Offset on part to 0. Select the Strategy tab and choose Pockets only for the machining mode
• •
Compute the tool path by using Replay button in the dialog-box. Check the pocket order by using Video simulation.
• •
Return to Geometry tab, Click on Zone order item
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Select a new pocket ordering by selecting the pockets in the desired order (your choice as to the order but not sequentially) one by one.
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• • • • • •
Double-click in an empty are of the 3D viewer to stop the current selection Replay to compute a new tool path and check the pocket ordering by using Video Click OK to end the Video, Next you will add now a limit contour in your operation. Click on the Limit Contour symbol and then expand the NC_Geometry part in the Product branch of the PPR and select Sketch.2 in the Geometrical Set.1 of the NC_Geometry part. Double-click in an empty are of the 3D viewer to stop the current selection
• •
Click Replay in the dialog-box to start the tool path computation. Check that your limit contour has been taken into account.
•
Close the CATProcess file without saving.
2. Imposed Plane definition in Roughing • •
Open the Start_ImposedPlanes_in_Roughing.CATProcess Click once on Manufacturing Program.1 in the PPR tree to make it active. It will turn orange
• •
Create a new roughing operation In Geometry tab select the Part symbol (same as before) and then select the part in the viewer. Double click on an empty area to end selection and accept.
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Right click on Imposed plane item and select “Search/View” option
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In the new dialog box click on Reachable planes,
• • •
Select each plane listed in the “Not selected” field by holding the Ctrl key and selecting them one by one as shown above left. Select the “ ” to move them to the “Selected” field as shown above right. Select OK to accept.
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Right click on one of the Imposed plane item and select the “Offset” option as shown below.
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• • • •
Set the offset to 1mm and hit OK to accept offset. Switch to Strategy tab and set the Axial strategy to 1mm Compute the tool path Use Photo simulation to check your result
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Click with the mouse in a planar area to check that the offset on the imposed planes has been taken into account.
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Close the CATProcess without saving.
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Step 2A: Create a Sweep Roughing Operation
Use result of Step:1 or Open Start_RoughingOperations.CATProcess 2.1 -
Create a Sweep Roughing operation by using a ZPlane roughing type
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Expand the tree so it looks as shown below.
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Click once on Manufacturing Program.1 in the PPR tree to make it active. It will turn orange as shown above.
• •
The Sweep Roughing menu opens up. Select the Sweep Roughing icon. To recall the Machining Area you previously created as “Whole part”: Click the down arrow in the “Feature” field and select “Whole part” from the list.
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Clear ‘Part autoLimit’.
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Select the tool in the Tool tab page,
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• • • • •
Clear the “Ball-end tool” button Change the tool name to “T1 End Mill D50 rc10”. Hit the “Enter” key to accept the changed name Double click on the tool diameter dimension “D” and change it from 10 to 50. Double click on the corner radius definition “Rc” and change it from 2 to 10. Double click on the body diameter dimension “db” and change it from 15 to 35.
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Select the “Strategy/Options” tab page.
Select the “Machining” tab and set the values as shown in the picture below:
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Select the “Radial” tab and set the values as shown in the picture below:
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Select the “Axial” tab and set the values as shown in the picture below:
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Click on the Replay icon to compute and reply.
Click on the Photo
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Click OK to end and close Photo window Click on Replay again and then click on the Video icon
• •
Click OK to accept and close the Video. Click OK to accept the creation of the Sweep Roughing operation.
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Step 2B: Create a Roughing Operation Use result of Step:1 or Open Start_RoughingOperations.CATProcess 2.2 -
Definition of the roughing operation
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Click on Roughing icon
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To select the geometry
Recall Whole part Machining Area the same way you did in the previous operation.
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Tool path style is Spiral
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Use tool T1 End Mill D50 rc10 which is same for previous operation
• Feeds & Speeds – Select only Spindle output •
Macros –
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Click on Replay button in the dialog-box.
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Check the result of the computation by using Photo simulation.
You can see that material remains on one side of the part and that the pass overlaps are not good. •
Click OK to close the Photo
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Click on Strategy tab,
Select the Radial tab and set the Tool diameter ratio to 65.
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Select the Axial tab and set the Maximum depth of cut to 4mm.
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Replay the current operation
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Click on Photo icon
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• • •
The result is now better than the previous one. Click OK to close the Photo Click on Strategy tab,
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In Machining tab, change the Tool path style from Spiral to One-way next.
• • •
Replay the operation. Using ICU (Instant Cycle Update) capability, the result is instantaneously updated. Re-compute the tool path with Helical mode and replay.
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Click OK to close the replay. Click OK again to accept and close the operation
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2.3 -
Definition of a roughing rework
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To duplicate Roughing.1 operation: Right click (MB3) on the Roughing.1 operation in the PPR tree and select Copy in the pop-up menu. Right click (MB3) on the Roughing.1 operation again and select Paste in the pop-up menu.
• •
Double-click on Roughing.2 operation to open it up. Select Tools tab page and change the name to T1 End Mill D 25 rc5 . Be sure to hit the Enter key after typing the name. Set the D & db to 25. Set the Rc to 5 as shown below.
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Select Geometry folder and change Offset on part from 1mm to 0.5mm.
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Set Minimum thickness to machine to 2mm
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Click on Replay button to compute and replay.
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Run a Photo simulation
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Click OK once to end Photo and then click OK again to accept and end the Roughing operation.
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Step 3: Create a Slope Area, a Sweeping, Zlevel and a Pencil Operation Use result of Step:2B Roughing Operation or Open Start_SlopeArea_SweepingZLevelPencilOperations First you will create a new tool change after the Roughing.2 operation.
Click once on Roughing.2 (Computed) in the PPR tree to make it active. It will turn orange as shown above.
Click on the Endmill Tool Change icon. In the Tool Change window and change the name to T1 Ball-nose D10 rc5. Be sure to hit the Enter key after typing the name. Set the D & db to 10. Select the Ball-end tool button as shown below.
Select OK to accept and create the tool change
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2.4 -
Select Machining/Slope area icon
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In the Name field change the name to Slope Area 1
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Select the Part symbol and select the part in the view by single clicking on it then double clicking in an empty area of the screen to accept and the end selection. Select the Slope Area checkbox and select Define tab. In the Tool Reference field select T1 Ball-nose D10 rc5 tool as the reference tool and change the Upper and Lower angles to 20.
• •
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Click on ‘Compute’ button
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Switch to Operations tab page Click in the Insertion Level field and select the last Tool Change in the PPR tree.
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Select Horizontal in the Area filed and change the associated operation from Spiral to Sweeping Click OK to accept. The Zlevel and Sweeping operations are automatically added in the PPR tree
• •
Expand the Tool Change by clicking the “ + “ next to it to see the operations that were added.
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• •
Change the order of two operations Right click on Manufacturing Program.1 and in the pop-up menu select Manufacturing Program.1 .object – Compute Tool path
• •
Select OK in the pop up window to compute. Open both operations and replay and simulate. Close when done.
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Select the last operation in the PPR (ZLevel.1) and then select the Pencil icon
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In the Pencil dialog box assign the Whole Part Machining Area the same way as you did in the Roughing operations..
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Click on Tool tab . Create a T1 Ball-nose D8 tool. Replay the operation and do a Photo or Video.
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You can see that the tool paths sometimes up mill and sometimes down mill. Next we will recomputed this operation but with other parameters. We will change to always up mill and to respect to a Climb cutting mode.
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Click on Strategy tab
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Change the Axial direction from to Up.
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• •
Replay the operation and do a Photo or Video, you can see that the tool path has been modified to take into account the modification of Axial strategy parameter. Click OK twice to end the Replay and close the current operation
• • •
Copy/Paste Pencil.1 after Pencil.1 the same way you copied and pasted the Roughing. Double-click on Pencil.2 operation; create now a T1 Ball-nose D5 tool. Replay the tool path and check the result.
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Click OK twice to end the Replay and close the current operation.
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Step 4: Create a Rework area, ZLevel and Contour-driven Operations Use result of previous operation or Open Start_ReworkArea_ZLevelContourDrivenOperations Create a new tool change operation after the Pencil.2 operation in the PPR tree. Use the same methods used previously to create a 2mm Diameter Ball-nose tool. Name it: T1 Ball-nose D2.
2.5 -
• •
Select Rework area icon
• •
Change the Name to Rework Area 1. In the dialog box use Load from button and then select in Pencil.2 operation. All of the parameters are automatically copied from in Pencil.2 ( tool definition, machining tolerance, part to machine definition) Click on the Other tab and change the Tolerance to 0.05mm Click on Compute button.
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The Cutting Areas are computed and displayed..
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2.6 -
Rework area edition
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Select Edit tab in the Rework area dialog box
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Right click on Vertical and select Add / Remove
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Click on the three lines shown above (pointed to with green arrows) (to change them from Horizontal (blue) to Vertical Double-click in an empty area to stop the selection. The selected lines turn Vertical (red)
• 2.7 •
Operations association Switch to Operation tab in the dialog-box,
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• • • •
• • •
Select in the Insertion Level field and then select the last created Tool Change in the PPR. Select the T1 Ball-nose D2 tool from the Tool Reference list. Select OK to accept and create the operations. All of the rework operations are automatically added inside the PPR tree. You just need to compute the tool path. Click the “ + “ next to the last tool change in the PPR to expand show the operations.
Right click on Manufacturing Program.1 and in the pop-up menu select Manufacturing Program.1 .object – Compute Tool path Select OK in the pop up window to compute. Replay both operations. The results will appear as shown on the next page.
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Recap Exercise: Create an Isoparametric Machining Operation • • •
Open Start_IsoparametricMachining.CATProcess Click once on Roughing.1 in the PPR tree to make it active. It will turn orange Create a new Isoparametric Machining operation. Click on the icon as shown below.
Select the Geometry tab and then select the two surfaces shown below starting with the long surface to the right. Make sure the arrow points inward as shown. If it doesn’t, click the arrow to reverse it.
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Click on the Navigates on belt of faces icon to select the rest of the surfaces.
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Select OK to accept
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Click on ”Add corners” symbol to define the operation direction
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Two yellow dots are displayed.
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Double click in empty space to accept and end selection. Select the Check symbol and select the bottom of the pocket as a check surface as shown below.
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Double click in empty space to accept and end selection
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Switch to the Tool tab Define a T-Slotter tool corresponding to the image above.
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Select the top dot as shown
Select the bottom dot
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Switch to the Strategy tab. Change the strategy from Zig-zag to One-way
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Replay and simulate the result by using Video Close the CATProcess file without saving.
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Recap Exercise: Create a Spiral Milling Operation • •
Open Start_SpiralMilling.CATProcess Click once on Zlevel.1 in the PPR tree to make it active. It will turn orange
• • • • •
Create a new spiral milling operation. Click on icon. In Geometry tab select New feature in combo box. Click on the Part symbol (same as before) and then select the part in the viewer. Double click on an empty area to end selection and accept. Select the Tool tab Create a new tool as T3 Ball-nose D 06. Click on Replay button to start the tool path computation.
• •
Use Photo simulation only on the last operation to check the quality of the computed tool path Close the CATProcess file without saving.
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Recap Exercise: Create NC Geometrical Element, Slope Area and Rework Area (Machining Feature) 1. Stock Creation • •
Open Demorasa.CATPart Activate SMG workbench
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Click on stock creation icon
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Validate the stock creation
and set the Zmax. Coordinate to 53.
2. Geometrical Zone Creation • •
Click on geometrical zone icon In the dialog-box select the whole body
3. Roughing Operation Creation • •
icon to create a Roughing operation Click on In the geometry tab page use MB3 to recall the geometrical element created previously
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Select the preciously created stock in geometry. •
Use a bull-nose tool diameter 25 radius 5
• •
Switch to strategy tab page Activate in the dialog-box the HSM option
• • •
In Bottom tab page, activate automatic horizontal areas detection Clear Same offset as bottom as on part option Define an offset on areas as 0 mm
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Compute the tool path and validate the dialog-box
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Click on icon in Auxiliary Operations tool bar to insert a tool change instruction Create a new ball nose of diameter 16mm tool
4. Slope Area Creation •
Click on machining area icon
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• •
Right click on part and click on select zone to recall the geometrical element previously created Activate Slope area button
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In Define tab, select Ball nose diameter 16 as reference tool for the slope area computation
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Click on Compute button (The areas are displayed by color on part) Use the filter visualization to have a better understanding of the computed areas.
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• •
Select operation tab page Select insertion level in the dialog-box and select toolchange.2 in the PPR tree
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Select Horizontal in the list and change the associated operation from Spiral milling to Sweeping
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Click on OK button in the dialog-box (the operations are automatically instantiated under the tool change instruction Select Manufacturing program.1 and in the associated pop-up menu select Compute tool path option.
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• •
Click on icon to insert a tool change instruction Create a new ball nose of diameter 3mm tool
5. Rework Area Definition: • •
Click on icon to define a rework area Select Load From button in the dialog-box
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• • • •
Select in the tree Sweeping.1 operation Click on Compute button in the dialog-box to launch the rework area computation Switch to Edit tab page Set the angle value to 30 and the Length value to 15mm
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Click on
• • •
Select Operations tab page Select insertion level and click in the PPR tree on Tool Change.3 Select the tool which will be used by the rework operations
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Validate the creation by clicking on the OK button inside the dialog-box
icon to create the different subsets (horizontal, Vertical,..)
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Select Manufacturing program.1 and in the associated pop-up menu select Compute tool path option.
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Recap Exercise: Create a Profile Contouring Operation 1. Contouring the part • •
Open Start_ProfileContouring.CATProcess Click once on Roughing.2 in the PPR tree to make it active. It will turn orange.
• •
Click on contouring icon To select the geometry: Click on the Bottom: Hard text to change it to Bottom: Soft as shown below.
Right click on the Bottom symbol and make sure that Contour detection is turned off as shown below left. If it is on as shown below right, click it to turn it off. Right click on the Bottom symbol again to confirm it is off.
Select the Bottom symbol and then select the bottom of the part as shown
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Set the Offset on bottom to –10mm Click on the Contour( Guiding element) and then by selecting one by one the 5 edges as shown below, starting with the 45 degree wall edge on the left working your way right:
Click OK to finish the selection Make sure the orange arrow is pointing outwards as shown above. If not, click on it to reverse it. •
Next we will assign a Check area to avoid: Right click on the Check symbol and select By Bodies from the contextual menu. then select the block as shown below.
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Click on Tool tab . Select T3 End Mill D10 RC0 tool by selecting the Select a tool in document button and then selecting the tool from the list as shown below.
•
Replay the operation
Click OK to end replay, and click OK to accept and close the operation
2. Contouring Pocket 1 • • •
Select the last operation Profile contouring.1 in the PPR tree to make it active. It will turn orange Click on contouring icon In the Geometry tab page: Change the Offset on bottom to 0mm
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Right click on the Bottom symbol and turn Contour Detection back on as shown above. Select the Bottom symbol and then select the bottom of the pocket as shown above. The bottom and the contour are selected and displayed. Make sure the orange arrow is pointing inward as shown. •
In the Strategy/Options tab page: Activate Close tool path as shown below
Set Percentage overlap to 80% as shown above. •
Replay the operation
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Click OK to end replay Click OK to accept part operation
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Recap Exercise: Analyze and Modify a Computed Tool Path 1. Computing the Minimum Tool Gage •
Open Start_ToolpathEditor.CATProcess
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Click on “Compute tool gage on assembly” icon
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In the dialog-box activate Select All button
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Click on Compute All button to compute the minimum Tool gage
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We can see that the current tool length is not enough for operations Zlevel.1 and Sweeping.1 • Close the dialog-box using OK button • Unlock Zlevel.1 and Sweeping.1
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Select T3 Ball Nose D10 tool and modify the cutting length in order to avoid the collisions.
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Now recompute both operations (Zlevel.1 and Sweeping.1)
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Select “Compute tool gage on assembly” icon
• • •
Select Zlevel.1 and Sweeping.1 Use MB3 to display the associated pop-up menu In this menu select Compute
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and click-on Select all button
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The Minimum tool gage is automatically computed
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Click OK
2. Split on collision points • •
Create a new Manufacturing program. Click on icon Define a new sweeping operation using a ball-nose diameter 10 tool with a cutting length of 10mm
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Compute this sweeping operation on the whole part, 1.5mm for the radial constant stepover.
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Use MB3 and lock the current Sweeping.2 operation
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• •
Select Tool path item under Sweeping.2 operation Click on MB3 and in the associated pop-up menu select “Split on collision points” item.
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Or you can click on icon in the ‘Tool Path Management’ toolbar.
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In the dialog-box, select T3 Ball Nose D 10 tool which has a cutting length of 60mm
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Clear the ‘Close split toolpath’ checkbox
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Click on apply button to start the computation of the collision points These points are displayed in RED in the current tool path
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Validate the creation by using OK button. You will see in the PPR tree that CATIA has automatically created a copy transformation item which is linked to the tool T3. The initial and tool path (Sweeping.2) is closed automatically.
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• • •
The split tool path is open. We will close the split tool path manually. Select copy transformation item. Use MB3 and select lock in the associated pop-up menu Select tool path item under copy transformation and click on Edit option in Tool Path Management toolbar. Then select “Connection” item
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In the new dialog-box select “Selection by polyline” icon
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Define the trap as described in the picture below:
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Validate the creation by double-clicking on the last point
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Change the distance value from 10mm to 20mm Validate the tool path modification. Note that now all the tool paths are connected and closed.
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Select tool path of Copy-transformation.1 and click on “Create geometries” option in Tool Path Management toolbar.
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Select Tools for the type of element that you would like to create
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Click on First point option to display the tool on the first point of your tool path Play/try the other capabilities (Last point,)
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Now select Destination item in Geometry Creation dialog box and click on NCGeometry_part1 item in the PPR tree
The dialog-box is now updated like this:
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Re-select first point creation and click on Apply button in the dialog-box. The tool position is now created in the PPR tree. You can use it for example to check the collision with the part.
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Close the dialog box.
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Use measure between surfaces.
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capability to check the distance between the tool and the
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