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Student Notes:
Advanced Part Machining����������
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Advanced Part Machining
CATIA V5 TrainingExercises
Version 5 Release 19January 2009
EDU_CAT_EN_AMG_FX_V5R19
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Table of Contents (1/2)
Exercise Presentation 4CATIA Settings 5
Multi-Axis Flank Contouring: Recap Exercises 7Multi-Axis Flank Contouring: Recap Exercise 1 8Multi-Axis Flank Contouring: Recap Exercise 2 13Multi-Axis Flank Contouring: Recap Exercise 3 15Multi-Axis Flank Contouring: Recap Exercise 4 22Multi-Axis Flank Contouring: Recap Exercise 5 25
Multi-Axis Helix Machining: Recap Exercises 29Multi-Axis Helix Machining: Recap Exercise 1 30Multi-Axis Helix Machining: Recap Exercise 2 33
Cavities Roughing: Recap Exercises 37Cavities Roughing: Recap Exercise 1 38Cavities Roughing: Recap Exercise 2 48
Master Exercise: Aerospace Part 51Pocketing Operation 52Roughing Operations 53Cavities Roughing Operation 55
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Table of Contents (2/2)
Profile Contouring Operation 56Multi-Axis Flank Contouring 57
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Aerospace PartExercise Presentation
180 min
Recap Exercises are provided at the end of each lesson to reinforce the concepts learnt.
Multi-Axis Flank Contouring
Multi-Axis Helix MachiningCavities Roughing Operation
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CATIA Settings (1/2)
Select Tools + Options.In the General view, select the Document tab.
12
In the Linked Document Localization field, select the line Other Folders then click the button Up until this line is on top of the list.
3
Click the button Configure... ; the Other Folders window is displayed.4
Search for the folder in which your data is located and select it.
5
Click OK twice to accept the new folder location.
6
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CATIA Settings (2/2)
Display Isoparametric CurvesTools/Option/ General/Display/Performances
Restart CATIASelect following option
OR
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Multi-Axis Flank Contouring: Recap ExercisesFollowing recap exercises are provided:
Multi-Axis Flank Contouring: Recap Exercise 1Multi-Axis Flank Contouring: Recap Exercise 2Multi-Axis Flank Contouring: Recap Exercise 3Multi-Axis Flank Contouring: Recap Exercise 4Multi-Axis Flank Contouring: Recap Exercise 5
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Multi-Axis Flank ContouringRecap Exercise 1
15 min
Tanto Fan Strategy (1)Combin Tanto Strategy (2)Combin Parelm Strategy (3)
In this exercise you will create a Multi- Axis Flank Contouring operation to machine back wall of part with:
1
2
3
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Tanto Fan Strategy (1/2)
Open Flank_RecapEx1_Start.CATProcess
Create a Multi-Axis Flank Operation
Define geometry (as shown):Select Part surfaceSelect drive surfaceSelect Start & End elements (surfaces)Define limit condition (On)
Define strategyMachining tab:� Max distance between
steps = 5mmStepover tab: � Number of paths =1� Number of levels =1
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Tanto Fan Strategy (2/2)
Define toolEnd Mill ball end T2 End Mill D 16 Rc8D=16mm, L=100mm, Lc=50mm
Feeds and Speeds:Use default parameters.
Replay Operation:
Tool Axis tab:� Guidance = Tanto Fan� Contact height = 0mm
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Combin Tanto Strategy
Use previous exercise result
Copy/Paste previous Multi-Axis Flank Contouring Operation (with Tanto Fan Strategy)
Modify strategy Tool Axis:�Guidance = Combin Tanto
Replay Operation
Modify Leave and Approach fanning distanceTool Axis:�Leave and Approach fanning distance = 15mm
Replay the operation again
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Combin Parelm Strategy
Copy/Paste Previous Multi-Axis Flank Contouring Operation (with Combin Tanto Strategy)
Modify strategy Tool Axis:�Guidance = Combin Parelm
Replay Operation
Modify Leave and Approach fanning distanceTool Axis:�Leave and Approach fanning distance = 5mm
Replay the operation again
Save the result
See result in Flank_RecapEx1_End.CATProcess
Use previous exercise result
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Multi-Axis Flank ContouringRecap Exercise 2
5 min
In this exercise you will create a Multi- Axis Flank Contouring operation to machine pocket walls with:
Mixed Combin Strategy
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Mixed Combin Strategy
Open Flank_RecapEx2_Start.CATProcess
Create a Multi-Axis Flank Operation
Define geometry (as shown)Select Part surfaceSelect drive surfaceSelect Start & End points (zx plane)Define limit conditions (On)
Define strategyMachining:
�Max distance between steps = 5mm�Activate : Close tool path
Tool Axis:�Guidance = Mixed Combin
Replay Operation
See result in Flank_RecapEx2_End.CATProcess
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Multi-Axis Flank ContouringRecap Exercise 3
45 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:
Flank Finishing (1)Start\End in the Closed Pocket (2)Joggle Management (3)Thickness On Tool Path (4)Curves As Part (5)Local Modifications (6)
52
3
6 41
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Flank Finishing
Open Flank_RecapEx3_Start.CATProcess
Do a video replay of ‘Rough Part’ Manufacturing Program and store video result. (options video must be ‘Part Operation level’)
Error message will appear: check that « close tool path »option is deactivated.
Insert a Multi-Axis Flank Contouring Operation in ‘finish left pocket’ Manufacturing Program.
Define operation Geometry as shown to finish walls of left open pocket.Tool path style: Zig zagTool Axis Guidance: Tanto FanDeactivate all macrosReplay the operation.
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Start\End in closed Pocket
Define operation Geometry as shown to finish closed pocket.
Use top edge of Drive.1 as start and stop element.
Close tool path
Stepover (as shown):
Tool Axis Guidance: Tanto Fan
Replay the operation.
Insert a Multi-Axis Flank Contouring Operation in “start/end closed pocket”Manufacturing Program.
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Joggle Management
Copy/paste previous operation
Reset Geometry and select new Geometry as shown to finish closed pocket with joggle.
Select top of the joggle as part element.
Replay the operation.
Insert a Multi-Axis Flank Contouring Operation in “joggle management”Manufacturing Program.
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Thickness on Tool Path
Define operation Geometry as shown.Select full bottom as Part element.Start element (curve)Select tapered fsur as Stop element.
Stepover definition shown as Axial Strategy
‘One way’ tool path style
‘Combin Tanto’ strategy
Disable fanning ‘On Stop’ element
Define Macros to obtain following result
Replay the operation.
Insert a Multi-Axis Flank Contouring Operation in “Thickness on toolpath”Manufacturing Program to finish external wall.
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Curves as Part
Define operation Geometry as shown.Select bottom curve as Part element.Start & Stop curve elements.
Make sure that ‘Close tool path’ is deactivated.
Combin Tanto strategy
Replay the operation.
Curve (red) as part element
Insert a Multi-Axis Flank Contouring Operation in “Curve as part”Manufacturing Program to finish the external walls in one operation.
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Local Modifications
Define operation Geometry as shown.Select bottom of any pocket out of two as a Part element.
StepoverNo of levels = 01
Tanto Fan strategy
Replay the operation.
See result in Flank_RecapEx3_End.CATProcess
Insert a Multi-Axis Flank Contouring Operation in “local modifications”Manufacturing Program to finish both open pockets.
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Multi-Axis Flank ContouringRecap Exercise 4
15 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:
Non-contiguous drives surfaces (1)Non-contiguous drives surfaces in the same plane (2)
1
2
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Define operation Geometry as shown.Bottom as part surfaceStart and Stop surfaces.
Set Tool Axis I,J,K as 0,0,1Use Local Modifications as shown.
Replay the operation.
Non- contiguous Drives Surfaces
Open Flank_RecapEx4_Start.CATProcess
Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation.
Start surface
Stop surface
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Non- contiguous Drives Surfaces in Same Plane
Define operation Geometry as shown.Bottom as part surfaceStart curve and Stop surface.
Tool Axis Guidance: Tanto FanUse Local Modifications as shown.
Replay the operation.
Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation.
See result in Flank_RecapEx4_End.CATProcess
Non- contiguous Drives BUT located in same plane.Hence a loft surface is defined. Then it is to be selected as a drive and local modifications are to be applied.
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Multi-Axis Flank ContouringRecap Exercise 5
20 min
In this exercise you will create a Multi- Axis Flank Contouring operation by using following options:
Non- Contiguous Drives SurfacesAuxiliary Guide Curve
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Non- contiguous Drives Surfaces
Open Flank_RecapEx5_Start.CATProcess
Define operation Geometry as shown.Select Drives: Blade1 extrado, top of the blisk, blade2 intradosSelect Part: blisk external surfaceSelect stop and start: bottom of the blisk
Define Tool Axis Guidance: Combin Tanto
Modify locally Stopping condition, restarting direction & tool side as following.
Define Ref point and tool axis (0,0,-1)Define Macros:
Approach = Axial 10 mmRetract = Axial 170 mm
Replay the operation.
Insert a Multi-Axis Flank Contouring Operation to machine blade1 extrado & blade2 intrado in one operation.
Drive 1 element 1Stop = PAST
Drive element 2Restart = LEFTStop = TOTool side = SWAP
Drive element 3Restart = LEFTTool side = Same as first
Bottom
Top
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Auxiliary Guide Curve (1/2)
Insert a Multi-Axis Flank Contouring Operation in Tool Change.3 T1 End Mill D 32 to perform a roughing between blades.
Define operation Geometry as shown.Select Drive: blade2 intradosSelect Part: blisk external surfaceSelect start: top of the bliskSelect stop: bottom of the bliskOffset on drive: 8 mm
Define Strategy Stepover as shown
Define Macros as given below:Return in a Level Retract: Axial 10 mmReturn in a Level Approach: Axial 100 mmReturn between levels Retract: Axial 100 mmReturn between levels Approach: Axial 10 mm
Replay the operation.
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Auxiliary Guide Curve (2/2)
Insert a Multi-Axis Flank Contouring Operation to perform a finishing on blade using auxiliary guide curve.
Copy/ paste previous roughing operation.
Define operation Geometry as shown.Offset on drive: 0 mmAll other parameters are same as previous roughing operation.
Define Strategy Select curve as Auxiliary Guide Stepover as shown
Define Tool T1 End Mill D16 Rc2
Define Macros as given below:Return between levels Retract & Approach:Add Axial motion up to a plane with offset = 50 mm.
Replay the operation.
See result in Flank_RecapEx5_End.CATProcessWithout Aux. Guide With Aux. Guide
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Multi-Axis Helix Machining: Recap ExercisesFollowing recap exercises are provided:
Multi-Axis Helix Machining: Recap Exercise 1Multi-Axis Helix Machining: Recap Exercise 2
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Multi-Axis Helix MachiningRecap Exercise 1
15 min
In this exercise you will create a Multi- Axis Helix Machining by using following options:
Rough Body Blade (1)Rough Foot Blade (2)
1
2
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Rough Body Blade
Open Helix_RecapEx1_Start.CATProcess
Create a Multi Axis Helix Machining operationDefine Geometry as shown.
Select Part surface ( 4 adjacent surfaces between Upper & Lower contours) Select leading & trailing edgesSelect Upper and Lower contours
Define Strategy as shownSelect start element� On upper contour
Radial:� Define 10 turns
Tool Axis:� Lead & Tilt� Fixed lead (10deg) and tilt (0deg)
Define ToolDefault End Mill tool
Define Approach and retract macro as shownCircular R=5mm, 90deg, 90deg
Replay Operation
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Rough Foot Blade
See result in Helix_RecapEx1_End.CATProcess
4X Plane
Copy/Paste previous operation
Modify Geometry as shown:Select Upper and lower contours
Modify strategy as shown:Modify starting point
� On upper contourModify Tool Axis:
� 4 axis Tilt� Tilt (35deg) and Lead (10deg)
Define 4X plane� Select Foot plane
Modify Radial:� Define 4 turns
Change tool to conical mill T2 Conical Mill D 25
Replay the operation
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Multi-Axis Helix MachiningRecap Exercise 2
20 min
In this exercise you will create a Multi-Axis Helix operation to finish blade without collision with other blades by using Interpol axis strategy with pre-defined axis.
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Interpolation (1/3)
Open Helix_RecapEx2_Start.CATProcess
Define Geometry as shown:Select Part surface (4 adjacent surfaces between Upper & Lower contours) Select Leading & Trailing edgesSelect Upper and Lower contours
Define Strategy as shown:Machining� Machining tolerance = 1mm
(for quick computation)Select starting point� On Lower contour
Radial:� Define 50 turns or use scallop
height valueTool Axis:� Lead and tilt� Fixed lead (10deg) and Tilt (45deg)
Define Tool:End Mill tool T3 End Mill D 15
Replay Operation: Display tools in replay
Collisions with the other blade as shown.���� Wrong Strategy
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Interpolation (2/3)
Define check elementsSelect surface of other blades.Add 2 mm offset on check.
Activate Collision Checking with ‘On tool assembly’.
Replay the operation.
Too many jumps as shown.���� Wrong strategy
check
Copy/paste previous Multi-Axis Helix Machining. Rename it as “with collision => check ON ”.
check
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Interpolation (3/3)
Copy/paste previous Multi-Axis Helix Machining. Rename it as “interpol without collision”.
Modify Strategy as shownTool Axis:� Interpolation
Select axis geometries� Edit: Change the directions of the
default axes (I.1,I.2,I.3 & I.4)� Add other axes: Select point + direction x time� Validate
Remove the check.Collision Checking with ‘On cutting part of tool’.Replay the operation.
Copy/paste previous Multi-Axis Helix Machining. Rename it as “interpol without collision => check ON”.
Define check elements as done before.Activate Collision Checking with ‘On tool assembly’.Replay the operation.
���� Good Strategy
See result in Helix_RecapEx2_Start.CATProcess
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Cavities Roughing: Recap ExercisesFollowing recap exercises are provided:
Cavities Roughing: Recap Exercise 1Cavities Roughing: Recap Exercise 2
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Cavities RoughingRecap Exercise 1
30 min
In this exercise you will learn how to create Cavities Roughing Operations using following options:
Basic Rough Top (1)Basic Rough Part (2)Basic Rework (3)
1
2
3
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Basic Rough Top
Open Cavity_RecapEx1_Start.CATProcess
Create a Cavity Roughing operation Define geometry as shown
Select Part: full partSelect Stock (not necessary as already defined in the PO) Select Top plane: top of the stock (optional)Select bottom plane: top of the part + 0.1mm offset by MB3 on Bottom in Geometry tab.
Define strategy as shownMachining
� Back and forth � Outer Part and Pockets
Radial� Max distance between pass = 31mm
HSM� Corner radius = 3mm
Zone� Activate pocket filter
Machining direction� Select optimized
Define toolSelect T4 End Mill D40 Rc4
Replay Operation
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Basic Rough Part
Use previous exercise result.
Create a Cavity Roughing operationDefine Geometry as shown
Select Part: full partStock selection is not requiredSelect bottom plane: bottom of the pocket + offset = 0mmSelect imposed planes: select Z15 & Z5 reachable plane
Define Strategy as shownMachining� Helical� Outward� Pockets only� Always stay on bottom� Forced cutting mode on part
contourRadial� Max distance between
pass = 11mmDefine Tool
Select T4 End Mill D 20 Rc4
Replay Operation
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Basic Rough Part
Use result of Basic Rough Top exercise
Create a Cavity Roughing operationDefine Geometry as shown
Select Part: full partSelect Stock (do not select stock) Select bottom plane: bottom of the pocket + offset = 0.1mmSelect imposed planes: select Z15 reachable plane
Define Strategy as shownMachining� Helical� Outward� Pockets only� Always stay on bottom� Forced cutting mode on part
contourRadial� Max distance between
pass = 11mmDefine Tool
T4 End Mill D 20 Rc4
Replay Operation
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Basic Rough Part
Analyze ResultMake a photo simulationPick point on horizontal area� Check offsets as shown
+0.1
+0.1
+0
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Bottom Z=5+0.1=5.1
Basic Rough Part
The critical value is Part offset. We always must have at least, this value on the part.
+5.05
+0.1
+4.02
Z=35
Z=15
Z=05Z=00
Stock Z=35.1
Part Z=15+0.5=15.5Imposed Z=15
Part Z=5+0.5=5.5
Z=19.02
Z=10.05
Modify part offset parameter:Add part offset = 0.5mmReplay by planeAnalyze
Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm
Max Depth of cut = 5mm
Depth of cut computationFrom stock to imposed plane:� No of level = (35.1-15)/5= 4.02���� 5� depth of cut = (35.1-15.5)/5=4.02 mm
From imposed plane to bottom� No of level = (15-5.1)/5= 1.98���� 2� depth of cut = (15-5.1)/2= 4.95 mm
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Basic Rough Part
Bottom Z=5+0.1=5.1
Z=35
Z=15
Z=05Z=00
Stock Z=35.1
Part Z=15+0.5=15.5Imposed Z=15
Part Z=5+0.5=5.5
Z=19.02
Z=10.05
Modify Strategy:Activate Machine horizontal area until minimum thicknessReplay by planeAnalyze
Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm
Max Depth of cut = 5mm
Depth of cut computationFrom stock to imposed plane:� No of level = (35.1-15)/5= 4.02���� 5� depth of cut = (35.1-15.5)/5=4.02 mm
From imposed plane to bottom� No of level = (15-5.1)/5= 1.98���� 2� depth of cut = (15-5.1)/2= 4.95 mm
Two Additional planes have been created to respect offset value on horizontal area.
+0.5
+0.1
+0.5
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Basic Rough Part
Bottom Z=5+0.1=5.1
Z=35
Z=15
Z=05Z=00
Stock Z=35.1
Part Z=15+0.5=15.5Imposed Z=15
Part Z=5+0.5=5.5
Z=19.02
Z=10.05
Modify Strategy:Add 1mm minimum thickness onhorizontal area (MTHA)Replay by planeAnalyze
Explanation:Offset: � Part = 0.5 mm� Bottom plane = 0.1 mm� Imposed plane = 0 mm� MTHA = 1 mm
Max Depth of cut = 5mm
Depth of cut computationFrom stock to imposed plane:� No of level = (35.1-15)/5= 4.02���� 5� depth of cut = (35.1-15.5)/5=4.02 mm
From imposed plane to bottom� No of level = (15-5.1)/5= 1.98���� 2� depth of cut = (15-5.1)/2= 4.95 mm
The 2 Additional planes have been translated to the value of MTHA to respect offset value on horizontal area: part offset+ MTHA offset
+1.5
+0.1
+1.5
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Basic Rough Part
Modify Strategy:You can make again all the previous test with a offset on imposed plane > part offset
� Example: Add offset = 1mm on imposed plane
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Basic Rework
Copy/paste previous cavity roughing operation Modify the tool
T4 End Mill D 16 Rc4Replay & Video simulation of the full programModify offset on part to 0mmReplay and video again
See result in Cavity_RecapEx1_End.CATProcess
Use previous exercise result without part offset & horizontal area parameters.
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Cavities RoughingRecap Exercise 2
15 min
In this exercise you will learn how to create Cavities Roughing Operation to rough frame part.
Student Notes:
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Rough Frame (1/2)
Open Cavity_RecapEx2_Start.CATProcess
Define geometry as shownSelect Part: Full part + Mask(in No Show)Select Stock in No Show (not necessary as it is already defined in the PO) Offset on part: 3 mmSelect bottom plane + offset 3 mm Select imposed plane by using search/view planes to impose Z=60mm (top of the wall) + offset 3 mm
Part Mask
Use mask methodology (mask is already defined in Stock CATPart).
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Rough Frame (2/2)
Define Strategy as shownRemaining thickness for sides: 3 mmRadial tab: Stepover length= 32 mmAxial tab: Maximum cut depth= 10 mmHSM: Corner radius= 2 mmZone: Activate Pocket filter
Define ToolT2 End Mill D 40 Rc4
Replay the operation.
Do not forget to add 3mm offset on each plane.
3mm
3mm 6mm
See result in Cavity_RecapEx2_End.CATProcess
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Master Exercise: Aerospace PartIn this exercise, you will machine a Aerospace Part using the Advanced Part Machining workbench.
60 min
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Pocketing Operation
Open MasterExercise_AMG_Start.CATProcess
Hide Machine elements
Create a Pocketing Operation in Tool Change.4
Define Geometry:Select bottom: Top of the partSelect inner contour of stock as guiding element. Offset on contour = 20 mm
Define StrategyMachining Tolerance = 0.3 mmNumber of levels = 1
Replay the operation
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Roughing.1 Operation
Create a Roughing.1 Operation after Pocketing Operation
Define Geometry:Select Part, Bottom (on round emboss) and Limiting Contour (red )No Offsets
Define StrategyTool path style: SpiralMaximum cut depth = 30mmDeactivate Part ContouringDeactivate Automatic horizontal areas detectionDeactivate High speed milling
Replay the operation
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Roughing.2 Operation
Create a Roughing.2 Operation in Tool Change.6
Define Geometry:Select bottom: bottom of the part.Select stock as Check.Offset on Part & Bottom = 2 mm
Define StrategyDeactivate Automatic horizontal areas detection
Replay the operation
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Cavities Roughing Operation
Create a Cavities Roughing Operation in Tool Change.3
Define Geometry:Select Bottom of the part and Limiting Contour.Offset on bottom = - 8 mmSelect Imposed plane as shown.
Define StrategyActivate Machine horizontal area until minimum thicknessMachining Tolerance = 0.1 mmPockets onlyActivate High speed milling and Corner radius on part contouring
Replay the operation
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Profile Contouring Operation
Create a Profile Contouring Operation after Cavities Roughing Operation
Define Geometry:Select Top and Bottom of the part.Select Guide, Relimiting points at endsOffset on Bottom = - 5mm
Define StrategyDistance between paths= 1 mmNo of levels = 3 mm
Replay the operation
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Multi-Axis Flank Contouring Operation
Create a Multi-Axis Flank Contouring Operation after Profile Contouring Operation
Define Geometry:Select bottom as Parts.Select drive elements (Drive1 & Drive2) Select Start & Stop elements (curves)Offset on part = - 5mm
Define StrategyTool Axis: Tanto Fan
Replay the operation
Do Machine SimulationShow Machine elements(Refer next foil for details)
See Result in MasterExercise_AMG_End.CATProcess
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Customization
Copy the following files to the location given as followsZIMMERMANN_FZ30_S840D.pp into the directory intel_a\startup\Manufacturing\PPParZIMMERMANN_FZ30_S840D.ce into the directory intel_a\startup\Manufacturing\CENITCECPOST_MILL.pptable into the directory intel_a\startup\Manufacturing\PPTABLES
Launch CATIA and select in Tools\Options\Machining\Output CENIT as Post Processor and Controller Emulator.
From Manufacturing Program, activate the option 'NC Code Based Simulation' and select the ISO Code (ProcessBulkhead.CATNCCode) saved (or regenerate it interactively) to start the simulation of the ISO Code for Machine-Tool simulation and Material Removal simulation.
Before to run the demonstration based on the BULKHEAD part on the Zimmermann machine-tool, you have the following customization to do: