Advanced Part Machining

Transcription

1 CATIA V5 Training Exercises Advanced Part Machining Version 5 Release 19 January 2009 EDU_CAT_EN_AMG_FX_V5R19 1

2 Table of Contents (1/2) Exercise Presentation 4 CATIA Settings 5 Multi-Axis Flank Contouring: Recap Exercises 7 Multi-Axis Flank Contouring: Recap Exercise 1 8 Multi-Axis Flank Contouring: Recap Exercise 2 13 Multi-Axis Flank Contouring: Recap Exercise 3 15 Multi-Axis Flank Contouring: Recap Exercise 4 22 Multi-Axis Flank Contouring: Recap Exercise 5 25 Multi-Axis Helix Machining: Recap Exercises 29 Multi-Axis Helix Machining: Recap Exercise 1 30 Multi-Axis Helix Machining: Recap Exercise 2 33 Cavities Roughing: Recap Exercises 37 Cavities Roughing: Recap Exercise 1 38 Cavities Roughing: Recap Exercise 2 48 Master Exercise: Aerospace Part 51 Pocketing Operation 52 Roughing Operations 53 Cavities Roughing Operation 55 2

3 Table of Contents (2/2) Profile Contouring Operation 56 Multi-Axis Flank Contouring 57 3

4 Aerospace Part Exercise Presentation 180 min Recap Exercises are provided at the end of each lesson to reinforce the concepts learnt. Multi-Axis Flank Contouring Cavities Roughing Operation Multi-Axis Helix Machining 4

5 CATIA Settings (1/2) 2 In the General view, select the Document tab. 1 Select Tools + Options. 5 Search for the folder in which your data is located and select it. 3 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. 4 Click the button Configure... ; the Other Folders window is displayed. 6 Click OK twice to accept the new folder location. 5

6 CATIA Settings (2/2) Display Isoparametric Curves Tools/Option/ General/Display/Performances Restart CATIA Select following option OR 6

7 Multi-Axis Flank Contouring: Recap Exercises Following recap exercises are provided: Multi-Axis Flank Contouring: Recap Exercise 1 Multi-Axis Flank Contouring: Recap Exercise 2 Multi-Axis Flank Contouring: Recap Exercise 3 Multi-Axis Flank Contouring: Recap Exercise 4 Multi-Axis Flank Contouring: Recap Exercise 5 7

8 Multi-Axis Flank Contouring Recap Exercise 1 15 min In this exercise you will create a Multi- Axis Flank Contouring operation to machine back wall of part with: Tanto Fan Strategy (1) Combin Tanto Strategy (2) Combin Parelm Strategy (3)

9 Tanto Fan Strategy (1/2) Open Flank_RecapEx1_Start.CATProcess Create a Multi-Axis Flank Operation Define geometry (as shown): Select Part surface Select drive surface Select Start & End elements (surfaces) Define limit condition (On) Define strategy Machining tab: Max distance between steps = 5mm Stepover tab: Number of paths =1 Number of levels =1 9

10 Tanto Fan Strategy (2/2) Tool Axis tab: Guidance = Tanto Fan Contact height = 0mm Define tool End Mill ball end T2 End Mill D 16 Rc8 D=16mm, L=100mm, Lc=50mm Feeds and Speeds: Use default parameters. Replay Operation: 10

11 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 distance Tool Axis: Leave and Approach fanning distance = 15mm Replay the operation again 11

12 Combin Parelm Strategy Use previous exercise result 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 distance Tool Axis: Leave and Approach fanning distance = 5mm Replay the operation again Save the result See result in Flank_RecapEx1_End.CATProcess 12

13 Multi-Axis Flank Contouring Recap Exercise 2 5 min In this exercise you will create a Multi- Axis Flank Contouring operation to machine pocket walls with: Mixed Combin Strategy 13

14 Mixed Combin Strategy Open Flank_RecapEx2_Start.CATProcess Create a Multi-Axis Flank Operation Define geometry (as shown) Select Part surface Select drive surface Select Start & End points (zx plane) Define limit conditions (On) Define strategy Machining: Max distance between steps = 5mm Activate : Close tool path Tool Axis: Guidance = Mixed Combin Replay Operation See result in Flank_RecapEx2_End.CATProcess 14

15 Multi-Axis Flank Contouring Recap 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)

16 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 ) 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 zag Tool Axis Guidance: Tanto Fan Deactivate all macros Replay the operation. Error message will appear: check that «close tool path» option is deactivated. 16

17 Start\End in closed Pocket Insert a Multi-Axis Flank Contouring Operation in start/end closed pocket Manufacturing Program. 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. 17

18 Joggle Management Insert a Multi-Axis Flank Contouring Operation in joggle management Manufacturing Program. 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. 18

19 Thickness on Tool Path Insert a Multi-Axis Flank Contouring Operation in Thickness on toolpath Manufacturing Program to finish external wall. 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. 19

20 Curves as Part Insert a Multi-Axis Flank Contouring Operation in Curve as part Manufacturing Program to finish the external walls in one operation. Curve (red) as part element 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. 20

21 Local Modifications Insert a Multi-Axis Flank Contouring Operation in local modifications Manufacturing Program to finish both open pockets. Define operation Geometry as shown. Select bottom of any pocket out of two as a Part element. Stepover No of levels = 01 Tanto Fan strategy Replay the operation. See result in Flank_RecapEx3_End.CATProcess 21

22 Multi-Axis Flank Contouring Recap 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)

23 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 Define operation Geometry as shown. Bottom as part surface Start and Stop surfaces. Set Tool Axis I,J,K as 0,0,1 Use Local Modifications as shown. Stop surface Replay the operation. 23

24 Non- contiguous Drives Surfaces in Same Plane Insert a Multi-Axis Flank Contouring Operation in Manufacturing Program to perform Flank finishing operation. Define operation Geometry as shown. Bottom as part surface Start curve and Stop surface. Tool Axis Guidance: Tanto Fan Use Local Modifications as shown. Replay the operation. 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. See result in Flank_RecapEx4_End.CATProcess 24

25 Multi-Axis Flank Contouring Recap Exercise 5 20 min In this exercise you will create a Multi- Axis Flank Contouring operation by using following options: Non- Contiguous Drives Surfaces Auxiliary Guide Curve 25

26 Non- contiguous Drives Surfaces Open Flank_RecapEx5_Start.CATProcess Insert a Multi-Axis Flank Contouring Operation to machine blade1 extrado & blade2 intrado in one operation. Top Define operation Geometry as shown. Select Drives: Blade1 extrado, top of the blisk, blade2 intrados Select Part: blisk external surface Select stop and start: bottom of the blisk Define Tool Axis Guidance: Combin Tanto Modify locally Stopping condition, restarting direction & tool side as following. Bottom Drive element 2 Restart = LEFT Stop = TO Tool side = SWAP Define Ref point and tool axis (0,0,-1) Define Macros: Approach = Axial 10 mm Retract = Axial 170 mm Replay the operation. Drive element 3 Restart = LEFT Tool side = Same as first Drive 1 element 1 Stop = PAST 26

27 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 intrados Select Part: blisk external surface Select start: top of the blisk Select stop: bottom of the blisk Offset on drive: 8 mm Define Strategy Stepover as shown Define Macros as given below: Return in a Level Retract: Axial 10 mm Return in a Level Approach: Axial 100 mm Return between levels Retract: Axial 100 mm Return between levels Approach: Axial 10 mm Replay the operation. 27

28 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 mm All 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.CATProcess Without Aux. Guide With Aux. Guide 28

29 Multi-Axis Helix Machining: Recap Exercises Following recap exercises are provided: Multi-Axis Helix Machining: Recap Exercise 1 Multi-Axis Helix Machining: Recap Exercise 2 29

30 Multi-Axis Helix Machining Recap 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)

31 Rough Body Blade Open Helix_RecapEx1_Start.CATProcess Create a Multi Axis Helix Machining operation Define Geometry as shown. Select Part surface ( 4 adjacent surfaces between Upper & Lower contours) Select leading & trailing edges Select Upper and Lower contours Define Strategy as shown Select start element On upper contour Radial: Define 10 turns Tool Axis: Lead & Tilt Fixed lead (10deg) and tilt (0deg) Define Tool Default End Mill tool Define Approach and retract macro as shown Circular R=5mm, 90deg, 90deg Replay Operation 31

32 Rough Foot Blade Copy/Paste previous operation Modify Geometry as shown: Select Upper and lower contours Modify strategy as shown: Modify starting point On upper contour Modify Tool Axis: 4 axis Tilt Tilt (35deg) and Lead (10deg) Define 4X plane Select Foot plane Modify Radial: Define 4 turns 4X Plane Change tool to conical mill T2 Conical Mill D 25 Replay the operation See result in Helix_RecapEx1_End.CATProcess 32

33 Multi-Axis Helix Machining Recap 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. 33

34 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 edges Select 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 value Tool 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 34

35 Interpolation (2/3) Copy/paste previous Multi-Axis Helix Machining. Rename it as with collision => check ON. Define check elements Select 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 check 35

36 Interpolation (3/3) Copy/paste previous Multi-Axis Helix Machining. Rename it as interpol without collision. Modify Strategy as shown Tool 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 36

37 Cavities Roughing: Recap Exercises Following recap exercises are provided: Cavities Roughing: Recap Exercise 1 Cavities Roughing: Recap Exercise 2 37

38 Cavities Roughing Recap 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)

39 Basic Rough Top Open Cavity_RecapEx1_Start.CATProcess Create a Cavity Roughing operation Define geometry as shown Select Part: full part Select 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 shown Machining 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 tool Select T4 End Mill D40 Rc4 Replay Operation 39

40 Basic Rough Part Use previous exercise result. Create a Cavity Roughing operation Define Geometry as shown Select Part: full part Stock selection is not required Select bottom plane: bottom of the pocket + offset = 0mm Select imposed planes: select Z15 & Z5 reachable plane Define Strategy as shown Machining Helical Outward Pockets only Always stay on bottom Forced cutting mode on part contour Radial Max distance between pass = 11mm Define Tool Select T4 End Mill D 20 Rc4 Replay Operation 40

41 Basic Rough Part Use result of Basic Rough Top exercise Create a Cavity Roughing operation Define Geometry as shown Select Part: full part Select Stock (do not select stock) Select bottom plane: bottom of the pocket + offset = 0.1mm Select imposed planes: select Z15 reachable plane Define Strategy as shown Machining Helical Outward Pockets only Always stay on bottom Forced cutting mode on part contour Radial Max distance between pass = 11mm Define Tool T4 End Mill D 20 Rc4 Replay Operation 41

42 Basic Rough Part Analyze Result Make a photo simulation Pick point on horizontal area Check offsets as shown

43 Basic Rough Part Modify part offset parameter: Add part offset = 0.5mm Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm Max Depth of cut = 5mm Z=35 Z=15 Z=05 Z=00 Z=19.02 Z=10.05 Stock Z=35.1 Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1 The critical value is Part offset. We always must have at least, this value on the part. Depth of cut computation From stock to imposed plane: No of level = ( )/5= depth of cut = ( )/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= depth of cut = (15-5.1)/2= 4.95 mm 43

44 Basic Rough Part Modify Strategy: Activate Machine horizontal area until minimum thickness Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm Max Depth of cut = 5mm Z=35 Z=15 Z=05 Z=00 Z=19.02 Z=10.05 Stock Z=35.1 Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1 Depth of cut computation From stock to imposed plane: No of level = ( )/5= depth of cut = ( )/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= depth of cut = (15-5.1)/2= 4.95 mm Two Additional planes have been created to respect offset value on horizontal area. 44

45 Basic Rough Part Modify Strategy: Add 1mm minimum thickness on horizontal area (MTHA) Replay by plane Analyze Explanation: Offset: Part = 0.5 mm Bottom plane = 0.1 mm Imposed plane = 0 mm MTHA = 1 mm Max Depth of cut = 5mm Z=35 Z=15 Z=05 Z=00 Z=19.02 Z=10.05 Stock Z=35.1 Part Z=15+0.5=15.5 Imposed Z=15 Part Z=5+0.5=5.5 Bottom Z=5+0.1=5.1 Depth of cut computation From stock to imposed plane: No of level = ( )/5= depth of cut = ( )/5=4.02 mm From imposed plane to bottom No of level = (15-5.1)/5= 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 45

46 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 46

47 Basic Rework Use previous exercise result without part offset & horizontal area parameters. Copy/paste previous cavity roughing operation Modify the tool T4 End Mill D 16 Rc4 Replay & Video simulation of the full program Modify offset on part to 0mm Replay and video again See result in Cavity_RecapEx1_End.CATProcess 47

48 Cavities Roughing Recap Exercise 2 15 min In this exercise you will learn how to create Cavities Roughing Operation to rough frame part. 48

49 Rough Frame (1/2) Open Cavity_RecapEx2_Start.CATProcess Define geometry as shown Select 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 mm Select 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). 49

50 Rough Frame (2/2) Define Strategy as shown Remaining thickness for sides: 3 mm Radial tab: Stepover length= 32 mm Axial tab: Maximum cut depth= 10 mm HSM: Corner radius= 2 mm Zone: Activate Pocket filter Define Tool T2 End Mill D 40 Rc4 Do not forget to add 3mm offset on each plane. 3mm 6mm Replay the operation. See result in Cavity_RecapEx2_End.CATProcess 3mm 50

51 Master Exercise: Aerospace Part In this exercise, you will machine a Aerospace Part using the Advanced Part Machining workbench. 60 min 51

52 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 part Select inner contour of stock as guiding element. Offset on contour = 20 mm Define Strategy Machining Tolerance = 0.3 mm Number of levels = 1 Replay the operation 52

53 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 Strategy Tool path style: Spiral Maximum cut depth = 30mm Deactivate Part Contouring Deactivate Automatic horizontal areas detection Deactivate High speed milling Replay the operation 53

54 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 Strategy Deactivate Automatic horizontal areas detection Replay the operation 54

55 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 mm Select Imposed plane as shown. Define Strategy Activate Machine horizontal area until minimum thickness Machining Tolerance = 0.1 mm Pockets only Activate High speed milling and Corner radius on part contouring Replay the operation 55

56 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 ends Offset on Bottom = - 5mm Define Strategy Distance between paths= 1 mm No of levels = 3 mm Replay the operation 56

57 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 Strategy Tool Axis: Tanto Fan Replay the operation Do Machine Simulation Show Machine elements (Refer next foil for details) See Result in MasterExercise_AMG_End.CATProcess 57

58 Customization Before to run the demonstration based on the BULKHEAD part on the Zimmermann machine-tool, you have the following customization to do: Copy the following files to the location given as follows ZIMMERMANN_FZ30_S840D.pp into the directory intel_a\startup\manufacturing\pppar ZIMMERMANN_FZ30_S840D.ce into the directory intel_a\startup\manufacturing\cenitce CPOST_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. 58