Programming of Complex machine tools (Mill-Turn) in NX CAM Dr. Tom van t Erve, Director Development - NX CAM

Transcription

1 Programming of Complex machine tools (Mill-Turn) in NX CAM Dr. Tom van t Erve, Director Development - NX CAM Restricted Siemens AG 2017 Realize innovation.

2 Mill-Turn / Multi-Function programming with NX CAM Best practices The use of Mill-Turn and Turn-Mill Machine Tools is growing rapidly Typical questions: How to setup the NX CAM Geometry structure How to combine Turning and Milling How to setup the In Process Workpiece (IPW) How to synchronization multiple channels How to define a Pinch Turning operation How to work with devices such as Tailstock & Steady rest Multi Channel Programming Page 2

3 Demonstration of OOTB Example Sim15 (shipped with NX available for Download now) DEMO Page 3

4 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 4

5 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 5

6 Create Setup File NewŁManufacturing It is highly recommended to start Programming Mill-Turn Machine Tools by using either Setup Templates or by opening an existing Part and replacing the component. You can use the OOTB Simulation examples as Setup Templates through File NewŁManufacturing (no additional installation needed anymore.) Replace Machine Tool will usually NOT work because Geometry structures could be different. In such a case, the Geometry structure needs to be adjusted to match the Postprocessor requirements. Page 6

7 Create Setup Geometry Structure and IPW Handling The NX CAM Geometry Structure is very important when you want to program a Part with cutting on both the Main and the Sub spindle including Part Pull-Out and Part Take-Over. Please also Note: No additional Geometry assignment required inside KIM Tree anymore! Page 7

8 Create Setup Geometry Structure and IPW Handling - the parts The Operation Navigator - Geometry structure includes 3 Part models for machining: One at the position before Pull Out, the second on the Main spindle and the third on the Sub spindle (covered by File New -> Manufacturing) IPW inside each Geometry Group is inherited from previous Geometry Group (fully supports Turning & Milling) Part and Blank Definition define relationship IPW Flow Blank inherited from Previous Geometry IPW Blank inherited from Previous Geometry IPW Page 8

9 Create Setup OLD Geometry Structure & IPW Handling the NC Programming blank NX CAM Operations will use the Blank defined inside the Operation Navigator Workpiece (at position after the Pull Out ) Customer Benefits The new IPW flow for Mill-Turn simplifies the Geometry structure, makes it much more transparent and The IPW Transfer (blank on thereduces the Programming time Sub spindle) is done using the Workspace type Page 9

10 Machine state Prototype available Not in Production yet! Shows actual machine state during operation definition & editing Positions the machine axes right before the start of the operation Allows users to program in the context of the machine Available as prototype in generate command and in sync manager Final implementation pending! Page 10

11 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 11

12 Create 3D Tool Assemblies 3D Tool Assemblies are necessary for meaningful turning simulation Regular documentation is available which details Preferred position & orientation of the 3D geometry Tool tip and mount junctions Cutting & non-cutting portions Tracking points, etc. Page 12

13 Create 3D Tool Assemblies Match it with the NX CAM parametric tool NX CAM uses parametric tools to create Toolpaths Retrieve Tool from Library Use the Tool in any Turning Operation to check if all settings (Tracking Points etc.) are correct (don t worry about the Toolpath) Create a grooving Operation for Grooving Tools to check if both Tracking Points are working Use Tool Path -> Verify and make sure that there is no difference between Tool and Assembly Page 13

14 Create 3D Tool Assemblies Multi-Tools Tool vendors offer new Tools called Multi-Tools; typically turning tools with multiple Inserts inside a single Tool The best practice is to: Create a single 3D Solid representation for the entire Multi-Tool Create a parametric representation per tool component Define spindle orientation angle (Index Notch) and tracking point(s) per tool component (cutter) You can now Retrieve Multi-Tools from either the (ASCII) tool library or MRL (Teamcenter) Export of Multi-Tools to the ASCII tool library is work in progress Page 14

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17 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 17

18 Create Devices And add them to the library For either a Chuck, Tool holder or Head device: Create a 3D Assembly Model Define junctions and kinematics Store the 3D models in the resource library device graphics folder Copy the 3D assembly file into the root directory of the Graphics Folder You can use a sub folder when it has the same name as the device Add the device to the library (device_database.dat) Page 18

19 Create Devices Create chucks with movable jaws Turning Chucks can be created with movable jaws Sim15 Simulation contains an example Extra care is required with the Kinematic Names of Movable Jaws when using two identical Chucks The 1 st Chuck will have the Names defined inside the Device. The 2 nd Chuck will have Names ending at _1 (third _2 ) This will create an issue for the CSE Driver which will use the Axis Names to move the Jaws. Because of this it is important which Chuck you bring first and which one you bring second Otherwise the wrong Jaws will be moving This is a known issue inside all NX CAM Versions. We plan to resolve this by allowing the use of Logical Names instead of real Names in a future release Page 19

20 Create Devices Create chuck with movable jaws Chuck on Main Spindle is loaded first so Machine Tool Navigator Tree will have Axis with the names defined inside the Device Page 20

21 Create Devices Create chuck with movable jaws Chuck on Sub spindle is loaded after Chuck on Main spindle is loaded. Because Axis Name has to be unique inside the Machine Tool Navigator tree, the names will automatically be extended with _1 Page 21

22 Create Devices Tailstock as Tool for Static Pocket We recommend to represent such a device as a Generic Solid Tool This will allow it to be used in a Generic Motion Operations We recommend to align the 3D tool shape into Z/X plane of ACS on Tool Tip junction (like any other solid tool) Page 22

23 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 23

24 Create Special Operations Using Generic Motion Control (GMC) to create a simple slot How to create a simple Slot Milling Operations on a Cylindrical Surface? This is often programmed using a Variable Axis Surface Contouring Operation But that doesn t offer the expected simple output: X/Y/Z Position C Axis Rotation Retract For situations like this, we recommend the use of a GMC Operation and Use the Rotary Point Vector Move to create 4 Sub Operations 1. Engage Position 2. Start Position 3. End PositionŁmake sure not to use arc segments >= Retract Position Page 24

25 Create Special Operations Using Generic Motion Control (GMC) Most customers know how to control Post Events by adding UDEs GMC offers another practicable way of creating Post Control Events Inside GMC you have the option to add User Defined Move Types. With this functionality you can create templates which enable moving Tools (Steady rest, Tail stock etc.) and adding additional output parameters. The NX CAM OOTB examples already have this included. You can use Sim15 Simulation as operation template. Check out the operations: PART_PULL_OUT MOVE_SUBSPINDLE MOVE_SUBSPINDLE_HOME Page 25

26 Create Special Operations Workpiece feeding or Part Pull Out Workpiece feeding or Workpiece Pull Out is often implemented using a UDE We recommend, however, to use a GMC Operation instead The sim15_millturn_setup_xxx_mm_dual_sync.prt can be used as template and contains an example Operation Page 26

27 Create Special Operations Part Take Over The sim15_millturn_setup_xxx_mm_dual_sync.prt can be used as template and contains an example Operation Part Take Over is implemented by a series of elementary operations; including two GMC operations Page 27

28 Create Special Operations Example GMC sub operations from Part Pull Out Chuck Motion; Jaw mode Open Close Position Sub spindle Motion move to Home move to Position travel to fixed Stop Workpiece Transfer Page 28

29 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 29

30 Referenced GMC Capabilities Front End for Key Input: The motion sequences are described by using regular sub-operations that have been extended. The suboperations now allow input to come from the operation level Allows to define a set of key input parameters such as points, vectors, values and so on that can be put on the main dialog Reference: Once defined, they can be referenced and reused within the sub-operations Page 30

31 Referenced GMC Steady Rest Example Customer Benefits Reduce Programming Time. Select Operation Create customized movements stored inside Operation Template by defining key input Parameters. Capabilities Define key input Parameters Puts all unique inputs at the operation level Re-use the inputs where needed in the suboperations Page 31 Generate Toolpath

32 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation future direction Page 32

33 Synchronization Manager General Information Before entering Synchronization Manager, make sure you have correctly defined Feeds and Speeds for all Operations to avoid long waiting times M30 will set all Spindles to 0, so take care if one channel is finished and the second channel isn t. To avoid this you need to add a sync mark before M30 (also required on the real machine) It is possible to Stop calculations by selecting Stop on the Dialog. But the Simulation will not work when no time is calculated If you did something wrong you will notice this by a long delay when entering Synchronization Manager You can easily see where your Problem is check the Time. The Time is not changing on Operations with wrong Parameters. Page 33

34 Synchronization Manager Mixed Position of Main/Sub Operation inside ONT Customer Benefits New IPW Flow allows Position of Operation inside ONT based on IPW structure coming out of Geometry view. Synch Manager Remember, before NX there was no way to drag an Operation on Sub in front of any Operation on Main Spindle as IPW was only Based on Program view! This was only possible inside Synch Manager! Drag Operation inside ONT Simulation Caveats (enhancement planned for NX ) Manuel IPW generation 1. First generate all Operations on Spindle 1 2. Update IPW on Spindle 2 3. Generate Operations on Spindle 2 Page 34

35 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation Today Future direction Page 35

36 Dual Channel Roughing Operation (Pinch Turning) Start Sync Editor to Synchronize both Roughing Operations Create two Synch Events, one before and a second one after both Operations So finely both Operation are between one Sync event By default, the Sync marks will split up the Operation because they are positioned right before START OF PATH. In this example Channel 2 Roughing Operation (ROUGH_TURN_CH2) is the first Operation on this channel. So additional Output is generated before start of Path Event. This Updated will reflect in the display of * on Operation. Manually move Synch mark so you get a picture like this! Change to Expand All Display Page 36

37 Dual Channel Roughing Operation (Pinch Turning) Set Display to first Sync Marker. Search for first Engage move and add another synch marker. Depending on the channel you insert the Sync Marker, position on other channel maybe wrong. So adjust Sync Marker on this channel to be also position above Engage Event. You have to repeat this for all Engage movements! Page 37

38 Dual Channel Roughing Operation (Pinch Turning) After this is done you can Simulate with 3D Material removal. Switch on IPW Display Change to settings and define common setting to better display 3D Material removal during Simulation. Maximum Length increment is depending on the size of your Part! Page 38

39 Agenda Create Setup, new Geometry Structure & IPW handling Create 3D Tool Assemblies and Multi-Tools Create Devices Create Special Operations Using upcoming GMC technology Synchronization Manager Dual Channel Roughing Operation Today Future direction Page 39

40 Dual Channel Roughing Operation Synonyms: Pinch Turning Merging Lathe Mass material removal on a lathe machine tool usually is a timeconsuming process with many cutting motions under heavy chipload. If two turning tools help each other, such that they are cutting in parallel, then the job gets done in almost half the time Dual Roughing 4X Roughing Parallel Machining Page 40

41 Dual Channel Roughing Operation (Pinch Turning) Concept: One operation generates tool path for two tools Both tools cut in same shared cut region but on opposing sides of the lathe centerline! Supports pinch OD-turning Supports pinch Facing Automatically creates Twin Operation Twin operation holds tool path for second tool ( Twin Tool ) Each roughing pass (consisting of multiple cutting motions) must be properly synchronized per tool No manual work required for parallel toolpath generation and synchronization Page 41

42 Dual Channel Roughing Operation (Pinch Turning) Capabilities Balanced mode => double feed rate Merged mode => double depth of cut requiring Lead Distance Easy to use; also for new users Automatic and correct IPW generation Supported by Simulation & Verification Linked Operation to share Parameters Standard example Post available Linked Operation to share Parameters Customer Benefits Reduced Programming Time: Standard Operation Automatic Synchronization Automatic Tool suggestion One click generates two Operations Page 42

43 Dual Channel Roughing Operation Dual Castling (grooving) Capabilities Two Grooving tools on either side of centerline One starts from the left, the other from the right Each tool skips every other plunge cut creating remaining disks in-between Once both tools meet in the middle each tool removes the respective disks the twin tool has left behind. Customer Benefits Machine at Double Speed Increase Tool Life as insert is equally engaged on both sides Page 43

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45 Q&A Questions As such, presentations help define the company s reputation and provide both internal and external orientation. Answers Page 45 May 3 May

46 Contact page Dr. Tom van t Erve Director Development - NX CAM Machinery and Automation Industrieplein 3, Gebouw LL Hengelo, Netherlands Tel. :+31 (74) Mobile :+31 (6) tom.vanterve@siemens.com siemens.com Page 46

47 Thank you.