NC Manufacturing Verification

Transcription

1 NC Manufacturing Verification Overview Conventions What's New? User Tasks Accessing NC Manufacturing Verification Comparing the Machined Stock Part and the Design Part Pick Point Analysis in Video Mode Using Collision Detection in Video Cross-referencing Collision Information Using Run Summary Generation Using Geometric Analysis Measure Between Measure Item Arc through 3 Points Point Hide/Show Using Video Measure Analysis Removing Detached Material in Video Defining Maximum Machining Feedrate Glossary Index

2 Preface Welcome to the NC Manufacturing Verification User's Guide! This guide is intended for users who need to become quickly familiar with the product. This overview provides the following information: NC Manufacturing Verification in a nutshell Before reading this guide Getting the most out of this guide Accessing sample documents Conventions used in this guide NC Manufacturing Verification in a nutshell NC Manufacturing Verification enables easy validation of machining processes and analysis of the accuracy of machined parts. This product detects and reports collisions between the tool/tool holder and stock/fixture in a graphical form. It also identifies machining operations and tools responsible for these errors. NC Manufacturing Verification helps analyze the accuracy of machined parts by detecting gouge and remaining material. These results are displayed in a graphical form with the innovative use of color contours on the machined part. Tools to analyze machined parts geometrically are also provided. NC Manufacturing Verification seamlessly provides analysis and validation capabilities to NC Manufacturing. It provides tight interaction between tool path generation, simulation (material removal) and edition. Before reading this guide Before reading this guide, you should be familiar with basic Version 5 concepts such as document windows, standard and view toolbars. Therefore, we recommend that you read the Infrastructure User's Guide that describes generic capabilities common to all Version 5 products. It also describes the general layout of V5 and the interoperability between workbenches.

3 You may also like to read the NC Manufacturing Infrastructure User's Guide, for which the appropriate license is required. Getting the most out of this guide To get the most out of this guide, we suggest that you start with the User Tasks section of the book, reading and performing the procedures that illustrate the features of NC Manufacturing Verification. The Glossary provides definitions of terms specific to Machine Tool Path Simulation and related products. Navigating in the Split View mode is recommended. This mode offers a framed layout allowing direct access from the table of contents to the information. Accessing sample documents To perform the scenarios, sample documents are provided. For more information about this, refer to "Accessing Sample Documents" in the Infrastructure User's Guide.

4 Conventions Certain conventions are used in CATIA, ENOVIA & DELMIA documentation to help you recognize and understand important concepts and specifications. Graphic Conventions The three categories of graphic conventions used are as follows: Graphic conventions structuring the tasks Graphic conventions indicating the configuration required Graphic conventions used in the table of contents Graphic Conventions Structuring the Tasks Graphic conventions structuring the tasks are denoted as follows: This icon... Identifies... estimated time to accomplish a task a target of a task the prerequisites the start of the scenario a tip a warning information basic concepts methodology reference information

5 information regarding settings, customization, etc. the end of a task functionalities that are new or enhanced with this release allows you to switch back to the full-window viewing mode Graphic Conventions Indicating the Configuration Required Graphic conventions indicating the configuration required are denoted as follows: This icon... Indicates functions that are... specific to the P1 configuration specific to the P2 configuration specific to the P3 configuration Graphic Conventions Used in the Table of Contents Graphic conventions used in the table of contents are denoted as follows: This icon... Gives access to... Site Map Split View mode What's New? Overview Getting Started Basic Tasks User Tasks or the Advanced Tasks Workbench Description Customizing

6 Text Conventions Reference Methodology Glossary Index The following text conventions are used: The titles of CATIA, ENOVIA and DELMIA documents appear in this manner throughout the text. File -> New identifies the commands to be used. Enhancements are identified by a blue-colored background on the text. How to Use the Mouse The use of the mouse differs according to the type of action you need to perform. Use this Whenever you read... mouse button... Select (menus, commands, geometry in graphics area,...) Click (icons, dialog box buttons, tabs, selection of a location in the document window,...) Double-click Shift-click Ctrl-click Check (check boxes) Drag Drag and drop (icons onto objects, objects onto objects)

7 Drag Move Right-click (to select contextual menu)

8 Enhanced Functionalities What's New? Analysis dialog box for video A streamlined analysis option (Less mode) is offered with three tolerancing bands for Remaining Material. The older version is supported with the More mode. Enhancements in the NC manufacturing infrastructure This product benefits from enhancements to the infrastructure's general functions. For more information, please see the What's New? section in the NC Manufacturing Infrastructure User's Guide.

9 User Tasks These are the tasks that a user performs using NC Manufacturing Verification. Accessing NC Manufacturing Verification Comparing the Machined Stock Part and the Design Part Pick Point Analysis in Video Mode Using Collision Detection in Video Cross-referencing Collision Information Using Run Summary Generation Using Geometric Analysis Using Video Measure Analysis Removing Detached Material in Video Defining Maximum Machining Feedrate

10 Accessing NC Manufacturing Verification This procedure describes how to access NC Manufacturing Verification through NC Manufacturing Review. You may use the file provided in the samples directory or your own data. 1. Open a V5 session. 2. From the samples directory, open the Processfinal.CATProcess file.

11 3. In the PPR tree, select any manufacturing operation.

12 4. Select the Tool Path Replay icon from the Tool Path Management toolbar. You can also right-click the operation in the PPR tree and select Tool Path Replay from the contextual menu.

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14 5. The Replay dialog box appears. Continue working through the basic tasks: Comparing the Machined Stock Part and the Design Part Pick Point Analysis in Video Mode Using Collision Detection in Video Cross-referencing Collision Information Using Run Summary Generation Using Geometric Analysis Using Video Measure Analysis Removing Detached Material in Video Defining Maximum Machining Feed Rate

15 Comparing the Machined Stock Part and the Design Part This procedure describes how to do a comparison between the machined stock and the target (design) part through the graphical comparison functionality in Video. Areas on the machined stock from which extra material has been removed are reported as gouges. Areas where material has not been removed completely are reported as remaining material. This functionality provides a visual comparison achieved by color-coding the stock according to how close the machined surface is to the surface of the target (design) part. A series of tolerance bands and a color for each band is defined. All points on the machined surface that lie within a particular band are given the corresponding band color. By defining the tolerance band appropriately, all remaining material points or gouge points on the machined surface can be identified and displayed in as many colors. The magnitude of remaining material or gouge can also be queried at a specified point. This magnitude is the shortest distance between the picked point on the stock and the nearest point on the target (design) part. The coordinates of the picked point on the stock are also displayed along with the magnitude of remaining material or gouge. Complete the procedures as described in Accessing NC Manufacturing Verification. 1. In the Replay dialog box, select the Full Video icon to simulate the material removal by the machining operation previously selected in the PPR tree. (For more information, see "Video Mode for Material Removal Simulation" in the NC Manufacturing Infrastructure User Guide.) The material removal video is displayed.

16 2. Select the Run button to run the video simulation. You can stop and continue the Video simulation using the buttons marked below. 3. In the Replay dialog box, select the Analyze icon. The Analysis dialog box appears giving details of all errors found. Select the fault type to be analyzed, (Remaining Material, or Gouge) and specify the tolerance for the comparison. The fault filter setting permits two types of faults: Remaining Material and Gouge. Remaining Material: Areas where the tool has left behind material on the workpiece.

17 The default appearance of this tab gives three tolerance bands for analysis. Select the button to access additional options. The values reflected in the Less mode are also reflected in the More mode and vice versa. Less More Gouge: Areas where the tool has removed excess material from the workpiece during a rapid move. Remaining material and gouges will be displayed as colored zones according to the specified tolerances.

18 Use the checkbox to control the window refresh after a view change. 4. Click the Apply button. The machined part is compared with design part based on the specified settings. Any point on the machined surface of the workpiece is considered to be part of a fault if the distance (deviation) to the design part surface is greater than the specified tolerance. Results of the comparison are reflected on the workpiece, based on the extent of severity of the fault and the customized color settings.

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20 Pick Point Analysis in Video Mode This procedure describes the pick point analysis feature in video mode. Complete the procedures as described in Accessing NC Manufacturing Verification. 1. In the Replay dialog box, select the Full Video command to simulate the material removal by the machining operation previously selected in the PPR tree. (For more information, see "Video Mode for Material Removal Simulation" in the NC Manufacturing Infrastructure User Guide.) The material removal video is displayed. 2. In the Replay dialog box, select the Analyze command, select the fault types to be analyzed, and specify the tolerance for the comparison. Click the apply button in the Analysis dialog box. 3. Pick a point on the machined stock. The Pick Point Information dialog box appears with the following information:

21 The new display fields are Arc radius and Arc center. These fields are displayed only if the picked point is on a circular entity. This information is available at every pick provided that the point picked is a "machined area pick". To get information about errors and deviation at the picked point, you first need to do a design part comparison. Design part comparison will render the stock in a colorcoded manner, depicting deviations from the design part. A subsequent pick will display the deviation value.

22 Using Collision Detection in Video This procedure describes how to use collision detection in video. Video provides a list of collisions that occurred during material removal simulation. You can select collisions from a list and see the exact point of collision. Later, even after exiting the video window, you can cross-reference and use this information regarding the collision to correct your tool path. For more information, see Cross-referencing Collision Information. You have the option of reporting "soft collisions" or ignoring them. To access the Video Collision options, go to Tools->Options->NC Manufacturing->Photo/Video tab. Select "Continue" and "Touch is Collision" (to report soft collisions) in the Video Collision field. If you select the Stop option in the Video Collision field, the simulation will stop during collision and you will be able to continue Video simulation from the stopped point. Complete the procedures as described in Accessing NC Manufacturing Verification. Run the Video mode simulation.

23 1. Select the Video Collision Report command. The Collision Report is generated and the collision list appears in the Fault Selection drop-down field. Click the button in the Collision Report dialog box to see more detailed information.

24 You have the option of choosing the collision filter type. Type options are: All (all the collisions) Fixture Stock Holder Tool Shank You have the option to display the tool sweep, the sweep transparency, and the collision point, as well as choose the tool sweep color. You also have the option to display the tool at the start point, the end point, or make the tool invisible at a collision location.

25 2. Select a collision in the list. The tool reported in the selected collision is shown at the point of collision along with the tool sweep.

26 Cross-referencing Collision Information This procedure describes how to cross-reference collision information using the Tool Path command. Video provides a list of collisions that occurred during material removal simulation. You can cross-reference and use this information regarding the collision to correct your tool path later, even after exiting the video window. Complete the procedures as described in Accessing NC Manufacturing Verification. Run the simulation in Full Video mode. Note: Video simulation must be run at least once to use the crossreferencing functionality. 1. Select the Video Collision Report command. The collision report is generated and the collision list appears in the Fault Selection drop-down field of the Collision Report dialog box.

27 Note this Collision Report dialog box differs from that generated in video mode. This Collision Report dialog box is available only after video simulation is complete. The Current MO check button shows collisions that occurred in the machine operation selected to access the Tool Path Replay dialog box. 2. Close both dialog boxes. 3. Select the Tool Path Replay icon from the Tool Path Management toolbar. OR Right-click the operation in the PPR tree and select Tool Path Replay from the contextual menu.

28 4. In the Replay dialog box, select the Video Collision Report command. The Collision List dialog box appears.

29 5. Select any collision in the Fault selection list. Use the check box to display collisions that have occurred in the current machining operation only. In the 3D view, the tool is positioned at the start point of the selected tool path. Also visible is the tool path segment where the collision occurs. The collision location is indicated by a cross-mark.

30 Using Run Summary Generation This procedure describes the run summary generation feature in Video. After material removal simulation, you have the option of saving the report of the simulation as a text file. The Run Summary report lists the time taken for each operation as well as the time taken for each tool being used for material removal. Complete the procedures as described in Accessing NC Manufacturing Verification. Run the simulation in Video mode. 1. Select the Run Summary Generation icon. 2. Name the text file and save it in the desired location.

31 Run Summary report Amount of time for each operation:

32 Amount of time each tool was used for material removal:

33 Using Geometric Analysis This procedure describes how to use the geometric analysis capabilities for Photo/Video mode. With this functionality, you can geometrically analyze the results of material removal after simulation. This would include: linear distance measure angular measurement between edges and surfaces center and radius measurement of arcs (3-point method) center-to-center distance Complete the procedures as described in Accessing NC Manufacturing Verification. Run the simulation in Video mode. Select the Measure command.

34 The Measure panel appears. Select one of the following commands: Measure Between Measure Item Arc through 3 Points Point Hide/Show Click on OK. The dialog box for the selected command appears. For more information about these commands, please see: Measure Between Measure Item Arc through 3 Points Point Hide/Show

35 Measure Between This procedure describes how to use the Measure Between command. 1. From the Measure dialog box, select the Measure Between command. 2. The Measure Between dialog box appears. By default, measures made on active products are done with respect to the product axis system. Measures made on active parts

36 are done with respect to the part axis system. Note: This distinction is not valid for measures made prior to Version 5 Release 8 Service Pack 1 where all measures are made with respect to the absolute axis system. You can also measure distances and angles with respect to a local V5 axis system. A Keep Measure option in the dialog box lets you keep the current and subsequent measures as features. This is useful if you want to keep the measures as annotations, for example. Defining measure types 3. Select the desired measure type. Notice that the image in the dialog box changes depending on the measure type selected. Between (default): Measures distance and angle between selected items. Chain: Allows you to chain measures with the last selected item becoming the first selection in the next measure.

37 Fan: Fixes the first selection as the reference so that you always measure from this item. Defining Selection 1 and Selection 2 modes 4. Set the desired mode in the Selection 1 and Selection 2 mode dropdown boxes. Any geometry (default mode): Measures distances and angles between defined geometrical entities (points, edges, surfaces, etc.). Note: The Arc center mode is activated in this selection mode. This mode recognizes the axis of cylinders and lets you measure the distance between two cylinder axes, for example. Any geometry, infinite: Measures distances and angles between the infinite geometry (plane or line) on which the selected geometrical entities lie. The Arc center mode is activated and this mode also recognizes cylinder axes. For all other selections, the measure mode is the same as any geometry. Picking point: Measures distances between points selected on defined geometrical entities. Always gives an approximate measure. Point only: Measures distances between points. Dynamic highlighting is limited to points. Edge only: Measures distances and angles between edges and surfaces respectively. Dynamic highlighting is limited to edges or surfaces and is thus simplified compared to the Any

38 geometry mode. All types of edge are supported. Surface only: Measures distances and angles between edges and surfaces respectively. Dynamic highlighting is limited to edges or surfaces and is thus simplified compared to the Any geometry mode. All types of edge are supported. Picking axis: Measures distances and angles between an entity and an infinite line perpendicular to the screen. Simply click to create infinite line perpendicular to the screen. Intersection: Measures distances between intersection points between two edges or an edge and a surface. In this case, two selections are necessary to define selection 1 and selection 2 items. Edge limits: Measures distances between endpoints or midpoints of edges. Endpoints only are proposed on curved surfaces. Arc center: Measures distances between the centers of arcs. Coordinate: Measures distances between coordinates entered for selection 1 and/or selection 2 items. Center of 3 points arc: Measures center-to-center distance between circular entities. Defining the calculation mode 5. Set the desired calculation mode in the Calculation mode dropdown list box. Exact else approximate (default mode): Measures access exact data and wherever possible true values are given. If exact values cannot be measured, approximate values are given (identified by a ~ sign). Exact: Measures access exact data and true values are given. Note that you can only select exact items in the geometry area

39 or specification tree. In certain cases, in particular if products are selected, a warning dialog box informs you that the exact measure could not be made. Approximate: measures are made on tessellated objects and approximate values are given (identified by a ~ sign). Note: You can hide the display of the ~ sign using the Tools -> Options command (General -> Parameters and Measure -> Measure Tools). 6. Click to select a surface, edge or vertex, or an entire product (selection 1). Notes: The appearance of the cursor has changed to reflect the measure command you are in. A number (1 for the selection 1 and 2 for the selection 2) also helps you identify where you are in your measure. Dynamic highlighting as you move your cursor over surfaces, faces and vertices helps you locate items to click on. Customizing your measure You can, at any time, customize the display of the results in both the geometry area and the dialog box. To do so, click Customize... in the Measure Between dialog box and set your display in the Measure Between Customization dialog box. By default, all results are displayed. Point 1 and point 2 give the coordinates of the two points between which the minimum distance is measured.

40 Measuring in a local axis system For this part of the task, you will need a V5 axis system. 7. Click Customize... and check Point 1 and Point 2 options in the Measure Between Customization dialog box. Click OK. 8. Check the Other Axis option in the Measure Between dialog box. 9. Select a V5 axis system in the specification tree of geometry area. 10. Make your measure. This is the same measure made with respect to the absolute axis system:

41 All subsequent measures are made with respect to the selected axis system. To change the axis system, click the Other Axis field and select another axis system. To return to the absolute axis system, uncheck the Other Axis option. This type of measure is associative: if you move the axis system, the measure is impacted and can be updated. 11. Click OK when done.

42 Measure Item This procedure describes how to use the Measure Item command to measure the properties associated to a selected item (points, edges, surfaces and entire products). This command lets you choose the selection mode, the calculation mode and axis system when measuring properties. 1. From the Measure dialog box, select the Measure Item command. 2. The Measure Item dialog box appears. By default, measures made on active products are done with respect to the product axis system. Measures made on active parts are done with respect to the part axis system.

43 Note: This distinction is not valid for measures made prior to Version 5 Release 8 Service Pack 1 where all measures are made with respect to the absolute axis system. You can also measure distances and angles with respect to a local V5 axis system. A Keep Measure option in the dialog box lets you keep the current and subsequent measures as features. This is useful if you want to keep the measures as annotations, for example. Defining the Selection 1 mode 3. Set the desired measure mode in the Selection 1 mode drop-down list. Any geometry (default mode): Measures the properties of the selected item (point, edge, surface, or entire product. Point only: Measures the properties of points. Dynamic highlighting is limited to points. Edge only: Measures the properties of edges. All types of edge are supported. Surface only: Measures the properties of surfaces. For Point only, Edge only, and Surface only modes, dynamic highlighting is limited to points, edges, or surfaces depending on the mode selected and is thus simplified compared to the Any geometry mode. Defining the Calculation mode

44 4. Set the desired calculation mode in the Calculation mode drop down list. Exact else approximate (default mode): Measures access exact data and, wherever possible, true values are given. If exact values cannot be measured, approximate values are given (identified by a ~ sign). Exact: Measures access exact data and true values are given. Note that you can only select exact items in the geometry area or specification tree. In certain cases, in particular if products are selected, a warning dialog box informs you that the exact measure could not be made. Approximate: measures are made on tessellated objects and approximate values are given (identified by a ~ sign). Note: You can hide the display of the ~ sign using the Tools -> Options command (General -> Parameters and Measure -> Measure Tools). 5. In the 3D view, click to select the desired item. Note that the appearance of the cursor has changed to reflect the measure command you are in.

45 The dialog box gives information about the selected item, in our case a surface, and indicates whether the result is an exact or approximate value. The surface area is also displayed in the geometry area. 6. In the Measure Item dialog box, click to see the properties the system can detect for the various types of item you can select. By default, you obtain:

46 Note: The center of gravity of surfaces is visualized by a point. In the case of non-planar surfaces, the center of gravity is attached to the surface over the minimum distance. 7. Set the display of results in both the geometry area and the Measure Item dialog box as follows, then click Apply. The Measure Item dialog box is updated and now gives the surface perimeter. 8. Try selecting other items to measure associated properties. Measuring properties in a local axis system For this part of the task, you will need a V5 axis system. 9. Check the Other Axis option in the Measure Item dialog box. 10. Select a V5 axis system in the specification tree or geometry area.

47 11. Make your measure. All subsequent measures are made with respect to the selected axis system. To change the axis system, click the Other Axis field and select another axis system. To return to the main axis system, uncheck the Other Axis option. This type of measure is associative: if you move the axis system, the measure is impacted and can be updated. 12. Click OK when finished. If you checked the Keep Measure option in the Measure Item dialog box, your measures are kept as features.

48 Arc through 3 Points This procedure describes how to use the Arc through 3 Points command. This command is used to measure the center and radius/diameter of circular entities using accurate point information. To use this command, point visibility must be ON. 1. From the Measure dialog box, select the Arc through 3 Points icon. 2. In the 3D view, select three points in the machined part geometry: the start point, the center point, and the end point. An arc is fitted through the three selected points and the Measure Between dialog box is updated with the length, angle, angle at vertex, and radius or diameter of the arc. Start, end and center point coordinates are also shown.

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50 Point Hide/Show This procedure describes how to use the Point Hide/Show command. This command disables/enables the display of accurate point geometries present on vertices of the machined part. From the Measure dialog box, select the Point Hide/Show command. The point geometries present on vertices of the machined part are hidden (OFF) or displayed (ON), depending on their current display state. The image below illustrates the points shown.

51 Using Video Measure Analysis This procedure describes how to do measure analysis in the video window without the need to go to the measure window. With this functionality, you can make the following types of measurements: distance and angle between planar surfaces and edges distance and angle between centerlines of circular entities distance and angle between circular entities and planes or edges distances between points and other supported entities Run the Full Video command. In the Replay dialog box, select the Video Measure command. The Video Measure dialog box appears.

52 Select the options "Display vertices" and "Display Edges" to display all the edges and vertices of the solid. The options in both Selection 1 Mode and Selection 2 Mode drop-down menus are: Arc Plane Edge Point These options can selected in any combination. Below are some of the possible selection combinations: Arc/Arc Plane/Plane Arc/Plane or Plane/Arc Measures the distance between two arc center axes. Measures the distance and angle between two planes Measures the distance between an arc center axis and a plane or vice versa.

53 Edge/Edge Point/Point Edge/Arc Edge/Plane Edge/Point Point/Arc Point/Plane Measures the distance and angle between two parallel edges. If they are not parallel, only the angle between them is measured. Measures the distance between two points. The coordinates of both points are also displayed. Measures the distance and angle between an edge and an arc center axis if the edge is parallel to the arc center axis. If they are not parallel, only the angle between them is measured. Measures the distance and angle between an edge and a plane if the edge is parallel to the plane. If they are not parallel, only the angle between them is measured. Measures the shortest distance between an edge and a vertex. The coordinates of the point on the edge from which the minimum distance is calculated is also displayed. Measures the shortest distance between the arc center axis and the vertex. Measures the shortest distance between a point and a plane

54 Removing Detached Material in Video During the material removal process, chunks of material may get detached from the stock. You can pick any of the unconnected material belonging to the stock and delete it after the simulation has been stopped. This functionality eliminates false collisions that occur when unwanted chunks remain after being detached from the stock. 1. In the Replay dialog box, select the Remove Chunks command.

55 The Delete Material dialog box appears. 2. In the 3D view, select the parts to be deleted. The select parts change color. 3. Click OK in the Delete Material dialog box. The unwanted material is deleted.

56 If there are no chunks of material from the stock and the command is invoked, the following error message will appear.

57 Defining Maximum Machining Feedrate This procedure describes how to define maximum machining feedrate for a part operation as well as for a specific machining operation. From the samples directory, open the Processfinal.CATProcess file or you may use your own data. Defining for a part operation 1. In the PPR tree, double-click on Part Operation.1. The Part Operation dialog box appears.

58 2. Click on the Machine icon in the Part Operation dialog box. The Machine Editor dialog box appears.

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60 3. Input the desired value in the Max machining feedrate field and click on OK. Errors (tool collision with the stock) will be reported if the feedrate exceeds this value. Defining for a specific machining operation 1. In the PPR tree, double-click on Tool Change.1 The following dialog box appears:

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62 2. In the dialog box, click on the button. The dialog box expands. The maximum machining feedrate can be set in the Feeds & Speeds tab. Errors (tool collision with the stock) will be reported if the feedrate exceeds this value.

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64 Glossary D DPM Digital Process for Manufacturing G gouge Area where the tool has removed too much material from the workpiece. N NC Numerical control R remaining material Area where the tool has not completely removed material from the workpiece. S stock part Raw material or base part T tool clash Area where the tool collided with the workpiece during a rapid move.

65 Index A analysis geometric pick point arc through 3 points C collision filter collision information, cross-referencing commands Collision Detection Compare Analysis Remove Chunks Video Measure cross-referencing collision information D design part, compare to machined stock part F feedrate, maximum machining filter, collision

66 G geometric analysis M machined part, compare to design part maximum machining feedrate measure types between chain fan measuring circular entities measuring items N NC Manufacturing Verification, accessing P pick point analysis point hide/show functionality R Remove Chunks command

67 S summary, running V Video Measure command