Training Guide Machines

Transcription

1 Training Guide Machines i

2 2013, Missler Software. 7, Rue du Bois Sauvage F Evry, FRANCE Web: All rights reserved. TopSolid Cam Machines This information is subject to change without warning. No material may be reproduced or transmitted, regardless of the manner, electronic or mechanical means used or purpose, without formal written consent from Missler Software. TopSolid is a registered trademark of Missler Software. TopSolid is a product name of Missler Software. The information and the software contained within this document are subject to change without prior warning and should not be construed as a commitment by Missler Software. The software covered by this document is supplied under license, and may only be used and duplicated in compliance with the terms of this license. Version 7.7 Rev.01 ii Missler Software

3 TopSolid Cam Machines Contents Exercise 01: 5-axis machining center... 1 Creating a new library... 1 Creating a new machine document... 1 Including the 3D of a machine in Parasolid, Step, Iges or other formats... 2 Defining the machine elements... 3 Defining the table... 4 Defining the spindle... 5 Defining the other machine elements... 7 Defining the machine kinematic... 9 Defining the axes... 9 Modifying, testing and checking the machine Modifying the machine Checking the machine Testing the machine Managing the machining configurations Exercise 02: 4-axis machining center Creating a new machine document Including the 3D of a machine in Parasolid, Step, Iges or other formats Defining the machine elements Defining the table Defining the chuck Defining the spindle Defining the magazine Defining the other machine elements Defining the machine kinematic Defining the axes Modifying, testing and checking the machine Modifying the machine Checking the machine Testing the machine Defining the numerical command Defining the tool change positions Exercise 03: 5-axis machining center Exercise 04: 6-axis machining center Including a TopSolid assembly file in a machine file Importing a TopPkg file Creating a new machine document Including the assembly file in the machine file Defining the machine kinematic Missler Software iii

4 TopSolid Cam Machines Modifying, testing and checking the machine Modifying the machine Checking the machine Testing the machine Exercise 05: 3-axis turning center Creating a new machine document Including the 3D of a machine in Parasolid, Step, Iges or other formats Defining the machine elements Defining the chuck Defining the turret Defining the other machine elements Defining the machine kinematic Defining the axes Defining the tool change positions Checking the machine Testing the machine Exercise 06: 9-axis turning center Creating a new machine document Including the 3D of a machine in Parasolid, Step, Iges or other formats Defining the machine elements Defining the main spindle Defining the rework spindle Defining the left turret Defining the right turret Defining the other machine elements Defining the machine kinematic Defining the axes Checking the machine Machining configurations Testing the machine Exercise 07: Steady and tailstock Importing a TopPkg file Defining the steady Defining the tailstock Defining the kinematic Kinematic of the steady Kinematic of the tailstock Checking the machine Testing the machine Notes Individual Course Evaluation Form iv Missler Software

5 TopSolid Cam Machines Exercise 01: 5-axis machining center Exercise 01: 5-axis machining center Concepts addressed: - Creating a new library - Creating a new machine document - Including the 3D of a machine in Parasolid, Step, Iges or other formats - Defining the machine elements - Defining the machine kinematic - Modifying, testing and checking the machine Creating a new library Create a new library. In the Name field, enter My Machines and choose Blank Template. Confirm the window. Note: When created or imported, a library appears as a reference in all the projects which will be created subsequently. In the library, create a new folder and rename it Exercise 01. Creating a new machine document Create a new document in the folder Exercise 01. In the Type section, click on the Advanced tab and choose Machine as the document type. In the Template section, choose Blank Template, and then confirm the window. Missler Software 1

6 Exercise 01: 5-axis machining center TopSolid Cam Machines Complete the dialog box as follows and confirm the window. Note: TopSolid retrieves the name you gave to your machine in the dialog above and renames the machine document the same way in the Library tree. Including the 3D of a machine in Parasolid, Step, Iges or other formats Include an x_t document. Select the file DMU_60EVO.x_t in the folder Exercise 01, then click on the Open button. Check the following options and confirm the window. The 3D machine is shown on the screen. 2 Missler Software

7 TopSolid Cam Machines Exercise 01: 5-axis machining center Defining the machine elements In the Machine tree, you can find the elements that make up the machine in the Elements folder. When including a Parasolid file, all entities that make up the machine are included in the ground by default. The next step will be to define and distinguish all the elements that make up the machine. Add an element. The following dialog box opens. Description: This field is used to give a name to the machine element to be defined. Note that a choice list is also available. Part Holder: Check this option if the element to be defined is a part holder (table, chuck, etc.). Tool Holder: Check this option if the element to be defined is a tool holder (spindle, turret, etc.). Magazine: Check this option if the element to be defined is the tool magazine of the machine. Removable: Check this option if the element to be defined is removable such as a milling head (extension head, angle head, twist head, etc.). Accessory Type: If the element to be defined is a steady or a tailstock, select the corresponding accessory in the drop-down list. Shapes: This box is used to indicate the objects (shapes, profiles, frames, points, etc.) related to the machine element being defined. Objects can be selected directly in the graphical area. Hide After Definition: When this option is checked, the objects selected in the graphical area are hidden as they are selected. Missler Software 3

8 Exercise 01: 5-axis machining center TopSolid Cam Machines Defining the table Since the table is a part holder, check Part Holder. The Part Holder tab then appears in the dialog and allows you to define the characteristics for the table. Note: The Part Holder Origin Frame field is used to designate the frame which will define the part holder origin. When including a machining part on the machine, this frame is selected by default. When creating the part holder element, the absolute frame is selected by default as the origin. Check the Part WCS is moving in RTCP mode option if the machining frame is moving when the machine works in RTCP mode. For this machine, keep the default parameters as shown above, and then confirm. The Table machine element will be added to the Machine tree. Note: To modify the parameters of an element, the Machine tree. double-click on the line of the element to be modified from 4 Missler Software

9 TopSolid Cam Machines Exercise 01: 5-axis machining center Defining the spindle Since the spindle is a tool holder, check Tool Holder. The Tool Holder tab then appears in the dialog and allows you to define the characteristics for the spindle. Workstations: When creating a tool holder element, a workstation is created by default. Since our machine has only one workstation, we will edit the one created by default. Tool length compensation in indexed mode: When checked, this option allows the link movements to rotate in place at the tool change point without being off stroke. Can manage RTCP: If this option is disabled, you cannot check the RTCP box in the link movements. Links: This allows you to choose a link movement already defined for each case. Missler Software 5

10 Exercise 01: 5-axis machining center TopSolid Cam Machines Modify the workstation shown in the table. In the Description field, enter Spindle. In the Machining Functions section, check the Milling and Drilling options. In the Driving Frame field, indicate the driving frame when no tool is assembled on the machine. For this machine, it is a frame whose Z+ axis is oriented in the spindle nose. In the Tool Rotation section, enter the maximum and minimum rotation speeds for the spindle tool. In the Pocket Definition section, modify the pocket shown in the table. In the Name field, enter T. In the Frame field, indicate the frame which will be used to assemble the tool on the machine. Its orientation and position are therefore very important. The Z+ axis must point toward the spindle. For this machine, it will be the same frame as the driving frame. Confirm the pocket definition. Confirm the workstation definition. Check the box Can manage RTCP. Confirm the dialog box. The Spindle machine element will be added to the Machine tree. 6 Missler Software

11 TopSolid Cam Machines Exercise 01: 5-axis machining center Defining the other machine elements Define the table support Confirm the window. The Table support machine element will be added to the Machine tree. Define the spindle support Confirm the window. The Spindle support machine element will be added to the Machine tree. Missler Software 7

12 Exercise 01: 5-axis machining center TopSolid Cam Machines Define the X crosshead Confirm the window. The X crosshead machine element will be added to the Machine tree. Define the Y crosshead Confirm the window. The Y crosshead machine element will be added to the Machine tree. 8 Missler Software

13 TopSolid Cam Machines Exercise 01: 5-axis machining center Defining the machine kinematic In the Machine tree, you can see the kinematic as well as the list of available axes. When including a Parasolid file, the machine kinematic is not defined. Therefore, the next step will be to define and distinguish all the axes that define the machine kinematic. To do this, three types of joints are available: - Add a translation - Add a rotation - Add a rigid joint Note: We must define the way an element moves in relation to another one; that means, if it translates or if it turns or if it is fixed relative to another group of parts. Defining the axes The goal is to describe the kinematic of the machine according to its axes and their type. When defining its axes, we will also have to consider their mechanical properties: initial position, stroke, minimum feed rate, maximum feed rate, rapid feed rate, power, etc. For this machine, the kinematic can be described as follows: Axes Type Carrying element X Y Z B C Spindle Warning: Carried element Properties X Programmable Y crosshead crosshead Continue Y Programmable Ground crosshead Continue Spindle Programmable X crosshead support Continue Ground Table support Spindle support Table support Table Programmable Continue Programmable Continue Initial position Mini. position Maxi. position Stroke Missler Software 9 Mini. feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min ortho ortho ortho infinite Spindle Power It is absolutely necessary to start from the ground and arrive at the end to the tool holder or the part holder. - If the axis moves the tool holder, the axis must be defined in positive direction. - If the axis moves the part holder, the axis must be defined in negative direction, and the signs for the initial, minimum and maximum positions must also be reversed.

14 Exercise 01: 5-axis machining center Define the translation axes TopSolid Cam Machines Add a translation. The following dialog box opens. Geometry tab Description: This field is used to give a name to the machine axis we are defining. Note that a choice list is also available. Carrying Element: Select the carrying element from the drop-down list or directly in the graphical area. Carried Element: Select the carried element from the drop-down list or directly in the graphical area. Direction: Select the translation direction from the drop-down list or directly in the graphical area. Limits: Enter the values for the initial distance, the minimum distance and the maximum distance. Properties tab Continue Mode: Check this box if the movement of the axis is continuous. Uncheck this box to enter data in the Indexed Positions fields. Programmable Axis: Check this box if the axis is programmable. Indexed Positions: This field is used to define the axis movement when it is not continuous (i.e. when it is indexed or incremental). Regular Step: Check this box if the axis movement is performed at regular positions. Then enter the position number and the step between each position. Uncheck this box if the axis movement is performed at non-regular positions, and then manually set indexed positions. Engine tab Minimum Feed Rate: Enter the minimum feed rate for this axis. Maximum Feed Rate: Enter the maximum feed rate for this axis. Rapid Feed Rate: Enter the rapid feed rate for this axis. 10 Missler Software

15 TopSolid Cam Machines Exercise 01: 5-axis machining center Define the X axis Add a translation. Note: The axis moves the tool holder, so the axis must be defined in positive direction. Confirm the window. The X translation axis will be added to the Machine tree. Note: To modify the parameters of an axis, Machine tree. double-click on the line of the axis to be modified from the Missler Software 11

16 Exercise 01: 5-axis machining center TopSolid Cam Machines Define the Y axis When validating the creation of the first translation axis, the Translation Axis dialog is still visible so that you can successively add all the translation axes. Note: The axis moves the tool holder, so the axis must be defined in positive direction. The values of the Properties and Engine tabs are identical to those of the X axis. Confirm. The Y translation axis will be added to the Machine tree. Define the Z axis Note: The axis moves the tool holder, so the axis must be defined in positive direction. The values of the Properties and Engine tabs are identical to those of the X and Y axes. Confirm and close the dialog box. The Z translation axis will be added to the Machine tree 12 Missler Software

17 TopSolid Cam Machines Exercise 01: 5-axis machining center Define the rotation axes Add a rotation. The following dialog box opens. Geometry tab Description: This field is used to give a name to the machine axis we are defining. Note that a choice list is also available. Carrying Element: Select the carrying element from the dropdown list or directly in the graphical area. Carried element: Select the carried element from the drop-down list or directly in the graphical area. Axis: Select the rotation axis from the drop-down list or select it directly in the graphical area. Limits: Enter the values for the initial angle, the minimum angle and the maximum angle. Properties tab Continue Mode: Check this box if the movement of the axis is continuous. Uncheck this box to enter data in the Indexed Positions fields. Power Axis: Check this box if the axis is a power axis. Programmable Axis: Check this box if the axis is programmable. Indexed Positions: This field is used to define the axis movement when it is not continuous (i.e. when it is indexed or incremental). Regular Step: Check this box if the axis movement is performed at regular positions. Then enter the position number and the step between each position. Uncheck the box if the axis movement is performed at non-regular positions, and then manually set indexed positions. Engine tab Minimum Rotation Speed: Enter the minimum rotation speed for this axis. Maximum Rotation Speed: Enter the maximum rotation speed for this axis. Missler Software 13

18 Exercise 01: 5-axis machining center TopSolid Cam Machines Define the B axis Add a rotation. Confirm. The B rotation axis will be added to the Machine tree. 14 Missler Software

19 TopSolid Cam Machines Exercise 01: 5-axis machining center Define the C axis Note: The values of the Properties and Engine tabs are identical to those of the B axis. Confirm. The C rotation axis will be added to the Machine tree. Missler Software 15

20 Exercise 01: 5-axis machining center TopSolid Cam Machines Define the spindle power axis Confirm and close the dialog box. The Spindle axis rotation axis will be added to the Machine tree. Note: In this case, the spindle axis is a non-programmable power axis. Thus, the spindle rotation speed is equivalent to that already filled in the spindle workstation definition. 16 Missler Software

21 TopSolid Cam Machines Exercise 01: 5-axis machining center Modifying, testing and checking the machine Modifying the machine At any time it is possible to modify the properties of the defined axes and the elements that make up the machine from the Machine tree. Double-click on the line of the axis or the element to be modified from the Machine tree. Note: Check that the preparation stage is enabled. Checking the machine Check the machine definition. If the machine definition is valid, the following dialog box opens. Missler Software 17

22 Exercise 01: 5-axis machining center TopSolid Cam Machines If the machine definition is invalid, the following dialog box opens. Correct the errors reported in the dialog, then check the machine definition again. Note: The Check Machine Definition command is used to automatically check whether the kinematic of the machine and its elements are valid or not, and detects and shows the consistency errors in the properties of the different machine elements. The machine must have at least a part holder and a tool holder. All defined elements must be linked to the kinematic chain. Testing the machine Test the machine axes Test the machine axes. The following window is shown on the screen. In the list, click on the axis to be tested to highlight it. Move the cursor to view the machine movement along the selected axis. Note: The Test Machine Axes command allows you to test: - the possible collisions and stroke limit over-ridings; - the correct definition of the axes (good direction, good pivot); - the right association of the different elements with the kinematic chain. 18 Missler Software

23 TopSolid Cam Machines Managing the machining configurations Exercise 01: 5-axis machining center Once the kinematic of the machine has been validated, it is possible to manage additional information related to each tool holder/part holder pair. The number of configurations will vary depending on the machine kinematic. These configurations are used to: - determine whether the tool holder/part holder pair is available to machine; - give a reference position for the automatic positioning or indexing of the tool holder (turret, certain platens); - define a transformation to be applied to the machining coordinates (for example, a transformation to be applied to the WCS solution frame). Select Machining configurations. The following dialog appears. Double-click on the configuration to be modified. Part Holder: This field indicates the part holder concerned by the machining configuration being edited. This field cannot be modified since the machining configurations are created automatically from the machine kinematic. Tool Holder: This field indicates the tool holder concerned by the machining configuration being edited. Is Allowed: This box indicates whether or not it is possible to machine with the given tool holder/part holder pair. If this box is unchecked, no WCS can be created with this tool holder if the part is on the part holder of this configuration. All the same, no tool change point will be defined between the elements of this configuration. Tool Indexing Point: This position, if defined, is used to change the reference point of the tool holder when it is in work position. This is the reference to reach in order to index the platens or the turrets automatically. The workstation driving frame will be positioned on this point. Coordinates Transform: This defines the change of frame to be applied to the WCS solution frames of the given tool holder/part holder pair. This is the transformation to be applied to the workstation driving frame to obtain the correct machining frame (WCS solution frame). Compute Orthogonal Rotations: These 3 fields are used to change the method used to compute the part rotations in the ISO code. Depending on the machines, the CN is based either on the real angles (related to the machine kinematic), or on the orthonormal angles (related to the machine absolute frame). Here, we specify on which components the orthogonal rotations will be computed. If the box is unchecked, the rotations will be computed based on the real angles defined by the machine kinematic. Missler Software 19

24 Exercise 01: 5-axis machining center TopSolid Cam Machines In our case, the B axis of the machine is not aligned with the absolute Y axis and we want the part rotations to be orthogonal and not real. Check the box Compute Orthogonal Rotations. In the Ry field select the absolute Y axis and in the Rz field select the absolute Z axis. To compute the orthogonal rotations, we need to take into account the fact that the B axis is off-center, and the rotation of the table around the C axis. So the two rotations to be computed are Ry and Rz in which the absolute Y and Z axes will be the reference for computation. Test the machine with a program Save and close the document. In the Project tree, right-click on the machine file, select Check In, then confirm the window. Always in the Project tree, right-click on the machine file, select Life Cycle, then confirm the window. Create a new project and rename it Blank Template. Create a machining program using your machine, and then perform a simulation in machine mode. 20 Missler Software

25 TopSolid Cam Machines Exercise 02: 4-axis machining center Exercise 02: 4-axis machining center Concepts addressed: - Defining several part holders - Defining a tool magazine - Defining the VCN settings - Defining several tool change positions Creating a new machine document Create a new folder and rename it Exercise 02. In this folder, create a new document. In the Type section, click on the Advanced tab and choose Machine as the document type In the Template section, select Blank Template, and then confirm. Complete the following dialog box, and then confirm. Missler Software 21

26 Exercise 02: 4-axis machining center Including the 3D of a machine in Parasolid, Step, Iges or other formats TopSolid Cam Machines Include an x_t document. Select the file ROSILIO_C850.x_t in the folder Exercise 02, then click on the Open button. Check the following options, and then confirm the dialog box. The machine is displayed in 3D on the screen. Defining the machine elements Defining the table Add an element, then complete the dialog as follows. Since the table is a part holder, check Part Holder. 22 Missler Software

27 TopSolid Cam Machines Exercise 02: 4-axis machining center In the Part Holder tab, in the Part Holder Origin Frame field, create a frame in the middle of the table, select it, and then confirm the dialog box. Defining the chuck Complete the dialog as follows. Since the chuck is a part holder, check Part Holder. In the Part Holder tab, in the Part Holder Origin Frame field, create an offset frame at 100mm from the chuck axis, select it, and then confirm the dialog box. Missler Software 23

28 Exercise 02: 4-axis machining center TopSolid Cam Machines Defining the spindle Complete the dialog as follows. Since the spindle is a tool holder, check Tool Holder. Modify the workstation shown in the table. In the Driving Frame field, create a frame on the spindle nose. In the Pocket Definition section, modify the pocket shown in the table. Select the frame previously created on the spindle nose and confirm. Confirm the workstation definition. Confirm the spindle definition. 24 Missler Software

29 TopSolid Cam Machines Exercise 02: 4-axis machining center Defining the magazine Complete the dialog as follows. Since the magazine is a magazine, check Magazine. The Magazine tab then appears in the dialog and allows you to define the characteristics for the magazine. Note: When creating the magazine element, a tool pocket is created by default in the Pockets Definition list. - Add Pocket: Used to add and define pockets one by one. - Modify Pocket: Used to modify an existing pocket in the list. - Delete Pocket: Used to delete an existing pocket in the list. - Wizard: Used to automatically define a set of pockets simultaneously. Missler Software 25

30 Exercise 02: 4-axis machining center TopSolid Cam Machines As our machine s magazine contains 24 pockets, delete the pocket created by default. Use the Wizard option and complete the dialog as follows. Note: The Assembly Frame field is used to create a frame in the first pocket of the magazine. The orientation of the frame is essential for the tool positioning. The Z+ axis gives the direction of the attachment axis for the tool to be assembled. Confirm. By default, the wizard defines all the pockets on the same assembly frame in the magazine. This makes it possible to modify the pockets one by one and assign different assembly frames to them. Note: In order to save time, it is recommended to define the assembly frames repeated around an axis before defining the magazine and its pockets. Activate the modeling stage by clicking on. 26 Missler Software

31 TopSolid Cam Machines Exercise 02: 4-axis machining center In the Tools tab, create a frame by point and 2 directions. Confirm. In the Tools tab, use the Repetition command. Click on the icon and choose Circular Pattern. Complete the dialog as below. Confirm the pattern, then the repetition. Switch to the preparation stage by clicking on. Add the magazine and use the wizard to define the 24 pockets. Modify each one of the pockets to assign their respective assembly frame to them. Missler Software 27

32 Exercise 02: 4-axis machining center Defining the other machine elements TopSolid Cam Machines Define the chuck support Define the table support 28 Missler Software

33 TopSolid Cam Machines Define the spindle support Exercise 02: 4-axis machining center Defining the machine kinematic Defining the axes The goal is to describe the kinematic of the machine according to its axes and their type. When defining its axes, we will also have to consider their mechanical properties: initial position, stroke, minimum feed rate, maximum feed rate, rapid feed rate, power, etc. For this machine, the kinematic can be described as follows: Axes X Y Z A Spindle Type Carrying element Table support Ground Ground Chuck support Spindle support - Table Carried element Table Table support Spindle support Chuck Properties Programmable Continue Programmable Continue Programmable Continue Programmable Continue Initial position Mini. position Maxi. position Stroke Mini. Feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min infinite Spindle Power Chuck support Ground Magazine Missler Software 29

34 Exercise 02: 4-axis machining center Reminder: TopSolid Cam Machines - It is absolutely necessary to start from the ground and arrive at the end to the tool holder or the part holder. - If the axis moves the tool holder, the axis must be defined in positive direction. - If the axis moves the part holder, the axis must be defined in negative direction, and the signs for the initial, minimum and maximum positions must also be reversed. Modifying, testing and checking the machine Modifying the machine At any time it is possible to modify the properties of the defined axes and the elements that make up the machine from the Machine tree. From the Machine tree, double-click on the line of the axis or the element to be modified. Reminder: Check that the preparation stage is enabled. Checking the machine Check the machine definition. If the machine definition is invalid, the following dialog opens. Correct the errors reported in the dialog, then check the machine definition again. Once the machine definition is valid, the following dialog opens. 30 Missler Software

35 TopSolid Cam Machines Exercise 02: 4-axis machining center Testing the machine Test the machine axes Test the machine axes. In the list, click on the axis to be tested to highlight it. Move the cursor to view the machine movement along the selected axis. Test the machine with a program Save and close the document. In the Project tree, right-click on the machine file, select Check In, and then confirm. Always in the Project tree, right-click on the machine file, select Life Cycle, and then confirm. Create a new project and rename it Blank Template. Create a machining program using your machine, and then perform a simulation in machine mode. Defining the numerical command In the Machine tab, select Numerical Command. The following dialog box opens. Machine Origin: Select the frame that defines the machine origin. Program Type: In the drop-down list, select the type of program that should be generated by default by the postprocessor for this machine (one program per part, one program per tool, etc.). Manage tilted planes: Check this box if the numerical command of the machine manages the tilted planes; otherwise, uncheck the box. Some machines with manual rotation axes do not manage the work plane rotation. Manage fast linear interpolations: Check this box if the rapid movements of the translation axes are linear; otherwise uncheck the box. Linear Non-linear Complete the dialog box as above, then confirm. Missler Software 31

36 Exercise 02: 4-axis machining center Defining the tool change positions TopSolid Cam Machines In the Machine tab, use the Tool Change Positions command. The following dialog box opens. Define the different tool change positions according to the tool holder and the part holder, as well as the time needed for the tool change. Note: In order to save time when programming, simply store the different tool change positions directly in the machine definition, for the different scenarios you need to consider in production: - position for the first operation in the range; - position for the other operations in the range; - position of the operator for manual tool changes; - safety position to move away from the part; - optimized position to reduce unnecessary movements; - etc. Complete the dialog as follows for the Table part holder. 32 Missler Software

37 TopSolid Cam Machines Exercise 02: 4-axis machining center Complete the dialog as follows for the Chuck part holder. Confirm the window. Missler Software 33

38 Exercise 03: 5-axis machining center TopSolid Cam Machines Exercise 03: 5-axis machining center Concepts addressed: - Exercise to apply the acquired knowledge. Open the file CMS_ARES.x_t in the folder Exercise 03. Axes X Y Z B C Spindle Type Carrying element Ground Portal X axis Crosshead Y axis C axis Slide Z axis Spindle support - Ground Carried element Properties Portal X axis Programmable Continue Crosshead Programmable Y axis Continue Slide Programmable Z axis Continue Spindle support C axis Programmable Continue Programmable Continue Initial position Mini. position Maxi. position Stroke Mini. feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min Spindle Power Central partition Ground Right table Ground Left table Missler Software

39 TopSolid Cam Machines Exercise 04: 6-axis machining center Exercise 04: 6-axis machining center Concepts addressed: - Including a TopSolid assembly document in a machine document - Inheriting the machine kinematic already defined in the assembly - Automatically associating the assembly kinematic with the machine kinematic Including a TopSolid assembly file in a machine file Importing a TopPkg file In the Project tree, right-click on the library My Machines, then select Import/Export > Import Package. Select the file TOS_KURIM_FUQ-150-KR8.TopPkg in the folder Exercise 04, click on the Open button, and then confirm. The folder Exercise 04, which includes the assembly document TOS_KURIM_FUQ-150-KR8, will appear in the Project tree. Double-click on the assembly document TOS_KURIM_FUQ-150-KR8 to open it. Missler Software 35

40 Exercise 04: 6-axis machining center TopSolid Cam Machines Creating a new machine document In the Project tree, right-click on the folder Exercise 04, then create a new document. In the Type section, click on the Advanced tab and choose Machine as the document type. In the Template section, select Blank Template, and then confirm. Complete the following dialog and confirm. 36 Missler Software

41 TopSolid Cam Machines Exercise 04: 6-axis machining center Including the assembly file in the machine file In the Assembly tab, select the Inclusion command. Complete the dialog as below, and then confirm. Note: When including the TOS_KURIM_FUQ-150-KR8 assembly document in the machine document, we inherit the characteristics of the assembly mechanism by checking the following options: - Inherit Rigid Groups: Used to inherit the definition of the element groups as defined in the assembly (table, spindle, column, etc.). - Inherit Joints: Used to inherit the joints as defined in the assembly (translation, rotation, rigid joint). Confirm the default positioning. Defining the machine kinematic In the Machine tab, select Set as machine. This command is used to automatically associate the assembly kinematic with the machine kinematic. Note that the machine elements, axes and kinematic are automatically created in the Machine tree. Missler Software 37

42 Exercise 04: 6-axis machining center TopSolid Cam Machines Modifying, testing and checking the machine Modifying the machine At any time it is possible to modify the properties of the defined axes and the elements that make up the machine from the Machine tree. From the Machine tree, double-click on the line of the axis or the element to be modified. Reminder: Check that the preparation stage is enabled. - Table: Part holder with the origin at the center of the table. - Right fixed table: Part holder with the origin at the center of the right fixed table. - Left fixed table: Part holder with the origin at the center of the left fixed table. - Spindle: Tool holder with the driving frame and the assembly frame on the spindle nose. Axes X Y Z V A B C Spindle Type Carrying element Ground Z axis Column X axis Ground B axis Ram Y axis Table support Spindle support - Ground - Ground - Column X axis Carried element Column X axis Ram Y axis Z axis Table support Spindle support B axis Table Properties Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Initial position Mini. position Maxi. position Stroke Mini. feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min infinite Spindle Power Right fixed table Left fixed table Casings Missler Software

43 TopSolid Cam Machines Exercise 04: 6-axis machining center Checking the machine Check the machine definition. If the machine definition is invalid, the following dialog opens. Correct the errors reported in the dialog, then check the machine definition again. Once the machine definition is valid, the following dialog opens. Missler Software 39

44 Exercise 04: 6-axis machining center TopSolid Cam Machines Testing the machine Test the machine axes Test the machine axes. In the list, click on the axis to be tested to highlight it Move the cursor to view the machine movement along the selected axis Test the machine with a program Save and close the document. In the Project tree, right-click on the machine file, select Check In, and then confirm. Always in the Project tree, right-click on the machine file, select Life Cycle, and then confirm. Create a new project and rename it Blank Template. Create a machining program using your machine, and then perform a simulation in machine mode. 40 Missler Software

45 TopSolid Cam Machines Exercise 05: 3-axis turning center Exercise 05: 3-axis turning center Concepts addressed: - Defining a turret Creating a new machine document Create a new folder and rename it Exercise 05 In this folder, create a new document. In the Type section, click on the Advanced tab and choose Machine as the document type. In the Template section, select Blank Template, and then confirm. Complete the following dialog box, and then confirm. Missler Software 41

46 Exercise 05: 3-axis turning center TopSolid Cam Machines Including the 3D of a machine in Parasolid, Step, Iges or other formats Include an x_t document. Select the file OKUMA_LB15.x_t in the folder Exercise 05 and click on the Open button. Check the following options, and then confirm. The machine is displayed in 3D on the screen. Defining the machine elements Defining the chuck Add an element and complete the dialog as follows. Since the chuck is a part holder, check Part Holder. In the Part Holder tab, in the Part Holder Origin Frame field, create a frame at the axis and on the face of the chuck. Confirm and close the dialog box. 42 Missler Software

47 TopSolid Cam Machines Exercise 05: 3-axis turning center Defining the turret Define the frames Note: To make it easier to define each workstation and the correct orientation of the tool assembly, it is recommended to create the frames beforehand and on the first pocket only. Workstation frame The workstation frame must be oriented in the same way as the frame which defines the machine axes. It is therefore oriented for axial machining with the Z+ axis oriented along the chuck axis. In the Tools tab, create a frame by point and 2 directions at the middle of the first face of the turret. Assembly frame The orientation of the assembly frame is essential for the tool positioning. It defines the tool machining direction (axial, radial, etc.). The Z+ axis gives the direction of the attachment axis for the tool to be assembled. The X+ axis gives the default tool machining direction. In the Tools tab, create a frame by point and 2 directions at the center of the first face of the turret with the X+ axis pointing toward the chuck (absolute Z-) and the Z axis pointing toward the center of the turret (absolute X+). The frame you created earlier for the workstation will also be used to assemble the tools. Missler Software 43

48 Exercise 05: 3-axis turning center TopSolid Cam Machines Add an element and complete the dialog as follows. Since the turret is a tool holder, check Tool Holder. The Tool Holder tab then appears in the dialog box and allows you to define the characteristics for the tool holder. In the Tool Holder tab, delete the default workstation, select the wizard, and then complete the dialog as follows. General Information: Indicate the turret axis and the workstation count. First Workstation Description: Enter the prefix description to assign to each workstation (T1, T2, T3,, T12). Machining: Check the boxes of the machining functions that are supported by the turret. Tool Rotation: Enter the minimum rotation speed and the maximum rotation speed for the powered tools. Pockets: Enter the pocket count (maximum 3) and the name. Then select the associated assembly frames. The assembly frame of the first pocket must be identical to the workstation frame (it is necessary to calculate the WCSs). Confirm the window. 44 Missler Software

49 TopSolid Cam Machines Note: For each face of the turret, the wizard has automatically created: - the workstations and the associated driving frames; - the pockets for each workstation as well as the associated assembly frames. Exercise 05: 3-axis turning center Confirm the window. Defining the other machine elements X crosshead Missler Software 45

50 Exercise 05: 3-axis turning center TopSolid Cam Machines Z crosshead Defining the machine kinematic Defining the axes The goal is to describe the kinematic of the machine according to its axes and their type. When defining its axes, we will also have to consider their mechanical properties: initial position, stroke, minimum feed rate, maximum feed rate, rapid feed rate, power, etc. For this machine, the kinematic can be described as follows: Axes Type Carrying element X Z Carried element Properties Z Programmable X crosshead crosshead Continue Ground Z crosshead Programmable Continue C Ground Chuck Turret X crosshead Programmable Power Initial position Mini. position Maxi. position Stroke Mini. feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min infinite Turret Power infinite Missler Software

51 TopSolid Cam Machines Exercise 05: 3-axis turning center Defining the tool change positions In the Machine tab, select the Tool Change Positions command. The following dialog box opens. Define the different tool change positions according to the tool holder and the part holder, as well as the time needed for the tool change. Checking the machine Check the machine definition until the machine is valid. Once the machine definition is valid, the following dialog box opens. Missler Software 47

52 Exercise 05: 3-axis turning center TopSolid Cam Machines Testing the machine Test the machine axes Test the machine axes. In the list, click on the axis to be tested to highlight it. Move the cursor to view the machine movement along the selected axis. Test the machine with a program Save and close the document. In the Project tree, right-click on the machine file, select Check In, and then confirm. Always in the Project tree, right-click on the machine file, select Life Cycle, and then confirm. Create a new project and rename it Blank Template. Create a machining program using your machine, and then perform a simulation in machine mode. 48 Missler Software

53 TopSolid Cam Machines Exercise 06: 9-axis turning center Exercise 06: 9-axis turning center Concepts addressed: - Defining two turrets - Defining two spindles Creating a new machine document Create a new folder and rename it Exercise 06. In this folder, create a new document. In the Type section, click on the Advanced tab and choose Machine as the document type. In the Template section, select Blank Template, and then confirm. Complete the following dialog box, and then confirm. Missler Software 49

54 Exercise 06: 9-axis turning center TopSolid Cam Machines Including the 3D of a machine in Parasolid, Step, Iges or other formats Include an x_t document. Select the file TRAUB_TNX_65-42.x_t in the folder Exercise 06 and click on the Open button. Check the following options and confirm. The machine is displayed in 3D on the screen. Defining the machine elements Defining the main spindle Add an element and complete the dialog as follows. 50 Missler Software

55 TopSolid Cam Machines Exercise 06: 9-axis turning center Defining the rework spindle Defining the left turret Reminder: To make it easier to define each workstation and the correct orientation of the tool assembly, it is recommended to create the frames beforehand and on the first pocket only. View 1 View 2 View 3 The left turret can machine on the main spindle and the rework spindle. In this case, you need to create: - View 1: A driving frame which will also be used as an assembly frame for axial milling and turning operations with turning tools. - View 2: An assembly frame for radial milling and turning operations on the main spindle. - View 3: An assembly frame for radial milling and turning operations on the rework spindle. Missler Software 51

56 Exercise 06: 9-axis turning center TopSolid Cam Machines Add an element and complete the following dialog using the wizard. Defining the right turret Repeat the previous operations for the right turret. Defining the other machine elements - X1 crosshead - Y1 crosshead - Z1 crosshead - X2 crosshead - Y2 crosshead - Z2 crosshead - Main spindle support (fixed to the ground) - Rework spindle support (mobile on the V axis) - Work area casings (fixed to the ground, but may be subject to collisions) - Doors (fixed, but this will allow the doors to be hidden without hiding the complete ground) 52 Missler Software

57 TopSolid Cam Machines Exercise 06: 9-axis turning center Defining the machine kinematic Defining the axes Axes X1 Y1 Z1 X2 Y2 Z2 V (Z) C1 C2 Left turret Right turret Type Carrying element Z1 crosshead X1 crosshead Ground Z2 crosshead X2 crosshead Ground Ground Main spindle support Rework spindle support Y1 crosshead Y2 crosshead - Ground - Ground Carried element X1 crosshead Y1 crosshead Z1 crosshead X2 crosshead Y2 crosshead Z2 crosshead Rework spindle support Main spindle Rework spindle Properties Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Continue Programmable Power Programmable Power Initial position Mini. position Maxi. position Stroke Mini. feed rate Maxi. feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min infinite infinite Left turret Continue infinite Right turret Main spindle support Work area casings Continue infinite Ground Doors Checking the machine Check the machine definition until the machine is valid. Once the machine definition is valid, the following dialog box appears. Missler Software 53

58 Exercise 06: 9-axis turning center TopSolid Cam Machines Machining configurations Select Machining configurations. Here we find our 4 machining configurations. We don t want that the right turret machine on the main spindle. In the list, click on the axis to be tested to highlight it. Uncheck the box Is Allowed. If the box Is Allowed is unchecked, the tool holder corresponding to the configuration (here the left turret) cannot machine on the part if it is positioned on the rework spindle, which is not the case for the other machining configurations. Testing the machine Test the machine axes Test the machine axes. In the list, click on the axis to be tested to highlight it. Move the cursor to view the machine movement along the selected axis. Test the machine with a program Save and close the document. In the Project tree, right-click on the machine file, select Check In, and then confirm. Always in the Project tree, right-click on the machine file, select Life Cycle, and then confirm. Create a new project and rename it Blank Template. Create a machining program using your machine, and then perform a simulation in machine mode. 54 Missler Software

59 TopSolid Cam Machines Exercise 07: Steady and tailstock Exercise 07: Steady and tailstock Concepts addressed: - Defining a steady - Defining a tailstock Importing a TopPkg file In the Project tree, right-click on the library My Machines, then select Import/Export > Import Package Select the file Exercise 07.TopPkg in the folder Exercise 07, click on Open, and then confirm. The machine is displayed in 3D on the screen. Note: The kinematic of this machine has already been partially defined. Now we must define the steady, the tailstock as well as their respective associated axes. Defining the steady Add an element and complete the following dialog. In the Description field, select Steady in the drop-down list. Missler Software 55

60 Exercise 07: Steady and tailstock Defining the tailstock Complete the following dialog. In the Description field, select Tailstock in the drop-down list. TopSolid Cam Machines In the Tool Holder tab, modify the workstation shown in the table. Modify the pocket. The tailstock is defined as a tool support with a single pocket. 56 Missler Software

61 TopSolid Cam Machines Add the tailstock support. Exercise 07: Steady and tailstock Defining the kinematic Axes Type Carrying element Carried element Properties X Z Programmable X crosshead crosshead Continue Z Ground Z crosshead Programmable Continue V (Z+) Ground Tailstock Programmable support Continue CP (Z-) Tailstock Programmable Tailstock support Continue W Ground Steady Programmable Continue C Ground Chuck Turret X crosshead Kinematic of the steady Programmable Power Initial position Mini. position Maxi. position Stroke Mini. feed rate Maxi. Feed rate Rapid feed rate mm mm mm mm mm/s m/s m/s degrees degrees degrees degrees tr/min tr/min infinite Turret Continue infinite Add a translation and add the W axis as shown in the table above. Kinematic of the tailstock Reminder: Add a translation and add the V and CP axes as shown in the table above. - It is absolutely necessary to start from the ground and arrive at the end to the tool holder or the part holder. - If the axis moves the tool holder, the axis must be defined in positive direction. - If the axis moves the part holder, the axis must be defined in negative direction, and the signs for the initial, minimum and maximum positions must also be reversed. Missler Software 57