Surface MachiningStudent Notes:CATIA TrainingFoilsSurface Machining Copyright DASSAULT SYSTEMES Version 5 pdf

Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 1 Copyright DASSAULT SYSTEMES Surface Machining CATIA Training Foils Version 5 Release 17 September 2006 EDU_CAT_EN_SMG_FF_V5R17 Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 2 Copyright DASSAULT SYSTEMES Surface Machining Objectives of the course Upon completion of this course you will be able to: - Identify and use the Surface Machining workbench tools - Define 3-Axis Surface Machining operations - Create a Machining Area before performing the operations - Define a Rework Area - Analyze and modify the Tool Path Targeted audience NC Programmers Prerequisites Students attending this course should have knowledge of CATIA V5 Fundamentals and Numerical Control Infrastructure workbench. 2 Days Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 3 Copyright DASSAULT SYSTEMES Table of Contents (1/3) Introduction to Surface Machining 7 About Surface Machining 8 Accessing the Workbench 9 Workbench User Interface 10 Process Product Resources Model 16 Manufacturing Terminology 17 General Process for Surface Machining 18 Creating Geometrical Elements 19 Creating a Geometrical Element: General Process 20 Creating Rough Stock 21 Inserting an STL File 22 Creating a Stock By Offset 23 Points Creation Wizard 25 Limit Lines Projection Wizard 27 Limit Lines Creation Wizard 28 Creating a Machining Feature 29 Creating a Machining Feature: General Process 30 What is a Geometrical Zone? 31 Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 4 Copyright DASSAULT SYSTEMES Table of Contents (2/3) More about Geometrical Zone 32 Machining/Slope Area 35 Rework Area 43 Offset Group: General Process 48 Creating a 3-Axis Surface Machining Operation 49 Introduction to 3-Axis Machining Operations 50 How to Create a 3-Axis Machining Operation 51 3-Axis Machining Operation: General Process 52 3-Axis Machining Operation: Geometry 53 3-Axis Machining Operation: Tools 54 3-Axis Machining Operation: Tool Axis Management 56 3-Axis Machining Operation: Feeds and Speeds 57 3-Axis Machining Operation: Macros 58 Various 3-Axis Machining Operations 64 3-Axis Roughing Operations 65 Sweep Roughing Operation: Introduction 66 Roughing Operation: Introduction 70 Plunge Milling: Introduction 82 Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 5 Copyright DASSAULT SYSTEMES Table of Contents (3/3) 3-Axis Semi-finishing and Finishing Operations 91 Sweeping Operation: Introduction 92 Pencil Operation: Introduction 99 ZLevel Operation: Introduction 102 Contour-driven Operation: Introduction 109 Isoparametric Machining Operation 120 Isoparametric Machining Operation: Introduction 121 Isoparametric Machining Operation: Strategy 122 Isoparametric Machining Operation: Geometry 124 Isoparametric Machining Operation: Tool 126 Spiral Milling Operation 127 Spiral Milling Operation: Introduction 128 Spiral Milling Operation: Strategy 129 Profile Contouring Operation 132 Profile Contouring Operation: Introduction 133 Profile Contouring Operation: Strategy 134 Profile Contouring Operation: Geometry 140 Profile Contouring Operation: Feeds and Speeds 142 Analyzing and Modifying Tool Path 143 Minimum Tool Length Computation 144 Tool Path Editor 146 Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 6 Copyright DASSAULT SYSTEMES How to Use This Course To assist in the presentation and learning process, the course has been structured as follows: Lessons: Lessons provide the key concepts, methodologies, and basic skill practice exercises. The goal of each lesson is to present the necessary knowledge and skills to master a basic level of understanding for a given topic. Master Exercises: Master Exercises provides a project where an industry type parts are used to assist you in applying the key knowledge and skills acquired in the individual lessons as they apply to real world scenarios. The master exercises also highlight the process and steps for completing industry parts. Recap Exercises: Recap Exercises are provided along with Master Exercise Steps. Note: According to preference, the Master Exercise individual steps will be completed after an individual lesson containing its key concepts. Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 7 Copyright DASSAULT SYSTEMES Introduction to Surface Machining In this lesson, you will learn basics of Surface Machining About Surface Machining Accessing the Workbench Workbench User Interface Process/Product/Resources (PPR) Model Manufacturing Terminology General Process Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 8 Copyright DASSAULT SYSTEMES About Surface Machining It is of paramount importance that the tool paths are correct and that the tool does not gouge the part or leave material in unexpected portions. Surface Machining offers the technology to generate Tool path for 3-Axis Machining Operations. This helps you to upgrade from 2 and 2.5-Axis operations. The key issues in milling of complex shapes are: 1) Accuracy and finish of the part 2) The machine time required to complete the operation 3) The time spent for preparing and validating tool paths for machining. A full set of 3-Axis milling and drilling operations for accurate tool path definition, including support of High Speed Milling technology. Automated detection and reworking of unmachined areas during roughing or finishing. Flexible management of tools stored in file-based tool catalogs or in external tool databases. Tool path verification by material removal simulation. Associativity with CATIA design parts for efficient Change Management. CATIA Surface Machining features include: Surface Machining is very much useful for manufacturing of Moulds, Dies and Prototypes in all types of industry. Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 9 Copyright DASSAULT SYSTEMES Accessing the Workbench Anywhere from A- Start menu or B- File menu + New or C- Workbench Icon Blank Manufacturing CATProcess to start B A Start Menu You will learn three methods to access the Surface Machining Workbench. See Tools + Customize + Start menu for the content of this Welcome Box C Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 10 Copyright DASSAULT SYSTEMES Workbench User Interface (1/6) Prompt Zone Manufacturing Items 3-Axis Surface Machining Items CATProcess file extension Manufacturing Tree Standard Tools [...]... will be created Copyright DASSAULT SYSTEMES 2 1 Copyright DASSAULT SYSTEMES 3 Created Limit line 28 Surface Machining Creating a Machining Feature Student Notes: In this lesson, you will see how to use Machining Features Copyright DASSAULT SYSTEMES General Process Geometrical Zone Machining/ Slope Area Rework Area Offset Group: General Process Copyright DASSAULT SYSTEMES 29 Surface Machining Student... plunge milling where the tool plunges at defined points Copyright DASSAULT SYSTEMES 25 Surface Machining Student Notes: Points Creation Wizard (2/2) To define the creation mode, you have three options: Copyright DASSAULT SYSTEMES Points Copyright DASSAULT SYSTEMES Polyline between points Closed Polyline between points Created Points 26 Surface Machining Student Notes: Limit Lines Projection Wizard Using... entities or select bodies Copyright DASSAULT SYSTEMES A B Copyright DASSAULT SYSTEMES 34 Surface Machining Student Notes: Machining/ Slope Area: General Process In Area-oriented Machining, you can use machining areas to define different zones on a part First you can define the machining/ slope areas and then the specific machining operations can be assigned to each of them 1 A machining area can be defined... if necessary 5 Click OK to create the rough stock 1 3 2 4 Copyright DASSAULT SYSTEMES 5 Copyright DASSAULT SYSTEMES The axis system can be changed by clicking on ‘Select’ button and then choosing either An axis in the other system A plane or A planar surface 21 Surface Machining Student Notes: Inserting an STL File This functionality helps you to open an STL file in the current Surface Machining session... machining area 5 Check the created machining area by using the Manufacturing feature view icon Copyright DASSAULT SYSTEMES 35 Surface Machining Student Notes: Machining/ Slope Area: Domain Definition To define the machining area you have three options: Definition by selecting the whole part Definition by selecting faces Definition by selecting Limiting Contour C1 A B1 Copyright DASSAULT SYSTEMES A Click... geometrical zone by using the Manufacturing feature view icon Copyright DASSAULT SYSTEMES 32 Surface Machining Student Notes: Geometrical Zone: Domain Definition (1/2) To define a geometrical zone, you have four options as follows: Definition by selecting Points Definition by selecting Planes A A Copyright DASSAULT SYSTEMES A Copyright DASSAULT SYSTEMES Select sensitive item in the dialog box Using contextual... Post-processor Copyright DASSAULT SYSTEMES 17 Surface Machining Student Notes: General Process for Surface Machining 1 Part designed using 3D Wireframe or Solid geometry If needed, Sequence the operations 4 2 Create Wireframe elements necessary for manufacturing (Safety Planes, Axis, Points, etc ) Create Machining Operations and simulate them Define Part Operation necessary to machine all the part 3 5 2 Copyright. .. stock will be added) Select the reference part 3 Define the offset value 4 Define the part set-up (optional) 5 Click on Preview button to visualize the result 6 Click OK to create the stock by offset 1 1 2 3 Copyright DASSAULT SYSTEMES 4 Copyright DASSAULT SYSTEMES Stock by offset 6 5 23 Surface Machining Creating a Stock by offset (2/2) Student Notes: You can select the Limited stock option to reduce... Define Part Operation necessary to machine all the part 3 5 2 Copyright DASSAULT SYSTEMES Generate Auxiliary Operations 6 Copyright DASSAULT SYSTEMES 3 Generate APT Source or ISO Code 18 Surface Machining Creating Geometrical Elements Student Notes: In this lesson, you will see how to manage Geometrical Elements Copyright DASSAULT SYSTEMES General Process Creating Rough Stock Inserting an STL File Creating... be projected 3 Select the sketch or polyline to project 4 Define the projection axis, if necessary 5 Preview the result & then click OK 1 2 3 4 Copyright DASSAULT SYSTEMES Projected polyline Copyright DASSAULT SYSTEMES 5 Selection of ‘Joins polylines’ enables to put all the polylines in a join 27 Surface Machining Student Notes: Limit Lines Creation Wizard Using this wizard you can create limit lines . Notes: Surface Machining  Copyright DASSAULT SYSTEMES 1 Copyright DASSAULT SYSTEMES Surface Machining CATIA Training Foils Version 5 Release 17 September 2006 EDU_CAT_EN_SMG_FF_V5R17 Student. Notes: Surface Machining  Copyright DASSAULT SYSTEMES 7 Copyright DASSAULT SYSTEMES Introduction to Surface Machining In this lesson, you will learn basics of Surface Machining About Surface. 31 Student Notes: Surface Machining  Copyright DASSAULT SYSTEMES 4 Copyright DASSAULT SYSTEMES Table of Contents (2/3) More about Geometrical Zone 32 Machining/ Slope Area 35 Rework Area