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Version 5 Release 5
November 2000
FOR-CAT-E-SMG-F-V5R5
Copyright DASSAULT SYSTEMES 2000 1
Objectives of the Course
In this course you will see how to define and manage NC programs
dedicated to machining parts designed with Surface or Solid
geometry using 3 Axis machining techniques.
Targeted audience
Manufacturing users knowing how to work with CATIA V5 Parts
2 days
Prerequisites:
Fundamentals about CatiaV5:
In this lesson, you will learn about the Surface Machining Workbench
by:
1-
3-
Blank Manufacturing
CATProcess to start
2-
Manufacturing tree
Manufacturing Items
3-Axis Surface
Machining Items ...
Standard Tools
Prompt Zone
Copyright DASSAULT SYSTEMES 2000 7
Workbench User Interface 1/2
3-Axis Surface Machining
Workbench
Manufacturing views
Generate Documentation
➘ The Process / Product / Resources model is shared by all the Manufacturing applications (such as
NC, Robotic, Welding, Painting, Inspection, etc…) and can be accessed by a Process Planning
Management tool
Process :
Part Operations
Process is the place where all the NC
entities will be created by the user
Product :
Parts or Products
used for
Manufacturing :
Design Parts,
Fixtures, Stock, Resources used in the Process are
automatically listed in the Resources
Manufacturing list and are available for the others
elements, etc … Manufacturing applications and for
Resources : a Process Planning Management tool
Machines & Tools
➘ With Product and Resources Assignment, links are made and managed between the Design World
(Product), the Manufacturing World (Process) and the Resources World
➘ Part Operation :
A Part Operation (or PO) links all the operations necessary for machining a part based on a
unique part registration on a machine. The Part Operation links these operations with the
associated fixture and set-up entities.
➘ Manufacturing Program :
A Manufacturing Program describes the processing order of the NC entities that are taken
into account for tool path computation : Machining Operations, Auxiliary Operations
➘ Machining Operation :
A Machining Operation (or MO) contains all the necessary information for machining a part
of a work piece using a single tool. (Such as Roughing, Sweeping, Drilling, …)
➘ Auxiliary Operation :
A control function such as Tool Change or Machine Table/Head Rotation. These commands
may be interpreted by a specific Post-processor.
Generate Auxiliary
Operations
Generate
APT Source or
ISO Code
The general layout of the user interface and the basic principles.
- Selecting a Machine-Tool :
3 Axis w/wo Table rotation or 5 Axis
3
Enter the Part Operation
specifications in the dialog
box and confirm
2 Enter Comments.
These comments will be generated at
the beginning of the APT (Optional)
1
Spindle Data :
- Coordinates of the Home point
2 - Initial Axis orientation
2
Axis Orientation :
Select the Reference Point -Selecting an element
(Line, Fsur, Edge, ..)
- By means of X,Y,Z
coordinates
- From a pre-defined
list (X-,X+,Y-,Y+,Z-,Z+)
Select the X Axis orientation
Origin checkbox.
Activate the Origin and specify the 3 Confirm axis creation
Number and Group to generate the Name of the Reference
following syntax in the Apt Source : Machining Axis System
ORIGIN/ X, Y, Z, Number, Group displayed in CATIA V5 window
2
3 Confirm selection
The Design Part and Stock geometry are only used for the
material removal simulation
2
1
Simulation Commands :
• Photo or Video
• Update
All the Machining Operations displayed in the Manufacturing program may have the
following status :
Operation Activate (Complete and Up to date)
Operation Not Updated (Tool path must be replayed to update the operation)
During the APT Source Code or ISO NC Code computation, if the system detects a
Machining Operation with a Deactivate or Not Complete Status, this operation is not taken
into account in the computation.
In the resulting Report of the APT or ISO computation, a warning is generated to advice the
user.
10min
In this exercise you will learn how to define a new Part Operation
- Machining area
- Rework area
Check the created machining area by using the Manufacturing feature view icon
2 3
1 Select Body option in the associated 2 Select Part sensitive item in the dialog-
pop-up menu of the Part sensitive box.
item of the dialog-box. In this case,
you select one or more bodies in the
working area. 3 Select faces on the part.
Once you have machined a part and visually checked it, you may
decide to rework certain areas where residual material remains.
Defining a rework area allows you to focus only on the areas where
there is residual material.
1
1 Enter the Name of the Rework Area.
(Optional because a default name is given
by the system ‘M3xRAFeature.X’)
2
2 Define the machining area or recall an existing
machining area 3
2
5 Validate the creation of the Rework Area
4
5
Check the created rework area by using the Manufacturing feature view icon
3
2 4
1
Tool definition :
You can define tool’s characteristics
according to the diameter, the radius and
overlap between path according to the tool
diameter ratio (% of diameter)
Filters definition :
•With the limit line you can restrict the area
to be reworked.
•If you find that there are too many areas to
be reworked or if you decide to concentrate
on only a part of the rework area, define a
selection contour
•Use the depth, Length and Width
parameters to filter out areas that you wish
to ignore because they are not deep, long
or wide enough.
10min
- Roughing Operation
- Sweeping Operation
- Pencil Operation
- Zlevel Operation
- Contour-driven Operation
5 4
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options.
(See the dedicated Job Aid ‘NC Manufacturing Settings’)
Machining Tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed
Axial Strategy
Definition of the maximum depth of cut
Radial Strategy
Definition of the distance which is the width of the
overlap between two successive passes
1 •Part
Geometry parameters
Part autoLimit
If you activate Part autolimit, the tool will not go
beyond the edge of the part
Limit Definition
• Stop position defines where the tool stops:
-outside stops the tool outside the limit line,
-inside stops inside the limit line, Limit line
-on stops the tool on the limit line. Outside
2 2
Under Mode item, you can choice among:
- Approach/Retract along tool axis
3
- Approach/Retract along a vector
- Approach/Retract Normal
- Approach/Retract tangent to movement
- None
15 min
•Zig-zag; the tool path alternates directions during One-way next One-way same
successive passes.
Machining mode
The machining mode can be:
Machining tolerance
Value of the maximum allowable distance
between the theoretical tool path and the tool
path computed
Axial Strategy
Definition of the maximum depth of cut
Radial Strategy
Definition of the distance which is the width of the
overlap between two successive passes
5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)
•A start point where the tool will start cutting. Use this option when
6 accessing the part from the outside (Optional)
Geometry parameters
Tool/Rough Stock
This option is used to define where the tool center
stops :
30 min
Sweeping operations machine the part and are used for finishing
and semi-finishing work. The tool paths are executed in
vertical parallel planes.
- For the stepover definition, you have the choice
between Constant and scallop height option,
- For the definition of the Machined zone, you have the
choice between different capabilities like All,
Frontal wall, Lateral walls, Horizontal zones.
- The area is machined with Zig-Zag, One way Next,
One Way Same tool path style
•Zig-zag; the tool path alternates directions during One-way next One-way same
successive passes.
Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed
Zig-zag
Stepover definition
For the stepover you have the choice between:
View direction
View direction has two options : - Along tool
axis, -Other axis.
1 •Part 2
1
2 •Check Elements (Optional)
5
• Limiting contour (Optional)
3
•Safety plane (Optional). By default the application computes a 6
4 safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.
5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)
•Start plane, End plane. In this case the tool path is limited by using
6 these two planes. (Optional)
Geometry parameters
Limit definition
This option is activated is you define a Limiting
Contour.
Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed
1 •Part
1 2
2 •Check Elements (Optional)
Geometry parameters
Limit definition
This option is activated is you define a Limiting
Contour.
Machining mode
The machining mode can be:
Stepover definition
1 •Part
5
1 2
2 •Check Elements (Optional)
5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)
Geometry parameters
Limit definition
This option is activated is you define a Limiting
Contour.
The Macro tab defines the tool approach, retract and plunge data.
There is a button where you can optimize retract distances. this means that if no
obstacle is detected between two passes, the tool will not rise to the safety
plane (because it is not necessary) and the operation will take less time.
The linking pass (i.e. the means of moving from the end of one pass to the
beginning of the next one) can be:
•Along tool axis; the tool moves along the tool axis,
•Ramping; the tool follows a slope defined by the ramping angle,
•Circular; the tool describes a circle defined by the value of Radius,
•Circular or ramping; the tool uses either circular or ramping mode
depending on whichever is best adapted to the part being machined.
In certain cases, notably where there is a risk of collision with a circular linking
pass, you should choose Circular or ramping rather than simply Circular in
order to ensure that your tool path will be produced.
Approach distance is the engagement distance for plunge mode.
Safety distance is the distance that the tool moves horizontally before it begins
its approach.
Copyright DASSAULT SYSTEMES 2000 102
Step5 : Create a Sweeping, a Zlevel
and a Pencil Operation
60 min
Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed
Constant parameters
Constant
Scallop height
View direction
View direction has two options : - Along tool
axis, -Other axis.
Geometry parameters
Limit definition
This option is activated is you define a Limiting
Contour.
There is a button where you can optimize retract distances. this means that if no
obstacle is detected between two passes, the tool will not rise to the safety
plane (because it is not necessary) and the operation will take less time.
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)
Number of levels
Number of paths :
You specify the number of
You enter directly the
levels from the bottom to
number of radial paths
the top
Number of levels
without top
you specify the bottom,
the number of levels and
the depth of cut.
Close contour
Option to machine the complete
contour of a closed area.
Percentage overlap
when « close contour option » is active, « percentage overlap » represents the
recovery of the tool path in tool diameter ratio
Machining Tolerance
Value of the maximum allowable distance between the theoretical tool path
and the tool path computed
Fixture Accuracy
Local machining tolerance for fixtures
Type of Contour
• Circular : The tool pivots around the corner point, following a contour whose radius
is equal to the tool radius
• Angular : The tool does not remain in contact with the corner point, following a
contour comprised of 2 line segments
• Optimized : The tool follows a contour derived from the corner that is continuous in
tangent
• Forced Circular : The tool follows a near-circular contour comprised of line segment
Optimized
Climb Milling
Conventional Milling
To start (or end) out of the part, click on Start (or Stop)
with right mouse button
7 different types of macros are available : Approach, Retract, Return between level, Return in a
level, Linking, Return to finish passes, Clearance
• Linking
• Approach • Return to finish pass
• Retract
Between those two motions, the system computes a transition tool path to avoid :
- Colisions
- Islands
- Fixtures
If you want this transition tool path to be a simple return to a safety plan, activate Clearance
Macro
Circular
Vertical
Circular
Ramping
30min
5
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options. 6
(See the dedicated Job Aid ‘NC Manufacturing Settings’)
Chamfering Step
4 - Motion at Machining feedrate to 2 (Chamfer Diameter)
5 - Dwell for specified duration
6 - Possibly, activation of first tool compensation number
7 - Retract at Retract feedrate (or Rapid) from 2 to 3
Tools allowed for a Boring & Chamfering Operation : The First Compensation is associated to the Boring
• Boring & Chamfering The Second Compensation is associated to the
• Multi-Diameter Drill Chamfering
Machining Strategy :
Radial : Number of paths and Distance
Axial : Depth of Cut or Number of Levels
Sequencing Mode :
Side First or Depth First
Direction of Cut :
Climb or Conventional
• End Mill
Rapid
Retract Feedrate
Approach Feedrate
Machining Feedrate
- Plunge Option
1 The Jump Distance is used to specify an offset on the top of the holes that will be applied for
the transition paths between two holes.
This transition path is perform in RAPID mode
2 The 2 ways for ordering pattern points are Manual and Closest
Manual : Successively select the points in the order you want them sequenced
Closest : The pattern point closest the first point is given the next sequence number, the
next closest to that is given the next sequence number and so on
Jump
Distance
Deactivate point
X1 X2 X0 X3 X4
Copyright DASSAULT SYSTEMES 2000 175
Plunge Options
1 4
Animation Stop
Backward Forward
The list of detected faults are listed in the Faults combo box (Gouge, Undercut and Tool Clash) and
detailed information related to these faults are displayed (Type, Operation, Normal Deviation and Area)
At any time you can pick on the surface of the workpiece and a dialog box appears giving information
about the picked point
1 - In the Faults Tab Page you can specify the colors used to
highlight the Remaining Material, Tool Clash and Gouge
according the tolerance. This tolerance is initialized in the
Analyze Tab Page.
By selecting the icon, you are able to save the result of the simulation as a new model
and to use it as the stock of the next Part Operation.
This new model will be saved as a CGR model (CATIA Geometric Representation)
Comment (attribute)
The different types of tool you can Select the catalog (the Windows
use for the operation path is specified in Tool/options)
The Radius register number is only available if the option Radius Compensation has been
activated on the Machine-Tool
The following tool types have only one compensation site (P1) and this site is located at
the extremity of the tool :
• End Mill
• Face Mill
• Boring Bar
• Tap
• Reamer
- Tool Change
- PP Instruction
CATIA will check that all the operations tool axis are reachable by the
Part Operation’s machine-tool and an Information Message or Warning
Message will be displayed
1
4 Select the Syntax Tab Page to display the syntaxes
associated to the Tool Change operation
• Init From PPTable : the predefined syntax is read on the
PPWords Table linked to the machine and the syntax
parameters are updated with the Tool Change parameters
• Otherwise : Key your own user-syntax that will have no
link with the PPTable
The Sequence Number allows the user to choose between the several syntaxes associated to this
command in this PPWords Table
To learn how to associate several syntaxes to a Tool Change Operation, see the dedicated Job Aid
‘PPwords Table Customization’
5min
5min
Activation of the Origin Checkbox, with a number and a group, will generate
in the output the following syntax :
$$ ORIGIN/ X, Y, Z, Number, Group
5min
5min
In this exercise you will insert a Post Processor word in the PPR tree
In the PPR Tree, for each Auxiliary Operation is associated a graphical icon which give
information to the user
All the Auxiliary Operations may have also the following status :
Operation Deactivate (done manually by the user)
- HTML Documentation
The APT Source Code can be also generated using the The resulting file is generated with the .aptsource extension.
MB3 on the Manufacturing Program entity In the same folder, a file with .LOG extension is generated and
it is including all the computation information
Batch Mode : You need to write the CATProcess before to generate the APT Source
Code, but during the computation, your CATIA V5 session is available
Automatic : the information are automatically The resulting file is generated with the .aptsource extension.
retrieved on the Machine-Tool associated to the In the same folder, a file with .LOG extension is generated and
current Part Operation it is including all the computation information
1
1 Use the same procedure as to generate APT
Source Code but specify ISO type for the Output
format in the In / Out Tab Page
2
3 Click on Execute to request computation of the
ISO NC Code
15 min
APT CODE
ISO CODE
Copyright DASSAULT SYSTEMES 2000 213
Generate HTML Documentation
Some samples and helps are delivered under intel_a/startup/Manufacturing/Documentation of your CATIA V5 installation
15 min
HTML document
1
1 Edit a None-Updated Operation
5 min
In this exercise you will make a change in the design and check that your
change is automatically taken into account in the toolpath replay
Replay