Edu Cat en Pmg Fs v5r18

8/3/2019 Edu Cat en Pmg Fs v5r18

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CATIA Training

COPYRIGHT DASSAULT SYSTEMES Version 5 Release 18September 2007EDU-CAT-EN-PMG-FS-V5R18

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Prismatic Machining Detailed Steps

COPYRIGHT DASSAULT SYSTEMES 2

TTaabbllee ooff CCoonntteennttssMaster Exercise: Aerospace Structure Part............................................................................................3

1. Step 1: Create a new Part Operation ..............................................................................................32. Step 2: Create a Facing Operation..................................................................................................53. Step 3: Create Pocketing Operations............................................................................................114. Step 4: Create Profile Contouring Operation.................................................................................325. Step 5: Create a Point-to-point Operation.....................................................................................396. Step 6: Create a Curve Following Operation.................................................................................427. Step 7: Create a Machining Process (stored in a catalog)............................................................ 468. Step 8: Use Cutter Compensation (CUTCOM) in Macro then store the Result in a Catalog........ 59

Added Exercise: Manuf Exercise ..........................................................................................................641. Step 0 - Create a new Part Operation ...........................................................................................642. Step 1 - Create Point-to-Point operation .......................................................................................643. Step 2 - Create a Facing operation. ..............................................................................................684. Step 3 - Create a Drilling operation with machining pattern.......................................................... 695. Step 4 - Create a Pocketing and Rework operation using a catalog with prismatic machining

area....................................................................................................................................................706. Step 5 - Create a Profile Contouring operation with macros catalog. ...........................................727. Step 6 - Create a Profile Contouring operation ............................................................................. 748. Step 7 - Create a Profile Contouring operation ............................................................................. 769. Step 8 - Create a Pocketing operation ..........................................................................................7810. Step 9 - Create a Pocketing operation ........................................................................................8011. Step 10 - Create a Profile Contouring operation ......................................................................... 8112. Step 11 - Create a Profile Contouring operation ......................................................................... 83


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Click on the Machine icon: to select the machine-tool

Click OK to accept the default 3-axis Machine.

To select the part to machine, click on the Design part for simulation icon:

in the 3D window, Double-click on the Design part

To select the stock, click on the Stock icon:

In the P.P.R tree, expand the Stock (stock.1) and double-click on the Pad.

To select the fixtures, click on Fixtures for Simulation icon:

Select in the 3D window the machine-table and the fixtures

To select the safety plane, click on Safety plane icon:

Select the bottom of the design part

Use the MB3 on text Safety Plane to specify an offset of 80mm.

Click OK to create the part operation


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2. Step 2: Create a Facing Operation

Use step1 result or Open Start_Step2_FacingOperation.CATProcess

Expand Part operation.1 : Click

Select Manufacturing Program.1,

Click Facing icon :2.1 - Select the geometry to machine

In Operation Definition window, select the top of the part; the contour will be automaticallyinitialized if the option Contour Detection is activated

Select the top of the designed part


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2.2 - Select the options for machining

Select the strategy tab page

Select Back and forth as tool path style

Define an Overhang value of 100% in the Radial tab page

2.3 - Select the tool

Select the tool assembly tab page

Select Face Mill icon and keep the default tool with a 50mm diameter


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2.4 - Define Macros

Select Macro tab page

Activate Approach macro by right click on the text (2)

Select Build by user mode (3)

Select Axial motion up to a plane icon (4)

Do the same thing for Retract macro

2.5 - Replay the facing operation

Click on Replay command

Test the various options for the replay:

To change an option, click on the right down arrow of the icon(Explanation for these options is available via ? button. )


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Click OK to end the replay

Click OK to create the Facing operation


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2.6 - Copy the facing operation andmodify it

Select Facing1 Operation

Right mouse button on Facing.1operation and select Copy

Select Paste to duplicate the facingoperation

Double click , rename it to Facing.2operation and edit it

Select Geometry tab page (5)

Tag Bounding envelope (6)

Click on Replay (7)


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Click OK to end the replay

Click OK to accept the operation


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3. Step 3: Create Pocketing Operations

We are going to machine the 5 pockets in this order:

Pocket 2: two operations

Pocket 1

Pocket 4

Pocket 3

Pocket 5


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Use step2 result or open Start_Step3_PocketingOperations.CATProcess3.1 - Create pocket 2

Select last operation in the PPR tree (Facing.2 operation)

Select Pocketing icon

Select the geometry:Select the top and the bottom to automatically initialized the boundary

Select the new bottom: (we want to machine the pocket only until the top of the island)In the Operation Definition window, select again the bottom representation then select theTop of the island as new bottom to relimit the depth of the pocket:


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Remove island: press right mouse button onto the island representation then selectRemove All Islands in the contextual menu.

Select the tool:In the Tool Assembly tab page

Select End Mill Tool iconThe default tool proposed (T1 End Mill D10) is acceptable.

In the Strategy tab page, set parameters as follows:


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In Macro tab pageDefine Ramping Approach macro with pre-defined Ramping modeAngle 20 and distance 15mm

Define Retract macro with Build by user mode, define following motions: circular then tangentthen axial (with 30mm).


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Then define appropriate Return between levels macro (be careful this macro is split into 2motions:

Return between levels Retract: AxialReturn between levels Approach: Ramping

Replay and simulate the pocketing operation.

Video mode including the fixturesrepresentation


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Click OK to close the replay panel.

Click OK to accept the pocketing operation.

3.2 - Finishing pocket 2

Select pocketing icon

Select the geometry: Top and Bottom to finish the pocket

Select the toolIn the Tool Assembly tab page:Enter a new name: T2 End Mill D10 Rc 0

Change the Corner radius of the tool to 0


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In the Strategy tab page:Radial: Change Percentage of tool diameter to 40%

Axial: Change Number of levels: 1Automatic draft angle: 0 deg

Select Macro tab pageDefine following macros:

Approach: axial mode with 30mm


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Retract: keep the retract macro automatically initialized by the previous operation

Return in a level approach: ramping 20 and 5mm

Return in a level retract: axial mode with 5mm


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Replay the pocketing operation

Select video simulation

Click OK to accept operation


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3.3 - Create Pocket 1

Select last operation (Pocketing.2)

Click on Pocketing icon

Select the geometry

Remove islands on the bottom:With the right mouse button, click on the word Island.1 (0mm) for contextual menuSelect Remove All Islands

In the Strategy tab page, set the following options:Radial: Percentage of tool diameter: 50%Axial: Number of levels: 2


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Select Macro tab pageDefine following macros:

Approach: ramping 20 and 15mm

Retract: keep the macro automatically initialized by the previous operation

Return between levels approach: ramping 20 and 5mm

Return between levels retract: keep the macro automatically initialized by the previousoperation (Axial with 5mm)


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Replay and simulate the pocketing operation


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Click OK to end replay

Click OK to accept the pocketing operation

Rename the operation

In the PPR tree, click on the operation Pocketing.3 with the right mouse button

Select Properties in the contextual menuEnter new name: Pocket 1 in the Label window


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Copy last pocketing operation: Pocket 1Click on the operation Pocket 1 with the right mouse buttonSelect Copy in the contextual menu

Click again on the operation with the right mouse buttonSelect Paste in the contextual menu

Edit this new operation: double click on it

Rename it as Pocket 4

Remove the current geometry by using contextual menu on Boundary (Remove all contours) andon Bottom (Remove)

Select the new bottom: the boundary is automatically initialized


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Remove all islands using contextual menu

in the Strategy tab page, set the following options:In Finishing tab page:

Mode: select Side finish last levelSide finish thickness: 1 mmActivate Spring pass

Replay and simulate this new operation


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Click OK to close the video panel

Click OK to accept the pocketing operation


Duplicate Pocket 1 operation:Copy operation Pocket 1 via contextual menuSelect the last operation: Pocket 4

Select Paste via contextual menu Edit the operation

Rename it in Pocket 3

Select the new geometry


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In the Strategy tab page, set the following options:In Radial tab page: Percentage of tool diameter: 10%In HSM tab page: Activate High speed milling



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7. Click OK to close the video panel

8. Click OK to create the pocketing operation


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Select last operation in the PPR tree (Pocket.3 operation)

Click on Pocketing icon

Rename it in Pocket 5

In the Geometry tab page, define Open Pocket and Start: Outside options

Edit Offset distance and fill it with 5mm


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Select the Bottom and the Top of the pocketing operation

Soft boundary is automatically put in dotted line (Soft boundary means that the tool can cross itcontrary to Hard boundary that the tool is not authorized to cross it)

In the Strategy tab page, select HSM Tab Page Deactivate High Speed Milling option

In the Macro tab page:Define the following macros:Approach: Axial mode with 30mmRetract: Keep the macro automatically initialized by the previous operationReturn between levels approach: Axial mode with 10mmReturn between levels retract: Axial mode with 5mm



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4. Step 4: Create Profile Contouring Operation

Use step3 result or open Start_Step4_ProfileContouringOperations.CATProcess4.1 - Machine Pocket 5 with a contouring operation

Select last operation: Pocket 5

Click on Profile Contouring icon

Select the geometry:Deactivate the option Contour Detection using the right mouse button on the Bottomrepresentation

Select the Top and the Bottom

As the option Contour Detection is no more activate, the boundary is not automaticallyinitialized.

For the contour selection, select 2 edges then click on Navigate on Belt of Edges iconClick OK to finish the edges selection

Select Limit1 and Limit2 edges for tool path (any vertex can be selected)


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Select Out option for the 2 Limits to start and to finish outside the partRight click on Start: In, then select Out

Right click on Stop: In, then select OutKey in 5mm for offset on start and end elements


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In Strategy tab page, set the following options:

Distance between paths: 8mmNumber of paths: 5Number of levels: 2

Set appropriate Approach and retract macros.

Replay the operation:

Click OK to close the replay panel

Click OK to accept the Profile Contouring operation4.2 - Contouring the part

Select last operation (Profile contouring 1)

Click on contouring icon:

Select the geometry:Change the bottom in soft by clicking on Bottom: Hard (Soft bottom means that the tool cango lower that the bottom of the part)


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Select the bottom

Select the contour by selecting Edge 1, Edge 2, Navigate on Edges Until an Edgeicon then select the last edge to navigate until it.

Check that the arrow is pointing outside the material. This arrow is used to display the sidewhere the tool will be positioning

Click OK to finish the edge selectionSelect Limit element shown below as starting element


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Indicate the fixture to avoid:Select the fixture as shown below

In the Strategy tab page, set the following optionsNumber of levels: 1Number of paths: 1

Set appropriate macros (Approach, Retract and Linking).

Replay the profile contouring operation


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Validate the operation4.3 - Contouring Pocket 1

Select last operation (profile contouring 2)

Click on contouring icon

Select the geometryActivate the option Contour Detection using Right mouse button on the Bottomrepresentation

Select the bottom as shown below

In the Strategy tab page, set the following options

In machining tab page:Activate Close tool pathPercentage overlap: key in 80%


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Set appropriate macros (circular-axial approach and retract).

Replay the operation

Click OK to close the replay panelClick OK to create the Profile Contouring operation


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5. Step 5: Create a Point-to-point Operation

Use step4 result or open Start_Step5_PointToPointOperation.CATProcess

5.1 - 1.1 Select last operation (Profile Contouring.3)

5.2 - 1.2 Select Point To Point icon

5.3 - 1.3 Create the tool path

Create a GOTO position:1.

Fill the Goto Position panel withPart: bottom of pocketDriveElement: wall edge and Position on drive: PastCheck Element: wall edgeRef point: limit of edge

2.

3.4.

Add an axial approach macro of 30mm

Select Goto Position icon


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Create a GOTO PointSelect the Goto Point iconSelect the bottom edge of the second corner

Add an Axial Retract macro of 30mm

There is now 2 motions defined:


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5.4 - 1.4 Select the tool

In the Tool tab page, change the name of the tool as T4 End Mill D20 Rc0

Key 20mm as Nominal DiameterKey 0mm as Corner Radius

Key 25mm as Body Diameter5.5 - 1.5 Replay the operation

Click OK to end replay



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6. Step 6: Create a Curve Following Operation

Use step5 result or open Start_Step6_CurveFollowingOperation.CATProcess

Bring back from No Show mode the curves located in the sketch.12 in the Design Part

6.1 - 1.1- Select last operation (Point to point.1)

6.2 - 1.2- Select Curve Following icon

6.3 - 1.3- Create the Tool Path

Click on the guiding element representation


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Select the first two edges then click on Navigate on Belt of Edges icon. The 10 following edges

are taking into account. Select manually the 2 last edges or modify in the Option Panel of the EdgeSelection panel the Maximum Steps Forward value.

6.4 - 1.4- Select the tool

In the Tool tab page, click on Select a tool with Query icon

Double-click on the offset on Curve tomodify it from 0 to 3mm


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Look in the ToolsSample02 Catalog Select first End Mill named R216-23-03B-708-025

Define appropriate Approach & Retract macros (Axial mode with 30mm)6.5 - 1.5-Replay the operation


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Click OK to close the replay panel


Close all your CATIA models: CATProduct and CATProcess


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7. Step 7: Create a Machining Process (stored in a catalog)

7.1 - 1.1- Launch the Prismatic Workbench

In the start menu, select Machining, then Prismatic Machining

You need to have an empty CATProcess in order to create a Machining process

In the View menu, Toolbars, select Machining Process tool bar

Select Machining Process View icon


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Select Machining Process icon


In the Geometry tab page, set the following options

Select Closed Pocket

Select Filter on Rework Area Type: None


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In the Macro tab pageSet Approach (ramping mode with angle: 20, 60mm) and Retract (axial mode with 60mm)macros.

Click OK to accept the predefined Pocketing operation

Double click on Tool Query in the machining process view tree

Fill the tool query definition window with:

Look in: ToolAssembliesSamples01 catalog that is delivered as a sample in the softwareinstallationSelect the End Mill icon to search a tool of this type in the catalogSpecify a query on the Name of the tool: End Mill D32 Rc0 ShortUse the Upward arrow to add this constraint in the list

Click OK, the predefined pocketing operation is completed

Select Prismatic Rework Area icon

Click on Load From option and select the Pocketing.1 in the Machining Process View window


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Enter 0mm in Tool radius field (1mm is a default value)

Click OK

Select Manufacturing View icon

Select in the contextual menu on the Manufacturing View: Sort by Machining Features


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We must see the Prismatic Rework area in the list

Click Close

Select the Pocketing.1 operation in the Machining Process View


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Key a new name: Rework Corner (1)

Select the feature to rework: Prismatic Rework Area.1 (2)

Select Corner to rework only the Corners of the pocket and not the channels (3)

In the Macro tab pageSet Approach (ramping mode with angle: 20, 60mm) and Retract (axial mode with 60mm)macros

Click OK to accept this pocketing operation to rework the previous operation in the corners

Double click on Tool Query in the Machining Process View tree


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Fill the tool query definition window with:

Look in: ToolAssembliesSamples01Select the End Mill iconSpecify a query on the Nominal Diameter


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Save it in the same directory of the previous CATProcess under the name:MyMachiningProcess.catalog

Click OK to save the catalog. This catalog is strongly linked to the CATProcess

7.3 - 1.3- Create a Prismatic Machining Area

Open Start_Step7_MachiningProcess.CATProcess


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Select Prismatic Machining Area icon


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Select Closed Pocket and the geometry

Rename it Pocket 3

Click OK

Select the Manufacturing View iconWith the contextual menu on the Manufacturing View select Sort by Machining Features


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Let the Manufacturing View window open

Click on Open Catalog icon in Auxiliary Commands toolbar

Access to your MyMachiningProcess.catalog using the Browse Another Catalog icon

Double click on Machining Processes then double click on Machining Process.1


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Select the following information in the Insert Object windowInsertion level in a program: select Facing.2 on the PPR treeGeometry to machine: select Pocket 3 in the Manufacturing View window

Click OK to create the two pocketing operations needed to machine pocket 3 after the Facing.2

operation

Close Manufacturing View and Catalog windows


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Replay the 2 pocketing operations


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8. Step 8: Use Cutter Compensation (CUTCOM) in Macro thenstore the Result in a Catalog

Open Start_Step8_Macros.CATProcess

8.1 - 1.1- Define an Approach and Retract Macros including CUTCOM syntaxes

Select Profile Contouring icon


Define following Approach macro in mode: Build by user: circular (20mm) + tangent (20mm) +axial (30mm).

Double click on the point where Cutter compensation must be inserted in the macro path

Select Add PP word list icon or use contextual menu PPword list

5.

Click on To access PP table iconNote: this icon is accessible only if a machine and a PPtable are already defined on the PartOperation.

Select the Major word CUTCOM in the list (Major words with parameters)


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Select the appropriate NC_CUTCOM_ON syntax:

Select Apply to add the syntax

Click Close on the PP Words Selection Assistant panel

Click OK in the PP Words Selection panel

in the Options tab page, Name it MyApproachMacro and add a comment


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Select Save Macro in Catalog icon

Save it in a new catalog named MyMacros.catalog in a directory

Click OK to create the catalog with your own macro

Define following Retract macro in mode: Build by user: circular (20mm) + tangent (20mm) +axial (30mm).

Double click on the point where Cutter compensation must be stopped in the macro path

As for Approach macro, select the Major Word CUTCOM in the list then the NC_CUTCOM_OFFsyntax


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Select Apply to add the syntax

Select Close on the PP Words Selection Assistant

Select OK in the PP Words Selection panel go on your operation.

In the Options tab page, Name it MyRetractMacro and add a comment


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Select Save Macro in Catalog icon Update the already existing catalog: MyMacros.catalog

Click OK to update the catalog

Select the Read macro from catalog icon

Search in the MyMacros.catalog for an Approach macro

Double click on Approach type to display your own approach macroNote: Now this macro is available for all your machining operations as Approach macro


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Added Exercise: Manuf Exercise

1. Step 0 - Create a new Part Operation

1.1 - 1.1- Open the product to machine

Open Start_AddEx_Manuf.CATProduct

Go to Prismatic Machining Workbench

In the Part Operation, select a 3-axis machine, the part to machine and the stock (in No Show)

2. Step 1 - Create Point-to-Point operation

Select Manufacturing program.1 in the PPR tree

Select Point to Point icon

In the Tool tag page, select a Face Mill (Diameter 50mm)

Select the Goto position icon


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Select the Drive, Check and Reference point as shownbelow:

Select as Bottom, the top of the part

Select Past for the Position on drive and On for the Position on check options

Click OK to accept this Sequential motion

Select Go Delta icon in the Point to Point panel

Select Parallel to line strategy with the contextual menu on Components


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Select as reference line the previous Check element

Add for offset value 250mm

Click OK to accept this Sequential motion

Repeat this operation as shown below with the different Go Delta option (along X or Y Components)in order to get this grid and schema:


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6. Select Macro tab page

Define an Axial Approach & Retract macros with 30mm

Replay the tool path


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3. Step 2 - Create a Facing operation.

Click Facing icon :

In the Strategy tab page, select Back & Forth as tool path style In the Geometry tab page, select the top of the part as Bottom

Activate the Bounding envelope option


Define an axial Approach & Retract macros with 10mm

Replay the facing operation and create it


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4. Step 3 - Create a Drilling operation with machining pattern

Create the Machining Pattern:

Select Machining Pattern icon

Select the 4 holes in the corners of the part

Add 15 mm to Jump distance between points

Rename the Machining Pattern: HoleDiameter4

Click OK to save this Machining Pattern

Select Drilling icon

In the Geometry tab page, select HoleDiameter4 as pattern to machine

In the tool tab page, select a drill tool

Specify a diameter=4mm and rename it T2 Drill D4

Replay the drilling operation


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5. Step 4 - Create a Pocketing and Rework operation using a catalogwith prismatic machining area.

Select the Prismatic Machining Area icon

Fill the Prismatic Machining Area window as follows:

Rename it: Pocket 1

Click OK to create the Prismatic Machining Area

Select the Manufacturing View icon and use the Sort by Machining Feature contextualmenu to display your Prismatic Machining Area

Select the Open Catalog icon

Select the catalog Myprocesscatalog.catalog

Double click on corner_and_ channel process in the Pocketing family

Select geometry to machine (Pocket 1) and level of insertion in the PPR tree (Drilling.1) as follows:


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Click OK to create the Pocketing and Rework operations

Define appropriate macros Replay the 2 operations


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6. Step 5 - Create a Profile Contouring operation with macroscatalog.

Select the Profile Contouring icon

In Strategy tab page, select Zig-zag as Tool path style

In Geometry tab page, select Between Two Curves Mode and geometry as shown below

You must have 2 Guides which are not connected, in other case check in the Edge Selection menuthe Options panel and select as Link types: No Link

Select Out for the Start and End condition with an offset of 5mm

In Tool tab page, select a tool with query icon

Look in ToolAssembliesSample01 catalog and select End Mill D10 Rc0 tool

In Macro tab page, select Approach macro

Select the Read macro from catalog icon and read the Mymacrocatalog.catalog


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Double click on Approach and select MyMacroApproachMotions_manuf.1 macro

Do the same thing for the following macrosRetract => load the MyMacroRetractMotions_manuf.1 macroLinking => load the MyMacroLinkingMotions_retract_manuf.1 macroReturn in a level => load the MyMacroReturnInOneLevelMotions_retract_manuf.1 macro

Replay the Profile Contouring operation


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7. Step 6 - Create a Profile Contouring operation


In Geometry tab, Select Between Two Planes Mode, and geometry as the picture below:

Note that we should select non continuous profiles (Guide 1 & Guide 2) In Tool tab, select a tool with query icon

Look in ToolAssembmiesSample01

Select an End Mill toolNominal diameter=6mmCorner radius=0mm

In Macro tab, define the following macros:

Approach macro: circular (3mm) + tangent (1mm) + axial (20mm)


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Retract macro: Axial mode with 30mmLinking Approach macro: circular (3mm) + tangent (3mm) + axial (20mm)Linking Retract macro: circular (3mm) + tangent (3mm) + axial (20mm)



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In Strategy tab page, define 3 as Numbers of levels

In Geometry tab page, select Between Two Planes Mode, and Top/Bottom as the picture below:

Note: Check that the arrow is pointing inside the pocket

In Macro tab page, specify the following macros:Approach macro: circular (5mm) + tangent (5mm) + axial (20mm)Retract macro: circular (5mm) + tangent (5mm) + axial (30mm)


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Replay the Profile Contouring Operation


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9. Step 8 - Create a Pocketing operation


In Strategy tab page, select Outward helical Tool path style and specify Number of levels=3

In Geometry tab page, select Top/Bottom as the picture below:

In Macro tab page, define the following macros:Approach macro: Ramping mode with 10mm and 20Retract macro: circular (5mm) + axial (30mm)Return between levels approach macro: Ramping mode with 10mm and 20

Return Between Levels retract macro: circular (5mm) + axial (5mm)


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Replay the Pocketing operation


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10. Step 9 - Create a Pocketing operation


In Strategy tab page, select Outward helical Tool path style and specify Number of levels=2

Activate the option Always stay on bottom to minimize the air cutting and Overhang=100%

In Geometry tab page, select geometry as the picture below:

Note: Check that the extremity of the pocket is open (Dotted line)

In Macro tab page, keep the default macros coming from the previous Pocketing operation

Replay the Pocketing operation


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In Strategy tab page, select One Way style, Distance between paths=2mm and Number ofpaths=8


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In Geometry tab page, select Between Two Planes and geometry as the picture below:

Note: Start by selecting the boundary (5 edges) rather the bottom. If you select first thebottom, you will have to delete the boundary to reselect the right one. Another option is todeactivate the option Contour Detection to not take automatically the boundary when youselect the bottom.

In Macro tab page, create the following macros:Approach macro: tangent (20mm in machining feedrate) + circular (5mm) + axial 10mm)Retract macro: tangent (20mm in machining feedrate) + circular (5mm) + axial (30mm)Return in a level approach macro: tangent (20mm in machining feedrate) + axial (5mm)Return in a level retract macro: tangent (20mm in machining feedrate) + axial (5mm)



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In the Strategy tab page, define a Distance between paths=2mm and a Number of paths=7

In Geometry tab page, select geometry as the picture below:

Note: Use the Edge Selection menu, select the 2 first edges then click on Navigate on beltof edges

In Macro tab page, keep the same macros as the previous operation but remove from the all the

tangent motions done in machining feedrate.



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