Lathe Machining Catia

� ��

COPYRIGHT DASSAULT SYSTEMES Version 5 Release 17 September 2006 EDU-CAT-EN-LMG-FS-V5R17

LLaatthhee MMaacchhiinniinngg DDeettaaiilleedd SStteeppss

��

COPYRIGHT DASSAULT SYSTEMES 2

TTaabbllee ooff CCoonntteennttss Master Exercise: Crankshaft 3

Step 1A: Open the V5 CATProduct 3 Step 1B: Define parameters of the Part Operation 5 Step 2A: Define a Drilling Operation 7 Step 2B: Define a Rough Turning Operation 10 Step 3: Define a Groove Turning Operation 14 Step 4: Define a Recess Turning Operation 18 Step 5: Define a Profile Finish Turning Operation 21 Step 6: Define a Thread Turning Operation 24 Step 7: Define a Sequential Turning Operation 26

Added Exercises: 30 Step 8: Create a Ramp Rough Turning Operation 30 Step 9: Modify the Design Part 34 Step 10: Generate Outputs 36

��


Master Exercise: Crankshaft

1. Step 1A: Open the V5 CATProduct

• File/Open… Open the Set-Up.CATProduct

• Access the Lathe Machining Workbench: • Start Lathe Machining workbench

The PPR Tree is displayed in the left of the CATIA Window

• Process: The Part Operation & NC Cycles

��


• Product: The Geometry necessary for NC such as Stock, Part, Fixtures, Machine-Tool table, Safety Planes, Starting points, etc • Resources: The shop floor resources such as Tools, Tool assemblies and Machine-tools

��


2. Step 1B: Define parameters of the Part Operation Use the result of previous step or Open Define_PartOperation_Start.CATProcess

2.1 - Define the Stock

• Double-click on the Part Operation to edit it (1) • Click on Stock icon (2) • Double-Click on the Stock model (3) • Activate the ‘Automatic Stock Selection for Turning Operations’ using MB3 on the Stock field

2.2 - Define the Machine-Tool (4)

• Select a Horizontal Lathe machine-tool

�� • Select the LATHE.pptable as Post Processor Words table in the Numerical Control tab page • Click OK 2.3 - Define the Machining Axis System

• Click on Reference Machining Axis System icon (5) • Select the origin point in the Machining Axis System panel and select the center point of the stock • Select the Z axis in the Machining Axis System panel and key 1, 0, 0 as spindle orientation • Select the X axis in the Machining Axis System panel and key 0, 0, -1 as profile orientation

��


• Click OK to create the Machining Axis system

• In Simulation tab page of the Part Operation: Define a Stock Accuracy of 0.05mm to have a better Video Simulation

• Click OK to create the Part Operation

��


3. Step 2A: Define a Drilling Operation Use result of previous step or Open Drilling_Operation_Start.CATProcess

Select Manufacturing Program and click on Drilling icon 3.1 - Define the geometry to machine

In Geometry tab page: • Select ‘No Point’ in the panel • Select the frontal hole on the part (put stock in no show )

3.2 - Define machining parameters

In Strategy tab page: Enter 3 mm as Approach Clearance value to take into account the stock

3.3 - Define the tool

In tool tab page: • Select external tool database icon • Select Personal_tools_catalog as tools catalog

(check whether Personal_tools_catalog file is copied in intel_a…) • Key 3.5 as nominal diameter for the query • Select the candidate tool (tool number 2401)

In tool change assembly panel:

• Key a name for the assembly (ex: DrillAssembly) • Set the Power value to Fixed (the part is turning not the tool)

��


��


3.4 - Replay the tool path

Simulate the tool path using the video capability

�

3.5 - Simulate the tool path using the Video capability

The Stock accuracy can be better by modifying the Stock Accuracy default value on the Part Operation in the Simulation tab page (key 0.02)

��


4. Step 2B: Define a Rough Turning Operation Use result of previous step or Open Rough_Turning_Operation_Start.CATProcess

Click on Rough Turning Operation icon 4.1 - Define the geometry to machine

• Select the Part element in the Geometry panel (1) • Select a white point of the blue profile on the Part in order to select the full profile (2)

It is not necessary to select the stock as it has already been selected on the Part Operation Key 0.5mm as Part offset

4.2 - Define the Tool Assembly

Select the Tool Assembly tab page in Insert tab : • Select the default diamond insert (1)

In Insert-Holder tab page:

• Click on more button (2)

��


4.3 - Define the strategy to machine

In strategy tab page: • Key 1.5 as new Max depth of cut • Add a part contouring path at the last path only

In Option tab page: • Key 3mm as new Lift-off distance • Tag Min Machining Radius option and key 1mm

��


4.4 - Define the macro

• Activate Approach macro (1) • Select a predefined macro: Axial-Radial (2)

Define the start point:

• Click on start point in the panel (3) • Select the red point on the part (4)

��



4.6 - Simulate the tool path using the video capability

��


5. Step 3: Define a Groove Turning Operation Use result of previous step or Open Groove_Turning_Operation_Start.CATProcess

Click on Groove Turning Operation icon 5.1 - Define the geometry to machine

• Select the Part element in the panel (1) • Select the edge on the part (2) • Key 0.0 mm as Part offset (3)

5.2 - Define the Strategy

In strategy tab page: • Key 1.5 mm as Max Depth of Cut • Select Center as First plunge Position • Activate Part contouring • Activate Change output point option

��


In Option tab page:

• Key 1.5mm as Lift-off distance • Key 45deg as Lift-off angle • Key 0 deg as Gouging Safety angle


In Insert tab page: • Select a Groove Insert • Key R1=R2=0.2 mm

��


In Insert-Holder tab page:

• Click on “More>>” • Key 2.5mm as Insert Width (la) • Select Compensation tab page • Select P9R • Key a value=10 for the corrector Number using MB3 on the P9R field


Create the same Axial-radial approach macro as in Rough Turning operation

��



5.6 - Simulate the tool path thanks the video capability

��


6. Step 4: Define a Recess Turning Operation Use Result of previous operation or Open Recess_Turning_Operation_Start.CATProcess Put in Show mode the following sketch: Crankshaft/PartBody/Remove.2/Sketch.12

Click on Recess Turning Operation icon

6.1 - Define the geometry to machine

• Select the Part element in the panel • Select the 3 edges on the Part belonging to the Sketch.12 (1)

��

6.2 - Define the strategy

In strategy tab page: Set the following parameters


In Tool Assembly tab page: • Click on the “…” button • Select the same tool assembly as for the Rough Turning operation

��



Create the same Axial-radial approach macro as in Rough Turning operation 6.5 - Replay the tool path


NB: You have to create another Recess Turning operation to machine the remaining material of the previous Recess Turning operation

��


��


7. Step 5: Define a Profile Finish Turning Operation Use Result of previous operation or Open Profile_Finish_Turning_Operation_Start.CATProcess

Click on Profile Finish Turning Operation icon 7.1 - Define the geometry to machine

• Select the Part element in the panel • Select the two first elements of the dark blue profile and click on “Navigate on Belt of Edges”(as shown)

�

�

• Click again on this icon to select also the following edges because by default the navigation take only 10 edges OR click on the Option icon of the Edge Selection tool bar to increase the Max Step Forward

• Select End limit mode plane on the tab

Select the limit surface (1) MB3 on None and select: In (2)


In Machining tab page: • Key -45 as Lift-off angle • Key 0 as Lead-in angle • Key 0 as Leading Safety angle

��


7.3 - Define local strategy

• MB3 on the part element • Select “Add local information” • Deselect Global feedrate and key 0.4 as local value • Key 0.1mm as local offset

In the same way put the same thickness on the next element of the profile MB3 on one of a profile element and select “Properties”. The selected elements are highlighted


Select the Turning Tooling Assembly.1 in the list


Create the same Axial-Radial approach macro as in previous operation

��




��


8. Step 6: Define a Thread Turning Operation Use Result of previous operation or Open Thread_Turning_Operation_Start.CATProcess

Click on Thread Turning Operation icon 8.1 - Define the geometry to machine

• Select the Part element in the panel • Double-click on the edge to select it (shown in Red) • Key 15 mm as Length to thread


In thread tab page: • Key 0.5 as Pitch • Select Trapezoidal Profile

In option tab page:

• Key 0.5 mm as Clearance on crest diameter. • Key 90 degrees as Lift-off angle • Do not select Change output point option • Do not select Output CYCLE syntax option

��



Create the same Axial-Radial approach macro as in previous turning operation



��


9. Step 7: Define a Sequential Turning Operation Use Result of previous operation or Open Sequential_Turning_Operation_Start.CATProcess

Click on Sequential Turning Operation icon


In the insert tab page: • Select a Groove Insert • Set the following values

In the Insert-Holder tab page:

• Select Groove Internal Insert-Holder • Set the following values

��


In the assembly tab page: Key 90 deg as Setup angle

9.2 - Define the motions

In the strategy tab page:

a) Create a Go to point motion: • Click on “Standard Go or Go-Go” icon • Select the first check element on the panel and select the first check element on the part • Select the second check element on the panel and the second check element on the part • Set the first and the second check mode to “To” using contextual menu • Create the tool motion

b) Create a Go in direction motion: • Select the created tool motion

• Click on “Go InDirV” icon • Select the driving element on the panel and select the Drive element on the part • Select the First check element on the panel and select the Check element on the part • Set the First check mode to “To” • Create the tool motion

c) Create a Follow motion:

• Click on “Follow” icon • Select the First check element on the panel and select the Check element on the part • Set the First Check mode to “Past”

��


• Create the tool motion

d) Create a Go in direction motion:

• Click on “Go InDirV” icon • Select the driving element on the panel and select the Drive element on the part • Select the First check element on the panel and select the Check element on the part • Set the First check mode to “Past” • Create the tool motion


Create an approach macro in direct mode starting from the standard start point

��




Close all the CATIA documents

��


Added Exercises:

1. Step 8: Create a Ramp Rough Turning Operation 1.1 - Create an New CATProcess

• Select File / New in the top menu bar • Select Process in the type of new document to create

1.2 - Go to Lathe Machining Workbench

1.3 - Create a Machining Process including a Ramp Rough Turning Operation

• Select the Machining Process View icon

• Click the Machining Process icon

• Select the Ramp Rough Turning operation icon • In Strategy / Rework tab page:

Activate Rework Mode option

• In Feeds & Speeds tab page:

Activate “Replace RAPID by Air Cutting Feedrate”

��


• In Macro tab page:

Create a linking macro with interrupt motion “On Time” = 500s Create Linking Axial-Radial Approach & Radial-Axial Retract

1.4 - Define the Tooling query

• Double-click on Tooling query in machining process view. • In the Holder query tab page:

Select External Insert-Holder Select the catalog to look in: LatheInsertsAndHoldersSample.catalog Define the 2 following constraints: Insert Length <2*Ramp Rough Turning. Max depth of cut Insert Length >1.4*Ramp Rough Turning. Max depth of cut

��


• In the Insert query tab page: Select the catalog to look in: LatheInsetrsAndHoldersSample.catalog Define the 2 following constraints: Nose Radius >1.5*Ramp Rough Turning.Max depth of cut Nose Radius <2*Ramp Rough Turning. Max depth of cut

��

1.5 - Save the current CATProcess

File / Save As and named it MyLMGMachiningProcess.CATProcess

1.6 - Store the Machining Process in a Catalog

Use MB3 on the Machining Process to save it in a new catalog (named it MyLMGCatalog.catalog)

1.7 - Close the current CATProcess

1.8 - Open the RampRough_Turning_Operation_Start.CATProcess

• Access to recently saved MyLMGCatalog.catalog through the ‘Open Catalog’ icon in LMG. • Select the new Machining Process previously created. • Instantiate (click OK) the Ramp Rough Turning operation without selecting any geometry.

��


1.9 - Define Geometry elements

• Edit the Ramp Rough Turning operation • Select the blue profile along the part as Part Element profile • Select Round Insert in Tool tab • Define the Start & End points for the linking Approach and Retract macro



Close all the CATIA documents

��


2. Step 9: Modify the Design Part • Open the DesignChange_Start.CATProcess • MB3 on the Manufacturing Program then “Compute Stock and Tool Path”

2.1 - Change parameters to modify the Part

• Double-click on the CATPart: Crankshaft to go to Product Structure Workbench • Open the Relation node

(if Relations node is not active, go to Tools-Options-Part Infrastructure-Display and make Relations node active.)

• Double click on Design Table to go to Knowledge Advisor Workbench • Expand it

• Select “Configuration 2” in the Design Table • Update manually the Crankshaft.CATPart if necessary • Click OK to update the impacted operations by the modification • Double-click on the Part operation to go back to LMG Workbench • Select the Manufacturing Program

2.2 - Replay the Operations on new geometry

• Select the Last Machining Operation • Click on Tool Path Replay icon

• Simulate the complete new program

Click on Video icon Click Forward Replay to replay all the manufacturing Program

��


��


3. Step 10: Generate Outputs Open GenerateNCOutput_Start.CATProcess �

3.1 - Processing a NC documentation

• Click on the “Generate Documentation” icon • Define the path for the output Generated files • Click on “OK” to generate the NC Documentation • Click on “Yes” in the VBScript panel to open the HTML document

��


3.2 - Processing an APT Source

• MB3 on Manufacturing Program.1 • Select “Generate NC code interactively” • In the NC Data Type, Select “APT” • Make sure that “Associate output NC file to the program” tab is active • Click on “Execute” • A Pop-up window appears at the end of the APT computation • Browse the result, using MB3 on the Manufacturing Program and “Display NC File”

Lathe Machining Catia

Documents

rough turning operation

sequential turning operation

stock icon

machining axis system

tool tab page

machining parameters

stock model

stock field