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3 Axis Surface MachiningPreface Methodology Recommendations
Where to Find More InformationWhat's New?Getting Started
Operation-oriented Machining Entering the Workbench Rough Machining
the Part ZLevel Machining of the Outside of a Part ZLevel Machining
of the Inside Walls of a Part Sweeping Checking the Results
Creating a Rework Area Reworking Generating an NC Output File
Generating an NC Output File Generating NC Shopfloor Documentation
Area-oriented Machining Entering the Workbench Defining the Areas
to Machine Defining the Tools to Use Sweep Roughing the Part
Sweeping the Top Surface Sweeping the Side Areas ZLevel on Vertical
Walls Reworking Between Contours Generating an NC Output File
Generating NC Shopfloor DocumentationBasic Tasks Roughing
Operations Sweep Roughing Geometric Components Machining Strategy
Macro Data Roughing Geometric Components Roughing -
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Ordering Zones Machining Strategy Macro Data Automatic Rough
Stock Finishing and Semi-finishing Operations Sweeping Geometric
Components Machining Strategy Macro Data ZLevel Machining Geometric
Components Machining Strategy Macro Data Spiral Milling Geometric
Components Machining Strategy Macro Data Contour-driven Machining
Geometric Components Machining Strategy Macro Data Isoparametric
Machining Geometric Components Machining Strategy Macro Data
Contouring Reworking Operations Pencil Operations Geometric
Components Machining Strategy Macro Data Roughing Rework Machining
Areas Defining an Area to Machine Defining an Area to Rework
Defining Offsets Tool path Editor Editing a Point Editing an Area
Transformations
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Connecting Tool paths Reversing a Tool path Tool Path Approaches
and Retracts Packing and Unpacking a Tool Path Checking for Tool
Holder Collision Importing Files STL Files NC Code
FilesCustomizationWorkbench Description Menu Bar Toolbars Machining
Operations Toolbar Tool Path Editor Toolbar Machining Areas Toolbar
Edge Selection Toolbar Face Selection Toolbar Specification
TreeGlossaryIndex
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Preface3 Axis Surface Machining is a new generation product that
defines and manages NC programs.3 Axis Surface Machining is
dedicated to the machining of 3D geometry work parts with
3-axismachining techniques. It is particularly adapted to the needs
of mold, die and tool makers andprototype manufacturers in all
branches and at all levels of industry.
3 Axis Surface Machining offers easy-to-learn and easy-to-use
shopfloor-oriented tool pathdefinition for 3-axis manufacturing. 3
Axis Surface Machining is based on industry-recognized,leading-edge
technologies which offer the tightest integration between tool path
definition,verification and instant cycle updates.
3 Axis Surface Machining covers full design-to-manufacture
processes offering functions for:defining the areas you want to
machine,rough machining either by vertical or horizontal
planes,roughing rework,sweeping,ZLevel machining,pencil
operations,contour-driven operations,profile
contouring,drilling,detecting residual material,defining areas to
rework,visualization of the result of the machining program,the
production of shopfloor documentation.
3 Axis Surface Machining gives you the freedom to choose the
working methods that best suityour needs.
MethodologyRecommendations
Where to Find More Information
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MethodologySurface Machining is a versatile application, fully
adapted to your needs and yourworking methods whether they are
machining area-oriented or operation-oriented. Youcan either define
the machining areas on your part and then assign an operation to
eachof them or you can define your machining process as a series of
operations with an areato machine for each operation.A machining
area can be:
the whole part (for example, in roughing),a subset of the faces
on the part,a subset of faces on the part with a limiting
contour.
The Getting Started chapter contains two sections, one which
demonstratesoperation-oriented machining and another which
demonstrates area-oriented machining.Before starting work with
Surface Machining, please ensure that you have an open file(CATPart
or CATProduct) and that you are in the Surface Machining workbench
(Start >NC Manufacturing > Surface Machining).
Here is a suggested order for operations in a machining
program:
rough machining operations,(semi-)finishing operations,detection
of unmachined areas,reworking of unmachined areas,generation and
output of documentation.
Area-oriented Area-oriented methodology is useful when you have
a complex partto machine and you know in advance what kind of
operation you aregoing to apply to each separate area.
This approach is of great use when, for example, you are going
tomachine a "family" of similar parts and when you have
dedicatedmachines for mass production.
You define the areas on one part, you assign an operation to
eacharea, and then you machine. At the end you have a program that
youcan apply to all of the "members" of the "family" at least
working costbecause:
the machining strategy has already been defined
(chosenoperations),the tool has already been defined,only the area
need be redefined,you know exactly what kind of output you
require,
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and as a result the computation can be run in batch to
furtherreduce time loss.
1. Define all of the separate areas to machine on your work
piece.
2. Select the area or areas you want to machine with a
particularoperation.
3. Click on the appropriate icon (for example, sweeping).
4. Change the parameters in that operation (if required).
The only mandatory data for a operation is the area to machine
(withthe exception of roughing which requires a rough stock too)
and all ofthe other parameters have default values.
We recommend that you use the default parameters first unless
youare sure of the values you wish to enter.
5. Compute the operation. If the results are satisfactory,
repeat steps 2,3, and 4 for all of the other areas to machine.
Operation-oriented Use operation-oriented machining when you
want to progressively
define your machining program operation-by-operation
sequentially.Each operation has the area it deals with defined as
part of its data.
This approach is useful for single or limited part production
becauseit allows you to define your requirements step-by-step.
1. Choose the operation you want to use.2. Click the "part" area
in the geometric components of the operation.3. Select the area(s)
to machine either as the whole part with the
contextual menu or as a face or group of faces with the
faceselection wizard.
4. Change the other parameters in the operation (if
required).
The only mandatory data for a operation is the area to machine
(withthe exception of roughing which requires a rough stock too)
and all ofthe other parameters have default values.
We recommend that you use the default parameters first unless
youare sure of the values you wish to enter.
5. Compute the operation. If the results are satisfactory,
continuedefining the remaining operations for your machining
program.
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RecommendationsIf you intend to create complementary geometry,
before you start 3 Axis Surface Machining goto Tools/Options and,
in the Display tab of the NC Manufacturing options, tick the box
thatallows you to create a CATPart to store necessary geometry. If
you are not going to modify thegeometry, then make sure that this
box is not ticked.
Before starting 3 Axis Surface Machining, go to Tools/Options
and in the Operation tab of theNC Manufacturing option and tick the
Use default values of the current program box. This willensure that
when a new operation is created its parameters will be initialized
with default valuesthat are appropriate to that operation and not
with the values from the operation just before it.
You should save your CATProcess before generating HTML workshop
documentation.
If you have defined a safety plane, you should deactivate the
Optimize retracts option. If you donot, the safety plane will be
ignored.
In an operation, if you cannot see the whole dialog box
(particularly the OK, Apply and Cancelbuttons), exit your CATIA
session and use Settings > Control Panel > Display >
Settings to:
give a higher value for your screen resolution,or, if you are
using large fonts, use small fonts.
Depending on your screen size, you may have to use both of the
solutions.
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Where to Find More InformationPrior to reading this book, we
recommend that you read the Version 5 ManufacturingInfrastructure
User's Guide.
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What's New?
General functionsNew: There is a new operation type for
isoparametric machining.
New: There is a new approach and retract mode, prolonged
section.
Enhanced: You can now use Part autolimit along with a limiting
contour for a more sophisticated definition of an area to
machine.
New: You can now define an offset on any of the planes in the
geometry tab of operations.
Enhanced: You can now select a plane to define any of the
required planes in the geometrytab of operations.Part to
machineEnhanced: Offset groups and areas are now easier to
manage.
New: There is now a progress indicator for rework area
computations.RoughingNew: You can now set a limiting contour.
New: You can now set an order in which zones and pockets will be
machined.
New: There is a new tool path style, Spiral.
New: A CGR file can now be used as rough stock.
New: Offset groups can now be used in this operation.
New: You can now define an origin for the rough stock that is
different from the one in the partsystem of axes.
New: You can now detect flat surfaces in a part and
automatically set them as imposedplanes.
New: You can define different cut depths for any given tool path
and specify the distance overwhich a given cut depth will be
used.
ZLevelNew: You can now use a conical tool with this
operation.
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Contour-drivenNew: Constant on Part stepover can now be used
with parallel contour cycles.
PencilNew: You can now define top and bottom planes in the
geometry tab.
OutputNew: APT/ISO files can now be generated with tool center
data or contact point data.
New: You can now generate one output file per operation.
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Getting StartedBefore getting to grips with all of the Surface
Machining capacities, here are two short step-bystep tutorials that
will help guide you through the key functionalities.
You will learn how to use the functions listed below and learn
how to define areas on the part tomachine, use specific machining
operations on the part and output data.
There are two ways of defining your machining program, you can
either base it on operationdefinition or on area definition. Try
both tutorials to see which method suits your workingtechniques
best.
The tutorials should take you 30 minutes each to complete.
Operation-oriented MachiningArea-oriented Machining
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Operation-oriented Machining Operation-oriented machining is a
method where you define each operation one-by-one. Whenyou define
an operation you decide (using the geometry tab) which areas of the
part you wantto machine with that particular operation.This
tutorial teaches you how to:
define the operations necessary for the machining of the part
below,run the program to create the tool paths,check for residual
material,rework the unmachined areas,and produce an APT file and a
workshop document.
Entering the WorkbenchRough Machining the Part
ZLevel Machining of the Outside of a PartZLevel Machining of the
Inside Walls of a Part
SweepingChecking the Results
Creating a Rework AreaReworking
Generating an NC Output FileGenerating an NC Output File
Generating NC Shopfloor Documentation
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Entering the Workbench
This task shows you how to open a part and enter the Surface
Machining workbench.
1.Open the SurfaceMachining3.CATProduct file in the samples
directory.
2. Select NC Manufacturing > Surface Machining from the Start
menu.
The Surface Machining workbench is displayed.
The part surrounded by the rough stock is displayed in the Set
Up Editor window along with themanufacturing specifications.
3. Select Product1 containing the shape to machine and the rough
stock in the specifications tree and
display them in wireframe mode using this icon .
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Double click Part Operation.1 in the tree. In the dialog box
that is displayed and click the design particon.
Select Shape to Machine in the tree and double click in the
viewer to validate your selection andredisplay the dialog box.
Then click the stock icon, select Rough Stock in the tree and
double click in the viewer to redisplay the dialog box.
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Click Ok to confirm.The design part defines the reference part
that will be used by the application to calculate theresidual
material.
The rough stock is the rough stock for the overall part. Each
successive operation works on theresidual material that is left by
the operation before it in the manufacturing program.
4. Select Manufacturing Program.1 (under PartOperation.1) in the
specifications tree to make it thecurrent entity.A program must be
current before you can insert program entities such as machining
operations,tools and auxiliary commands.
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Rough Machining the PartThis task shows you how to insert a
rough machining operation in the program.
As this operation will use the default tool and options proposed
by the program, you justspecify the geometry to be machined.
1.Select the Roughing icon .
A Roughing.1 entity and a default tool are added to the
program.The Roughing dialog box is displayed.
The status light on the geometric components tab is red ( )
which means thatyou must select the part geometry in order to
create the operation.
2. Hold MB3 down over the red area (do not click) that
represents the part.
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Choose Body in the contextual menu. The dialog box shrinks to
allow you to selectthe part in the viewer.
3. In the viewer, click on the part. Double click anywhere in
the viewer to confirm yourselection and to redisplay the dialog
box. The red area in the geometric area isnow green to indicate
that the geometry has been selected.
4. Click the sensitive area that represents the rough stock. The
dialog box shrinks toallow you to select the rough stock in the
viewer.
5. In the viewer, click on the geometry that defines the rough
stock. The red area inthe geometric components tab is now green to
indicate that the geometry has beenselected.
6. Click Replay.7. The tool path is displayed and the display
and analysis dialog box is called up.
Click OK.8. The tool path is erased from the viewer and you come
back to the operation dialog
box.
Click OK to close the dialog box.
Now we are going to use ZLevel machining on the walls of the
pocket and theoutside of the part.
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ZLevel Machining of the Outside of a Part
This task shows you how to use ZLevel machining for finishing
the outside of the part.
To simplify the selection of faces in this task, select Rough
Stock in the ProductList and,using the Hide/Show option in the
contextual menu, make it invisible. Then select Shape
to Machine in the ProductList and display it in shading with
edges mode ( ).
Make sure that Roughing.1 is the current entity so that the
ZLevel operation will beinserted after it.
1.Select the ZLevel machining icon .
A Zlevel.1 entity is added to the program.
The Zlevel dialog box is displayed.
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2. Click the sensitive red area that represents the part. The
dialog box shrinks and the
face selection wizard is displayed.
Select all of the walls that form a belt around the part. Click
OK.
The dialog box is redisplayed and the red area is now green.
In the viewer, the edges around the selected faces are
highlighted.
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3. Click the check element in the sensitive icon and select the
upper face of the part.
4.Go to the machining strategy tab ( ) and choose Outer part for
the Machiningmode.
5. Click Replay.6. The tool path is displayed and the display
and analysis dialog box is called up.
Click OK.7. The tool path is erased from the viewer and you come
back to the operation dialog
box.
Click OK to close the dialog box.
The operation you have just created should still be the current
entity. Now we aregoing to define the ZLevel machining of the
pocket.
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ZLevel Machining of the Inside Walls of aPart
This task shows you how to use ZLevel machining for finishing
the inside walls of thepocket.
Make sure thatZLevel.1 is the current entity so that this
operation will be inserted afterit.
1.Select the ZLevel machining icon .
A Zlevel.2 entity is added to the program.
The Zlevel dialog box is displayed.
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2. Click the sensitive red area that represents the part. The
dialog box shrinks and theface selection wizard is displayed.
Select all of the faces that form the inside wall of the pocket.
Click OK.
The dialog box is redisplayed and the red area is now green.
In the viewer, the edges around the selected faces are
highlighted.
3.
Go to the machining strategy tab ( ) and choose Pockets only for
the Machiningmode.
4. Click Replay. 5. The tool path is displayed and the display
and analysis dialog box is called up.
Click OK.6. The tool path is erased from the viewer and you come
back to the operation dialog
box.
Click OK to close the dialog box.
The operation you have just created should still be the current
entity.
Now we are going to define a sweeping operation for the top
surface of the part andthe bottom of the pocket.
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Sweeping
This task shows you how to use sweeping for finishing the
part.
You are going to define two separate operations one for the top
surface and another forthe bottom of the pocket.Make sure that
ZLevel2 is the current entity so that the sweeping operation will
beinserted after it.
1.Select the Sweeping icon .
A Sweeping.1 entity is added to the program.
The Sweeping dialog box is displayed.
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2. Click the sensitive red area that represents the part. The
dialog box shrinks and theface selection wizard is displayed.
Select the top surface of the part. Click OK.
The dialog box is redisplayed and the red area is now green.
In the viewer, the edges around the top surface are now
highlighted.
3. Click Replay. 4. The tool path is displayed and the display
and analysis dialog box is called up.
Click OK.5. The operation you have just created should still be
the current entity.
Repeat all of the above steps for the bottom surface of the
pocket.
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Checking the ResultsThis task shows you how to visually check
the machined part resulting from the toolpaths for the operations
you defined in your machining program.
Your specification treeshould look like this.
1. Select Manufacturing Program.1.
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2. In the contextual menu, choose Manufacturing Program.1 object
> Tool Path Replay.
The Display and Analysis dialog box is displayed.
Click this icon to go from one operation to the next displaying
the computed toolpath after each operation. If any of the
operations were not computed with Replay,they will be computed at
this stage.
You can display a photo of how the finished part would look with
.
Press OK to close the dialog box.
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Creating a Rework Area
This task shows you how to define an area to rework from the
areas of the part that werenot machined with the tool used in the
operations. You must compute the tool paths for your machining
program first.
1.Click the Rework Area icon .
2. Hold MB3 down over the red area (do not click) that
represents the part. ChooseBody in the contextual menu. The dialog
box shrinks to allow you to select the part inthe viewer. Select
the part. Double click anywhere in the viewer to confirm
yourselection and to redisplay the dialog box.
3. Enter a value of 10mm for the
Entry diameter and 2mm for theCorner radius (values used in
themachining operations).
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Be careful not to hit Return while entering this data as that
will close the dialog box.
4. Click Compute. This creates a Rework Area which remains the
current entity. Theareas that we are going to rework are
displayed.
5. Click OK to close the dialog box.
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Reworking
This task shows you how to rework the areas of the part that
have not been machinedand were there is residual material.You must
have created a rework area. A rework area is an area that cannot be
machinedwith a given tool.
The rework area must be the current entity. If you have doubts
about whether the rework area you just defined is still the
currententity or not (i.e. if you performed another action since),
click the Manufacturing Features
icon and select the rework area from the list.
1.Click the ZLevel icon and click OK.
2.In the Manufacturing Features window ( ), double click the
tool that isassociated with the third ZLevel operation.
3. Double click the tool diameter.
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Enter a value of 5.
Press OK to confirm the tool diameter and then OK to close the
tool definition dialogbox.
4. Still in the Machining Features window, double click ZLevel.3
to display the ZLeveldialog box.
5.Go to the strategy tab .
In the Machining tab, choose Outer part for the Machining
mode.5. Press Replay. The new tool path is displayed.
6. Click OK to close the operation dialog box and Close to close
the manufacturingview.
Now we are going to generate an NC data file.
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Generating an NC Output FileThis task explains how to
interactively generate NC code from the program you have
justcreated.
1. Save your program with File/Save as ... in the directory of
your choice (here we havea directory called models)
and call your program MySurfaceMachining.Press Save.
2. Select Manufacturing Program.1 in the specifications tree and
select Generate NCCode interactively in the contextual menu.
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In the dialog box that is displayed, call your file
SurfaceMachining (the aptsource suffixis automatic). Browse to the
directory where you want to save it (here we have chosento put it
in the same directory as the CATProcess but this is not
obligatory).
Click Save to create the APT file.
The APT file can be read with any kind of text editor.
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Generating One File Per OperationThis task explains how to
generate one file per operation in the machining program .
Step 1. is only necessary if you hav not already saved your
CATProcess.
1. Save your program with File/Save as ... in the directory of
your choice (here we havea directory called models)
and call your program MySurfaceMachining.Press Save.
2. Select Manufacturing Program.1 in the specifications tree and
click on the Generate
NC Code in Batch Mode icon .
Enter the following data in the dialog box that is
displayed:
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Call your file SurfaceMachiningOperations and store it in the
same directory as yourCATProcess (the choice of directory is not
obligatory, you can store your files in thedirectory of your
choice).
Make sure that the Split files by operation is selected.
Click Save to create the APT file.
The APT file can be read with any kind of text editor.3. Press
Execute.
One file is created per operation.
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Generating NC Shopfloor Documentation
This task explains how to interactively generate shopfloor NC
documentation in HTMLformat from the program you have just
created.
1.Select the Generate documentation icon .
The process documentation dialog box is displayed.
2. Select the SurfaceMachinist4.CATScript file from the samples
directory.
Leave "Process" as the process name.
Choose the directory where you want to store your new file (we
have chosenMyFiles, but this is not obligatory).
Enter "Process" in the Main File Name field.3. Press OK.
Your NC document has been created.
Press Close to close the dialog box.
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Area-oriented Machining Area-oriented machining is a method
where you define all of the separate areas you want tomachine on
the part before assigning an operation to each one.
In this tutorial you are going to learn how to:define areas
(including a rework area) on the part below,define tools to use on
the areas,use a safety plane,change a tool axis,create an APT file
and a workshop document.
Entering the WorkbenchDefining the Areas to Machine
Defining the Tools to UseSweep Roughing the PartSweeping the Top
SurfaceSweeping the Side AreasZLevel on Vertical Walls
Reworking Between ContoursGenerating an NC Output File
Generating NC Shopfloor Documentation
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Entering the WorkbenchThis task shows you how to open a part and
enter the Surface Machining workbench.
1.Open the Gets2.CATPart in the samples directory.
2. Select NC Manufacturing > Surface Machining from the Start
menu.
The Surface Machining workbench is displayed.
The part is displayed in the viewer along with the manufacturing
specifications.3. Press MB2 and MB3 at the same time and turn the
part round so that it looks like this.
4. Double click Part Operation.1 in the tree. In the dialog box
that is displayed, click thedesign part icon and click the part in
the viewer.
The double click anywhere in the viewer and press OK.
This step is necessary for the visualization and analysis part
of the process.
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You might find it easier to select the surfaces if you hide the
planes and the machining axissystem. Select the planes in the tree
and use the Hide/Show option in the contextualmenu:
Select the machining axis system in the viewer:
and hide it in the same manner.
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Defining the Areas to Machine
This task teaches you how to define the specific areas on the
part that you are going tomachine. You are going to define:
the whole part as a machining area for rough machining purposes
four other areas for use with different cycle typesand a rework
area.
1.Click on the Machining Area icon .
2. Place your mouse cursor over the red, sensitive area in the
dialog box and pressMB3.
3. Choose Body(ies) in the contextual menu.
4. Click the part in the view. The whole part is selected.
Double click anywhere in theviewer to redisplay the dialog box.
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5. Give the machining area a name. Replace the text in the name
box by Whole.
Click OK. You have just created your first machining area.6. Now
create an area on the top of the part. Select the Machining area
icon and click
(MB1 this time) on the red, sensitive area in the dialog box.
Now select the areasthat you see selected in the picture below.
Click on OK in the face selection toolbar.
Call this area Top.7. Now do the same for the left side of the
part with these faces:
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Call this area Left.8. Define a third area with these faces and
call it Right.
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9. Finally, create the last machining area with the 3 faces
below and call it Bottom.
10.Check the areas that you have just created in the
Manufacturing view .
The view should look like this:
11. Now you are going to create a rework area to use when
removing residualmaterial.. Select Whole in the manufacturing
view.
12.Click the Rework area icon .
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13. In the dialog box that is displayed, change the Entry
diameter to 10 mm, theCorner radius to 5 mm and the name to
Rework.
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14. Press Compute to compute the area. The rework area should
look like this on thepart:
15. Press OK to close the dialog box.
Press Close to close the manufacturing view.
The next step is to define the tools that you will need to
machine the areas youhave just defined.
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Defining the Tools to Use
This task defines the three tools that you are going to need to
machine the part.
1. Click Manufacturing Program.1 in the PPR
and then click the End mill tool change icon . If you cannot see
this icon, useView > Toolbars and activate Auxiliary
Operations.
2. In the dialog box that is displayed, click the box to select
a ball-end tool
and confirm with OK.3. Click the End mill tool change icon
again.
4. Activate the ball-end tool box.
5. Double click the diameter.
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6. Enter a value of 20 in the dialog box that is displayed.
Click OK7. Change the tool name to T2 End Mill D 20.
Click OK.8. Now define a third tool that:
is ball end,has a diameter of 4 mm,and is called T3 End Mill D
04.
9. You now have the three tools that you will need to machine
the part. Your PPRshould look like this:
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We are now going to move on to the next step where you will
rough machine thepart.
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Sweep Roughing the PartThis task will show you how to rough
machine the whole part using a sweeproughing operation.
1.Open the manufacturing view by clicking this icon .
2. Select Whole from the list of areas.
3.Click the Sweep roughing icon .
4. Go to the tool tab and choose tool T2 End Mill D20.
5. Press Replay to compute the operation. The toolpath is
displayed on the part.Press OK to close the small dialog box that
is displayed (bottom right).
6. Press OK to close the operation dialog box.
Now you are going to machine the Top surface.
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Sweeping the Top SurfaceThis task will show you how to sweep the
top surface of the part and how tochange a tool.
1. In the manufacturing view, select the machining area called
Top from the list ofareas.
2.Click the Sweeping icon .
3. In the strategy tab, give a stepover distance value of
1mm.
4. Go to the geometry tab and make sure that Part autolimit is
turned on.
5. Go to the tool tab and choose tool T1 End Mill D 10.
6. Press Replay to compute the tool path.7. Press OK to close
the operation dialog box.
Now you are going to machine the sides of the part.
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Sweeping the Side Areas
This task is going to teach you how to:sweep machining areas
Left and Right and change the orientation of the tool axis.
1. In the manufacturing view, select the machining area called
Left.
2.Click the Sweeping icon .
3. In the strategy tab, define a new tool axis like this:
4. Go to the tool tab and Select T1 End Mill D 10.
5.
Press Replay to compute the tool path.
6.Press OK to close the operation dialog box.
7. Now you are going to machine the area called Right. Select it
in the manufacturingview.
8.Click the Sweeping icon .
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9. Change the tool axis like this:
10.Define the same tool as for area Left.
11.Press Replay to compute the tool path.
12.Press OK to close the operation dialog box.
The next step is to machine the area called Bottom.
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ZLevel on the Vertical WallsThis task teaches you how to:
use ZLevel millingchange a tool axisuse the safety plane.
1. In the manufacturing view, select the machining area called
Bottom.
2.Click the ZLevel icon .
3. In the strategy tab, define a new tool axis like this:
Click here:
Define the tool axis with these settings:
4. Go to the Macro tab and deactivate the Optimize retracts
option.
The purpose of this is to ensure that the tool rises high enough
over the area to avoidgouging the rest of the part.
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5. Press Replay to compute the tool path.6. Press OK to close
the operation dialog box.
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Reworking Between Contours
This task shows you how to take an area that has not been
machined because the toolused was too big and rework it with a
smaller tool.
1. Select Rework in the manufacturing view.
2.Click the Contour-driven operation icon .
3. Go to the Stepover tab and choose Constant on part.
4. Now go to the tool tab and select tool T3 End Mill D 04.
5. Press Replay to compute the tool path.
6. Press OK to close the operation dialog box.
Now, you are going to create an APT file.
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Generating an NC Output File
This task explains how to interactively generate NC code from
the program you have justcreated.
1. Save your program with File/Save as ... in the directory of
your choice (here wehave a directory called models)
Call your program MyGettingStarted.
Press Save.2. Select Manufacturing Program.1 in the
specifications tree then select the
Generate NC Code Interactively icon .
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Call your file SurfaceMachining (the aptsource suffix is
automatic). Browse to thedirectory where you want to save it (here
we have chosen to put it in the samedirectory as the CATPRocess but
this is not obligatory).
Click Save to create the APT file.
The APT file can be read with any kind of editor.
Next you are going to generate workshop documentation in HTML
format.
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Generating NC Workshop Documentation
This task explains how to interactively generate shopfloor NC
documentation in HTMLformat from the program you have just
created.
1.Select the Generate documentation icon .
The process documentation dialog box is displayed.
2. Select the SurfaceMachinist4.CATScript file from the samples
directory.
Leave "Process" as the process name.
Choose the directory where you want to store your new file (we
have chosenMyFiles, but this is not obligatory).
Enter "Process" in the Main File Name field.3. Press OK.
Your NC document has been created.
Press Close to close the dialog box.
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Basic TasksThe basic tasks in this section involve creating,
editing and managing machining operationsand other entities of the
manufacturing process.
Roughing operations
Finishing and semi-finishing operationsReworking operations
Axial machining operationsMachining areasTool path editor
Reading STL filesAuxiliary operations
Part operation and manufacturing programManaging manufacturing
entities
Verification, simulation and program output
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Rough Machining OperationsThese are the tasks that you will use
for rough machining the part.
Create a sweep roughing operation: Select the sweep roughing
icon, choose a part tomachine and specify the tool to be used. You
can also specify machining parameters,feedrates and spindle
speeds.Create a roughing operation: Select the roughing icon,
choose a part to machine andspecify the tool to be used. You can
also specify machining parameters, feedrates andspindle speeds.
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Sweep RoughingThis task shows you how to insert a sweep roughing
operation into the program. Sweeproughing is an operation which
allows you to rough machine parts by vertical planes.
To create the operation you define:
the geometry of the part to machine ,
the parameters of the machining strategy ,
the tool to use ;only end mill tools are available for this
operation,
the feedrates and spindle speeds ,
the macros .
Only the geometry is obligatory, all of the other requirements
have a default value.Either:
make the Manufacturing Program current in the specification tree
if you want todefine an operation and the part/area to machine at
the same time,or select a machining feature from the list if you
have already defined the area tomachine and now you want to define
the operation to apply to it.
Below we are going to see how to do the first of these.
Open file Basic1.CATPart then select NC Manufacturing >
Surface Machining in the Startmenu.
1.Select the sweep roughing icon .
A SweepRoughing entity and a default tool are added to the
program.
The dialog box opens at the geometry tab page .
This page includes a sensitive icon to help you specify the
geometry to be machined. The area that represents the part geometry
is colored red indicating that the geometryis required for defining
the area to machine. All of the other geometry parameters
areoptional.
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2. Press MB 3 over the red area in the sensitive icon and choose
Body(ies)
and click on the part in the viewer.Then double click anywhere
in the viewer to confirm your selection and redisplay thedialog
box.
3. Press Replay. You will see that the top area of the part has
been rough machined.
You can cancel toolpath computation atany moment before100%
completion.
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Sweep Roughing - GeometricComponents
In the geometric component tab you can define the area to
machine either:by clicking on the face definition area and using
the face selection wizard,by passing the mouse over the face
definition area and choosing Body in thecontextual menu if you wish
to machine a whole part and not just an area on it,or by choosing a
pre-defined area like this:
The other geometric components that you can select in the view
(but that are notobligatory) are:
the check element. The check is often a clamp that holds the
part and therefore isnot an area to be machined.an area to avoid if
you do not wish to machine it (the small light brown cornernear the
part selection area).the safety plane. The safety plane is the
plane that the tool will rise to at the end ofthe tool path in
order to avoid collisions with the part. You can also define a
newsafety plane with the Offset option in the safety plane
contextual menu. The newplane will be offset from the original by
the distance that you enter in the dialogbox.an upper plane which
defines the highest plane that will be machined on the part,a lower
plane which defines the lowest plane that will be machined on the
part,the limiting contour which defines the outer machining limit
on the part. the offset on the part.the offset on the check
element.
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All of the above planes can be defined by selecting a point or a
plane in the viewer.
You can also set an offset on all of the planes using the
contextual menu over eachplane. The offset can be either positive
or negative and is previewed in the viewer beforeit is
validated.
Press OK in the dialog box to confirm.
In the case of imposed planes, the offset value will be applied
to all of the planes youhave imposed. The tool will pass through
all of the planes defined by the offset and notthrough the planes
that are imposed. One advantage of this is that if the top surface
ofthe part is flat and you have defined an Offset on part of, for
example of 1mm, you candefine the same offset on the imposed planes
so as to ensure that there will be noresidual material remaining on
the top surface.
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You can also define the following parameters:Stop position
defines where the tool stops:
outside stops the tool outside the limit line,inside stops
inside the limit line,on stops the tool on the limit line.
Stop mode defines which part of the tool is considered at the
Stop Position, i.e.whether it is the contact point or the tool
tip.Offset is the distance that the tool will be either inside or
outside the limit linedepending on the Stop Mode that you
chose.Part autolimit. If you activate Part autolimit, the tool will
not go beyond the edge ofthe part.
Part autolimit and the limiting contour can beused individually
or together to define thearea you want to machine. In the pictures,
theblue outline is the part edge, the yellow partis the area that
will be machined, the blackline is the limiting contour:
If you use Part autolimit alone, thewhole part is machined.
If you use a Limiting contour, only thearea inside the limiting
contour ismachined..
If you wish to machine the areaoutside the limiting contour,
chooseOutside as the Side to machine.
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You can now either run the operation on the part, store the
operation that you have justdefined or define other parameters in
the machining strategy, tool data, speeds andrates, or macro data
tabs first.
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Sweep Roughing - Machining StrategyIn the machining strategy
tab, you can define the cycle type, the tool path style,
themachining tolerance, the stepover distance and the maximum cut
depth. You can alsochoose the tool stepover direction and the tool
axis.
The sensitive icon illustrates the roughing type you
select:ZOffset; the tool path is offset from the part.ZPlane; the
part is machined plane by plane.ZProgressive; the part is machined
by interpolating the tool path between the partand the top of a
theoretical rough stock.
You can change the tool axis and the machining direction in the
sensitive icon. Change the tool axis and the machining direction
with Select in the contextual menuwhich will display a dialog box
where you can choose between selection by angle andselection by
coordinates. Selection by angle lets you choose the tool axis by
rotationaround a main axis. Angle 1 and Angle 2 are used to define
the location of the tool axisaround the main axis that you select.
There is also a button that lets you reverse thedirection of the
axis with respect to the coordinate system origin.
Selection by coordinates has the following
options:Feature-defined; you select a 3D element such as a plane
that will serve toautomatically define the best tool axis.
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Selection; you select a 2D element such as a line or a straight
edge that will serveto define the tool axis or machining
direction,Manual; you enter the XYZ coordinates,Points in the view;
click on two points anywhere in the view to define the tool axisor
machining direction.
The machining tab concernsthe tool path style, stepoverside and
machiningtolerance. Consider thetolerance value to be theacceptable
chord error.
The tool path style can be: Zig-zag; the tool pathalternates
directionsduring successivepasses,
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One-way next; the toolpath always followsthe same
directionduring successivepasses and goesdiagonally from theend of
one tool path tothe beginning of thenext.One-way same; thetool path
always hasthe same directionduring successivepasses and returns
tothe first point in eachpass before moving onto the first point in
thenext pass.
The stepover side can beeither to the left or the right ofthe
tool path and is definedwith respect to the machiningdirection.
The strategy tab allows youto define
the distance which isthe width of theoverlap between
twosuccessive passes and the maximumdepth of cut.
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Sweep Roughing - Macro DataThe Macro tab defines the tool
approach and retract data.
The approach/retract mode can be:Along tool axis; the tool moves
along the tool axis,Along a vector; the tool moves along a vector
that you define with theApproach/Retract direction: X/Y/Z
boxes,Normal; the tool moves in a direction perpendicular to the
surface beingmachined,Tangent to movement; the approach/retract is
tangent at its end to the rest of thetool path.and None; no
approach/retract.Prolonged section;the tool moves in astraight line
that mayslant upwards. Themovement is definedby:
theengagementdistance(1),the length oftheprolongation(2),the
slantanglebetween thecutting pathand the pathprolongation(4),a
safetydistance (3).
The advantage ofthis mode is thatcollisions
areautomaticallydetected. In theevent that a possiblecollision is
detected,the angle will be
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adjusted to avoidcollision. If the anglecannot be
adjusted(because of theshape of the part, forinstance), the
lengthof the prolongationwill be automaticallyadjusted to
avoiccollision.
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RoughingThis task shows you how to insert a roughing operation
into the program. Roughing isan operation which allows you to rough
machine parts by horizontal planes.
To create the geometry you define:
geometric components ,
machining strategy ,
tool data ;only end mill tools are available for this
operation,
speeds and rates ,
macro data .
Only the geometry is obligatory, all of the other requirements
have a default value.Either:
make the Manufacturing Program current in the specification tree
if you want todefine an operation and the part/area to machine at
the same time,or select a machining feature from the list if you
have already defined the areato machine and now you want to define
the operation to apply to it.
Below we are going to see how to do the first of these.
Open file SurfaceMachining3.CATProduct, then select NC
Manufacturing > SurfaceMachining in the Start menu.
Then display the model in wireframe mode with this icon .1.
Select the Roughing icon .
A roughing entity and a default tool area added to the
program.
The dialog box opens at the geometry tab page .
This page includes a sensitive icon to help you specify the
geometry to be machined.The red area in the sensitive icon
represents the part geometry. It is obligatory, as isthe rough
stock. All of the other parameters are optional.
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2. Press MB3 over thered area in thesensitive icon andchoose
Body(ies).
Click on the part inthe viewer.
Then double clickanywhere in theviewer to confirmyour selection
andredisplay the dialogbox.
3. Click on the rough stock in the sensitive icon.
Click on the stock in the viewer.4. Press Replay to compute the
operation. You will see that the part has been rough
machined.
You can cancel toolpath computation atany moment before100%
completion.
5. If you want to perform another roughing operation, you can
use the result of the aboveoperation as the rough stock for the
next:
Click on the Full video icon ( ) and running the animation,
Click on the Save video icon ( ),Call the file Roughing
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and press Save.Close all of the dialog boxes.Double click on
Product 1 in the tree and, using the contextual menu,
chooseComponents > Existing Component ...,Browse to the right
directory and choose Roughing.cgr.Double click on Part Operation in
the tree.
You can now select Roughing in the tree as your rough stock for
the next operation.
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Roughing - Geometric ComponentsIn the geometric component tab.
You can define the area to machine either:
by clicking on the face definition area and using the face
selection wizard,by passing the mouse over the face definition area
and choosing Body in the contextual menu if youwish to machine a
whole part and not just an area on it,or by choosing a pre-defined
area like this:
You can also use an Offset Group on the part.
The other geometric components that you can select in the view
are:the rough stock. If you do not have a rough stock you can
create one automatically. Youmust define a rough stock if you have
not already defined one in the Part Operation. See theNC
Manufacturing Infrastructure user's guide for further
information.the check element. The check is often a clamp that
holds the part and therefore is not anarea to be machined.an area
to avoid if you do not wish to machine it (the small light brown
corner near the partselection area).
the safety plane. The safety plane is the plane that the tool
will rise to at the end of the tool path inorder to avoid
collisions with the part. You can also define a new safety plane
with the Offset optionin the safety plane contextual menu. The new
plane will be offset from the original by the distancethat you
enter in the dialog box.an upper plane which defines the highest
plane that will be machined on the part,a lower plane which defines
the lowest plane that will be machined on the part,an imposed plane
that the tool must obligatorily pass through. Use this option if
the part that you aregoing to machine has a particular shape (a
groove or a step) that you want to be sure will be cut.
If you wish to use all of the planar surfaces in a part as
imposed surfaces, use the Search/View... option in the contextual
menu to select them.
When searching for planar planes, you can choose to find either:
all of the planar surfaces in the part,or only the planes that can
be reached by the tool you are using.
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Here is an example with the gets2.CATPart.
a start point where the tool will start cutting. There are
specific conditions for start points:
They must be outside the machining limit. Examples of machining
limits are the rough stockcontour; a limit line, an offset on the
rough stock, an offset on the limit line, etc.They must not be
positioned so as to cause collisions with either the part or the
checkelement. If a start point for a given zone causes a collision,
the tool will automatically adoptramping approach mode.The distance
between the start point and the machining limit must be greater
than the toolradius plus the machining tolerance. If the distance
between the start point and themachining limit is greater than the
tool radius plus the safety distance, the start point will
onlyserve to define the engagement direction. If there are several
start points for a given area, the one that is used is the first
valid one (inthe order in which they were selected) for that
area.One start point may be valid and for more than one area.If a
limit line is used, the tool will approach outer areas of the part
and pockets in rampingmode. towards the outside of the contour. The
tool moves from the outside towards theinside of this type of area.
In this case, you must define the start point.
Start points are automatically defined when using concentric
tool path style. In this case, the start point isthe center of the
largest circle that can be described in the area to machine.
Lateral approach modescannot be used.
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the limiting contour which defines the machining limit on the
part.
the offset on the part.the offset on the check element.
there is also the possibility of setting the order in which the
zones on the part are machined.
All of the above planes can be defined by selecting a point or a
plane in the viewer.
You can also set an offset on all of the planes using the
contextual menu over each plane. The offset canbe either positive
or negative and is previewed in the viewer before it is
validated.
Press OK in the dialog box to confirm.
In the case of imposed planes, the offset value will be applied
to all of the planes you have imposed. Thetool will pass through
all of the planes defined by the offset and not through the planes
that are imposed.One advantage of this is that if the top surface
of the part is flat and you have defined an Offset on part of,for
example of 1mm, you can define the same offset on the imposed
planes so as to ensure that there willbe no residual material
remaining on the top surface.
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You can also define the followingparameters:
Position defines where the toolcenter stops:
outside stops the tool outsidethe rough stock,inside stops the
tool insidethe rough stock,on stops the tool on therough stock.
Offset defines the distance that thetool can overshoot the
Position. It isexpressed as a percentage of thetool diameter. This
parameter isuseful in cases where there is anisland near the edge
of the part andthe tool diameter is too wide toallow the area
behind the island tobe machined. This parameter can only be used
ifthe Position is inside or outside.
If the Position is On and there is anisland near the edge of the
part andthe tool diameter is too wide toallow the area behind the
island tobe machined, you must check theOvershoot box to allow the
tool togo beyond the rough stock andeffectively cut the material
behindthe island.
Rework threshold is the quantity of material, horizontally or
vertically, that must remain (over andabove any offset there may
be) in order for the tool to engage. Limit Definition defines what
area of the part will be machined with respect to the limiting
contour(s).It can either be inside or outside. In the pictures
below, there are three limiting contours on therough stock. The
yellow areas will be machined.
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Side to machine Inside Side to machine: Outside
If you are using a limiting contour, you should define the start
point so as to avoid tool-material collision.
The Force replay button is only used for reworking operations.
Its purpose is to compute the residualrough stock remaining from
operations preceding the current one, providing a rough stock has
not beendefined for this operation.
. Use it before pressing Replay.You can now either run the
operation on the part, store the operation that you have just
defined or defineother parameters in the machining strategy, tool
data, speeds and rates, or macro data tabs first.
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Roughing - Ordering ZonesThis task will show you how to set the
order in which the zones on a part are machined. Zones can beeither
pockets or the outside of the part.
You must have a part that has a point or a plane defined in the
each of the zones you want to select.
1. Open ZoneOrder.CATProcess from thesamples directory.
Click the Roughing icon .
2. Select the whole part for the to be machined via Body(ies) in
the contextual menu.
3. Click Zone order
and select the zones to machine by clicking on the point in each
as shown below:
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Press Replay.The zones will be machined in the order they were
selected.
Use the Zipmill Full Video function ( ) to check that the zones
were machined in te right order.4. Now create another Roughing
cycle with the same ordered zones and, in Zone order contextual
menu,
deactivate the Machine only ordered zones option.
Press Replay.Notice that the whole part is machined (including
the outside of the part) and not only the zones youordered.
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Roughing - Machining StrategyHere you can define parameters
concerning the style of machining, the machining strategy, and the
zone tomachine. You can also choose the tool axis.
The sensitive icon illustrates the tool path style that you
chose. Change the tool axis with Select in the contextual menu
which will display a dialog box where you can choosebetween
selection by angle and selection by coordinates. Selection by angle
lets you choose the tool axis byrotation around a main axis. Angle
1 and Angle 2 are used to define the location of the tool axis
around themain axis that you select. There is also a button that
lets you reverse the direction of the axis with respect tothe
coordinate system origin.
Selection by coordinates has the following
options:Feature-defined; you select a 3D element such as a plane
that will serve to automatically define thebest tool
axis.Selection; you select a 2D element such as a line or a
straight edge that will serve to define the toolaxis,Manual; you
enter the XYZ coordinates,Points in the view; click on two points
anywhere in the view to define the tool axis,
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The Machining tab defines: the Tool path style which can be:
One-way next; the tool path alwayshas the same direction
duringsuccessive passes and goesdiagonally from the end of one
toolpath to the beginning of the next.One-way same; the tool path
alwayshas the same direction duringsuccessive passes and returns to
thefirst point in each pass beforemoving on to the first point in
thenext pass.Zig-zag; the tool path alternatesdirections during
successive passes.Helical; the tool moves in successiveconcentric
passes from the boundaryof the area to machine towards theinterior.
The tool moves from onepass to the next by stepping over.Contour
only; only machines aroundthe external contour of the
part.Concentric; the tool removes themost constant amount of
materialpossible at each concentric pass.The tool is never directly
in the heartof material. It also respects the givencutting mode in
all cases. Theapproach mode with this style isalways Helix. Spiral;
the tool moves in successiveconcentric passes from the boundaryof
the area to machine towards theinterior. The tool moves from
onepass to the next by stepping over.
The difference between Spiral and Helical style is most obvious
when using high speedmilling options. Spiral has a rounded tool
path in the corners of pockets whereas aHelical tool path will form
loops.
Helical Spiral
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the Machining tolerance value, consider it to be the acceptable
chord error,the Machining mode which defines the type of area to be
machined and can be:
By plane; the whole part is machined plane by plane,Pockets
only; only pockets on the part are machined,Outer part; only the
outside of the part is machined,Outer part and pockets; the whole
part is machined outer area by outer area and then pocket
bypocket.
the Cutting mode which can be Climb or Conventional.
The Strategy tab defines:
the maximum depth of cut which is thedepth of the cut effected
by the tool at eachpassthe overlap between two successivepasses.
Define this distance by choosingeither:
By ratio and enter a percentage ofthe tool diameter,By length
and enter a length.
variable cutting depths (press the Add pass depths button).
When the dialog box opens the distance between passes from the
top to the bottom of the part isconstant and is the same as the
Maximum cut depth.
Change the Distance from top value and the Inter-pass value and
then press Add to give adifferent depth value over a given
distance.
In the example below the cut depth: from the top of the part to
15mm from the top is of 2 mm,from 15mm from the top to 25mm from
the top is 5mm and from 25 mm from the top to the bottom of the
part is 10 mm.
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The Zone tab includes:Min. area which lets you filter out areas
thatyou consider to be too small (in millimeters)to be
machined.Tool core diameter is the diameter of thetool tip that
does not actually cut thematerial.Part contouring is an option that
is onlyused with the zig-zag tool path style. Withpart contouring
switched on, the tool goesround the outside contour of the part
beforecontinuing to zig-zag. Deactivating thisoption allows you to
gain machining time.The tool that you are using and the part youare
working on must be such thatcontouring the rough stock is
superfluous.
With part contouring switched on. Note how thetool went round
the area to machine first:
With part contouring switched off and exactly the
sameparameters. Note that the tool goes straight into
zig-zagmode:
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The HSM tab defines the parameters for highspeed milling. Corner
radius defines the radius ofthe rounded ends of passes when cutting
with aConcentric tool path style and the radius of therounded end
of retracts with Helical andConcentric tool path styles. The ends
are roundedto give a smoother path that is machined muchfaster.
This is what a tool path will look like if you do not use high
speed milling parameters:
Here is the same tool path with the High speed milling switched
on. Note how the round tool path ends. In bothcases a concentric
tool path style is used.
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Similarly, here is what retracts look like without the high
speed milling option:
And here is the same tool path with high speed milling switched
on:
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Roughing - Macro DataThe Macro tab defines the tool engagement
parameters.
There is a button that optimizes tool retract movements. This
means that when the toolmoves over a surface where there are no
obstructions, it will not rise as high as thesafety plane because
there is no danger of tool-part collisions. The result is a gain
intime.In some cases (where areas of the part are higher than the
zone you are machining andwhen you are using a safety plane), the
tool will cut into the part. When this happens,deactivate the
Optimize retracts button.
The Axial safety distance is the maximum distance that the tool
will rise to when movingfrom the end of one pass to the beginning
of the next.
The approach mode can be:
Plunge; the tool plunges vertically,Drilling; the tool plunges
into previously drilled holes. You can change the drillingtool
diameter, angle and length,Ramping; the tool moves progressively
down at the Ramping angle,Helix; the tool moves progressively down
at the ramping angle with its centeralong a (vertical) circular
helix of Helix diameter.
Approach distance is the engagement distance for plunge
mode.
The Radial safety distance is the tool clearance distance with
respect to the sides of thepart.
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Automatic Rough StockThis task explains how to create an
automatic rough stock for a roughing operation.
You must have a part to machine in your workbench.
1. Open file AutoRoughStock.CATPart in the samples
directory.
Go to the Wireframe and Surface Design workbench.
Display the Automatic rough stock icon via View > Toolbars
> Surface Machiningtools.
The automatic rough stock icon is in the bottom right hand
corner ofthe screen. Depending on your screen size, you might have
to moveanother toolbar to see it.
2.Select the Automatic rough stock icon
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3. Select the part. A dialog box is displayed that contains the
minimum and maximumvalues that are required in X, Y and Z to create
a box that would surround the part.
4. You can modify the X,Y,Z values if you choose.
5. You can also change the axis system used to define the rough
stock by clicking onSelect an axis and then choosing either:
an axis in one of the other axis systems, a plane or a planar
surface.
6. Press OK to create the rough stock.
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Finishing and Semi-finishing OperationsThese are the operations
that you will need to finish or semi-finish the machining of the
part.
SweepingZLevel machiningContour-driven machiningProfile
contouringSpiral millingIsoparametric machining
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SweepingThis task shows you how to insert a sweeping operation
into the program. Sweeping is asemi-finishing and finishing
operation that is used after a part has been rough machineand that
machines the whole part. The tool paths are executed in vertical
parallel planes.
To create the operation you define:
the geometry of the part to machine ,
the tool to use ; you have the choice of end mill or conical
tools forthis operation,
the parameters of the machining strategy ,
the feedrates and spindle speeds ,
the macros .
Only the geometry is obligatory, all of the other requirements
have a default value.Either:
make the Manufacturing Program current in the specification tree
if you want todefine an operation and the part/area to machine at
the same time,or select a machining feature from the list if you
have already defined the area tomachine and now you want to define
the operation to apply to it.
Below we are going to see how to do the first of these.
Open file Basic1.CATPart then select NC Manufacturing >
Surface Machining in the Startmenu.
1.Select the Sweeping icon .
A Sweeping entity and a default tool are added to the program.
The dialog box
opens at the geometry tab page .
This page includes a sensitive icon to help you specify the
geometry to bemachined.The area that represents the part geometry
is colored red indicating that thegeometry is required for defining
the area to machine.
-
2. Press MB3 over the red area in the sensitive icon and choose
Body(ies)
and click on the part in the viewer.
Then double click anywhere in the viewer to confirm your
selection and redisplaythe dialog box.
3. Press Replay. You will see that the top surface and the
bottom of the pocket havebeen sweep machined.
You can canceltool pathcomputation at anymoment before100%
completion.
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Sweeping - Geometric ComponentsIn the geometric component tab
you can define the area to machine either:
by clicking on the face definition area and using the face
selection wizard,by passing the mouse over the face definition area
and choosing Body in thecontextual menu if you wish to machine a
whole part and not just an area on it,or by choosing a pre-defined
area like this:
You can also use an Offset Group on the part.
The other geometric components that you can select in the view
(but that are notobligatory) are:
the check element. The check is often a clamp that holds the
part and therefore isnot an area to be machined.an area to avoid if
you do not wish to machine it.the safety plane. The safety plane is
the plane that the tool will rise to at the end ofthe tool path in
order to avoid collisions with the part. The safety plane
contextualmenu allows you to define:
an offset safety plane at a distance that you give in a dialog
box that isdisplayed,and the tool retract mode which may be either
normal to the safety plane ornormal to the tool axis.
an upper plane which defines the highest plane that will be
machined on the part,a lower plane which defines the lowest plane
that will be machined on the part,a start plane which is the first
plane that will be machined,an end plane which is the last plane
that will be machined,the limiting contour which defines the
machining limit on the part. The contour thatdefines the outer
machining limit on the part.the offset on the part.the offset on
the check element.
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All of the above planes can be defined by selecting a point or a
plane in the viewer.
You can also set an offset on all of the planes using the
contextual menu over eachplane. The offset can be either positive
or negative and is previewed in the viewer beforeit is
validated.
Press OK in the dialog box to confirm.
In the case of imposed planes, the offset value will be applied
to all of the planes youhave imposed. The tool will pass through
all of the planes defined by the offset and notthrough the planes
that are imposed. One advantage of this is that if the top surface
ofthe part is flat and you have defined an Offset on part of, for
example of 1mm, you candefine the same offset on the imposed planes
so as to ensure that there will be noresidual material remaining on
the top surface.
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The picture is slightly different if you are using a rework area
and will have fewerparameters.
There is also an Info button that, when pressed, gives the
details on the parameters thatwere defined with the rework
area.
You can also define the following parameters:Stop position
defines where the tool stops:
outside stops the tool outside the limit line,inside stops
inside the limit line,on stops the tool on the limit line.
Stop mode defines which part of the tool is considered at the
Stop position,whether it is the contact point or the tool
tip.Offset is the distance that the tool that the tool will be
either inside or outside thelimit line depending on the Stop mode
that you chose.Part autolimit. I f you activate Part autolimit, the
tool will not go beyond the edge ofthe part.
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Part autolimit and the limiting contour can beused individually
or together to define thearea you want to machine. In the pictures,
theblue outline is the part edge, the yellow partis the area that
will be machined, the blackline is the limiting contour:
If you use Part autolimit, the wholepart is machined.
If you use a Limiting contour, only thearea inside the limiting
contour ismachined.
If you wish to machine the areaoutside the limiting contour,
chooseOutside as the Side to machine.
You can now either run the operation on the part, store the
operation that you have justdefined or define other parameters in
the machining strategy, tool data, speeds andrates, or macro data
tabs first.
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Sweeping - Machining StrategyIn the machining strategy tab, you
can define the tool path style, the machining tolerance,
thestepover and the types of area to machine. You can also choose
the tool stepover directionand distance, the tool axis and the tool
advance direction.
A button allows you to reverse the tool path direction.
The sensitive icon illustrates the mode that you have
chosen.
Change the tool axis and the machining direction with Select in
the contextual menu whichwill display a dialog box where you can
choose between selection by angle and selection bycoordinates.
Selection by angle lets you choose the tool axis by rotation around
a main axis.Angle 1 and Angle 2 are used to define the location of
the tool axis around the main axis thatyou select. There is also a
button that lets you reverse the direction of the axis with respect
tothe coordinate system origin.
Selection by coordinates has the following
options:Feature-defined; you select a 3D element such as a plane
that will serve toautomatically define the best tool axis.
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Selection; you select a 2D element such as a line or a straight
edge that will serve todefine the tool axis or machining
direction,Manual; you enter the XYZ coordinates,Points in the view;
click on two points anywhere in the view to define the tool axis
ormachining direction.
The machining tab lets you: define the tool path stylewhich can
be :
One-way next; thetool path always hasthe same directionduring
successivepasses and goesdiagonally from theend of one tool pathto
the beginning ofthe next.
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One-way same; thetool path always hasthe same directionduring
successivepasses and returnsto the first point ineach pass
beforemoving on to thefirst point in the nextpass.Zig-zag; the
toolpath alternatesdirections duringsuccessive passes.
define the machiningtolerance value, consider itto be the
acceptable chorderror.reverse the tool pathdirection.
The stepover tab concerns the distance between successive passes
and has two possibilities:ConstantScallop Height
Constant has a constant stepover distance defined in a plane and
projected onto the part.You can modify the stepover distance.
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Scallop height has a stepover which depends on the scallop
height that you choose. You canalso define the maximum and minimum
distances that can exist between passes with thescallop height that
you defined.
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There are three parameters in theStepover Strategy area:
Maximum distance is thestepover distance if youhave selected
Constant asthe value or the maximumstepover distance if youchose
Scallop height.Minimum distance is theminimum stepover distanceif
you chose Via Scallopheight.Scallop height is a valuethat you
define for themaximum allowable heightof the crests of material
leftuncut after machining.The stepover side can beleft or right and
is definedwith respect to themachining direction.
Use Along tool axis when you want to machine along the axis you
have selected (or along thedefault axis).
Other axis can only be used with a ball-nose tool. When it is
selected, the axis/direction iconlets you define a second axis (the
other axis - the one pointing up to the left).
Activating Other axis displays a button for collision checking.
When this is turned on, all of thepoints where the toolholder would
have collided with the part are displayed on the tool path(after
Replay).
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The Machined Zone tab lets youdefine:
which parts of the part ormachining area you wish tomachine:
All; all of thesurfaces aremachined, Frontal walls;
frontalsurfaces of the partare machined,Lateral walls;
lateralsurfaces of the partare machined,Horizontal zones;horizontal
surfacesof the part aremachined.
Min. lateral slope gives theminimum angle betweenthe tool axis
and the partsurface normal for thesurface to be considered tobe a
lateral wall.Min. frontal slope gives theminimum angle betweenthe
tool axis and the partsurface normal for thesurface to be
considered tobe a frontal wall.Max. horizontal slope givesthe
maximum anglebetween the tool axis andthe part surface for
thesurface to be considered tobe a horizontal area.
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Sweeping - Macro DataThe Macro tab defines the tool approach,
retract and plunge data as well as the parameters for high speed
milling andoptimization of retracts.
There is a button where you can optimize retracts. This means
that if no collisions are detected, the tool will not rise tothe
safety plane. It will only rise as high as necessary in order to
clear the part. The result is a faster machining process.In some
cases (where areas of the part are higher than the zone you are
machining and when you are using a safetyplane), the tool will cut
into the part. When this happens, deactivate the Optimize retracts
button.
High speed milling parameters are:Transition radius is the
radius of the arc thatjoins successive passes,Discretization angle
is a value which, whenreduced, gives a smoother tool path.Safety
distance is the clearance distancethat the tool passes over the
part at thefeedrate in order to disengage the tool fromcutting
between passes.
The approach/retract mode can be:Along tool axis; the tool moves
along thetool axis,Along a vector; the tool moves along avector
that you define with theApproach/Retract direction: X/Y/Z
boxes,Normal; the tool moves in a directionperpendicular to the
surface beingmachined,Tangent to movement; the approach/retractis
tangent at its end to the rest of thetoolpath.None; no
approach/retract.
Back; the tool doubles back like an arrowabove the cutting tool
path. You can eitherdefine this type with two lengths or a
lengthand an angle. The parameters that you canmodify are:
the length (1)the height (2)the ramp angle (3).
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Circular; the tool moves towards/away fromthe part in an arc.
The parameters that youcan set are:
the length (1),the angle (2)the radius (3).
If you do not use Part autolimit, the curvewill be below the
surface of the part.
If you use the manual plane computationmode, the
approach/retract arc will benormal to the plane that you
select.
Box; the tool moves across the diagonal ofan imaginary box,
either in a straight line orin a curve (Linking mode). The
Length(4) isthe distance that the tool will move in onceit has
crossed the box. The box is definedby three distance values:
the distance along the normal axis(1),the distance along the
tangent (2) ,the distance (can be a negativevalue) along the tool
axis (3),
The direction of the box diagonal isdefined by whether you want
to usethe normal to the left or the right of theend of the tool
path. Left or right isdetermined by looking along the toolpath in
the direction of theapproach/retract. In the image, it is thethe
right side that is used.
Prolonged section; the tool moves in astraight line that may
slant upwards. Themovement is defined by:
the engagement distance(1),the length of the prolongation
(2),the slant angle between the cuttingpath and the path
prolongation (4),a safety distance (3).
The advantage of this mode is thatcollisions are automatically
detected.In the event that a possible collision isdetected, the
angle will be adjusted toavoid collision. If the angle cannot
beadjusted (because of the shape of thepart, for instance), the
length of theprolongation will be automaticallyadjusted to avoic
collision.
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Plunges can only be defined if you selected a one-way sweeping
mode in the machining strategy tab. Plunges can be :No check; the
tool can plunge and rise with the surface,No plunge; the tool
cannot plunge,Same height; the tool does not plunge but will not
stop when it encounters a peak.
In the Linking tab, check the Island skip box if youwant to use
intermediate approaches and retracts(i.e. those that link two
different areas to machineand that are not at the beginning nor the
end ofthe tool path).
With Island skip turned on: With Island skip turned off:
Island skip length is the height that the tool will rise to on
intermediate approaches and retracts.The Feedrate length defines
the distance beyond which tool path straight lines will be replaced
by intermediateapproaches and retracts. In the picture below, the
Feedrate length was set to 45 mm. Note that the gaps thatwere less
than 45 mm are crossed by a straight line tool path and those that
are greater than 45 mm are crossedwith a standard intermediate tool
path with an approach and a retract.
Feedrate length is only active if the Island skip length is 0
mm.
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ZLevel MachiningThis task shows you how to insert a ZLevel
operation into the program.
ZLevel operations are finishing or semi-finishing operations
that machine thewhole part by parallel horizontal planes that are
perpendicular to the tool axis.
To create the operation you define:
the geometry of the part to machine ,
the tool to use ;o you have the choice of end mill or
conical
tools for this operation,
the parameters of the machining strategy ,
the feedrates and spindle speeds ,
the macros .
Only the geometry is obligatory, all of the other requirements
have a defaultvalue.
Either:
make the Manufacturing Program current in the specification tree
if youwant to define an operation and the part/area to machine at
the sametime,or select a machining feature from the list if you
have already defined thearea to machine and now you want to define
the operation to apply to it.
Below we are going to see how to do the first of these.
Open file Basic1.CATPart then select NC Manufacturing >
Surface Machining inthe Start menu.
1.Select the ZLevel icon .
The ZLevel dialog box is displayed.
A ZLevel entity and a default tool area added to the
program.
The dialog box opens at the geometry tab page . This page
includes asensitive icon to help you specify the geometry to be
machined.
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The area that represents the part geometry is colored red
indicating that thegeometry is required for defining the area to
machine. All the other geometryparameters are optional.
2. Click on the red area that represents the part geometry then
select the belt offaces around the outside of the part.
The edges surrounding the selected faces are highlighted.
Double click anywhere in the viewer to confirm your selection.3.
Press Replay. You will see that the outside of the part has been
machined.
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You can canceltool pathcomputation atany momentbefore
100%completion.
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ZLevel Machining - GeometricComponents
In the geometric component tab you can define the area to
machine either:by clicking on the face definition area and using
the face selection wizard,by passing the mouse over the face
definition area and choosing Body in thecontextual menu if you wish
to machine a whole part and not just an area on it,or by choosing a
pre-defined area like this:
You can also use an Offset Group on the part.The other geometric
components that you can select in the view (but that are
notobligatory) are:
the check element. The check is often a clamp that holds the
part and therefore isnot an area to be machined.an area to avoid if
you do not wish to machine it (small light brown corner nearthe red
part selection area).the safety plane which is the plane that the
tool will rise to at the end of the toolpath in order to avoid
collisions with the part.an upper plane which defines the highest
plane that will be machined on the part,a lower plane which defines
the lowest plane that will be machined on the part,an imposed plane
that the tool must obligatorily pass through. Use this option ifthe
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,
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a start point where the tool will start cutting. There are
specific conditions for startpoints:
They must be outside the machining limit. Examples of machining
limitsare the rough stock contour; a limit line, an offset on the
rough stock, anoffset on the limit line, etc.They must not be
positioned so as to cause collisions with either the partor the
check element. If a start point for a given zone causes a
collision,the tool will automatically adopt ramping approach
mode.The distance between the start point and the machining limit
must begreater than the tool radius plus the machining tolerance.
If the distancebetween the start point and the machining limit is
greater than the toolradius plus the safety distance, the start
point will only serve to define theengagement direction. If there
are several start points for a given area, the one that is used is
thefirst valid one (in the order in which they were selected) for
that area.One start point may be valid and for more than one
area.If a limit line is used, the tool will approach outer areas of
the part andpockets in ramping mode. towards the outside of the
contour. The toolmoves from the outside towards the inside of this
type of area. In this case,you must define the start point.
All of the above planes can be defined by selecting a point or a
plane in the viewer.
You can also set an offset on all of the planes using the
contextual menu over eachplane. The offset can be either positive
or negative and is previewed in the viewer beforeit is
validated.
Press OK in the dialog box to confirm.
In the case of imposed planes, the offset value will be applied
to all of the planes youhave imposed. The tool will pass through
all of the planes defined by the offset and notthrough the planes
that are imposed. One advantage of this is that if the top surface
ofthe part is flat and you have defined an Offset on part of, for
example of 1mm, you candefine the same offset on the imposed planes
so as to ensure that there will be noresidual material remaining on
the top surface.If you use a limiting contour that results in
successive passes not being closed, the startpoint(s) will be
ignored.
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the limiting contour which is the contour that defines the outer
machining limit onthe part.the offset on the part.the offset on the
check element.
The picture is slightly different if you are using a rework area
and will have fewerparameters.
There is also an Info button that, when pressed, gives the
details on the parameters that
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were defined with the rework area.You can also define the
following parameters:
Stop position defines where the tool stops:outside stops the
tool outside the limit line,inside stops inside the limit line,on
stops the tool on the limit line.
Stop mode defines which part of the tool is considered at the
Stop Position,whether it is the contact point or the tool
tip.Offset is the distance that the tool will be either inside or
outside the limit linedepending on the Stop mode that you
chose.Part autolimit. If you activate Part Autolimit, the tool will
not go beyond the edge ofthe part.
Part autolimit and the limiting contourcan be used individually
or together todefine the area you want to machine. Inthe pictures,
the blue outline is the partedge, the yellow part is the area that
willbe machined, the black line is thelimiting contour: