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Multi-Pockets Machining

e r v i e w

h a t ' s Ne w ?

t t i n g S t a r t e d

Setting the Options

Selecting the Geometry

Optimizing the Power Machining

e r T a s k s

Recommendations

Automatic Rough Stock

Ordering Zones

Selecting Geometry

Using Geometrical Zones

Changing the Tool Axis

Power Machining - Center

Power Machining - Side

o r k b e n c h De s c r ip t io n

f e r e n c e I n f o r m a t i o n

Power Machining Parameters

o s s a r y

d e x

1Pageulti-Pockets Machining Version 5 Release 14

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etting the Most Out of this Guidemake the most out of this book, we suggest that a beginning user reads the Getting Started chapter

st of all and the Workbench Description to find his way around the Multi-Pocket Machining workbench.

ccessing Sample Documentsperform the scenarios, sample documents are provided all along this documentation. For more informatout this, refer to Accessing Sample Documents in the In fra s t ru ct u re Us e r's Gu id e.


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What's New?

ew Functionalities

e machining is now available.

posed planes

You can now define two sets of imposed planes (with different offset).ck and forthtool path style

It can be optimized on each area.


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Getting Started

fore getting to grips with the Multi-Pockets Machining capacities, here is a short step-by step tutorial thap guide you through the key functionalities.

The tutorial should take you 30 minutes to complete.

Setting the Options




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Setting the Multi-Pockets Machining Options

This task shows you how to open a part and start a Multi-Pockets Machining operation.

1 . Open the MultiPockets1.CATPart from the samples directory.

2 . Select T o o l s > O p t i o n s . . . > M a c h i n i n g . In the G e n e r a l tab, make sure that Cr e a t e a C AT Pa r t t o s t o r e g e o m e t r y is checked.

3 . Multi-Pockets Machining is available as an add-on to A d v a n c e d M a c h i n i n g , S u r f a c e M a c h i n i n g or P r i s m a t i c Ma c h i n i n g . In the S t a r t / M a c h in i n g menu, select the workbench you wan

work with. Then go to the M u l t i - P o c k e t s O p e r a t i o n s toolbar that contains the P o w e r M a c h i n i n g icon:

6Pageti-Pockets Machining Version 5 Release 14
http://e%7C/www/CATEvmuCXR14/Doc/online/mpgug_c2/samples/MultiPockets1.CATParthttp://e%7C/www/CATEvmuCXR14/Doc/online/mpgug_c2/samples/MultiPockets1.CATPart

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4 . Under P r o d u c t L i s t , you find P a r t 1 that is the part to machine and N C G e o m e t r y _ P a r t 1 _ x x . y y . z z (the exact name may vary) that is the CATPart created automatically to store

geometry.


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We are going to define the geometry:

q the rough stock

q the part to machine and the associated bottom and imposed planes.

Creating the rough stock

1 . Go to the Geometry Management tool bar and pick the C re a t e s r o u g h s t o c k icon.

The C re a t e R o u g h S t o c k dialog box is displayed. Select N C G e o m e t r y _ P a r t 1 _ 1 4 . 1 8 . 5 7 as the Destination and pick the part to fill in automatically the D e f in i t i o n o f t h e S t o c k fields.

Click OK, the Rough stock is created in the specification tree.


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Defining the geometry for the operation

1 . In the M u l t i - P o c k e t s O p e r a t i o n s toolbar, pick the P o w e r M a c h i n i n g icon

and select M a n u f a c t u r i n g P r o g r a m . 1 in the specification tree. A P o w e r m a c h i n in g . 1 operation is created in the specification tree.

The P o w e r m a c h i n in g dialog box is open.


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The sensitive area P a r t is red, which indicates that you must select a part to machine. The other definitions are optional. If necessary, hide the rough stock or the reference planes to make

picking easier).

2 . Pick the sensitive area P a r t . The dialog box shrinks to allow you to select the part in the viewer.

In the viewer, pick the part

Double click anywhere in the viewer to confirm your selection and to redisplay the dialog box. The red area P a r t is now green to indicate that the geometry has been selected.

3 . Pick the sensitive area R o u g h s t o c k and select the rough stock in N C G e o m e t r y _ P a r t 1 _ 1 4 . 1 8 . 5 7 . You may then hide it for an easier selection of the geometry.


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4 . Pick the sensitive area B o t t o m and select the geometry as shown:


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The sensitive area B o t t o m has turned green.

5 . Pick one sensitive area I m p o s e d and select the geometry as shown:


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Use the Offset contextual menu item to set an offset on this plane.

6 . Now pick the other sensitive area Imposed and repeat the step above with the following plane:


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7 . Pick Center zone order and define in which order the center zones are to be machined.

You have the following result:


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8 . In the Machining strategy tab, make sure the Ma c h i n i n g m o d e is set to B y p l a n e and O u t e r p a r t a n d p o c k e t .

Leave the options at their default values and push the T o o l P a t h R e p l a y button, then OK twice.

A P o w e r m a c h i n i n g .1 operation is created in the specification tree.


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1 . Double-click P a r t O p e r a t i o n . 1 in the specification tree. Add the part and the rough stock you are using:

2 . Create a second operation as explained before but with the following parameters:

q O ff s e t o n P a r t : 0 . 5 m m

q M a c h in i n g s t r a t e g y : C e n t e r ( 1 ) a n d S id e ( 2 )

q M a c h in i n g m o d e : P o c k e t o n l y ,

q M a c h in i n g t o l e r a n c e : 0 . 1 m m


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q R e m a i n i n g t h i c k n e s s f o r s i d e s : 1 m m

q B o t t o m f i n is h t h i ck n e s s : 0 . 5 m m


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The specificity of the Power Machining is the tool loading management in Back and Forth (several contouring passes, no full diameter cuts with zig zag passes, possibility to perform the contouringprior or after the zig-zag passes, possibility to define a contouring pass ratio).


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Above is the tool path with the values we have defined.

3 . Place the cursor on the machining direction arrow and select O p t i m i z e from its contextual menu.

Push the T o o l P a t h R e p l a y button.


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You can see that the tool path direction has been adapted to the geometry to machine, i.e. defined by the shape of each pocket and set along the main direction (X or Y).

4 . Now let's have a look at the C o n t o u r in g p a s s r a t i o

This parameter is available when the tool path style is set to B a c k a n d F o r t h.

It adjusts the position of the final pass for removing scallops. This is done by entering a percentage of the tool diameter (0 to 50).


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This is what you get when the Co n t o u r i n g p a s s r a t i o is set to 0:

This is what you get when the Co n t o u r i n g p a s s r a t i o is set to 20:


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5 . Now go to the HSM tab and make sure the H i g h s p e e d m i l l in g option is selected.


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This is what you get without the H i g h s p e e d m i l li n g option:

This is what you get with H i g h s p e e d m i l l in g option:

The tool path is rounded to give a smoother path that can be machined faster.

6 . Push the M ix e d P h o t o / Vi d e o button to simulate the material removed by the machining operation in Video mode.


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User Tasks

u will find the following user tasks to help you perform a Multi-Pockets machining:

commendations

tomatic Rough Stock

dering Zones

ecting Geometryng Geometrical Zones

anging the Tool Axis

wer Machining - Center

wer Machining - Side

ase refer to the Getting Started section for information about the operating mode of the Multi-Pockets

chining and to the Reference section for more information about the parameters.


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Recommendations

you intend to create complementary geometry, before you start a Machining workbench go to Tools/Optid, in the Dis p lay tab of the Manufacturing options, tick the box that allows you to create a CATPart to stc e s s a ry g e o m e t r y. If you are n o t going to modify the geometry, then make sure that this box is not tick

fore starting Machining workbench, go to Tools/Options and in the Operation tab of the Man u fact u rin g op

d tick the Use de fault v a lue s o f th e cu rren t program box. This will ensure that when a new operation isated its parameters will be initialized with default values that are appropriate to that operation and not we values from the operation just before it.

u should save your CATProcess before generating HTML workshop documentation.

an operation, if you cannot see the whole dialog box (particularly the OK, App ly and Cancel buttons), exur CATIA session and use S et t ings > Control Pane l > Display > S et t ings to:

give a higher value for your screen resolution,

or, if you are using large fonts, use small fonts.

pending on your screen size, you may have to use both of the solutions.


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Automatic Rough Stock

This 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.CATPartin the samples directory.

2 . Select the Cr e a t e s r o u g h s t o c k icon . The dialog box is displayed


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3 . Select the D e s t i n a t i o n , i.e. select the specification tree body where the rough stock is to be

created.

Pick the part on which the rough stock is to be created. The P a r t b o d y information is update

accordingly. A dialog box is updated with the minimum and maximum values that are require

X, Y and Z to create a box that would surround the part. The default box is displayed in bold

lines.


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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 on S e l e c t an

then choosing either:

q an axis in one of the other axis systems,

q a plane

q or a planar surface.


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6 . Press OK to create the rough stock.


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Roughing - Ordering Zones

This task will show you how to set the order in which the zones on a part are machined. Zones can beeither pockets or the outer 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 the samples directory.

2 . Click the R o u g h i n g icon .

3 . Click the red sensitive area and select the whole part to be machined.

4 . Click Zo n e o r d e r

and select the zones to machine by clicking on the point in each as shown below:

http://e%7C/www/CATEvmuCXR14/Doc/online/cfyugtpe_C2/cfyugtpegpocket.htmhttp://e%7C/www/CATEvmuCXR14/Doc/online/cfyugtpe_C2/cfyugtpegpocket.htm

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Press R e p l a y .

The zones will be machined in the order they were selected.

Use the Vid e o f r o m la s t s a v e d function ( ) to check that the zones were machined in theright order.


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5 . Now create another Roughing cycle with the same ordered zones and, in Zone order contextu

menu, deactivate the Ma c h i n e o n l y o r d e r e d a r e a s option.

Press R e p l a y .

q If a tool path cannot be computed because of invalid faces, an explicit error message like this oneappear:

q Notice that the whole part is machined (including the outside of the part) and not only the zonesordered.


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Selecting Geometry

Either:

q make the Manufacturing Program current in the specification tree if you want to define an operation and tpart/area to machine at the same time,

q or select a machining feature from the list if you have already defined the area to machine and now you wdefine the operation to apply to it.

q When you use a boundary of faces to define a limiting contour, if the faces are not perfectly connected theonly the first face will be selected.

q In the face selection wizard, the Polygon trap option does not always select all of the faces inside the polyand sometimes selects extra ones, i.e. it goes through the surface and selects faces from the other side ofmodel.

q Occasionally, when selecting a complex area on a tool path using either a polygon or a contour, the areaoutside the boundary is selected rather than the area inside.

q When using a polygon to select an area on a tool path, display of the polygon before confirmation may beerratic (it may rise to a point that is not on the tool path itself), particularly around areas where the polygintersects itself.

1 . Select a M a c h i n i n g O p e r a t i o n icon.

2 . The dialog box opens at the G e o m e t r y tab page .

This page includes a sensitive icon to help you specify the geometry to be machined. The red status lig

the tab indicates that you must select the geometry in order to create the operation

q Each machining operation offers its own sensitive icon. In addition, the icon is slightly different if you are a rework area or a slope area and will have fewer parameters.


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Example: initial sensitive icon for Sweeping the same icon with a rework area

q If you are editing a rework or a slope area, anadditional information is displayed, indicating whichtype of subset you are working on. This field is noteditable (you can not go from one subset to another).

q There is also an Info button that, when pressed, gives the details on the parameters that were defined witrework area.

In the Ge o m e t r ic c o m p o n e n t tab you can define the part to machine (obligatory, the corresponding portionthe icon turns from red to green once you have defined it).

The other geometric components that you can select in the view (but that are not obligatory) are:

q the check element,

q an area to avoid,

q the safety plane,

q a top plane,q a bottom plane,

q a start plane,

q an end plane,

q inner points,

q the limiting contour,

q the offset on the part (double-click on ),

q the offset on the check element (double-click on ).

Please refer to the Reference information of each machining operation for more details.

3 . Select a part to machine:

q by clicking the part definition area: the dialog box shrinks to let you select one or several bodies.Double-click anywhere in the viewer to revert to the dialog box.

q by using the contextual menu of the part definition area:choose S e l e c t fa c e s . . . to select zones of a body with the face selection toolbar,


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4 . Select another geometry

q by clicking on a face definition area and using the face selection toolbar,

q by clicking on a contour definition area and using the edge selection toolbar.

q by passing the mouse over an element definition area:choose B o d y ( i e s ) in the contextual menu if you wish to machine a whole part and not just an area

on it,or Select zones if you wish to select zones.

q or by choosing a pre-defined area like this:

You can use Offset Groups and Features when defining geometry.


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q The types of selection by default (reached by clicking a sensitive zone) are adapted to the types of theelements to select (bodies for a part to machine, but faces for check elements, for instance).

q The contextual menus vary also with the type of elements to select.

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 can

be either positive or negative and is previewed in the viewer before it is validated.

Press O K 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 O ffs e t o n p a r tof, for example of 1mm, you can define the same offset on the imposed planes so as to ensure thatthere will be no residual material remaining on the top surface.

5 . Use P a r t a u t o l im it and the limiting contour individually or together to define the area you want to

machine:

In the pictures, the blue outline is the part edge, the yellow part is the area that will be machined, the

black line is the limiting contour:

q If you use P a r t a u t o lim it , the whole part is machined.I f you activate P a r t a u t o l im it , the tool will not go beyond the edge of the part.


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q If you use a Lim it i n g c o n t o u r ,only the area inside the limiting contour is machined.

q If you wish to machine the area outside the limiting contour,choose O u t s i d e as the S id e t o m a c h in e .

6 . Once the limiting contour is defined, you can also define the following parameters:

q Stop position defines where the tool stops:

r O u t s i d e stops the tool outside the limit line,

r I n s i d e stops inside the limit line,

r O n s t o p s the tool on the limit line.

q S t o p m o d e defines which part of the tool is considered at the S t o p p o s i t io n , whether it is thecontact point or the tool tip.

q O f f s e t is the distance that the tool that the tool will be either inside or outside the limit linedepending on the S t o p m o d e that you chose.


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You can now either run the operation on the part, store the operation that you have just defined or define otparameters in the machining strategy, tool data, speeds and rates, or macro data tabs first.


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Using Geometrical Zones

This task shows you how to define and use geometrical areas.

1 . Open file DemoRASA.CATPart in the samples directory.

2 . Click the Ge o m e t r ic a l Zo n e icon .

3 . Select the Line button, call the contour you are about to select "M y C o n t o u r" and click the

orange outline in the sensitive icon.


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4 . Select this contour:

Press OK

5 . Create a sweeping operation in the tree and select the whole body for the part.

6 . Choose S e le c t z o n e s in the limiting contour contextual menu. In the dialog box that is displa

choose M y C o n t o u r and select it with the arrow. Press OK.

7 .


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Press To o l P a t h R e p l a y .

7 . You can also define geometrical zones in an operation dialog box.

Open the sweeping operation you have just defined. Select this face as an area to avoid:

Select Ex p o r t in t h e Ar e a to avoid contextual menu and call it M y P l a n e .

Press OK. You can now use this surface in the same way as you used the contour above.


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q All geometrical zones that you create can be used in any number of operations.

q The Hide/Show item in the contextual menu does not work for geometrical zones .


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Changing the Tool Axis

This task will show you how to change the Tool Axis to define a machining operation, or a machining/area or a rework area.

Please note that the Display tool and position options are not available for the definition of amachining/slope area or a rework area.

To change the tool axis click the T o o l a x i s represented in the sensitive icon (depending on the mach

operation, the representation may change), or use Select in its contextual menu.

The Too l Axis dialog box is displayed.


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S e l e c t i o n has the following options:

You can choose between selection by C o o r d i n a t e s (X, Y, Z) or by A n g l e s . Angles lets you choose thtool axis by rotation around a main axis. An g le 1 and An g le 2 are used to define the location of theaxis around the main axis that you select.

q F e a t u r e - d e f i n e d : you select a 3D element such as a plane that will serve to automatically definebest tool axis.

q S e l e c t i o n : you select a 2D element such as a line or a straight edge that will serve to define the axis.

q M a n u a l

q P o i n t s i n t h e v ie w : click two points anywhere in the view to define the tool axis.

There is also a button that lets you reverse the direction of the axis with respect to the coordinate syorigin.

When available, you can also choose to display the tool and select the position of the tool (default or

defined).


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Power Machining: Center

This task shows you how to machine the center of a part.


2 . Create the rough stock:

q select the C re a t e s r o u g h s t o c k icon,

q pick the part,

q select P a r t B o d y as the D e s t i n a t i o n .

3 . In the M u l t i - P o c k e t s O p e r a t i o n s toolbar, pick the P o w e r M a c h in i n g icon


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and select M a c h in i n g P r o g r a m . 1 in the specification tree.



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4 . Select the Rough stock and the part to machine.

5 . Go to the M a c h i n i n g tab and make sure the M a c h in i n g s t r a t e g y is set to Center(1) only.


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6 . Press the T o o l p a t h r e p l a y button.


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Now we are going to optimize the tool path:

7 . In the G e o m e t r y tab, place the cursor on the machining direction arrow and select O p t i m i z e from its contextual menu.

Push the T o o l P a t h R e p l a y button.


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You can see that the tool path direction has been adapted to the geometry to machine, i.e. defined by the shape of each pocket and set along the main direction (X or Y).

In the M a c h i n i n g tab, in the Center parameters, go to the HSM tab and make sure the HSM option is selected.

Push the T o o l P a t h R e p l a y button. You can note that the corners are rounded.


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Power Machining: Side

This task shows you how to machine the center and the sides of a part in one shot.


2 . Create the rough stock:

q select the C re a t e s r o u g h s t o c k icon,

q pick the part,

q select P a r t B o d y as the D e s t i n a t i o n .

3 . In the M u l t i - P o c k e t s o p e r a t i o n s toolbar, pick the P o w e r M a c h in i n g icon


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and select M a c h in i n g P r o g r a m . 1 in the specification tree.



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4 . Select the Rough stock and the part to machine.

5 . Define imposed planes:

q Click one area I m p o s e d and select a first plane as shown below:


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q repeat with the other area I m p o s e d and select a second plane:


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You see that it is possible to impose two sets of planes. Using their contextual menu, you can set an offset on each of them.


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6 . Go to the M a c h i n i n g tab and make sure the M a c h in i n g s t r a t e g y is set to C e n t e r ( 1 ) a n d S i d e ( 2 ) .

7 . Press the T o o l p a t h r e p l a y button. The center and the walls are machined in one shot.


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Workbench Description

l t i - P o c k e t s M a c h i n i n g is available as an add-on to Ad v a n c e d Ma c h in i n g , S u r f a c e Ma c h in i n g ors m a t ic Ma c h in i n g .

the S t a r t / Ma c h i n in g menu, select the workbench you want to work with. Then go to the M u l t i - P o c k e te r a t i o n s toolbar that contains the P o w e r Ma c h in i n g icon:


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Reference Information

ference information that is specific to the Mu l t i- P o c k e t s Ma c h i n i n g product can be found in this sectio



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The information in this section will help you create and edit Power Machining operations in your Manufacturing Program.

In the M u lt i -P o c k e t s o p e r a t i o n s toolbar, pick the P o w e r M a c h in i n g icon

Then, in the tab select the geometric components to be machined.

In the Machining strategy tab you will find:

q A field dedicated to the choice of the machining strategy,

q a sensitive icon,

q tabs dedicated to:

r the General machining strategy,

r the Center machining,

r the Side machining.

Specify the tool to be used (only end mill tools are available for this operation) and speeds and rates .

You can also define transition paths in your machining operations by means of NCmacros as needed. These transition paths are useful to:

q optimize retract distances,

q set the Approach and Retract parameters.

Only the geometry is obligatory, all of the other requirements have a default value.

Power Machining: Strategy parameters


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M a c h i n i n g S t r a t e g y T y p e

Two types of machining are available:

q C e n t e r ( 1 ) o n l y , provides a roughing of the center of the part,

q C e n t e r ( 1 ) a n d S i d e ( 2 ) , provides a ZLevel finishing of the sides in addition to the roughing of the centers.

The sensitive icon is adapted to the type of machining strategy selected, and the Side tab becomes available if necessary.S e n s i t iv e i c o n

For C e n t e r ( 1 ) o n l y:

For C e n t e r ( 1 ) a n d S i d e ( 2 ) :


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Those drawings are for information only, 1 represents the center machining tool paths, 2 the side machining tool paths.

Tool ax i s

Place the cursor on the upper vertical arrow and right-click to display the contextual menu.

The item S e l e c t opens a dialog box to select the tool axis:

You can choose between selection by C o o r d i n a t e s (X, Y, Z) or by A n g l e s . Angles lets you choose the tool axis by rotation around a main axis. A n g l e 1 and A n g l e 2 are used to define the location of the tool axis around the main axisselect.

q F e a t u r e - d e f i n e d : you select a 3D element such as a plane that will serve to automatically define the best tool axis.

q S e l e c t i o n : you select a 2D element such as a line or a straight edge that will serve to define the tool axis.

q M a n u a l: you enter the coordinates of the tool axis.

q P o i n t s i n t h e v i e w : click two points anywhere in the view to define the tool axis.

The R e v e r s e D i r e c t i o n button lets you reverse the direction of the axis with respect to the coordinate system origin.

When available, you can also choose to display the tool and select the position of the tool (default or user-defined).

The item A n a l y z e opens the Geometry Analyser.


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M a c h i n i n g d i r e c t i o n

Available for the B a c k a n d f o r t h tool path style.

Place the cursor on the lower horizontal arrow and right-click to display the contextual menu.

The item S e l e c t opens a dialog box to select the machining direction:

You can choose between selection by C o o r d i n a t e s (X, Y, Z) or by A n g l e s . Angles lets you choose the machining direction by rotation around a main axis. A n g l e 1 and A n g l e 2 are used to define the location of the machining directiothe main axis that you select.

q S e l e c t i o n : you select a 2D element such as a line or a straight edge that will serve to define the machining direction.

q M a n u a l: you enter the coordinates of the machining direction.

q P o i n t s i n t h e v i e w : click two points anywhere in the view to define the machining direction.

The R e v e r s e D i r e c t i o n button lets you reverse the direction of the axis with respect to the coordinate system origin.

The item O p t i m i z e provides an automatic selection of the machining direction: the machining direction is defined by the shape of each pocket and set along the main direction of the pocket (X or Y).

The item A n a l y z e opens the Geometry Analyser.


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Power Machining: General Parameters

C e n t e r / S id e / B o t t o m d e f in i t io n

Used to define the thickness to leave on the sides and on the horizontal areas. They are represented as follows on the icon.

M a c h in e h o r i z o n t a l a r e a s u n t i l m i n i m u m t h i c k n e s s

If you check this option, at least the minimum thickness defined above will be left on the horizontal areas.

M a c h i n i n g t o l e r a n c e

Maximum allowed distance between the theoretical and computed tool path. Consider the value to be the acceptable chord error.

C u t t in g m o d e

Specifies the position of the tool regarding the surface to be machined. It can be:

Climb or Conventional.


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The cutting mode (C li m b / C o n v e n t io n a l) is respected on the contouring tool passes generated by the H el i ca l tool path style.69Pageti-Pockets Machining Version 5 Release 14

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M a c h in i n g m o d e

Defines the type of area to be machined:

q B y p l a n e : the whole part is machined plane by plane,

q B y a r e a : the whole part is machined area by area, (not available for the Center(1) and Side(2) strategy.

then

q P o c k e t s o n l y : only pockets on the part are machined,

q O u t e r p a r t : only the outside of the part is machined,

q O u t e r p a r t a n d p o c k e t s : the whole part is machined outer area by outer area and then pocket by pocket.

See alsoD e f in i t io n o f P o c k e t s a n d O u t e r p a r t

Power Machining: Center Parameters

Those parameters are dedicated to the roughing of the centers of the part.

Power Machining: Center Machining Parameters

Depending on the tool path style:

T o o l p a t h s t y l e

Indicates the cutting style of the operation:

q C o n c e n t r i c : the tool removes the most constant amount of material possible at each concentric pass. The tool is never directly in the heart of material. It also respects the given cutting mode in all cases. The approach mode with always Helix.The associated parameters are M a c h i n i n g t o l e r a n c e . C u t t in g m o d e , M a c h in i n g m o d e .

q H el i ca l: the tool moves in successive concentric passes from the boundary of the area to machine towards the interior. The tool moves from one pass to the next by stepping over.The associated parameters are M a c h i n i n g t o l e r a n c e . C u t t in g m o d e , M a c h in i n g m o d e , H e l ic a l m o v e m e n t , A lw a y s s t a y o n b o t t o m andF o r c e d c u t t in g m o d e o n p a r t c o n t o u r .

q B a c k a n d f o r t h : this cutting style is made of two kinds of passes:

r back and forth passes,

r part contouring passes. The contouring passes can be applied before or after the back and forth passes.

The associated parameters are M a c h i n i n g t o l e r a n c e . C u t t in g m o d e , M a c h in i n g m o d e , C o n t o u r in g p a s s andC o n t o u r in g p a s s r a t i o. You can choose to apply the H i g h s p e e d m i l li n g option to this tool path style. You can als

the machining direction.

http://e%7C/www/CATEvmuCXR14/Doc/online/cfyugtpe_C2/cfyugtpegpocket.htmhttp://e%7C/www/CATEvmuCXR14/Doc/online/cfyugtpe_C2/cfyugtpegpocket.htm

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C o n t o u r in g p a s s

Lets you decide whether the contouring passes are applied prior to or after the back and forth passes.

If the contouring passes are applied prior to the back and forth passes, the contouring passes can be computed on intermediate Z levels in order to reduce the tool loading.

In that case:

q an approach motion is done on each motion,

q the back and forth passes are organized to avoid full diameter milling,

q you can define the N u m b e r o f c o n t o u r s .

C o n t o u r in g p a s s r a t i o

This parameter is available when the tool path style is set to B a c k a n d F o r t h . It adjusts the position of the final pass for removing scallops. This is done by entering a percentage of the tool diameter (0 to 50).

H e li c a l m o v e m e n t

Specifies the way the tool moves in a pocket or an external zone. It can be:

q I n w a r d : the tool starts from a point inside the zone and follows inward paths parallel to the boundary.

q O u t w a r d : the tool starts from a point inside the zone and follows outward paths parallel to the boundary.


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q B o t h :

q for pockets, the tool starts from a point inside the pocket and follows outward paths parallel to the boundary.

q for external zones, the tool starts from a point on the rough stock boundary and follows inwardpaths parallel to the boundary.

In Helical mode, the control of the Non Cutting Diameter (Dnc) has been enhanced, in particular in the computation of the ramping approaches. This improvement may cause a computation failure, resulting in this specific message:T hc o r e d i a m e t e r i s n o t c o m p a t i b le w i t h s o m e r a m p i n g m o t i o n s .

A lw a y s s t a y o n b o t t o m

This option becomes available when at least one tool path style is set to Helical.

When machining a multi-domain pocket using a helical tool path style, this parameter forces the tool to remain in contact with the pocket bottom when moving from one domain to another. This avoids unnecessary linking transitions.

A lw a y s s t a y o n b o t t o m is not active:

A lw a y s s t a y o n b o t t o m is active:


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F o r c e d c u t t in g m o d e o n p a r t c o n t o u r

Only used with the helical tool path style.

With part contouring switched on, the tool goes round the outside contour of the part before continuing. Deactivating this option allows you to gain machining time. The tool that you are using and the part you are working on must becontouring the rough stock is superfluous.

With part contouring switched on. Note how the tool went round the area to machine first: With part contouring switched off. Note that the tool goes straight into helical mode:

Power Machining: Center Radial Parameters


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S t e p o v e r

It can be defined by:

q the O v e r l a p r a t i o , i.e. the overlap between two passes, given as a percentage of the tool diameter(T o o l d ia m e t e r r a t i o),

q the O v e r la p l e n g t h between two passes,

q the S t e p o v e r r a t i o , i.e. the stepover between two passes, given as a percentage of the tool diameter(T o o l d ia m e t e r r a t i o),

q the S t e p o v e r l e n g t h between two passes given by theM a x . d i s t a n c e b e t w e e n p a s s ,

Power Machining: Center Axial Parameters


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M a x im u m c u t d e p t h

Depth of the cut effected by the tool at each pass

V a r ia b l e c u t d e p t h s

When the dialog box opens the distance between passes from the top to the bottom of the part is constant and is the same as theM a x im u m c u t d e p t h .

Change the D is t a n c e f r o m t o p value and the Inter-pass value and then press Ad d to give a different depth value over a given distance.

In the example below the cut depth:

q from the top of the part to 15mm from the top is of 2 mm,

q from 15mm from the top to 25mm from the top is 5mm,

q and from 25 mm from the top to the bottom of the part is 10 mm.


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Power Machining: Center High Speed Milling Parameters

H i g h s p e e d m i l li n g activates and defines the parameters for High speed milling.

C o r n e r r a d i u s

Defines the radius of the rounded ends of passes when cutting with a Concentric tool path style and the radius of the rounded end of retracts with Helical and Concentric tool path styles. The ends are rounded to give a smoother path machined much faster.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 both cases a concentric tool path style is used.

Similarly, here is what retracts look like without the high speed milling option:


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And here is the same tool path with high speed milling switched on:

q With HSM and helical mode, the corner radius must be less than half the stepover distance. It will be forced to this value.

q The corner radius is not applied to the finish path.

C o r n e r r a d i u s o n p a r t c o n t o u r i n g

Specifies the radius used for rounding the corners along the Part contouring pass of a HSM operation. This radius must be smaller than the value set for the C o r n e r r a d i u s parameter

Power Machining: Center Zone Parameters

P o c k e t f i lt e r

Check this option to activate the filter for small passes. The non-cutting diameter of the tool can be entered in the Tool tab, pushing the M o r e button. It is given as an information only in the Zone tab.

Not all pockets will be machined if there is not enough depth for the tool to plunge. A null value means that tool is allowed to plunge in pockets. The size of the smallest pocket is given below the data field.


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However, the S m a l l e s t a r e a t o m a c h i n e is taken into account only if the area detected has no impact on larger areas beneath.

The Tool core diameter is taken into account:

q in pockets (default operating mode),

q also for outer parts when limiting contours are used.

When areas are filtered (i.e. not machined) with the Tool core diameter, the areas beneath those areas are not machined.

Power Machining: Side Parameters

Those parameters are dedicated to the finishing of the sides of the parts. This is done by inserting Zlevel passes after each center level is machined.

Whenever possible, the tool path must be made of arc of circles. For each side ZLevel pass, an automatic Approach and Retract are computed and have the following features:

q the approach point is situated on the longest linear segment of the area,

q an arc of circle with a particular radius (by default it is the HSM corner radius),

q a segment in order to insure that the tool plunges beside the material and that the compensation can be activated

Only the By plane machining type is available.

Power Machining: Side Machining Parameters

B o t t o m f i n is h t h i c k n e s s

Defines the thickness of material left on the bottom by the ZLevel side pass so that the tool does not touch the bottom of the previous center machining pass:

This thickness is usually very small.

C o m p e n s a t i o n o u t p u t

Defines how compensation instructions are generated in the NC data output:

N o n e : there is no compensation

2 D r a d i a l t ip : compensation is computed in a plane normal to the tool axis, and activated with respect of the cutter side (left or right). The radius compensated is the cutter radius, the output is the tool tip point (XT, YT, ZT).


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Power Machining: Side Axial Parameters

M a x im u m c u t d e p t h

Defines the maximum pass depth for the ZLevel passes: the Zlevel passes are synchronized with the center passes.Center machining by plane Side machining, step 1

Side machining, step 2 Side machining, step 3

Side machining, step 4 Side machining, step 5

Geometry


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You can also specify the following geometry:

q P a r t with possible offset.

q R o u g h s t o c k . If you do not have a rough stock you can create one automatically. You must define a rough stock if you have not already defined one in the Part Operation. See the Machining Infrastructure user's guide for further i

q C h e c k e le m e n t with possible offset. The check element is often a clamp that holds the part and therefore is not an area to be machined.

q S a f e t y p l a n e . The safety plane is the plane that the tool will rise to at the end of the tool path in order to avoid collisions with the part. You can also define a new safety plane with the Offset option in the safety plane contextual mnew plane will be offset from the original by the distance that you enter in the dialog box along the normal to the safety plane. If the safety plane normal and the tool axis have opposed directions, the direction of the safety plane ninverted to ensure that the safety plane is not inside the part to machine.


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q T o p p l a n e which defines the highest plane that will be machined on the part,

q B o t t o m p l a n e which defines the lowest plane that will be machined on the part,

q I m p o s e d p l a n e that the tool must obligatorily pass through. Use this option if the part that you are going to machine has a particular shape (a groove or a step) that you want to be sure will be cut.

If you wish to use all of the planar surfaces in a part as imposed surfaces, use the S e a r c h / V ie w . .. option in the contextual menu to select them (the Part to machine must be selected first).

When searching for planar surfaces, you can choose to find either:

q all of the planar surfaces in the part,

q or only the planes that can be reached by the tool you are using.


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When you are using planar surfaces in a part as imposed surfaces and you are using an offset on the part, select Offset in the contextual menu and then enter an offset value that is the same as the offset on part value plus the machitolerance value, e.g. if the offset on part is 1 mm and the machining tolerance is 0.1 mm, give a value 1.1mm.

This ensures that the imposed planar surface is respected to within the offset and tolerance values.

Using the two I m p o s e d icons, you can define two sets of imposed planes, with eventually a different offset on each set.

q S t a r t p o i n t where the tool will start cutting. There are specific conditions for start points:

q They must be outside the machining limit. Examples of machining limits are the rough stock contour; a limit line, an offset on the rough stock, an offset on the limit line, etc.

q They must not be positioned so as to cause collisions with either the part or the check element. If a start point for a given zone causes a collision, the tool will automatically adopt ramping approach mode.

q The distance between the start point and the machining limit must be greater than the tool radius plus the machining tolerance. If the distance between the start point and the machining limit is greater than the tool radius plus safety distance, the start point will only serve to define the engagement direction.

q If there are several start points for a given area, the one that is used is the first valid one (in the order in which they were selected) for that area. If there are several possible valid points, the nearest one is taken into account.

q One start point may be valid and for more than one area.

q If a limit line is used, the tool will approach outer areas of the part and pockets in ramping mode. towards the outside of the contour. The tool moves from the outside towards the inside of this type of area. In this case, you m udefine the start point.

If you use a limit line or if you use an inner offset on the rough stock, the start point may be defined inside the initial rough stock. The rules concerning the domain of the contour line or the offset on the rough stock contour line abovapplied.

q Concentric tool path style:Start points are automatically defined. In this case, the start point is the center of the largest circle that can be described in the area to machine. Lateral approach modes cannot be used.

q Helical Tool path styles:Whenever possible, the end of the engagement associated to the start point corresponds to the beginning of the sweeping path.


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If this is no possible, the path will be cut to respect the constraint imposed by the start point.

q I n n e r p o i n t s (only active if the Drilling mode has been selected in the Macro data tab). There are specific conditions for inner points:

q they are usable for pockets only,

q They must not be positioned so as to cause collisions with either the part or the check element. If an inner point for a given pocket causes a collision, the tool will adopt a new inner point generated automatically.

q the inner point must lay inside the pocket or inside the portion of the pocket that is machined.

q If there are several inner points for a given pocket, the one that is used is the first valid one (in the order in which they were selected) for that pocket.

q A point can not be valid for several pockets.

q L im i t i n g c o n t o u r which defines the machining limit on the part, with the Side to machine parameter.


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There is also the possibility ofs e t t i n g t h e o r d e r in which the zones on the part are machined.

Please refer to the Selecting Geometric Componentsto learn how to select the geometry.

Minimum thickness to machine

Specifies the minimum material thickness that will be removed when using overshoot or in a rework operation.

In a given level, the thickness of material left can amount up to the value of the Minimum thickness to machine + twice the value of the tolerance. Therefore, on a level below you may have to mill a thickness amounting to the value oMinimum thickness to machine + twice the value of the tolerance of one or several levels above.

Lim i t D e f i n i t i on

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 the rough stock. The yellow areas will be machined.

Side to machine: Inside

Side to machine: Outside

q If you are using a limiting contour, you should define the start point so as to avoid tool-material collision.

q The use of limiting contours is totally safe is the limiting contour is fully contained by the roughing rough stock. Example of use: restricting the machining to a group of pockets.

q But w e s t r o n g l y a d v i s e a g a i n s t using a limiting contour that is partly outside the roughing or residual rough stock. Example: roughing rework or a first roughing with a complex rough stock). In that case, we recommend that yosurface with holes or a mask to define the machining zone to work on.


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S t o p p o s i t i o n

Specifies where the tool stops:

q O u t s i d e stops the tool outside the limit line,

q I n s i d e stops the tool inside the limit line,

q On stops the tool on the limit line.

O f f s e t

Specifies the distance that the tool will be either inside or outside the limit line depending on the stop mode that you chose.

F o r c e r e p l a y button is only used for reworking operations.

Its purpose is to compute the residual rough stock remaining from operations preceding the current one, providing a rough stock has not been defined for this operation. Use it before pressingR e p l a y .

Power Machining: Macro data

For more information on how to save or load an existing macro, please refer to Build and use a macros catalog.

O p t im i z e r e t r a c t

This button optimizes tool retract movements. This means that when the tool moves over a surface where there are no obstructions, it will not rise as high as the safety plane because there is no danger of tool-part collisions. The resuin time.

q In some cases (where areas of the part are higher than the zone you are machining and when you are using a safety plane), the tool will cut into the part. When this happens, deactivate the Optimize retract button.

q The axial safety distance should be larger than the axial cut depth of the last Power Machining operation.

q Parameter O p t i m i z e R e t r a c t is only available for the part to machine, not for the rough stock.

A x ia l s a f e t y d i s t a n c e

Maximum distance that the tool will rise to when moving from the end of one pass to the beginning of the next.

M o d e

Specifies the engagement of the tool in the material:

q P l u n g e ; the tool plunges vertically,

q Dri l l ing ; the tool plunges into previously drilled holes. You can change the Drilling tool diameter, D ri l l i ng t oo l ang l e and D ri l l i ng t oo l l eng t h ,

q R a m p i n g ; the tool moves progressively down at the R a m p i n g a n g l e ,

q H el i x; the tool moves progressively down at the ramping angle with its center along a (vertical) circular helix ofH e l ix d ia m e t e r .

Those four approach modes apply to pockets.

q If the Tool Path is C o n c e n t r i c , the approach is always H el i x , either on outer areas or pockets.

q Ramping approach mode applies to pockets but also outer areas in given conditions:

q If a limit line is used, the tool will approach outer areas of the part and pockets in ramping mode.

q If a lateral approach is not possible (due to the check element), the approach is made in ramping mode.

A p p r o a c h d i s t a n c e

Engagement distance for plunge mode.

R a d i a l s a f e t y d i s t a n c e

Distance that the tool moves horizontally before it begins its approach.


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Glossary

p r o a c h The part of a tool path that ends where the tool begins to cut the material

p r o a c h fe e d r a t e The speed of linear advancement of the tool during its approach, before cutting.

m b m il li n g A cutting mode where the front of the tool (advancing in the machining direction) into the material first.

e c k e le m e n t Geometry that represents material that is not to be machined in an operation. It orepresents a clamp that holds the part to machine in place.

n t o u r - d r i v e n

a c h i n i n g

This type of machining uses a contour as guide. There are three types of contour

driven machining:q parallel contours where the tool sweeps out an area by following progressively

distant (or closer) parallel offsets of a given guide contour.

q between contours where the tool sweeps between two guide contours along a path that is obtained by interpolating between the guide contours. The ends oeach pass lie on two stop contours.

q spine contour where the tool sweeps across a contour in perpendicular planes.

n v e n t i o n a l m illin g A cutting mode where the back of the tool (advancing in the machining direction) into the material first. See Climb milling.


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t d e p t h The maximum depth of the cut effected by the tool at each pass.

e d r a t e The speed of linear advancement of the tool into the material while cutting.

o n t a l w a l l An area of the part surface that forms an inclined wall that the advancing tool wilclimb or descend.

Gid e c o n t o u r A contour used to guide the tool during an operation.

See Contour-driven machining.

p o s e d p la n e A plane that the tool must pass through. This option is useful for machining partshave grooves or steps and when you want to make sure that these areas are cut.

n e r p o in t The point where the tool will start cutting in a roughing operation when the surfacmachine has pockets.

e r a l w a l l An area of the part surface that forms an inclined wall that the tool will advance alaterally instead of climbing or descending.

m it l in e A contour that is used to delimit the areas to machine in an operation.

w e r p la n e One of the two planes normal to the tool axis that confines the area to machine. Toperation will only machine between this plane and the upper plane.

Ma c h in in g a r e a An area defined on a part either:

q during an operation as part of the machining geometry ,

q or before an operation, the operation being assigned to a machining areaafterwards.

A machining area can be:

q

the whole part (for example, in roughing),q a subset of the faces on the part,

q a subset of faces on the part with a limiting contour.

n c il o p e r a t io n s A pencil operation is one where the tool remains tangent in two places to the surfto be machined during the cycle. It is often used to remove crests along theintersection of two surfaces that were left behind by a previous operation.


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u n g e A movement where the tool plunges deeper into the material, advancing along the(negative) tool axis.

c k e t An area on a part surface that represents an internal depression (in Z) relative tosurrounding part surfaces. An internal depression is one that does not extend to toutside edge of the part.

P . R . Process Product Resources.

Rt r a c t The part of a tool path that begins where the tool stops cutting the material.

w o r k a r e a An area that cannot be machined with a given tool.

w o r k i n g An operation which touches up zones that are left completely unmachined by prevoperations.

u g h i n g An operation where a part is rough-machined by horizontal planes.

u g h s t o c k The block of raw material to be machined to produce a part.

fe t y d is t a n c e A horizontal clearance distance that the tool moves over at the feedrate in order disengage the tool from cutting between passes.

a llo p h e ig h t The maximum allowable height of the crests of material left uncut after machining

in d le s p e e d The speed of the spinning tool around its axis.

a r t p o in t The point where the tool will start cutting in a roughing operation where the surfacut is accessed from the outside of the part.

e p o v e r d is t a n c e The width of the overlap between two successive passes.

o p c o n t o u r s The two contours connecting the ends of two guide contours in contour-drivenmachining (between contours option). The ends of each pass lie on the stop conto

e e p in g o p e r a t io n s Sweeping operations machine the whole part and are used for finishing and semi-finishing work. The tool paths are executed in vertical parallel planes.

w e e p r o u g h in g An operation where a part is rough-machined by vertical planes.

p e r p la n e One of the two planes normal to the tool axis that confines the area to machine. Toperation will only machine between this plane and the lower plane.

Le v e l m a c h in i n g An operation where the tool progressively follows the part surface at different

constant Z values (heights).


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Index

Always stay on bottom

Power Machining

Analyze machining direction

Power Machining

Analyze tool axis

Power Machining

Approach distance

Power Machining

Approach modes

Power Machining

Automatic rough stock

Axial safety distance

Power Machining

Axis system

Rough Stock

Bottom finish thickness

Power Machining

Center Axial Parameters

Power Machining

Center definition

Power Machining

Center High Speed Milling Parameters

Power Machining

Center Machining Parameters


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Power Machining

Center Parameters

Power Machining

Center Radial Parameters

Power Machining

Center Zone Parameters

Power Machining

ommand

Creates rough stock

Geometrical Zone

Roughing

Compensation output

Power Machining

Contouring pass

Power Machining

Contouring pass ratio

Power Machining

Corner radius

Power Machining

Corner radius on part contouring

Power Machining

Creates rough stock

command

Cutting mode

Power Machining

orce replay

Power Machining

orced cutting mode on part contour

Power Machining

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General Parameters

Power Machining

Geometric components tab

Power Machining

Geometrical Zone

command

Geometry

Part autolimit

Helical movement

Power Machining

High speed milling

Power Machining

mposed plane

Power Machining

imit Definition

Power Machining

Machine horizontal areas until minimum thickness

Power Machining

Machining direction

Power Machining

Machining mode

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Power Machining

Machining tolerance

Power Machining

Macro data tab

Power Machining

Maximum cut depth

Power Machining

Minimum thickness on horizontal areas

Power Machining


Power Machining

Offset for limit line

Power Machining

Optimize

Power Machining

Optimize retract

Power Machining

Ordering Zones

Roughing

Overlap length

Power Machining

arameters

Power Machining

art autolimit

Geometry

ocket filter

Power Machining

ower Machining

Always stay on bottom

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7/30/2019 mpgug

93/96

Analyze machining direction

Analyze tool axis

Approach distance

Approach modes

Axial safety distance

Bottom finish thickness

Center Axial Parameters

Center definition

Center High Speed Milling Parameters

Center Machining Parameters

Center Parameters

Center Radial Parameters

Center Zone Parameters

Compensation output

Contouring pass

Contouring pass ratio

Corner radius

Corner radius on part contouring

Cutting mode

Force replay

Forced cutting mode on part contour

General Parameters

Geometric components tab

Helical movement

High speed milling

Imposed plane

Limit Definition

Machine horizontal areas until minimum thickness

Machining direction

Machining mode

Machining tolerance

Macro data tab


7/30/2019 mpgug

94/96

Maximum cut depth

Minimum thickness on horizontal areas


Offset for limit line

Optimize

Optimize retract

Overlap length

Parameters

Pocket filter

Radial safety distance

Remaining thickness for sides

Select machining direction

Select tool axis

Setting zones order

Side Axial Parameters

Side Machining Parameters

Side Parameters

Stepover

Stop position

Strategy parameters

Tool axis

Tool diameter ratio

Tool path style

Tools

Type

Variable cut depths

Radial safety distance

Power Machining

Remaining thickness for sides


7/30/2019 mpgug

95/96

Power Machining

Rough Stock

Axis system

Roughing

command

Ordering Zones

Select machining direction

Power Machining

Select tool axis

Power Machining

Setting zones order

Power Machining

Side Axial Parameters

Power Machining

Side Machining Parameters

Power Machining

Side Parameters

Power Machining

Stepover

Power Machining

Stop position

Power Machining

Strategy parameters

Power Machining

Tool axis

Power Machining

Tool diameter ratio

Power Machining

Tool path style


7/30/2019 mpgug

96/96

Power Machining

Tools

Power Machining

Type

Power Machining

Variable cut depths

Power Machining
