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1、3 Axis Surface Machining Overview Whats 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 to finish the Part Checking the results Creating a Rework Area R
2、eworking Generating an NC Output File Generating One File Per Operation Generating NC Shopfloor Documentation Area-oriented Machining Entering the workbench Defining the areas to machine Defining the tools to use Rough machining the part Sweeping the top surface Sweeping the side areas ZLevel on ver
3、tical walls Reworking between contours Generating an output file Generating workshop documentation User Tasks Recommendations Selecting Geometry Using Geometrical Zones Changing the Tool Axis Computing the Tool Gage Roughing operations Sweep roughing Roughing Ordering Zones Automatic Rough Stock Rou
4、ghing - Offset on Part Finishing and Semi-finishing Operations Sweeping 1Page 3 Axis Surface Machining Version 5 Release 15 ZLevel machining Contour-driven machining Contour-driven - Stepover Strategy Contour Driven View and Options Strategy Isoparametric Machining Spiral milling Contouring Points a
5、nd Lines Wizards Reworking Operations Pencil operations Roughing rework Machining features Defining an area to machine Defining an area to rework Offset Groups Tool path Editor Editing a point Editing an area Split on Collision Points Transformations Connecting tool paths Reversing a toolpath Approa
6、ches and Retracts in tool paths Packing a tool path Checking tool holder collision Creating Geometries Importing Files STL Files Importing Files Workbench Description Menu bar description Toolbar description Machining Operations Toolbar Tool Path Editor Toolbar Machining Features Toolbar Geometry Ma
7、nagement Minimum Tool Length Specification Tree Customizing General Resources Operation Output Program Photo/Video Reference Information Sweep Roughing Parameters Roughing Parameters 2Page 3 Axis Surface Machining Version 5 Release 15 Sweeping Parameters ZLevel Parameters Spiral Milling Parameters C
8、ontour-driven Parameters Pencil Parameters Isoparametric Machining Parameters Tool Path Editor Parameters Machining/Slope Areas Parameters Macros Parameters Glossary Index 3Page 3 Axis Surface Machining Version 5 Release 15 Overview Welcome to the 3 Axis Surface Machining Users Guide! This guide is
9、intended for users who need to become quickly familiar with the product. This overview provides the following information: G 3 Axis Surface Machining in a Nutshell G Before Reading this Guide G Getting the Most Out of this Guide G Accessing Sample Documents G Conventions Used in this Guide 3 Axis Su
10、rface Machining in a Nutshell 3 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-axis machining techniques. It is particularly adapted to the needs of mold, die and tool ma
11、kers and prototype 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 path definition for 3-axis Machining. 3 Axis Surface Machining is based on industry-recognized, leading-edge technologies which offer
12、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: G defining the areas you want to machine, G rough machining either by vertical or horizontal planes, G roughing
13、rework, G sweeping, G ZLevel machining, G pencil operations, G contour-driven operations, G profile contouring, G drilling, G detecting residual material, G defining areas to rework, G visualization of the result of the Manufacturing Program, G the production of shopfloor documentation. 4Page 3 Axis
14、 Surface Machining Version 5 Release 15 3 Axis Surface Machining gives you the freedom to choose the working methods that best suit your needs. Before Reading this Guide Prior to reading the 3 Axis Surface Machining Users Guide, you are recommended to have a look at the Infrastructure Users Guide fo
15、r information on the generic capabilities common to all products. Getting the Most Out of this Guide 3 Axis Surface Machining is a versatile application, fully adapted to your needs and your working methods whether they are machining area-oriented or operation-oriented. You can either define the mac
16、hining areas on your part and then assign an operation to each of them or you can define your machining process as a series of operations with an area to machine for each operation. A machining area can be: G the whole part (for example, in roughing), G a subset of the faces on the part, G a subset
17、of faces on the part with a limiting contour. The Getting Started chapter contains two sections, one which demonstrates operation-oriented machining and another which demonstrates area-oriented machining. Before starting work with Surface Machining, please ensure that you have an open file (CATPart
18、or CATProduct) and that you are in the Surface Machining workbench (Start Machining Surface Machining). Here is a suggested order for operations in a Manufacturing Program: G rough machining operations, G (semi-)finishing operations, G detection of unmachined areas, G reworking of unmachined areas,
19、G generation and output of documentation. Area-oriented methodology is useful when you have a complex part to machine and you know in advance what kind of operation you are going to apply to each separate area. This approach is of great use when, for example, you are going to machine a “family“ of s
20、imilar parts and when you have dedicated machines for mass production. You define the areas on one part, you assign an operation to each area, and then you machine. At the end you have a program that you can apply to all of the “members“ of the “family“ at least working cost because: 5Page 3 Axis Su
21、rface Machining Version 5 Release 15 G the machining strategy has already been defined (chosen operations), G the tool has already been defined, G only the area need be redefined, G you know exactly what kind of output you require, G and as a result the computation can be run in batch to further red
22、uce 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 particular operation. 3. Click the appropriate icon (for example, sweeping). 4. Change the parameters in that operation (if required). The only mandatory data for
23、a operation is the area to machine (with the exception of roughing which requires a rough stock too) and all of the other parameters have default values. We recommend that you use the default parameters first unless you are sure of the values you wish to enter. Compute the operation. If the results
24、are satisfactory, repeat steps 2, 3, and 4 for all of the other areas to machine. Use operation-oriented machining when you want to progressively define your Manufacturing Program operation-by-operation sequentially. Each operation has the area it deals with defined as part of its data. This approac
25、h is useful for single or limited part production because it 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 context
26、ual menu or as a face or group of faces with the face selection wizard. 4. Change the other parameters in the operation (if required). The only mandatory data for a operation is the area to machine (with the exception of roughing which requires a rough stock too) and all of the other parameters have
27、 default values. We recommend that you use the default parameters first unless you are sure of the values you wish to enter. 6Page 3 Axis Surface Machining Version 5 Release 15 Compute the operation. If the results are satisfactory, continue defining the remaining operations for your Manufacturing P
28、rogram. Accessing Sample Documents To perform the scenarios, sample documents are provided all along this documentation. For more information about this, refer to Accessing Sample Documents in the Infrastructure Users Guide. 7Page 3 Axis Surface Machining Version 5 Release 15 Whats New? No enhanceme
29、nts in this release. 8Page 3 Axis Surface Machining Version 5 Release 15 Getting Started Before getting to grips with all of the Surface Machining capacities, here are two short step-by step tutorials that will help guide you through the key functionalities. You will learn how to use the functions l
30、isted below and learn how to define areas on the part to machine, use specific machining operations on the part and output data. There are two ways of defining your Manufacturing Program, you can either base it on operation definition or on area definition. Try both tutorials to see which method sui
31、ts your working techniques best. The tutorials should take you 30 minutes each to complete. Operation-oriented Machining Area-oriented Machining 9Page 3 Axis Surface Machining Version 5 Release 15 Operation-oriented Machining Operation-oriented machining is a method where you define each operation o
32、ne-by-one. When you define an operation you decide (using the geometry tab) which areas of the part you want to machine with that particular operation. This tutorial teaches you how to: G define the operations necessary for the machining of the part below, G run the program to create the tool paths,
33、 G check for residual material, G rework the unmachined areas, G and produce an APT file and a workshop document. 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 to finish the Part Checking the results
34、Creating a Rework Area Reworking Generating an NC Output File Generating One File Per Operation Generating NC Shopfloor Documentation 10Page 3 Axis Surface Machining Version 5 Release 15 Entering the Workbench This task shows you how to open a part and enter the Surface Machining workbench. 1. Open
35、the SurfaceMachining3.CATProduct file in the samples directory. 2. Select Machining 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 the Machining specifications. 3. Select
36、Product1 containing the shape to machine and the rough stock in the specifications tree and display them in wireframe mode using the View/Render Style/Customize View command: 11Page 3 Axis Surface Machining Version 5 Release 15 Double click Part Operation.1 in the tree. In the dialog box that is dis
37、played click the design part icon. 12Page 3 Axis Surface Machining Version 5 Release 15 Select Open-body.1 in Shape to Machine in the tree and double click in the viewer to validate your selection and redisplay the dialog box. Then click the stock icon, select PartBody in Rough Stock in the tree and
38、 double click in the viewer to redisplay the dialog box. Click OK to confirm. The design part defines the reference part that will be used by the application to compute the residual material. The rough stock is the rough stock for the overall part. Each successive operation works on the residual mat
39、erial that is left by the operation before it in the Manufacturing Program. 13Page 3 Axis Surface Machining Version 5 Release 15 4. Select Manufacturing Program.1 (under PartOperation.1) in the specifications tree to make it the current entity. A program must be current before you can insert program
40、 entities such as machining operations, tools and auxiliary commands. 14Page 3 Axis Surface Machining Version 5 Release 15 Rough Machining the Part This task shows you how to insert a rough machining operation in the program. In this operation you will specify the geometry, the tool path style and t
41、he tool characteristics. 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 that you must select the part geometry in order to create the operation
42、. 2. Click the red area that represents the part. 15Page 3 Axis Surface Machining Version 5 Release 15 The dialog box shrinks to allow you to select the part in the viewer. 3. In the viewer, click the part. Double click anywhere in the viewer to confirm your selection and to redisplay the dialog box
43、. The red area in the geometric area is now green to indicate that the geometry has been selected. 4. Click the sensitive area that represents the rough stock. The dialog box shrinks to allow you to select the rough stock in the viewer. 5. In the viewer, click the geometry that defines the rough sto
44、ck. The red area in the geometric components tab is now green to indicate that the geometry has been selected. 16Page 3 Axis Surface Machining Version 5 Release 15 6. Go to the Machining strategy tab () and select Helical as Tool path style. 17Page 3 Axis Surface Machining Version 5 Release 15 7. Go
45、 to the Tool tab () and change the Name of the tool to T1 End Mill D20. Then press the More button. 18Page 3 Axis Surface Machining Version 5 Release 15 Change: G Nominal diameter (D) to 20mm G Corner radius (Rc) to 2 mm G Overall length (L) to 120 mm G Cutting length (Lc) to 90 mm 19Page 3 Axis Sur
46、face Machining Version 5 Release 15 8. Click Tool Path Replay . The tool path is displayed and the display and analysis dialog box is called up. 9. Click OK. The tool path is erased from the viewer and you come back to the operation dialog box. 10. Click OK to close the dialog box. Now we are going
47、to use ZLevel machining on the walls of the pocket and the outside of the part. 20Page 3 Axis Surface Machining Version 5 Release 15 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
48、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
49、be inserted after it. 1. Select the ZLevel icon . A Zlevel.1 entity is added to the program. The Zlevel dialog box is displayed. 21Page 3 Axis Surface Machining Version 5 Release 15 2. Call the contextual menu of the sensitive red area that represents the part and choose Select faces. The dialog box shrinks and the face selection toolbar 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