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1、OPEN MIND . THE CAM COMPANY Version 8.1 5 Axes Machining hyperMILL -25 AXIS Version 8 This manual applies to the software package 5 Axes Machining, Version 8.1, that is available as an optional module to to hyperMILL , hyperMILL in Autodesk Mechnical Desktop, hyperMILL in Autodesk Inventor and hyper
2、MILL in Pro/ENGINEER WildfireTM. As we constantly work on further developments, we reserve the right to make changes. OPEN MIND Technologies AG All rights reserved. Reproduction in any form is prohibited except with the express written permission of OPEN MIND Technologies AG. The contents of this ma
3、nual as well as the accompanying software are the property of OPEN MIND Technologies AG. Printed in Germany 10/04 http:/www.openmind- -35 AXIS Version 8 Symbols Used Text sections in all OPEN MIND documentation are marked with symbols to assist quick and easy access to information. The following sym
4、bols are used: Functions purpose and application Description of operating sequences Special notes and background information Alert to possible sources of error Additional information on individual parameters Cross-reference to other menus or administration levels Chapter or page references Example;
5、special use for a function Preparations, requirements for a function or for subsequent job 5 AXIS Version 8-4 Abbreviations Used FRMFrame = Machining Coordinate System NCSNumerical Control System, Program Zero Point WCSWorld Coordinate System 5 AXIS Version 8Content-1 1Overview:5X Cycles 1.1 Handboo
6、k Structure .1-2 1.2 Overview: 5X cycles1-2 1.2.1 Terms.1-2 1.2.2 Settings.1-3 1.3 Approach/retract macros 1-4 2Cavity Cycles 2.1 5X Cavity Machining 2-2 2.2 Overview of Cycles.2-3 2.3 General Basic Settings 2-6 2.3.1 Job List Setup 2-6 2.4 Settings in the Cycles2-6 2.4.1 Tool Check.2-6 2.5 Paramete
7、rs (only Cutting edge).2-6 2.6 The 5X Parameters .2-7 2.6.1 Position Strategies .2-7 2.6.1.1Overview . 2-7 2.6.1.2Offset curve . 2-8 2.6.1.3Inclination curve . 2-10 2.6.1.4Radial curve . 2-13 2.6.2 Tilt angle .2-15 2.6.3 Path smoothing.2-16 2.6.4 Automatic indexing .2-17 2.6.4.1Automatic segment bou
8、ndaries . 2-18 2.6.4.2Manual segment boundaries 2-18 2.6.4.3Connection macro . 2-19 2.6.5 Fixed inclination of the rotary axes.2-20 2.7 5X Free Path Milling .2-20 3Surface Cycles 3.1 5X Surface Machining 3-2 3.2 Overview of Cycles.3-3 3.3 The 5X parameters.3-5 3.3.1 Position Strategy3-5 3.3.2 Synchr
9、onisation Lines.3-6 3.4 Contouring.3-7 3.4.1 Parameters: .3-7 3.4.2 Macros:.3-8 3.5 Swarf Cutting with 1 Curve3-9 3.5.1 Strategy.3-9 3.5.2 Parameters 3-10 Content-25 AXIS Version 8 3.5.3 Macros 3-11 3.5.4 5x Parameters . 3-11 3.5.5 Settings. 3-11 3.6 Swarf Cutting with 2 Curves 3-12 3.6.1 Strategy:
10、. 3-12 3.7 ISO Top Milling. 3-13 3.7.1 Strategy 3-13 3.7.2 5X Parameters. 3-14 3.8 Drilling. 3-15 3.8.1 Parameters 3-15 3.8.2 Contours. 3-15 4Blade Cycles 4.1 5X Turbine Blade Machining. 4-2 4.2 Overview of Cycles. 4-2 4.3 Basics (only 5X Cycles) . 4-3 4.4 Strategy. 4-4 4.5 Parameters. 4-6 4.6 5X Pa
11、rameters . 4-7 4.7 3D Roughing . 4-9 4.7.1 Strategy 4-9 4.7.2 Boundary 4-9 4.8 Top milling. 4-10 4.8.1 Strategy 4-10 4.9 Swarf cutting. 4-11 4.9.1 Strategy 4-11 4.9.2 Parameters 4-11 4.9.3 5X Parameters. 4-13 5Tube Cycles 5.1 5X Tube Machining 5-2 5.2 Overview of Cycles. 5-3 5.3 Strategy. 5-4 5.4 Pa
12、rameters. 5-7 5.5 5 Axes-Parameters . 5-9 6Multiblade Cycles 6.1 Overview of Cycles. 6-2 6.2 Tools 6-5 6.3 Geometry 6-5 6.3.1 Model Data. 6-5 5 AXIS Version 8Content-3 6.3.2 Coordinate System 6-6 6.3.3 Selecting the Geometry .6-7 6.4 Job Settings and Collision Checks.6-10 6.5 MB Roughing.6-12 6.5.1
13、Strategy.6-12 6.5.2 Parameters 6-15 6.5.3 5 Axes.6-23 6.5.4 Macros6-25 6.6 MB Hub Finishing.6-26 6.6.1 Strategy.6-26 6.6.2 Parameters 6-28 6.6.3 5 Axes, Macros6-29 6.7 MB Point Milling.6-30 6.7.1 Strategy.6-30 6.7.2 Parameters 6-31 6.7.3 5 Axes.6-34 6.7.4 Macros6-35 6.8 MB Flank Milling.6-36 6.8.1 S
14、trategy.6-36 6.8.2 Parameters 6-37 6.8.3 5 Axes.6-38 6.8.4 Macros6-39 6.9 MB Fillet Milling6-40 6.9.1 Strategy.6-40 6.9.2 Parameters 6-41 6.9.3 5 Axes, Macros6-42 6.10MB Edge Milling.6-42 6.10.1Strategy.6-42 6.10.2Parameters 6-43 6.10.35Axes6-44 6.10.4Macros6-45 Content-45 AXIS Version 8 Overview:5X
15、 Cycles 1-25 AXIS Version 8 Overview:5X Cycles 1Handbook StructureTerms 1.1 Handbook Structure 1.2 Overview: 5X cycles 1.2.1Terms Overview: 5X cyclesThe basic settings in the cycles shown in this chapter apply to all 5X cycles. Information for all cycles in a packageInformation that applies to all c
16、ycles of a package is summarised at the beginning of the respective chapter. Cycle-specific informationSpecial parameters and settings that only apply to a specific cycle are dealt with in the following chapters. Orientation of the axes 1st rotary axis: Rotation around Z - corresponds to the C axis
17、2nd rotary axis: Position to Z - normally corresponds to the A or B axis 5 AXIS Version 81-3 Overview:5X Cycles 1Overview: 5X cyclesSettings 1.2.2Settings NC parametersMaximum angle increment The maximum angle increment restricts the permissible change of the tool position between two points. The ma
18、ximum G1 length as well as the value for the maximum angle increment depend on the interpolation capability of the RTCP or comparable commands of the controllers. Tool checkIn addition to the known factors (see hyperMILL and hyperFORM product documentation), the complete definition of the tools and
19、tool holder form the basis for proper collision monitoring during 5-axis machining. Collision check When the collision check is activated, the toolpath is only calculated and executed up to the collision situation. Since the collision check can only check against model geometry, and not the (potenti
20、ally) present material, the tool holder dimensions should be assigned generously. 1-45 AXIS Version 8 Overview:5X Cycles 1Approach/retract macrosSettings 1.3 Approach/retract macros The collision check should only be deactivated, if based on the Model geometry Tool holder geometry and Defined tilt a
21、ngle no collisions, with absolute certainty, are to be expected (quicker calculation of the toolpaths). Collision avoidance If a potential collision of the tool tip or tool holder is determined, the system modifies the defined tilt angle accordingly. If there is no possible tilt angle that prevents
22、a collision, the toolpath is only calculated and executed up to the collision situation. Additional axial distance Increases the approach and retract path of the macros in the tool axis direction. Cavity Cycles 2-25 AXIS Version 8 Cavity Cycles 25X Cavity Machining 2.1 5X Cavity Machining The cycles
23、 in the “cavity machining” package are primarily used for 5-axis machining of cavities and steep domes without undercuts for which unfavourable process parameters result in 3-axis machining. Simultaneous machining Calculation of NC paths with simultaneous movement of all 5 axes. Automatic indexing (
24、5-2) Calculation of NC paths with automatic division into segments with fixed axis position as well as simultaneous movement of all 5 axes for the transitions between segments. Fixed inclination Calculation of NC paths with fixed tool position in the entire machining area. The package contains the f
25、ollowing cycles: 5X Z-Level roughing 5X Z-Level finishing 5X Profile finishing 5X Equidistant finishing 5X Rest machining 5X Free path milling 5X Rework 5X Cutting edge 5 AXIS Version 82-3 Cavity Cycles 2Overview of Cycles 2.2 Overview of Cycles 5X Z-level roughing Machining cavities in 3D Z-level r
26、oughing mode with collision avoidance. If collisions occur, an automatic transition to a 5X strategy occurs. Tools: Ball mills 5X Z-level finishing Machining a plane or pocket of steep surfaces with smooth transitions between the machining levels. Tools: Ball mills 5X profile finishing Detail machin
27、ing across surfaces for flat and/or slightly curved surfaces. Usability restricted to 5-axis roughing. Tools: Ball mills 2-45 AXIS Version 8 Cavity Cycles 2Overview of Cycles 5X equidistant finishing Machining of floor areas in cavities as well as flatly curved surface formations with smooth transit
28、ions between the individual toolpaths. Tools: Ball mills 5X rest machining Rest machining includes all strategy variations of 3D machining. The additional simultaneous tool positioning reduces the required cutting length of the generally thin tools. Tools: Ball mills 5X free path milling Free path c
29、utting performs collision- checked machining along a freely specifiable center point path with multiple axial infeed. It is possible to machine undercuts. Tools: Ballmill, endmill and bullnose endmill 5 AXIS Version 82-5 Cavity Cycles 2Overview of Cycles 5x Rework Machining 5-axis machining is calcu
30、lated for any prior (3D/5X) reference job. Tool paths that are hidden due to collisions can thus be machined using a 5-axis strategy; the automatic collision check ensures absolute collision avoidance for the selected tool. The same tool that was used in the prior reference job, or any other tool, c
31、an be used. Tools: Ballmill, endmill and bullnose endmill 5X Cutting edge Machining of 3D cutting edges with undercuts lacking guide surfaces. Automatic calculation of the tool position and automatic indexing. Tools: Ballmill, endmill and bullnose endmill 2-65 AXIS Version 8 Cavity Cycles 2General B
32、asic SettingsJob List Setup 2.3 General Basic Settings 2.3.1Job List Setup 2.4 Settings in the Cycles 2.4.1Tool Check 2.5 Parameters (only Cutting edge) Tool reference pointThe tool reference point should be set to center point in the job list setup. In particular for strong tilting movements betwee
33、n two points, the center point path is considerably smoother than a path with “tip” reference point. Always activate both collision functions in narrow cavities and/or for small desired tilt angles. Tool position Left of contour / Right of contour The tool moves to the right/left of the cross-sectio
34、n contour. Major cutting edge hight Defines the offset of the contour along which the tool is guided in the direction of the Z axis. Minor cutting edge hight Defines the depth of the undercut by an axial offset of the tool reference point. Cross-section contour Height of major cutting edge minor cut
35、ting edge 5 AXIS Version 82-7 Cavity Cycles 2The 5X ParametersPosition Strategies 2.6 The 5X Parameters 2.6.1Position Strategies 2.6.1.1Overview In all cycles of 5X cavity machining, the tools are oriented about the Z axis of the selected frame from the contact situation with the shortest distance t
36、o a guide curve. Three different position strategies are avai- lable: Position strategy Z-level finishing Profile finishing Equidistant finishing Rest machining Curve machining Offset curve The position curve is automatically calculated in each machining level according to a freely specifiable offse
37、t value. x-xx- Inclination curve Alignment of the tool shank to the guide curve. xxxxx Radial curve Alignment of the tool tip to the guide curve. xxxxx 2-85 AXIS Version 8 Cavity Cycles 2The 5X ParametersPosition Strategies 2.6.1.2Offset curve The offset curve is used for orienting the tool shank. W
38、ith this strategy, the system forms a curve that corresponds to the defined off- set value in each machining level for the calculated center point path of the tool. The surfaces to be machined must not be too flat, as there is then the possibility that no useful offset curves can be formed. Size of
39、the offset value Using the offset variable, you can control how precisely the positioning of the milling tool follows the surface profiles. 5 AXIS Version 82-9 Cavity Cycles 2The 5X ParametersPosition Strategies Large offset values reduce the rotary motion around the Z axis in small narrow areas. Ho
40、wever they increase the danger of the offset curve breaking down into numerous, separate curves and then switching over to 3-axis machining. If the offset strategy results in a large number rotary motions around the Z axis that are not necessary for milling, the inclination or radial curves should b
41、e used. If it is not possible to avoid a break- down into individual curves, the machi- ning should be divided up into several jobs with different machining areas and different offsets. 2-105 AXIS Version 8 Cavity Cycles 2The 5X ParametersPosition Strategies 2.6.1.3Inclination curve The inclination
42、curve is used for orienting the tool shank. It normally lies in front of the surface to be machined from the tool axis perspective. Profile of the inclination curveThe movement of both rotary axes can largely be guided independently of the surface formation of the machining area, using the user-defi
43、ned inclination curve. Compared to the offset strategy, a more harmonious movement sequence around the Z axis of the selected frame can be achieved. The inclination curve should Be only roughly oriented to the profile of the surfaces Have a smooth profile without abrupt changes in direction Enable c
44、ontinuous movements of the rotary axes C axis C axis Path (Length) Path (Length) Offset curve Inclination curve 5 AXIS Version 82-11 Cavity Cycles 2The 5X ParametersPosition Strategies Z height of the inclination curveIf the tool axis arrives at the curve, the tool is positioned to it, possibly up t
45、o a perpendicular position. Depending on the machining conditions, this can allow the tilt angle and the move- ment guidance of the second rotary axis to be influenced using the Z height of the inc- lination curve. 1. Constant tilt angleTo attain a constant tilt angle, the inclina- tion curve must b
46、e defined such that cut- tings with the tool axis are avoided during machining. The inclination curve should normally be as deep as possible. If necessary, create several jobs with different inclination curves. 2. Modifiable tilt angleaAvoiding collisions To avoid collisions between tool shank and m
47、odel surfaces of the opposite wall, set the inclination curve high enough in order to position the tool onto it while the machining depth is increasing. 2-125 AXIS Version 8 Cavity Cycles 2The 5X ParametersPosition Strategies bSmooth tilting of the second rotary axis For back-and-forth machining of
48、basic surfaces, it also is recommended to set the inclination curve higher. Since the positioning of the tool on the inclination curve then begins earlier and ends later, it results in a smoother move- ment guidance of the second rotary axis. 5 AXIS Version 82-13 Cavity Cycles 2The 5X ParametersPosi
49、tion Strategies 2.6.1.4Radial curve The radial curve is used for orienting the tool tip. It normally lies behind the surface to be machined from the tool axis perspective. The radial curve allows for, in particular, a specific definition of the position direction for convex surfaces. Profile of the radial curveThe same criteria apply to the profile of the radial curve as to the inclination curve (cf. also chap. 2.6.1.3) Z height of the radial curveWhen the tool axis arrives at the curve, the tool is positioning onto it, possibly up to a perpendicular