DELMIA Surface Machining - Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xTABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Machining Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Area Oriented Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Operation Oriented Machining Operations . . . . . . . . . . . . . . . . . . . . . . . . . . 3Mill-Turn Machining Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Specifications Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Mill-Turn Machining Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Roughing Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Sweep Roughing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Geometry Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Roughing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Geometry Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Machining Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Macros Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96Roughing Rework Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107Geometry Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108Machining Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Surface Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132ZLevel Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Spiral Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152Pencil Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163Contour Driven Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Advanced Finishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193Isoparametric Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Geometry Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199Machining Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202 Wichita State UniversityTable of Contents, Page i
DELMIA Surface Machining3DEXPERIENCE R2019xProfile Contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211Between Two Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212Between Curve and Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213Machining Surfaces and Solids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225Multi-Axis Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Rotary Axis Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243Five Axis Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Multi-Axis Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277Macros . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305Multi-Axis Contour Driven . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Machining Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Multi-Axis Isoparametric Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317Multi-Axis Flank Contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Strategy Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Multi-Axis Curve Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Multi-Axis Helix Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Multi-Axis Tube Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Practice Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415SMAC - Problem1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415SMAC - Problem2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416SMAC - Problem3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417SMAC - Problem4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418SMAC - Problem5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419SMAC - Problem6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420SMAC - Problem7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421SMAC - Problem8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422SMAC - Problem9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423SMAC - Problem10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Machining - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Machining - Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427Machining - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Machining - Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Machining - Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Machining - Photo/Video . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Machining - Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Table of Contents, Page ii Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xIntroductionDELMIA Version 6 Surface MachiningUpon completion of this course, you should have a full understanding of the followingtopics.-Use the Surface and Advanced Machining workbench to machine complexcontours and part surfaces-Machine through the use of various roughing, sweeping, and reworkingoperations-Integrate Prismatic Machining, Surface Machining, and AdvancedMachining workbenches together to get a full range of manufacturing tools-Machine through the use of multiple part operations and stock material atvarious stages-Machine surfaces as well as part bodies-Machine complex parts utilizing multi-axis machining operation Wichita State UniversityIntroduction, Page 1
DELMIA Surface Machining3DEXPERIENCE R2019xRoughingSweep roughing works well when a series of surfaces need to be machined. Unfortunately,not all parts are simple surfaces. Many times pockets, channels, or various other featuresare present, which the sweep roughing operation does not work well with. This is where theRoughing Operation comes into play.Open the SMAC030 - Roughing process document. This machining process alreadyhas the Part Operation geometry and parameters defined.Select the Roughing icon and select Manufacturing Program.1.window appears.The RoughingThe basic geometry definition of the roughing operation is the same as the sweep roughing,with a few extra options. Take a quick look at the sensitive area of the geometry definitiontab.Note: Many of the options found here are the same as what you investigated in the SweepRoughing operation. If you find an option that you would like more information on, pleaserefer to the Sweep Roughing section. Wichita State UniversityRoughing Operations, Page 67
DELMIA Surface Machining3DEXPERIENCE R2019xGeometry TabStart point(s)Defines a point or multiple points that the roughing operation canstart from.Rough stockDefines the rough stock around the part. If a rough stock is definedin the part operation setup, then it is not necessary here.ImposedDefines an imposed plane position. This will require the tool to makea pass at that Zlevel. This option is useful when machining with flatregions.Zone orderDefines what areas are to be machined in what order. With thecontextual menu, you can also require that only ordered zones getmachined.Tool/Rough StockRoughing Operations, Page 68 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xMinimum thickness. Defines the minimum amount of material that will beremoved when performing a reworking operationLimit DefinitionThese options become available when you define a Limiting Contour.The options are the same as what you learned in the SweepRoughing.Ignore holes on.Ignores holes in the rough stockDiameterDefines the size of holes to ignoreCompute with tool. Computes the tool path to avoid collisions with the tool holderOffset on assemblyForce ReplayDefines the offset on the tool holder assemblyWhen using the Roughing operation as a reworking operation, ForceReplay will calculate the rough stock remaining on the finished part,allowing for tool paths to be computed. Typically, forcing the replayis not needed.If you remember from the Sweep Roughing operation, you can select the part definition,and then select the part body. There is also a contextual menu available for the partdefinition.With the third mouse button, select on the Part definition. This will display thecontextual menu.Select faces.Allows you to select only a few faces to machineDesign on PO.Allows you to use the part defined at the Part Operation levelRemoveAllows you to remove a body, or surfaces from the part selectionAnalyze.Displays a part analysis window that will highlight the surfaces orbodiesSelect zonesAllows you to select pre-defined zones to machine through the ZoneSelection windowExportAllows you to save the part definition as a zone, later to be selectedwith Select Zones Wichita State UniversityRoughing Operations, Page 69
DELMIA Surface Machining3DEXPERIENCE R2019xNow to actually define geometry to machine the part.Select the Part Definition, then select the design part. You may have to hide the stockmodel or select the design part from the specification tree.Double select in space when done. Remember, you can always define multiple parts tomachine. Therefore, when done selecting the parts you want to machine, you must alwaysdouble select in space to finalize the selection.Select the Tool parameters tab and define the SMAC030 - T0 End Mill D 1.0 x 0.25 x6.0 L tool for the operation. It should appear as shown.Roughing Operations, Page 70 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xReplay the operation. Notice that by simply defining the part definition, you have giventhe roughing operation enough information to machine the part. As you can see, theroughing operation is designed to take a piece of stock material and convert the entire solidinto chips until it reaches the design part. The remaining parameters help control how itmachines the part.Change the Offset on part to be 0.125in. This will tell the roughing operation to leave an1/8th inch on the part surface. The surfaces will be finished with other operations.Since the rough stock is defined in the Part Operation, it is unnecessary to define it here. Ifyou did not define the stock material, or are using a separate CGR file as the stock, then youwould want to select the Rough Stock sensitive area, and select the appropriate stockmaterial. Wichita State UniversityRoughing Operations, Page 71
DELMIA Surface Machining3DEXPERIENCE R2019xWatch the replay with material removal. Notice that the entire stock material withinreach of the tool is removed. Also the side of the part has divots where the holes exist.This is common to the roughing operation. If the holes in the flanges were large enough orthe tool small enough, they would be roughed out as well.Switch to the geometry tab. You are going to work with the various Tool / Rough Stockoptions.Select the Imposed plane and the plane as shown. The imposed plane allows you todefine flat planar areas that the tool will make a pass on. This is also helpful to definepoints that must be cut by the tool.Roughing Operations, Page 72 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xReplay the operation. There is now a tool path at the same level as the imposed plane. Ifyou look close, you should notice that the tool does not actually cut the top of the part.Even though you imposed the plane, the offset on part is always obeyed. This is why thetool does not cut across the top of the part.With the third mouse button, select on the Imposed plane. This will bring up thecontextual menu for the imposed plane.Select Offset and set it to 0.050in. This will make the tool pass 0.050in above the imposedplane. Wichita State UniversityRoughing Operations, Page 73
DELMIA Surface Machining3DEXPERIENCE R2019xEven though you have added a 0.050in offset, the tool still does not cut at the imposedplane location. Until you make the imposed plane offset equal the Offset on part the toolwill not cut at the imposed plane.Change the offset on the Imposed plane to 0.125in and replay. This will set the imposedplane offset equal to offset on the part. Now the tool cuts at the imposed plane location. Nomatter what you define the Offset on part will never be violated.This method of defining imposed planes works, but what happens when a lot of planes needto be selected? There is another option to define imposed planes.With the third mouse button, select on the Imposed plane and select Remove. This willremove all the imposed planes.With the third mouse button, select on the Imposed plane again and selectSearch/View. This will display the Imposed planes search/view window.The Imposed planes search/view window will seek out all horizontal planes on the definedfinished part and display them in the Not Selected frame. You can then decide which planesneed to be imposed and which do not.Roughing Operations, Page 74 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xSelect All planes from the Imposed planes search/view window. This will display all ofthe horizontal planes on the finished part.Select on the -0.625in depth. Notice areas highlight in red. This allows you to visuallyinspect the area that will be imposed before making your decision.Select the Reachable planes button in the Search frame of the Imposed planessearch/view window. This time, the list is reduced to the horizontal areas that can bereached by the tool. In this case, the 0.5in plane was removed. If other non-reachableplanes existed, they would have been removed as well. Wichita State UniversityRoughing Operations, Page 75
DELMIA Surface MachiningSelect the -0.625in depth, then select the Right Arrow icon.0.625in into the Selected field.3DEXPERIENCE R2019xThis will move the -Move the -1.875in and -3.125in depths into the selected field as well. This will causethe tool to machine all three horizontal planes.Select OK. This will make all the planes imposed. They should be called out in thedisplay.You can always go back and analyze the geometry that you have attached various areas toby using the Geometry Analyzer.With the third mouse button, select on the Imposed plane definition, and selectAnalyze. This will display the Geometry Analyzer window.Roughing Operations, Page 76 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xSelect the Imposed#1: 1 item from the list. The top face representing that plane will turna teal blue, indicating what plane is currently selected. The other faces representing planes2 & 3, are royal blue.Select the Imposed#1: 3 item from the list. This will change the teal emphasis from theupper plane, to the plane down inside the slot.The Geometry Analyzer works with any geometry specification area. Any time you wish toview what has been selected, or what another user used in the definition of a geometry item,the Geometry Analyzer is exceptionally useful.Select Close. It is not always necessary to ensure the selection of the surfaces, butsometimes, it is nice to know what was defined.This now has the tool passing 0.125in above each of the three selected horizontal areas.Before moving on, there is one last option that needs to be set.Select the Bottom definition, then select the bottom of the part. This will keep the toolfrom cutting into the vise below the part.Change the offset on the Imposed plane to 0.050in. Wichita State UniversityRoughing Operations, Page 77
DELMIA Surface Machining3DEXPERIENCE R2019xWatch the replay with material removal. Notice the overall progress of the machining.You will see that the center holes in the part are machined prior to the exterior profile.Select the Zone order from the geometry definition area. The zone order allows you todefine pockets or areas in the order you want them machined.Select both of the outer boundary surfaces around the bottom of the part. This willidentify the first two zones to be machined.Double select in space when done. This will indicate that you are done selecting zones.Roughing Operations, Page 78 Wichita State University
DELMIA Surface Machining3DEXPERIENCE R2019xReplay the operation. The exterior profile is now the first to be machined.Gene
- Integrate Prismatic Machining, Surface Machining, and Advanced Machining workbenches together to get a full range of manufacturing tools - Machine through the use of multiple part operations and stock material at various stages - Machine surfaces as well as part bodies - Machine complex parts utilizing multi-axis machining operation
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There are different types of machining process used for sapphire material. The fig. 1 shows a graphical representation of sapphire machining processes i.e. laser machining process, grinding process, polishing process, lapping process, new developed machining process, compound machining process and electro discharge machining process. Fig.1.
Machining metals follows a predictable pattern with minimal creep. When machining plastics, quick adjustments must be made to accommodate substantial creep — not to mention that the material has a strong propensity for chipping and melting during machining. Simply stated, the basic principles of machining metals do not apply when machining
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