CAM Basic 1 - Getting Started with WorkNC V23 · Table of Contents ... Catia® V4/V5/V6, Parasolid®, Unigraphics®, ProE®, CADDS®, SolidWorks ... You can change this path for all

Training Guide

CAM Basic 1 Getting Started with WorkNC

Table of Contents

Copyright 2014 © Sescoi International i SESINT_EN_WNCBAS1 240414 - CAM Basic 1

Table of Contents

1 Training Guide Objectives 1-1

2 Introduction 2-1

2.1 Part Geometry Preparation 2-1

2.2 Starting WorkNC 2-2

3 Workzones 3-1

3.1 Creating a New Workzone in the CAM Mode 3-1

3.2 Creating a Workzone in the CAD Mode 3-7

3.3 Opening/Closing Workzones and CAD Files 3-11

4 Manipulating Parts 4-1

4.1 Predefined Orientations 4-1

4.2 Dynamic Rotation 4-2

4.3 Zoom Functions 4-4

4.4 Axis Rotation Toolbar 4-4

4.5 Dynamic Viewing 4-5

4.6 Measurements 4-6

4.7 Part Analysis 4-9

5 Creating Toolpaths 5-1

5.1 Selecting a Strategy 5-2

6 3-Axis Roughing Toolpaths 6-1

6.1 Global Rough/Rerough 6-1

6.1.1 Programming a Global Rough/Rerough Toolpath: Standard Parameters 6-1 6.1.2 Programming a Global Rough/Rerough Toolpath: Specific Parameters 6-12

6.2 Initializing the Stock Model and Calculating the Roughing Toolpath 6-18

6.3 Displaying Toolpaths 6-21

6.4 Opening the Toolpath Parameters Menu of a Toolpath 6-24

6.5 Updating the Stock Model 6-24

6.6 Reroughing 6-26

6.7 Flat Surface Rough/Rerough 6-28

6.8 Practicing: 3-Axis Roughing Toolpaths 6-30

6.8.1 Using the Final Allowance Parameter 6-30

Table of Contents

SESINT_EN_WNCBAS1 240414 - CAM Basic 1 ii Copyright 2014 © Sescoi International

6.8.2 Defining an Initial Lateral Step on the Global Roughing Toolpath 6-32 6.8.3 Exercise : Roughing a Part 6-34

7 3-Axis Finishing Toolpaths 7-1

7.1 Flat Surface Finishing 7-1

7.2 Z-Level Finishing 7-4

7.3 Planar Finishing 7-10

7.4 Combined Z-Level Finishing and Optimization 7-14

7.5 Practicing: 3-Axis Finishing Toolpaths 7-16

7.5.1 Deleting Passes on Vertical Areas 7-16 7.5.2 Exercise: 3-Axis Finishing 7-18

8 Stock Simulation 8-1

9 3-Axis Optimization Toolpaths 9-1

9.1 Optimized Z-Level Finishing 9-1

9.2 Optimized Planar Finishing 9-5

9.3 Practicing: 3-Axis Optimization Toolpaths 9-7

9.3.1 Optimized Z-Level Finishing: Material left by Previous Smoothing Radius 9-7 9.3.2 Optimized Z-Level Finishing: Pocket Detection And Flat Surface Machining 9-9

10 Editing Toolpaths 10-1

10.1 Removing Toolpath Sections 10-2

10.2 Isolating Toolpath Blocks 10-5

10.3 Offsetting Toolpath Sections 10-8

10.4 Inverting Toolpath Sections 10-9

10.5 Validating or Cancelling Modifications 10-11

11 Calculating the Recommended Safe Tool Length 11-1

12 Postprocessing Toolpaths 12-1

13 Exercise: Basic Functions 13-1

Training Guide Objectives 1

Copyright 2014 © Sescoi International 1-1 SESINT_EN_WNCBAS1 240414 - CAM Basic 1

1 Training Guide Objectives This manual presents the basic key concepts concerning WorkNC. The particular examples given in the manual may not concern all users or applications of WorkNC. The main goal of this manual is to provide users with the tools (knowledge and concepts) that may be applied to specific problems that they may encounter when working with WorkNC for the first time.

At the end of the training session, the user should be able to:

Create a workzone Manipulate and analyze CAD parts in the user interface Program a toolpath using standard and some specific parameters Calculate and display toolpaths Edit toolpaths Postprocess toolpaths using basic settings

PARTS AND WORKZONES USED IN THIS TRAINING GUIDE Parts Workzones

Pump_body.igs Pumpe

Plate_cover.xdw

Corner_smoothing.xdw

Plate_wing.xdw

This training manual is a basic instruction guide for WorkNC, but it is not a comprehensive manual. For more help you can go to our online help or read our other training manuals.

Introduction Part Geometry Preparation 2


2 Introduction

2.1 Part Geometry Preparation The following points should be taken into consideration when preparing part geometry before creating a WorkNC workzone.

1. Make sure that your CAD format interface matches those available in WorkNC:

- Standard translators: STL.

- Direct translators: Catia® V4/V5/V6, Parasolid®, Unigraphics®, ProE®, CADDS®, SolidWorks®, SolidEdge®, JT, Inventor®, STEP, IGES.

2. Prepare your part in the CAD system so that you can create a workzone from which machining toolpaths can then be generated.

WORKNC CHECKS COLLISIONS ON SURFACES, CURVES AND POINTS:

Surface Collision Check Surface Collision Check 2

WORKNC LINKS TOGETHER ALL SURFACE ELEMENTS WHATEVER THEIR SHAPE, SIZE, NUMBER OF

SURFACES OR COMPLEXITY:

WORKNC TAKES INTO ACCOUNT THE SURFACES WITH NON-CONTINUOUS TANGENTS:

WORKNC DOES NOT REQUIRE MODIFICATIONS FOR SUPERIMPOSED SURFACES:

Superimposed Surfaces 1 Superimposed Surfaces 2

WORKNC CAN CREATE A TOOLPATH OVER DISJOINTED SURFACES: a ball-end tool will waterfall off a surface by an amount equal to the body radius of the cutter. a bull-nose tool will waterfall off a surface by an amount equal to the corner radius of the

cutter. a flat-end tool will stay at the level of a surface.

2 Introduction Starting WorkNC

SESINT_EN_WNCBAS1 240414 - CAM Basic 1 2-2 Copyright 2014 © Sescoi International

WORKNC HANDLES UNDERCUT SHAPES BY NOT VIOLATING THE GEOMETRY:

WORKNC CAN MACHINE TRIANGULAR SURFACES WITHOUT FURTHER MODIFICATION:

WORKNC MACHINES WHAT IT CAN SEE UNLESS YOU PREVENT IT:

WORKNC HAS NO RESTRICTION CONCERNING THE NUMBER OR THE COMPLEXITY OF PATCHES.

SURFACE / CURVE TYPES: Curve Types Other Entities

NURBS Structured Triangular Meshes

2.2 Starting WorkNC

To start working with WorkNC, you just need to double click the icon on your computer desktop.

The New/Open dialog box is automatically displayed:

WorkNC New/Open Dialog Box

This dialog box shows the CAD and CAM icons which will allow you to open/create any workzone or CAD file.

Workzones Creating a New Workzone in the CAM Mode 3


3 Workzones A workzone is the directory or folder created by WorkNC to store the surface database and toolpath files for each set of surfaces.

You can create workzones from the New/Open dialog box of WorkNC. They represent a “working” environment where you can visualize, orientate and analyze parts. You can also define machining strategies by creating toolpaths and create points, curves and views that might be helpful for some toolpaths.

There are 2 ways of creating a workzone :

You can use the New Workzone function to create a workzone directly in the CAM mode by selecting an existing CAD file (WNC, IGS , STL, etc.).

You can create/open a CAD file (XDW, IGS, DXF, etc.), modify it and create a workzone from the CAD mode.

3.1 Creating a New Workzone in the CAM Mode This option allows you to create a workzone from an existing CAD file.

CAD FILE EDITION

It does not allow you to modify your CAD file. NOTE

On the left side of the New/Open dialog box, 2 CAM functions allow you to create a new workzone or open an existing one.

1. In the CAM functions, click on the New Workzone button.

The Create a Workzone dialog box is displayed:

Create a Workzone Dialog Box

2. Define a directory where your workzone will be saved by clicking on the button next to the Workzone Name field.

The Open File dialog box is displayed.

3 Workzones Creating a New Workzone in the CAM Mode


Open File Dalog Box

WORKZONE LOCATION

As you can see, the directory displayed by default is disk C. If you are equipped with a second hard disk, we recommend you to store the workzone on the disk that is dedicated to personal data storage. NOTE

3. Select the disk you want to define for your workzone by clicking in the Look in drop-down list, for example disk D.

4. Select the directory where you want to stock your workzone (e.g. Workzones) and click on the OK button.

The Open File dialog box is closed and you are back to the Create Workzone dialog box.

5. In the Workzone Name field, enter the name of the workzone you are creating, for example Training_test.

WORKZONE DIRECTORY AND NAME

Remember that no spaces should be used in the workzone directory or name. ATTENTION

CAD FILE SELECTION

1. Click on the Add button to select your CAD file.


CAD FILE SELECTION

WorkNC displays a location path by default. You can change this path for all types of CAD files by clicking on the Set Default Paths button. NOTE

2. In the File Types section, select the type of CAD file you want to add. For our example, select IGES 3D Files.

3. Select the CAD file pump_body.igs (located in the Training directory of the WorkNC installation folder).



Open File Dialog Box: CAD File Selected

4. Click on the Open button.

5. If necessary, define the Offset Allowance by right cliking on the value of the Offset… field and entering the your own value. An Offset Allowance is an additional machining allowance applied to the surfaces activated from your CAD system. For our example, keep the default value.

For IGES 3D files, you have the possibility to select a standard reading format.

6. Right click on the Format field and select the IGES 3D UV Trimmed option.

WORKZONE INFORMATION AND CONFIGURATION

1. Make sure that the appropriate Machining Type option is activated (Surface in our example). If not, click on the option to select it.

2. If necessary, modify the Geometry Activation Parameters.

Scaling Factor: allows you to apply a scaling factor to the model before activation. Global Stock: allows you to define a global stock allowance over the whole of the part geometry. Tolerance: allows you to define the tolerance value to be applied during activation. The Default option allows you to restore the default tolerance value when it has been modified. Final Allowance: allows you to define the absolute final allowance to which the part will be finished when activating or editing the part geometry. WorkNC uses this parameter in association with individual toolpaths in order to reduce calculation times, especially on big parts.

3. If necessary, enter your name in the NC Programmer field of the Worzone Information section. You can also fill in the Comment field.

5-AXIS ACTIVATION

The Activate for 5-Axis Toolpaths option is activated by default. This option allows you to machine the corresponding workzone in 5 axis according to your licence codes. NOTE

4. For our training session, deactivate the workzone for 5-axis toolpaths.



MACHINING CONTEXT

You can click in the Use a Favorite Machining Context when creating Workzone drop-down list and select a favorite Machining Context, if any. Refer to the Machining Context training guide or press the [F1] key to use the Online Help.

NOTE

5. Make sure that the Load the Workzone After Creation option is activated. If not, check the corresponding box to activate this option.

6. Activate the Automatic Surface Orientation Calculation option.

This option allows you to automatically orient surfaces towards the outside of the part. Orienting surfaces is very important for 5-axis toolpaths and view creation.

Create a Workzone: Parameters Defined

7. Click on the Create Workzone button.

Once the calculations are completed, the part selected is displayed with the Surface Orientation Tool.

Surface Orientation Tool



8. Click OK in the dialog box to validate the surface orientation.

The part is now displayed in the CAM mode.

3.1.1 User Interface in the CAM Mode The WorkNC user interface is composed of two main areas: the Workzone Manager and the Viewing Area.

WORKZONE MANAGER

The Workzone Manager is displayed on the left side of the WorkNC user interface. You can open it and close

it by clicking on the icon in the toolbar.

Workzone Manager: Icon Construction

In the workzone you have just opened, the CAM mode is automatically activated and the geometry to machine appears in the Part Geometry section.

Workzone Manager: Geometry to Machine (Pump Body)

The Part Geometry section also allows you to manage the Stock Model, Rest Material and CAM Axis entities.

If you click on the CAM Entities section, you can see that this section allows you to create entities such as Surface Lists, Curves, Points, etc…



CAM Entities

In the last section, the Toolpaths section, you are able to create and edit toolpaths.

VIEWING AREA (CAM MODE)

When opening a workzone, your part is displayed in the Viewing Area. From this area you will be able to perform such operations as viewing the geometry, displaying and simulating toolpaths, analysing the model, editing the toolpath, etc. The numerous icons and toolbars available in each mode will allow you to do so.

CAM Overview: Toolbar Descriptions

Switch between the CAD, Preparation and CAM modes

Create curves, points sets, views

Stock Model, holder parameters and Rest Material Model

Toolpath display, simulation, edition, dimension, picture documentation

Toolpath creation, toolpath calculation and postprocessing

Detailed display of toolpaths: rapids, apporaches, points, normals, etc.

Display of the machine, tool and tool holder

Display of the part and Rest Material

Show/Hide entities

Part orientation, zoom and display

Workzones Creating a Workzone in the CAD Mode 3


Close the workzone by clicking on the icon.

3.2 Creating a Workzone in the CAD Mode This function allows you to view and/or modify your part in the CAD environment before creating a workzone and then working on it.

You can create your workzone from a new or from an existing CAD file.

On the left side of the New/Open dialog box, select the function corresponding to your requirements:

CREATING A NEW CAD FILE

You can create a new CAD File by clicking on the icon.

The description for this function is not given in this section since it deals with CAD training. This guide focuses on the CAM training only.

OPENING A CAD FILE

1. In the New/Open dialog box, click on the button of the CAD functions.


Open File Dialog Box: Open CAD File

As you can see, when opening a CAD file, WorkNC displays a directory by default. You can define a default directory to be opened when looking for a CAD file:

2. Make sure that the Use Default Paths option is activated.

3. Click on the Set Default Paths button.

3 Workzones Creating a Workzone in the CAD Mode


Open File: Set Default Paths Button

4. In the Parameters panel, use the various Browser buttons to define the default paths for the different types of CAD files.

Parameters Panel: Setting Default Directories

5. Click on the Apply button, then on the OK button.

Once you have set the default paths for your CAD files, you can filter the CAD files displayed in the Open File dialog box according to their type:

6. In the File Types section, activate the option corresponding to the type of file that you want to open, WorkNC CAD Files in our example.

7. Select the CAD file, plate_cover.xdw for our example.

As you can see, a preview of the file is displayed on the right side of the Open File dialog box:

Workzones Creating a Workzone in the CAD Mode 3


Open File Dialog Box: CAD File Selected and Preview

8. Click on the Open button.

Your CAD file is displayed in the CAD mode of the user interface.

CAD MODE OVERVIEW

CAD Mode Overview: Toolbar Descriptions

CAD Function Toolbar

User Input Dialog Box

Object Snap Menu

Axis Rotation

Show/Hide Entities

CREATING THE WORKZONE

1. Click on WorkNC in the text menu bar and select Create Workzone or click on the icon.

3 Workzones Creating a Workzone in the CAD Mode


CAD Mode: Create Workzone

The Create a Workzone dialog box is displayed:

Create a Workzone Dialog Box: from CAD File

2. Click on the New Selection button.

Now, you have to select the surfaces you want to include in the workzone.

SURFACE SELECTION

For your selection, you can click each surface, draw a rectangle selection or press the [Ctrl] + [A] keys on your keyboard to select all part surfaces. This option will be the option that is used in this training exercise.

NOTE

3. Press the [Ctrl] + [A] keys to select all the surfaces.

The selected surfaces appear in purple in the Viewing Area.

CAD Mode: Surfaces Selected for Workzone Creation

4. Click on the icon in the top right-hand corner of the Viewing Area to validate your selection.

SURFACE SELECTION: VALIDATE OR CANCEL

You can also validate your selection by right clicking on the Viewing Area. You can cancel your selection by clicking on the icon. NOTE

Workzones Opening/Closing Workzones and CAD Files 3


The Create Workzone dialog box is displayed again and you can see that your CAD file has been added to the Geometries tab.

5. Define a name for your workzone.

6. Make sure that the Load the Workzone After Creation option is activated.

7. Deactivate the workzone for 5-axis toolpaths and activate the Automatic Surface Orientation Calculation option.

Note that you have the possibility to include all CAD entities from all layers and make them available in the Preparation mode (Include Unselected Entities option). Do not activate this option for our training session.


9. Once the calculations are completed, validate the surface orientation.

Your workzone is displayed in the CAM mode of the WorkNC user interface.

3.3 Opening/Closing Workzones and CAD Files

OPENING A WORKZONE

In the New/Open dialog box, if no workzone is displayed in the Recent Workzones tab, or if you want to open a workzone that does not appear under this tab, you have the possibility to search for a particular workzone. To do so, proceed as follows:

1. Click on the button.


Open File Dialog Box

3 Workzones Opening/Closing Workzones and CAD Files


2. Select the directory where your workzone is located.

FAVORITE DIRECTORY

If you always save your workzones in the same directory, click on the Favorite button once you have reached the appropriate directory. It will automatically opened the next time you open a workzone. NOTE

3. Click on the workzone you want to open.

Open File Dialog Box: Workzone Preview

A preview of the part in the selected directory is now displayed in the right part of the screen so that you are sure to choose the right one.

4. Click on the OK button.

RECENT WORKZONE/CAD FILES TABS

Once workzones/CAD files have been opened in WorkNC, they wil be displayed in the Recent Workzones or Recent CAD Files tabs the next time you start the application.

Recent Workzones Tab

Workzones Opening/Closing Workzones and CAD Files 3


You can open workzones/CAD files directly from these tabs:

1. Click on the workzone/CAD file image to select it.

2. Click on the Load button.

DOUBLE CLICK

You can also open workzones/CAD files by double clicking on them in the Recent Workzones/CAD Files tabs. NOTE

OPENING WORKZONES AND CAD FILES BY DRAG & DROP

WorkNC allows you to open workzones or CAD files quickly by dragging them from a Windows explorer and dropping them onto the user interface of the application.

1. Once you have started the WorkNC application, click on the Cancel button in the New/Open dialog box to hide it.

2. Open a Windows explorer and browse your workzone/CAD file directory.

3. Drag and drop your CAD file/workzone onto the gray area of the user interface.

Dragging the CAD File onto the User Interface

3 Workzones Opening/Closing Workzones and CAD Files


Dragging the Workzone onto the User Interface

The CAD file/Workzone is automatically opened in the CAD or CAM mode of the application.

NEW/OPEN DIALOG BOX

To display the New/Open dialog box again, click on the icon in the top left-hand corner of the user interface.

NOTE

CLOSING A WORKZONE/CAD FILE

You can close a workzone/CAD file in different ways:

Click on the icon in the top right-hand corner of the WorkNC user interface.

Click on File in the text menu bar and select Close.

File Menu (CAM Mode): Close

Manipulating Parts Predefined Orientations 4


4 Manipulating Parts The CAM mode of the WorkNC user interface allows you to perform various part manipulation using predefined views, zoom functions, rotate functions, etc.

These display functions allow you to analyze the part and the toolpaths when using the Progressive Display mode.

In this section, we are going to view the basic display functions, using the Training_test workzone.

4.1 Predefined Orientations

Using the Orientation toolbar , you can orientate the part in seven predefined views.

Just click on the various icons or use the shortcuts (if any) given in the table below:

Right View Left View

[Ctrl] + [R]

[Ctrl] + [L]

Rear View Front View

[Ctrl] + [F]

Top View Bottom View

[Ctrl] + [T]

[Ctrl] + [B]

4 Manipulating Parts Dynamic Rotation


Iso View

[Ctrl] + [I]

4.2 Dynamic Rotation

The and icons allow you to rotate the part dynamically in the Viewing Area.

CAM Mode - Orientation & Zoom Toolbar: Dynamic Rotation

The icon allows you to rotate the part dynamically with the left mouse button, with a rotational center located by default in the center of the defined view:

1. Click on the icon.

2. Click in the Viewing Area and maintain the left button pressed.

3. Move the mouse to rotate the part dynamically.

As you can see, the mouse cursor is replaced by the symbol and the rotational center is represented by a red ball.

Example of Dynamic Rotation of the Part

4. Click again on the icon to deactivate the function.

ALTERNATIVE METHODS

- Alternative method to select this function: press and hold the [Shift] key and rotate the part by pressing and holding Down the right mouse button. - While in Dynamic Rotation mode, pressing the left and right mouse button at the same time will temporarily freeze display at the current position.

NOTE

Manipulating Parts Dynamic Rotation 4


The icon allows you to rotate the part dynamically with the mouse after having defined the rotational center. To do so, proceed as follows:

1. Click on the icon to activate the function.

2. Position your cursor where you want the rotational cursor to be defined.

3. Press and hold down the [Ctrl] key and click with the mouse wheel in the Viewing Area.

The red ball, representing the rotational center, is positioned where you have clicked.

Rotational Center Defined

4. Move your mouse to rotate the part:

While holding down the left mouse button if the icon is activated.

While holding down the [Shift] key and the right mouse button if the icon is deactivated. The part rotates around the user-defined rotational center.

Example of Dynamic Rotation With a User-defined Rotational Center

You can use the [Shift] key and the right mouse button when the and/or icons are activated:

If the Use new Spherical Dynamic Rotation option is not selected in the software configuration, the rotational center is the point where you click in the active view.

If the Use new Spherical Dynamic Rotation option is selected in the software configuration, the rotational center is user-defined by the [Ctrl] + mouse wheel click combination.

DYNAMIC ROTATION CONFIGURATION

To define the dynamic rotation options, go to Utilities > Software Configuration > Display Settings and activate or deactivate the corresponding options in the 3D Dynamic Rotation section. NOTE

4 Manipulating Parts Zoom Functions


4.3 Zoom Functions You have several possibilities to zoom in and out on specific areas.

USING THE MOUSE WHEEL BUTTON

1. In the Viewing Area, click on the specific area that you want to analyze.

2. Rotate the mouse wheel button forward to zoom in.

3. Rotate the mouse wheel button backward to zoom out.

USING THE ZOOM WINDOW

1. Click on the icon.

2. In the Viewing Area, click to define the first corner of the zoom window.

3. Drag the mouse diagonally to form the zoom window.

4. Click again to define the opposite corner of the zoom window.

Zoom Window

The Viewing Area now only displays the area contained in the zoom window.

FITTING THE GEOMETRY BACK TO THE SCREEN

To fit the part back to the Viewing Area, click on the Zoom all Views icon.

USING THE SPACE BAR

1. In the Viewing Area, click on the specific area that you want to analyze.

2. Press and hold the Space bar of your keyboard to zoom in.

3. Release the Space bar to go back to the previous display.

4.4 Axis Rotation Toolbar

Axis Rotation Toolbar

Manipulating Parts Dynamic Viewing 4


This toolbar allows you to apply a precise orientation to the part according to a selected axis and a user-defined rotation degree.

Let’s suppose that you want to rotate the part by 45 degrees according to the Z axis. To do so, proceed as follows:

1. Select the Z-axis in the Axis Rotation toolbar.

2. Click on the drop-down list to select the rotation degree or enter the specified value directly in the field.

Axis and Rotation Degree Defined

3. Click on the “-” or “+” button to apply the rotation, whether you want to rotate the part in –Z or +Z.

Example of Z+ 45 Degrees Rotation

4.5 Dynamic Viewing

Simultaneously pressing the [Ctrl] key and the right mouse button will dynamically zoom the part. Move the mouse up to zoom in, move the mouse down to zoom out.

Zoom out Zoom in

As you can see, the mouse cursor turns into a magnifying glass.

4 Manipulating Parts Measurements


Pressing the right mouse button and moving the mouse will dynamically pan the part across the screen.

Right Click and Pan the Part Accross the Screen

As you can see, the mouse cursor turns into a pan.

4.6 Measurements You can make different measurements directly on the part in the Viewing Area. You can obtain the coordinates of a clicked point, the length of a line or some radius information.

Click on Utilities in the text menu bar and select CAM Information in the Enquiries menu.

Utilities Menu: Measurement Function

Or...

Click on the icon in the toolbar located at the bottom of the user interface.

In all cases, you obtain the following dialog box:

CAM Measurement Tool

Manipulating Parts Measurements 4


OSNAP UTILITY

Click on the icon in the toolbar located at the bottom of the user interface.

The OSnap utility is displayed:

OSnap Utility

This utility allows you to select how you would snap to the geometry. For practical reasons, you can click on the Multiple button: this will activate the most useful OSnap objects. You can also click on the Off button to deactivate all the options of the utility.

Once you have activated an option in this utility, you only have to move the mouse cursor over the geometry. The objects to which you can snap will be automatically displayed.

Now let’s see how to make these different measurements.

OBTAINING THE COORDINATES OF A POINT

1. Make sure that the Point option is activated.

CAM Measurement Tool: Point

2. Click a point on the part in the Viewing Area.

You can use the OSnap utility to help you selecting the point.

4 Manipulating Parts Measurements


Point Coordinates

Click on the Keep Measures button before clicking another point if you want to keep the coordinates displayed.

Click on the Clear Measures button to remove all the coordinates.

Click on the Add Point button to add the point to the Points section of the Workzone Manager.

Add Point to the Workzone Manager

MEASURING THE LENGTH OF A LINE

1. In the CAM Measurement Tool, activate the Line option.

2. Click on both line ends in the Viewing Area.

The coordinates of the end points, the middle point as well as the length of the line are displayed on the part.

Length of a Line

Manipulating Parts Part Analysis 4


Click on the Keep Measures button before measuring another line if you want to keep the previous measures displayed.

Click on the Clear Measures button to remove all the measures.

Click on the Add Point button to add the middle point of the line to the last Pointset created in the Points section.

MEASURING A RADIUS

1. In the CAM Measurement Tool, activate the Radius option.

2. Click on 3 points of a circle in the Viewing Area.

The coordinates of the three points, the center point of the circle as well as the circle radius are displayed on the part.

Circle Radius

Click on the Keep Measures button before measuring another radius if you want to keep the previous measures displayed.

Click on the Clear Measures button to remove all the measures.

Click on the Add Point button to add the center point of the circle to the last Pointset created in the Points section.

4.7 Part Analysis You can use the Analysis functions to analyze CAD parts. This function is available in the CAM, CAD and Preparation modes.

To illustrate this, we are going to use a workzone created from the plate_wing.xdw CAD file.

Click on the icon in the toolbar at the top of the user interface.

The Analysis tab is displayed in the Workzone Manager.

4 Manipulating Parts Part Analysis


Workzone Manager: Analysis Tab

This tab contains sections headers which allow you to access the different Analysis functions. In our example, the Dynamic Sectioning function is activated.

Once you have finished analyzing your CAD model, you can exit the function by clicking on the Close button.

4.7.1 Dynamic Sectioning

Click on Sections in the Analysis tab to activate the function.

This function displays the part cut into two sections, one section of the part is shaded, the other one transparent. The two sections are separated by a curve according to the section plane.

Select the section plane in the Cutting Plane drop-down list. Note you can also press the [F10] key to switch between section planes.

Move the section curve by using the cursor below the Cutting Plane drop-down list or by using the mouse wheel button.



Dynamic Section: Cutting Plane and Cursor

SWITCH SIDE KEYBOARD SHORTCUT

Press the [End] key to invert the transparent side and the shaded side or click the Switch Side button. NOTE

You can also adjust the size and color of the section curve, or adjust the transparency of the hidden part.

You can also deactivate the border display by deactivating the Show Border option at the bottom of the Analysis tab.

Dynamic Section: New Settings

You can also create a curve where the section is poisitioned by using the Create Curves button.

4.7.2 Analyzing Curvature The Curvature Radius function displays the part with different colors according to the curvature radius of the surfaces. This allows you to rapidly determine the required minimum cutter diameter to machine the part.



Click on Curvatures in the Analysis tab to activate the function.

When this function is activated, the application automatically calculates the maximum and minimum radius of the part. They are displayed in the Max. Found and Min. Found fields in the Analysis tab. If there are radii exceeding a certain limit, e.g. on flat surfaces, the Max. Found and Min. found displays the limit values. Defining the Radii Range

Enter the desired value in the Greater and Smaller fields and then press [Enter]. Or

Drag the cursor in the bar located near the green field until you reach the value that you want.

Click on button between the cursor bars to link the displacement of the two cursors to the same value. It will

appear as .

The application will show in blue all curvatures appreciably larger than 10 and in red all curvatures appreciably less than 0.001. Everything else will be color coded with green, yellow and cyan. The following picture shows an example of curvature analysis.

Curvature Analysis

Activating the Highlight =/-0.125 option allows you to have the upper and lower limit in blue and just the curvature in green.

Activating the Show Concaves option allows you to only show inside concave fillets and not convex ones.



4.7.3 Analyzing Altitudes The Altitude function shows the part using different colors according to Z-levels of the part.

Click on the Altitude in the Analysis tab to activate the function.

When this function is activated, the application automatically calculates the total Height and the Middle position between the Max. Found and Min. Found of the part. An average value is proposed as default in the Z Min and Z Max fields. This can be particularly helpful when determining depths. Defining the Altitude Range

To define the Altitude range to be displayed, enter the desired value in the Z Max and Z Min input fields then press [Enter]. Or

Drag the cursor in the bar located near the Z-level fields until you reach the value that you want.

Click on icon between the cursor bars to link the displacement of the two cursors to the same value. It will

appear as .

Altitude Analysis



Altitude display in the Viewing Area is separated into 3 colors:

Altitudes below the defined Z-Level range are displayed in red. Altitudes equal (+/- a tolerance) to the defined Z-level range are displayed in green. Altitudes greater than the defined Z-Level range are displayed in blue.

Activating the Enable Gradient option allows you to obtain a progressive color scale from red to blue.

You can click anywhere on the part in order to obtain Z-Level information about this specific point. A small information box will pop up:

Part Analysis - Altitude Information Box

4.7.4 Analyzing Draft Angles This function shows the part with different colors according to the draft of the surfaces which is calculated with respect to the Z axis. This will allow you to rapidly determine which parts of the workpiece may present demolding problems.

Click on the Draft Angles in the Analysis tab to activate the function.

When this function is activated, the application automatically calculates the maximum and minimum draft angles of the part which are displayed in the Max. Found and Min. Found fields. Defining the Draft Angle Range

Enter the desired value in the Min. Found and Max. Found fields then press [Enter]. Or

Drag the cursors in the bars located next to these fields until you reach the desired value.



Draft Angle Analysis

The part will be color coded based on draft angles. Draft of 0 or less will be red, draft larger than 1 will be blue and every other part will be in shades of yellow, green and cyan. This can also be particularly helpful in analyzing the part for mold design consideration.

Activating the Enable Gradient option allows you to obtain a progressive color scale from red to blue.

Activating the Show Undercuts optuion allows you to display the undercut areas in dark orange (see above image). In this case the Enable Gradient option is disabled.

You can click anywhere on the part in order to obtain Draft Angle information about this specific point. A small information box will pop up:

Part Analysis - Draft Angle Information Box

SHOWING ONLY FLAT AREAS

If you activate the Show only flat Areas option, all other options are disabled and the part is displayed according to the different types of surfaces:

Vertical surfaces are displayed in red. Horizontal surfaces are displayed in blue. All the other surfaces are displayed in green.

4.7.5 Analyzing Borders This function allows you to quickly review all borders of the part and see whether they are sharp or smooth.

Click on Borders in the Analysis tab to activate the function.



Activate the option which corresponds to the type of borders that you want to display: Concave Borders, Smooth Borders, Other Borders.

You can adjust the size of the border lines by dragging the Border Thickness cursor and make the part more or less transparent by dragging the Part Transparency cursor. You can change the color of the different types of borders by clicking on the Concave Borders, Smooth Borders, and Other Borders buttons.

Border Analysis

Creating Toolpaths Part Analysis 5


5 Creating Toolpaths There are different ways of creating toolpaths.

From the Toolpath Creation and Calculation toolbar:

Click on the icon on the left side of the user interface.

From the Workzone Manager:

Right click on the Toolpaths section and select New Toolpath in the context menu.

From the Viewing Area:

Right click on the part in the Viewing Area and select New Toolpath in the context menu:

Choose one of the 3 methods given in the table above to create your toolpath.

The Toolpath Parameters menu is displayed.

Global Rough/Rerough Toolpath Parameters

In this dialog box, you can select your toolpath strategy by clicking on the Type button.

When you create the first toolpath in a workzone, the Global Rough/Rerough strategy is selected by default.

5 Creating Toolpaths Selecting a Strategy


5.1 Selecting a Strategy 1. In the Toolpath Details section, click on the Type button, which displays the name of the current strategy

(Gobal Rough/Rerough in our example).

The Toolpath Strategy dialog box is displayed with the different toolpaths available in WorkNC. These toolpaths are classified in various tabs according to their types.

Toolpath Strategy Dialog Box

2. Select your strategy by clicking on the appropriate tab (3-Axis Roughing in our example).

3. Select one of the toolpath below the selected tab (Global Rough/Rerough).

The Current Selection section gives an overview and an explanation related to the toolpath.

4. Click on the OK button.

The Toolpath Strategy dialog box is closed and you are back to the Toolpath Parameters menu.

Once your toolpath strategy is defined, you can set the parameters for your toolpath.

3-Axis Roughing Toolpaths Global Rough/Rerough 6


6 3-Axis Roughing Toolpaths Roughing is the preliminary stage of a machining job. At the end of the roughing stage, the workpiece should be in a state suitable for a semi-finishing or a finishing toolpath.

The aim is to use relatively large cutters to remove large amounts of stock and to approximate the final shape of the workpiece.

There are standard and specialized roughing toolpaths. This training guide will focus on standard roughing toolpaths.

6.1 Global Rough/Rerough This toolpath is designed for high torque milling machines capable of machining large amounts of stock with one single toolpath.

The Toolpath Parameters menu of the Global Rough/Rerough toolpath, like all the toolpaths in the application, is divided into 2 sections:

Global Rough/Rerough: Standard and Specific Parameters

Standard parameters: common to all toolpaths.

Specific parameters: particular to each individual toolpath.

6.1.1 Programming a Global Rough/Rerough Toolpath: Standard Parameters

6 3-Axis Roughing Toolpaths Global Rough/Rerough


Machining Zone This section allows you to define which areas you want to machine.

The machining zone for each toolpath can be specified as a rectangular window or as a rectangular view created by the user.

A View is necessary if you want to machine with an inclined tool axis. A Window or a View can be limited in the horizontal plane by Boundary Curves or in the Z plane by a Machining Plane.

You can also restrict machining to certain surfaces using the Surface Selection function.

1. For our example, make sure that the Expand Window by option is activated.

2. Activate of the By Diam+Stock option.

The application expands the machining zone by adding the tool diameter (i.e. twice the Body Radius) and the Stock Allowance, to ensure that all surfaces are fully machined.

Cutter Details This section allows you to define the type of cutter, its dimensions and form or to choose a specific cutter from the Tool Library.

1. Activate the Bullnose/Flat option.

2. Enter 16 in the Body Radius field.

3. Enter 8 in the Corner Radius field.

4. Click on the Straight button.

The Define Cutter dialog box is displayed. A preview of the tool is displayed in accordance with the parameters that you have just entered.

Define Cutter Dialog Box



DEFINE CUTTER DIALOG BOX

In this dialog box, you can define further parameters for tools such as the shape and the length. NOTE

5. Define the Tool Number in the corresponding field, 1 in our example.

TOOL NUMBER

Defining a tool number is mandatory for concatenated postprocessing.

ATTENTION

You can also use this dialog box to change the cutter type and the shape of the tip:

Click on the Type button, which displays the shape of the current cutter (Bull-nose Cutter in our example).

The Select Cutter Type dialog box is displayed.

Select Cutter Type Dialog Box

You can define a standard or conical cutter and select the shape of the tip (Ball, Bull-nose or Flat).

All calculations are performed using the center of the cutter.

Ball End Cutter (R = Radius)

For a Ball-end cutter the following condition applies :

Cutter Radius + Stock Allowance + Part Offset Allowance (with activated Part Geometry) > 0.2 (0.008”)

Flat End Cutter (R = Radius, r = Corner Radius)



Bull Nose Cutter (R = Radius, r = Corner Radius)

All toolpaths can use cutters with a corner radius of 0 mm or inches but the following condition still applies :

Corner Radius + Stock Allowance + Part Offset Allowance (with activated Part Geometry) >= 0

A basic cutter can be defined directly in the Toolpath Parameters menu by selecting the appropriate tip shape and defining the Body Radius and eventually the Corner Radius.

You can also define conic cutters by clicking on the Cone tab.

Select Cutter Type: Cone Tab

In the case of the Global Rough/Rerough toolpath, flat conic cutters are not allowed.

Correct cutter definition reduces the stock ‘stairs’ effect on inclined surfaces by corresponding to the shape of the part to be machined.

Conic Cutter

Using conic cutters improves machine stability by reducing vibrations. Tool service life is prolonged and machining cycles are reduced by elimination of stock steps leading to shorter re-roughing cycles.

Z-STEP VALUE

When using a conic cutter, the Z-step value must be inferior to the Corner Radius value. ATTENTION

For our example, click on the Standard tab and select the Bull-nose cutter.

Click on the button to validate the cutter type selection.



Click on the OK button to validate and exit the Define Cutter dialog box.

Machining Parameters All Machining Parameters are regrouped in a single dialog box.

Click on the Method, Cycle or Direction button to access the Method, Cycle and Direction dialog box.

Method, Cycle and Direction Dialog Box

NON AVAILABLE OPTIONS

When one of the Method, Cycle or Direction parameters is not available for the current toolpath, the corresponding button and section in the dialog box will be grayed out. In our case, the Direction button in the Toolpath Parameters menu and the corresponding Machining Angle section in the Method, Cycle and Direction dialog box are unavailable.

NOTE

METHOD

The 3 machining method options are Climb, Conventional or Mixed. You can select one of these machining methods according to the toolpath you are creating. Any options which are not available for a particular toolpath will be grayed out.



Climb Climb milling implies that the cutter teeth enter the material perpendicular to the cutting direction and with the material to the right of the cutting direction.

Climb Method (1 – Material)

Conventional Conventional milling is the opposite to Climb milling, i.e. the cutter teeth enter the material perpendicular to the cutting direction and with the material to the left of the cutting direction.

Mixed The Mixed method is a combination of Climb and Conventional milling and can be used to avoid an excessive number of retracts.

DUAL SURFACE MACHINING

In cases where the "base" surface is at an angle less than 90 degrees from the tool axis, an ambiguity exists allowing two walls to be climb cut at the same time (e.g. Pencil Tracing, Z-Level Finishing and Z-Level Remachining). For this reason, you may want select the Mixed option to use a mixture of Climb and Conventional milling and hence avoid excessive retracts.

NOTE

DRIVE CURVES

For machining strategies using Drive Curves (e.g. 2D and 3D Drive Curve Finishing), WorkNC considers that the stock to be machined is always inside the machining limit and to the right of the cutting direction along the drive curve (open or closed).

NOTE

CYCLE

The 4 machining cycle options are Box, Lace, Spiral or Trochoïd. You can select one of these machining cycles according to the toolpath you are creating. Any options which are not available for a particular toolpath will be grayed out.

Box The Box cycle implies that the cutter removes material in one direction only and retracts at the end of each pass. Using this cycle can result in a high number of retracts as shown in the following example.

Box Cycle machining example



Lace The Lace cycle allows the cutter to remove material in both directions. Stepovers are performed at the end of each pass according to how Lead-ins and Lead-outs are programmed. Using this cycle can significantly reduce the number of retracts in a toolpath.

Lace Cycle machining example

Spiral Spiral machining implies that the trajectory has a spiral form and is especially used in roughing toolpaths and for machining pockets.

Spiral Cycle machining example

Trochoid The Trochoidal cycle is only available for the Adaptive Trochoidal Roughing toolpath. Supplementary parameters are displayed in the dialog box in this case.

You can force the spiral cycle to always use close contours by activating the corresponding option. This allows you to reduce the number of retracts on certain areas of the part.

Always close Contours with a Spiral Cycle



Note that the Always close Contours option is only available for the Global Rough/Rerough toolpath.

Toolpath Areas without Closed Contours Toolpath Areas with Closed Contours

DIRECTION

The 4 machining direction options are Angle from X, Parallel to X, Parallel to Y or Automatic.

The Automatic option only applies to flat surface machining toolpaths and allows WorkNC to determine the optimal, most efficient direction for machining.

NC Machining Parameters Clicking the NC Machining Parameters button in the toolpath menu will display the following Feeds and Speeds dialog box.

Feeds and Speeds Dialog Box

This dialog box allows you to define a number of parameters which WorkNC uses (if the Auto options are activated) to automatically calculate spindle speed and/or cutting feed rate values.

If these parameters are automatically calculated by WorkNC, the results can be optimized by additionally defining the depth of the cut (Z-Step) and the width of the cut (Stepover).

Activating these 2 parameters allows you to activate the Z-Step and Stepover fields.

You can then enter the values or transfer them from the Toolpath Parameters menu by checking the corresponding boxes.



Applying Toolpath Z-Step and Stepover

The following diagram shows the different feed rates in a single pass.

1 Rapid Feed Rate 2 Approach Feed Rate

2A Approach Distance 3 Cut Feed Rate 4 Rapid Feed Rate A Safe Z level (high Z of part + retract distance)

1. For our example, keep the default settings.

2. Click OK to validate and exit the dialog box

Tolerances

STOCK ALLOWANCE

The Stock Allowance parameter defines the minimum amount of material, with respect to the part geometry, to be left on the part after machining.

The Stock Allowance can be positive or negative but must respect the following conditions:

Cutter Condition

Bull Nose or Flat End Corner Radius + Stock Allowance + Offset Allowance > or = 0mm / 0”

Ball End Cutter Radius + Stock Allowance + Offset Allowance > or = 0.2mm / 0.008”

LEAVE EXACT STOCK ALLOWANCE

This option is only available if the Final Allowance parameter in the Part Geometry Activation dialog box has been activated, if not it is grayed out.

If it is activated and you activate this option, WorkNC will always respect the Stock Allowance value defined above.

If you leave this option deactivated, WorkNC will apply a tolerance to the Stock Allowance value defined above this option. In other words, WorkNC will not explicity respect the defined Stock Allowance value and may leave more or



less stock than has been defined. In any case, WorkNC takes into account the Final Allowance value defined in the Part Geometry Activation dialog box to ensure that this parameter is respected. The defined Tolerance value is also always respected. This functionality allows WorkNC to reduce calculation times, especially on large parts. For example, a Global Roughing toolpath on a fender part required 10m 25s when the Leave Exact Stock Allowance option was checked. For the same toolpath, with this option deactivated the calculation time was 8m 40s.

TOLERANCE

The Tolerance parameter defines the maximum allowed error resulting from intersection calculations, also known as Chordal Deviation.

Chordal Deviation

For roughing/semi-finishing toolpaths, the Stock Allowance should have at least the same value as the Tolerance parameter to prevent the cutter from undercutting the surface. The Tolerance value has a direct influence on the number of points in the calculation file.

STEPOVER

The Stepover is the distance separating two parallel intersection planes. It is constant in the plan view. Scallop height is determined by the Stepover value.

1: Stepover Distance 2: Scallop Height 3: Center of cutter

Activating the Auto option associated with the Stepover parameter allows WorkNC to calculate the most appropriate value based on the cutter radius and the Tolerance value. This will ensure that the cusp height on slopes up to 45° will be less than or equal to the defined Tolerance value. In the case of the Global Rough/Rerough toolpath, the Auto option is unavailable.

1. Four our example, keep the Stock Allowance and the Tolerance default settings.

2. Enter 10 in the Stepover field.

Z-Step This parameter allows you to define the distance between 2 consecutive machining levels in the cutter Z axis.

You can enter the Z-Step value directly in the field to define a fixed distance.

You can also click on the Fixed button if you want to specify the Z-Step. In the case of the Global Rough/Rerough toolpath, you can only define a fixed Z-Step.



Enter 5 in the corresponding field.

Cutter Movements This section allows you to define parameters concerning approach/retracts movements/distances, and how Lead-ins and Lead-outs are performed.

Click on any button of the Cutter Movements section.

The Cutter Movements dialog box is displayed.

Cutter Movements Dialog Box for the Global Rough/Rerough Toolpath

This dialog box is available for the 3-Axis Roughing, 3-Axis Finishing, 5-Axis toolpaths and some of the 2 ½-Axis toolpaths. The number of available parameters in this dialog box varies according to the selected toolpath.

In the case of the Global rough/Rerough toolpath, only a few parameters are available.

APPROACH DISTANCE

This is the distance at which the cutter changes from the Rapid Rate to the Approach Rate.

SAFETY PLANE RETRACT MOVEMENTS 2D Activating this option implies that the retract movement follows the Z axis to the security distance. 3D Selecting this option implies that WorkNC will not directly retract by the security distance in the Z

axis only but will calculate the complete movement from one retract point to a new lead-in point as a 3D movement according to the part geometry.

RETRACT DISTANCE

This is the distance between the highest point of the Z axis within the machining zone and the security distance (this distance is relative).



RETRACT SAFETY PLANE RADIUS

This parameter allows all directional movements from the retract to a new lead-in point to be performed as an arc of a circle with a radius equal to the defined value.

1 Retract Safety Plane Radius 2 Retract in Z axis only

HIGH Z VALUE

The Safety Plane Radius value and the Retract Distance value are both added to the highest Z point of the part to determine the security distance. NOTE

LEAD-INS/LEAD-OUTS

This section allows you to define how the lead-in/lead-out movements will be performed.

With the Global Rough/Rerough toolpath, you can define vertical or ramped movements.

When the Vertical option is activated, the cutter moves in a plane which is perpendicular to the tool axis (the height of the plane depends on the profile of the part) to a zone just above the Lead-in point. It then descends along the cutter Z-axis at the Rapid Rate until it reaches the Approach Distance. It then finishes the Vertical Lead-in at the Approach Speed.

1 Rapid Rate along Z-axis to Approach Distance 2 Vertical Lead-In at Approach Rate 3 Vertical Lead-Out at Rapid Rate 4 Second Lead-In cycle

When the Ramp option is activated, the cutter spirals down from one Z-level to the next following the trajectory of the next contour. This avoids the cutter plunging directly into the stock.

Example of a Ramp Lead-In

1. For our example, keep the default settings.

2. Click OK to validate and exit the dialog box.

6.1.2 Programming a Global Rough/Rerough Toolpath: Specific Parameters

Tool Holder Collision Avoidance The Tool Holder Collision Avoidance function provides dynamic collision avoidance during toolpath calculations with respect to the Stock Model. If a potential collision is detected by WorkNC, the toolpath is modified so that the collision is avoided.



The No Collision Check button allows you to open the Holder Collision Avoidance Parameters dialog box, in which you can activate the holder collision avoidance function.

For our example, do not activate this function.

Stock Parameters 1. Click on the button in the Stock Parameters section.

The Stock Parameters dialog box is displayed.

Stock Parameters Dialog Box

By default this dialog box allows you to use the global Stock Model. It also allows you to define a local Stock Model with the following possibilities: Specified by Curve: allows you to define a curve which determines the stock boundary. Specified by Machining Zone: allows you to use the Machining Zone (defined by a View or a Window with or without an associated Boundary Curve) to determine the stock boundary. Max Z: allows you to define a maximum Z value from which machining will start.

2. For our example, leave the Use Global Stock Model option activated.


Pocket Selection This parameter allows you to select the pockets to be machined. This function is useful for ignoring pockets which cannot be machined by the cutter you are using.

For example, for cutters which use tool inserts, the center of the cutter does not have any cutting edges. If the tool does not have enough “room” to move around and clear material, eventually the non-cutting center of the cutter will rub against the material being cut.

Minimum Width

Any pockets smaller than the minimum width value specified for this parameter will not be machined. If you check the Auto option, only pockets which are equal to at least twice the size of the cutter diameter plus twice the value of the Stock Allowance will be machined.

Minimum Depth

In some cases, an additional parameter is made available to define a minimum depth for the pockets to be machined.



HOW WORKNC INTERPRETS THE MINIMUM WIDTH AND DEPTH

Pocket Width and Depth

Internally, WorkNC creates a view around the pocket and takes into account the length of the longest side of the view as the Minimum Width value. This is illustrated by the following diagram.

Pocket Selection: Size Definition

In this example the Minimum Width value is 96.74mm.

In the case of circular or square pockets the automatically defined Minimum Width value is respectively equal to the diameter or the width.

For our example, keep the Pocket Selection default values.

Cut Link Distance The principal use of the Cut Link Distance parameter is to reduce the number of retracts by allowing the cutting feed rate to be continued over a distance where, without this parameter, WorkNC would normally perform a retract.

The following diagram illustrates how this parameter works.

1: Retract performed A: Value greater than Cut Link Distance 2: No Retract B: Value inferior to Cut Link Distance

The following example shows the same section of a toolpath with different values for the Cut Link Distance parameter.



Cut Link Distance = 5 Cut Link Distance = 10

For our example, keep the Cut Link Distance default value.

Reroughing Areas Activating of this optional parameter allows you to limit machining to specific areas of the part by defining the minimum amount of stock to be found and optionally ignoring areas whose surface area is smaller than the cutter diameter.

If you leave this optional parameter deactivated, WorkNC will calculate the toolpath to machine all areas where the remaining stock is superior to the stock allowance.

This optional parameter is used in reroughing stages.

Do not activate this option as we are programming a basic roughing toolpath.

Flat Surface Roughing Rough Flat Surfaces

Activating the Rough Flat Surfaces option integrates the machining of any flat areas of the part in the Global Rough/Rerough toolpath.

This option allows the stock material to be machined in order to have the same thickness over the whole part and offers reduced preparation times by avoiding to have to define two separate toolpaths.

The following two examples illustrate this strategy.

Flat Surface Roughing Option Deactivated Flat Surface Roughing Option Activated

For our example, deactivate the Rough Flat Surfaces option.



Cusp Height The Cusp Height parameter is used to control the height of remaining cusp when machining a given level.

Machining strategy should take into account that this extra cusp height will have to be removed when the next level is machined.

This value can be user-defined or an automatic minimum value is calculated by WorkNC. This value is calculated according to the Stepover value defined by the user and the shape and dimensions of the cutter. Error message(s) will be displayed if any values are found to be invalid by WorkNC.

The following example illustrates authorized remaining cusp after machining a level with a roughing toolpath.

Stock Model showing remaining Cusp

For our example, do not enter a value for the Cusp Height.

Corner Smoothing

CORNER SMOOTHING

This parameter only applies to surface contours. NOTE

If the Corner Smoothing Radius is set to zero, machining will be made with a sharp angle in corners.

If the value is set different to zero, the angle will be machined as a smooth corner. However, this means that more stock material will remain in corners as the radius is increased.

Corner Smoothing Radius = 0 Corner Smoothing Radius = 2

For our example, set the Corner Smoothing Radius to 1.

Machining Order

Click on the button of the Machining Order section.



The Machining Order dialog box is displayed to allow you to select the machining order of the toolpath.

Opening the Machining Order Dialog Box

BY ZONE

If you specify machining By Zone, the part will be automatically divided up into zones by WorkNC and all the levels of one zone will be machined before moving on to the following zone.

For example, on a part featuring pockets, each pocket may be defined as a zone by WorkNC. In this case, all the levels of one pocket will be machined before the cutter moves on to machine the next pocket and so on.

Machining by Zone

Each single pocket is treated as a separate zone and all the levels of one pocket are machined before the next pocket (or zone) is machined.

BY LEVEL

When you specify machining By Level, WorkNC machines all areas of the machining zone at one level before stepping down to the next level. Choosing this option on a part featuring several pockets will create many retracts in the generated toolpath.

Machining by Level

1. For our example, activate the By Zone option.


Initial Step This parameter allows you to define an Initial Lateral Step value that is different from the standard Stepover value. This parameter is enabled when the Spiral machining cycle option is selected. Accepted values are between 0.05 and 95% of the tool diameter.

This option ensures better positioning of the cutter on the first pass of the toolpath, i.e. avoiding the situation where the cutter center is on the edge of the stock.

6 3-Axis Roughing Toolpaths Initializing the Stock Model and Calculating the Roughing Toolpath


For our example, do not activate the Initial Lateral Step option.

6.2 Initializing the Stock Model and Calculating the Roughing Toolpath Once you have finished defining your toolpath strategy, you have to validate your parameters and run calculations:

1. Make sure that your parameters are defined as in the following example:

Toolpath Parameters Menu: Validate Parameters

2. Click on the OK button in the Toolpath Parameters menu.

The Part Geometry dialog box is displayed. As you have programmed the first roughing toolpath on the workzone, the Stock Initialization tab of this dialog box allows you to select the type of Stock Model that will be used for toolpath calculations.

Part Geometry Dialog Box: Stock Initialization

3-Axis Roughing Toolpaths Initializing the Stock Model and Calculating the Roughing Toolpath 6


The Stock Model is an additional data structure in your workzone which is distinct from the part geometry.

The Stock Model is used for calculating the state of stock on the part. It can be used at any stage of machining, however it is particularly designed for use at the roughing, re-roughing and semi-finishing stages. The Stock Model can also be used as the Remachining Reference in all three remachining toolpaths (Z-level, Planar and Contour Remachining toolpaths).

3. We will choose the default 3D Solid Block proposed by the system, so click on the OK button.

A new toolpath is created under the Toolpaths section in the Workzone Manager. The yellow icon ( ) and the C- symbol next to the toolpath name indicate that the toolpath has not yet been calculated. The Stock Model has also been added to the Workzone Manager with a C- symbol.

New Toolpath in the Workzone Manager

You can start toolpath calculations in 3 different ways:

Right click on the icon or on the toolpath status in the Workzone Manager and select Execute in the

context menu ( in the picture below).

Use the icon in the bottom right-hand corner of the Viewing Area ( in the picture below). Right click on this icon to start calculations immediately or left click to display all pending calculations and click on the Execute button. You can invert the functions of the mouse buttons. To do so, go to Utilities > Software Configuration > Display Settings > Execute and uncheck the Left Click (Execution Dialog). Right Click (Immediate Calculation) option.

Select the toolpath in the Workzone Manager and click on the icon ( in the picture below).

6 3-Axis Roughing Toolpaths Initializing the Stock Model and Calculating the Roughing Toolpath


Starting Toolpath Calculations

4. Click on the icon ( in the picture above).

The Execution dialog box is displayed, asking you to execute pending toolpaths.

Execution Window: Stock Model Initialization and Toolpath Calculation

5. Click on the Execute button.

The WorkNC Parallel Calculation Window is displayed. It shows the progress of calculations.

3-Axis Roughing Toolpaths Displaying Toolpaths 6


WorkNC Parallel Calculation Window

OPTIONS AND

If you select the other two options, the WorkNC Parallel Calculation Window pops up directly after selecting the corresponding option.

NOTE

The circle appears now in green and a C+ is displayed meaning that your toolpath calculations have been successfully executed. If a C* is displayed instead, it means that an error has been detected during toolpath calculations. In this case, check the parameters of your toolpath and try again.

Workzone Manager: Calculated Toolpath

6.3 Displaying Toolpaths Once you have executed your first toolpath, you have several possibilities to visualize the results in the Viewing Area.

GLOBAL VIEW

There are 2 ways of obtaining a global view of a toolpath in the Viewing Area:

Check the box of the corresponding toolpath in the Workzone Manager ( in the picture below).

Double click on the toolpath name in the Workzone Manager ( in the picture below).

The complete toolpath is displayed in the Viewing Area.

6 3-Axis Roughing Toolpaths Displaying Toolpaths


Toolpath Display Activation

You can show/hide the various elements of the toolpath displayed in the Viewing Area by activating/deactivating the corresponding icons on the right side of the user interface.

In the example below, we have deactivated the display for the aproach and rapid movements:

Toolpath Display: No Approaches and Rapids

Note that you can also show/hide the part ( icon) or the cutter ( icon).

PROGRESSIVE DISPLAY

The Toolpath Progressive Display dialog box allows you to dynamically visualize and control how the toolpath is displayed on the part.

1. Select the toolpath in the Workzone Manager.

3-Axis Roughing Toolpaths Displaying Toolpaths 6


2. Click on the icon on the left side of the user interface.

Toolpath Selected: Activating Progressive Display

The Toolpath Progressive Display dialog box is displayed.

Toolpath Progressive Display Dialog Box

Click on the icon to start and stop the progressive display.

Several additional functions are also available so that you can manage the display:

Use the icon to quickly get the final result of the simulation. If you want to go back to the

beginning of the simulation, simply click on the icon.

Click on the icon to start a progressive display or simulation while hiding all points that have already been displayed.

Click on the on the icon to restart the progressive display from the very beginning or from

the point when you clicked on the icon.

Click on the and icons to show the progressive display or simulation from point to point.

When using the Progressive Display mode, you can also click on any point of the toolpath in the Viewing Area.

The cutter is automatically positionned where you have clicked and you can orientate the part and use the zoom functions to check the different passes of the toolpath:

6 3-Axis Roughing Toolpaths Opening the Toolpath Parameters Menu of a Toolpath


Progressive Display: Point Selction

6.4 Opening the Toolpath Parameters Menu of a Toolpath Once you have created/calculated a toolpath, you can re-open its Toolpath Parameters menu to modify the parameters.

There are several ways of doing it:

Click on the / icon next to the toolpath in the Workzone Manager.

Right click on the toolpath name in the Workzone Manager and select Parameters.

Click with the mouse wheel button on the toolpath name in the Workzone Manager.

You can open the Toolpath Parameters menu of a toolpath which is being calculated but you cannot modify its parameters during calculations.

6.5 Updating the Stock Model You can display the Stock Model state after the roughing toolpath. To do so, proceed as follows:

1. In the Workzone Manager, click on the toolpath you have just defined.


Stock Model Update Selected

3-Axis Roughing Toolpaths Updating the Stock Model 6


3. Right click on icon in the bottom right-hand corner of the Viewing Area.

4. Once calculations are completed, position your cursor on the Workzone Manager and press the Space bar on your keyboard.

The Workzone Manager is widened and you can see a S+ sign that indicates that the Stock Model has been updated.

Workzone Manager: Stock Model Updated

WORKZONE MANAGER DISPLAY

When you place the cursor on the Workzone Manager and press the Space bar, the Workzone Manager is widened. You can undo this operation by pressing the Space bar again so that Workzone Manager is displayed in its default size.

NOTE

5. In the Workzone Manager, under the Part Geometry section, activate the Stock State option.

Part Geometry: Stock State

As you can see, the Stock Model is displayed on the part in the Viewing Area. It displays the state of the Stock Model after the Global Roughing toolpath we have executed.

Stock Model Displayed

You can compare the state of the stock model after each toolpath you calculate in the Previous State option:

Click on the + icon below the Stock State option and compare the initial stock with the stock model after toolpath #1.

6 3-Axis Roughing Toolpaths Reroughing


Initial Stock State

Stock State After Toolpath #1

Now you can see that you need to execute a reroughing toolpath and change the toolpath parameters to prepare the part before executing finishing toolpaths.

6.6 Reroughing After having executed your first roughing toolpath on a part, you can rerough the part by selecting the Global Rough/Rerough toolpath strategy again.

You can then refine your toolpath parameters by selecting a smaller cutter, reducing the values of the Tolerances fields, activating the Rough Flat Surfaces option, etc.

The reroughing stage is not a mandatory step for machining a part, but the part will be more suitably adapted for the finishing phase.

3-Axis Roughing Toolpaths Reroughing 6


6.6.1 Programming a Reroughing Toolpath 1. Create a new toolpath.

The Global Rough/Rerough strategy is already selected.

2. Define the following parameters:

Global Rough/Rerough Parameters: Reroughing Stage

3. Give a number to the new tool.

4. Validate the parameters and run the toolpath calculations.

STOCK MODEL

The new toolpath will be calculated on the Stock Model that has been updated with the first toolpath.

NOTE

5. Activate the toolpath display.

You should obtain the following result:

Global Rough/Rerough Toolpath Calculated on Updated Stock Model

6. Update the Stock Model with this new toolpath.

6 3-Axis Roughing Toolpaths Flat Surface Rough/Rerough


6.7 Flat Surface Rough/Rerough The Flat Surface Roughing/Reroughing toolpath is designed for machining flat surfaces. This strategy allows both roughing and re-roughing flat areas where excess stock remains. This toolpath is typically used after a roughing or re-roughing toolpath to clean up flat surfaces.

6.7.1 Programming a Flat Surface Roughing Toolpath 1. Create a new toolpath.

2. Click on the Type button in the Toolpath Parameters menu.

3. In the Toolpath Strategy dialog box, select the Flat Surface Rough/Rerough toolpath.

Flat Surface Rough/Rerough in the Toolpath Strategy Dialog Box

4. Click OK to validate.

STANDARD PARAMETERS

1. Click on the Straight button.

2. In the Define Cutter dialog box, click on the Type button.

The Select Cutter Type dialog box is displayed. Note that in the case of the Flat Rough/Rerough toolpath, the ball-end cutter type is not available.

Select Cutter Type Dialog Box: Flat Cutter

3-Axis Roughing Toolpaths Flat Surface Rough/Rerough 6


3. Select the Flat cutter type and validate.

4. Define the following cutter parameters:

Cutter Parameters


6. Define the following parameters in the Tolerances and Z-Step section:

Flat Surface Rough/Rerough: Tolerances and Z-Step

6 3-Axis Roughing Toolpaths Practicing: 3-Axis Roughing Toolpaths


SPECIFIC PARAMETERS

This toolpath presents nearly the same specific parameters as the Global Rough/Rerough toolpath except for the Additional Lateral Stock parameter.

Even though this toolpath takes into account the Stock Model, this parameter is available for users to define an additional lateral stock value on surfaces adjacent to the flat areas machined by this toolpath. It is particularly useful when there are vertical or near vertical walls next to the flat surfaces and avoids the cutter coming into contact with these areas where stock remains from a previous toolpath.

1. For our example, enter 1 in the Additional Lateral Stock field.

2. Keep the other values in the other specific parameters.



Flat Surface Roughing Toolpath

6.8 Practicing: 3-Axis Roughing Toolpaths In this section, you are going to see more details about some standard and specific parameters of the roughing toolpaths. An exercise will allow you to practice what you have learned so far.

6.8.1 Using the Final Allowance Parameter The Final Allowance parameter allows you to define the absolute final allowance to which the part will be finished, which means that you can use this parameter to indicate the final dimension of the part to be produced.

This parameter is available when activating the part geometry during the workzone creation or when editing the part geometry in the CAM mode. WorkNC uses this parameter in association with individual toolpaths in order to reduce calculation times, especially on big parts.

Combining this parameter with the tolerances defined in the tooltpath allows WorkNC to save time by trying not to leave a constant amount of stock over the whole part.

REQUIRED CONDITIONS TO SAVE TIME WHEN CALCULATING TOOLPATHS The Scaling Factor (when activating the geometry) must be 1. The geometry size must be at least 100mm wide and 100mm long. The tool diameter must be at least 10mm. The difference between the Stock Allowance defined in the Toolpath menu and the Final

Allowance defined in the Part Geometry dialog box must at least 0.01.

3-Axis Roughing Toolpaths Practicing: 3-Axis Roughing Toolpaths 6


To illustrate this parameter, we are going to use the plate_cover.xdw CAD file.

Plate Cover

1. Open the CAD file and start the workzone creation process.

2. Activate the Final Allowance option in the Geometry Activation Parameters section.

3. Let’s suppose that you want to add a 1mm final allowance to the part: enter the value in the corresponding input field.

Geometry Activation Parameters: Final Allowance


5. Once the workzone is loaded, initialize the stock model and select a 3D Solid Block.

6. Create a new roughing toolpath with the following parameters.



Roughing Toolpath Parameters

7. Activate the Leave Exact Stock Allowance option in the Tolerances section.

This option is only available if the Final Allowance parameter in the Part Geometry dialog box has been enabled, if not it is grayed out. If it is enabled and you activate this option, WorkNC will always respect the Stock Allowance value defined above. If you leave this option unchecked, WorkNC will apply a tolerance to the Stock Allowance value defined above this option. In other words, WorkNC will not explicitly respect the defined Stock Allowance value and may leave more or less stock than has been defined. In any case, WorkNC takes into account the Final Allowance value defined in the Part Geometry dialog box to ensure that this parameter is respected. The defined Tolerance value is also always respected.


CONSTANT STOCK AMOUNT

This is particularly useful to reduce calculation times on big parts, but do not deactivate this option if you want to leave a constant amount of stock over the whole part. NOTE

6.8.2 Defining an Initial Lateral Step on the Global Roughing Toolpath You can ensure better positioning of the cutter on the first pass of the Global Roughing toolpath: for example, you can avoid the situation where the cutter center is on the edge of the stock.

When machining hard materials, you can define a larger initial step so that a larger part of the cutter enter the stock and thus reduce the tool vibrations. Accepted values are between 0.05 and 95% of the tool diameter.



Small Initial Step Larger Initial Step

To illustrate this, create a workzone from the Plate_cover.xdw CAD file.

1. Create a Global Roughing toolpath with the following parameters:

Global Roughing Toolpath

EXPAND WINDOW BY

You must define a value in the Expand Window by field to allow the cutter to engage from outside the part. Otherwise, the toolpath will not perform the Initial Lateral Step. ATTENTION

2. Initialize a 3D Stock Model and run the toolpath calculations.

3. Make a copy of this toolpath and open the Toolpath Parameters menu of the copy.

4. Activate the Initial Lateral Step option.

MACHINING CYCLE FOR THE INITIAL LATERAL STEP

This option is only available with the Spiral machining cycle.

NOTE



5. Enter the Initial Lateral Step value in the corresponding field. Enter a smaller value than the Stepover, for example 10.


7. Make another copy of the toolpath and this time define a higher Initial Lateral Step, for example 22.


9. Define a color for each toolpath and display the 3 of them in a top view of the part.

Global Roughing Toolpath with Different Initial Step Values

In our example, the initial step of the first toolpath (blue) has the same value as the Stepover, the initial step of the second toolpath (green) is smaller than the Stepover and the initial step of the third toolpath (red) is higher than the Stepover.

6.8.3 Exercise : Roughing a Part

OBJECTIVES

In this exercise, you are asked to use what you have learned in the 3-Axis Roughing Toolpaths section to rough the part of the Plate_cover workzone (Creating a Workzone in the CAD Mode section).

The idea is to obtain a Stock Model state as illustrated below:

Stock Model State After the Roughing Phase

INSTRUCTIONS

1. Create a roughing toolpath.

2. Initialize a 3D Stock Model and calculate the toolpath.

3. Update the Stock Model with this toolpath.

4. Create a reroughing toolpath and update the Stock Model.

5. Create a Flat Surface Rough/Rerough toolpath and update the Stock Model.

See also... Creating a Workzone in the CAD Mode [ 3-7] 3-Axis Roughing Toolpaths [ 6-1]



Solution: Roughing a Part The following parameters are given as an example.

1. Roughing toolpath:

Expand Window by Diam+Stock: activated Bull-nose cutter, Body Radius: 24 – Corner Radius: 12 Stock Allowance: 2 Tolerance: 0.1 Stepover: 20 Z-Step: 5 (fixed) Rough Flat Surface: deactivated

2. Reroughing toolpath:

Expand Window by Diam+Stock: activated Bull-nose cutter, Body Radius: 16 – Corner Radius: 8 Stock Allowance: 0.5 Tolerance: 0.1 Stepover: 10 Z-Step: 2 (fixed) Rough Flat Surface: activated

3. Flat Surface Rough/Rerough toolpath

Expand Window by Diam+Stock: activated Flat cutter, Body Radius: 16 Stock Allowance: 0.05 Tolerance: 0.03 Stepover: 10 Z-Step: 2 (fixed) Additional Lateral Stock: 0

3-Axis Finishing Toolpaths Flat Surface Finishing 7


7 3-Axis Finishing Toolpaths After the roughing stage, you can go on machining the part with the finishing toolpaths.

These toolpaths are available in the 3-Axis Finishing tab of the Toolpath Strategy dialog box.

Finishing Toolpaths in the Toolpath Strategy Dialog Box

In this section, we are going to give you details about the most common 3-axis finishing toolpaths, using the Training_test workzone.

7.1 Flat Surface Finishing The Flat Surface Finishing toolpath is useful for machining parts with large flat surfaces such as parting surfaces, or as a complimentary toolpath after the roughing toolpaths on parts with flat surfaces at different Z-levels where stock material remains.

This toolpath can be used on all types of material with bull nose and flat cutters.

7.1.1 Programming a Flat Surface Finishing Toolpath 1. Create a new toolpath.


3. In the Toolpath Strategy dialog box, activate the 3-Axis Finishing tab.

4. Select the Flat Surface Finishing toolpath and click OK to validate.

5. Define the following standard parameters:

7 3-Axis Finishing Toolpaths Flat Surface Finishing


Flat Surface Finishing: Standard Parameters

Now you have to define the specific parameters:

FLAT SURFACE DETECTION

This parameter defines the tolerance of the flat surface with respect to the machining plane. This allows detection of some flat areas that may otherwise be ignored.

For our example, leave the default value in the Tolerance field.

STOCK DEFINITION

This parameter allows you to define a Surface Stock which is valid only for the selected Machining Option parameter explained below. The defined value is considered by WorkNC as a global stock applied to all surfaces to be machined.

For our example, enter 0.5 in the Surface Stock field.

MACHINING OPTIONS

This parameter allows you to determine whether walls or flats or both walls and flat surfaces are to be machined. The button of this parameter displays the option that is activated. The default option is Flats.

Click on the Flats button.

The Areas to Machine dialog box is displayed.

3-Axis Finishing Toolpaths Flat Surface Finishing 7


Areas to Machine Dialog Box

If you activate the Walls option, the With Cutter Compensation option is displayed. Activating this option implies that the code for cutter compensation in the X and Y coordinates is automatically generated in the Postprocessor output file (the user must enter the compensation value when programming the NC machine).

For our example, activate the Flats option.

Click OK to validate and exit the dialog box.

STOCK ALLOWANCES

These parameters allow you to define the amount of stock to be respectively left on walls and/or flat surfaces.

For our example, enter 0 in the On Walls (Lateral) and On Flat Areas fields.

Enter 0 in the Corner Smoothing Radius field.

Validate the parameters and run the toolpath calculations.


Flat Surface Finishing Toolpath

7 3-Axis Finishing Toolpaths Z-Level Finishing


7.2 Z-Level Finishing The Z-Level Finishing toolpath is useful for machining parts with vertical or very curved shapes in a high speed machining context. It is particularly adpated for use with bull-nose cutters on all kinds of materials.

7.2.1 Programming a Z-Level Finishing Toolpath 1. Create a new toolpath.


3. Select the Z-Level Finishing toolpath in the Toolpath Strategy dialog box and validate.


Z-Level Finishing: Standard Parameters

CUTTER MOVEMENTS

Click on any button in the Cutter Movements section.

The Cutter Movements dialog box is displayed:

3-Axis Finishing Toolpaths Z-Level Finishing 7


Cutter Movements Dialog Box

The Z-Level Finishing toolpath allows you to define ramped or radial lead-in/out movements.

Below are the parameters that are common to the Ramp and Radial options:

Lead-in Radius Defines the default Lead-in Radius. Minimum Lead-in Radius

This parameter is used if the default Lead-in Radius cannot be performed because of part geometry restrictions. The value of the Minimum Lead-in Radius must be greater than twice the tolerance, if not an error message is displayed.

Ramp Angle This parameter is used when WorkNC cannot perform either of the Radial Lead-In movements.

Maximum Overlap Distance

This parameter allows you to define an overlap distance between the Lead-in point and the Lead-out point on a pass to avoid marking the part. The maximum distance is 2mm.

Lead-in without overlap distance Lead-in with overlap distance



When you activate the Ramp option, you can force the tool to follow an S-shape path when moving laterally from one level above the other:

S-shape Stepovers Activated

With S-Shape Stepovers

Activate the Vertical option.

When using Vertical or Radial lead-in movements, you can force the toolpath to perform spiral transitions between passes. This allows you to obtain a continuous toolpath trajectory with a minimum number of retracts on geometries which evolve in a regular manner along the machining Z axis such as electrodes, core and cavity shapes, etc.



Vertical Lead-ins

Activate the Radial option.

Define the appropriate radii.

Activate the 3D Spiral Transitions in the Transitions section.

Radial Lead-ins




Now you have to define the specific parameters.

ENTRY POINTS

This parameter is used in a wide variety of toolpaths and, in general, allow the user to define where lead-ins will be performed for a particular toolpath.

For our example, do not define any entry points.

MACHINING ORDER

This parameter determines if WorkNC will machine all the levels of a given zone in one sequence (By Zone option) or if it will machine the same level of each different zone (By Level option) one after the other.

1. Click on the button of the Machining Order section.

The Machining Order dialog box is displayed:

Machining Order Dialog Box

2. Activate the By Zone or By Level option. For our example, make sure that the By Zone option is activated.

3D SPIRAL TRANSITIONS

The spiral transitions are not possible when activating the By Level option. The 3D Spiral Transitions option is automatically deactivated when you choose this machining order. NOTE


CUT LINK DISTANCES

The principal use of the Cut Link Distance parameter is to reduce the number of retracts by allowing the cutting feed rate to be continued over a distance where, without this parameter, WorkNC would normally perform a retract.

Setting the Zone Link Distance parameter value sufficiently high allows you to consider separate zones (e.g. islands) as one single zone. Movements between the individual zones will be performed at the cutting feed rate.

For our example, leave the default values in the Cut Link Distance and Zone Link Distance fields.

MACHINING ORDER AND CUT LINK DISTANCES

Press the [F1] key to display the Online Help. The Z-Level Finishing Machining Strategies section illustrates various combinations of these 2 parameters. NOTE



SLOPE LIMIT

This parameter allows you to determine which areas of a part are machined according to the slope angle.

For our example, leave the default value in the Minimum Slope field.

MACHINE BASE OF WALLS

This parameter allows you to ensure that walls are machined over their full height. This is because some stock may remain at the base of the walls depending upon the overall height of the wall and the value defined for the Z-Step parameter.

Make sure that the Machine Base of Walls option is activated.



Z-Level Finishing Toolpath

On the regular portions of the part, the toolpath follows a spiral movement. It performs regular lead-in and lead-out movements when the geometry become more complex.

Spiral Transitions

7 3-Axis Finishing Toolpaths Planar Finishing


7.3 Planar Finishing This toolpath has been specially designed to machine in parallel passes following the surface profile of the part, with a constant stepover in the plane view. On parts with vertical walls, this toolpath may leave scallops on steep walls.

7.3.1 Programming a Planar Finishing Toolpath 1. Create a new toolpath.


3. Select the Planar Finishing toolpath in the Toolpath Strategy dialog box and validate.


Planar Finishing: Standard Parameters

CYCLE AND DIRECTION

Click on any of the available buttons in the Machining Parameters section.

The Method, Cycle and Direction dialog box is displayed:

3-Axis Finishing Toolpaths Planar Finishing 7


Method,Cycle and Direction Dialog Box

Only the Box and Lace cycles are available for this toolpath.

Activate the Lace and the Parallel to Y options.


CUTTER MOVEMENTS

Click on any button in the Cutter Movements section.

Activate the Vertical option in the Lead-ins/Lead-outs section.

Vertical Lead-ins

7 3-Axis Finishing Toolpaths Planar Finishing


When defining vertical lead-in movements, you can make the toolpath execute stepovers on the surface(s) to machine without retracting by activating the Stay on Surface option.

For our example, do not activate the Stay on Surface option.



SPECIFY THE START POINT

This parameter allows you to define in which corner of the Machining Zone machining will start.

Leave the default settings for this parameter.

POCKETS/FLATS SELECTION

This parameter allows you to determine the pocket and flat surface machining strategy.

Click on the button in this section.

The Pockets/Flats Selection dialog box is displayed:

Pockets/Flats Selection Dialog Box


For detailed information about these parameters, press the [F1] key to open the Online Help and refer to the Pockets/Flats Selection section. NOTE

3-Axis Finishing Toolpaths Planar Finishing 7


Activating the Avoid Pockets option allows you to define Detection Parameters which determine how pockets and surrounding areas are detected and processed by WorkNC. It also allows to enter a Cut Link Distance value.

Activating the Avoid Flat Surfaces option allows you to specify that flat surfaces will not be machined. You can define the Flat Surface Overlap value, i.e. a distance which will be machined within the flat surface boundaries. This is used to avoid marking the part when a complementary toolpath is used to machine the flat surfaces. It also allows to enter a Cut Link Distance value.

Activating the Limit Distance between Passes option allows you to delete the passes generated on the vertical areas. You can define the Maximum Distance as Multiple of Stepover value: when the distance between the passes exceeds this value, the corresponding passes are deleted.

7 3-Axis Finishing Toolpaths Combined Z-Level Finishing and Optimization


POCKETS/FLATS MACHINING STRATEGIES

When the Pockets/Flats Selection dialog box is opened, press the [F1] key to display the Online Help. The Pockets/Flats Selection section illustrates these parameters. NOTE

For our example, do not activate any of these parameters and exit the dialog box.


You should obtain the following results:

Planar Finishing Toolpath

7.4 Combined Z-Level Finishing and Optimization WorkNC allows defining both Z-Level Finishing and Optimization toolpaths in one single operation. This reduces the programming time and the risk of tool breakage due to wrong definition of minimum pockets. When programming a combined Z-Level Finishing and Optimization toolpath, the minimum value for pockets is applied to both toolpaths.

7.4.1 Programming a Combined Z-Level Finishing and Optimization

To illustrate this toolpath, create a new workzone from the plate_wing.xdw file.

1. Create a new toolpath.


3. Activate the 3-Axis Finishing tab in the Toolpath Strategy dialog box.

4. Select the Combined Z-Level Finishing + Optimization toolpath and validate.

3-Axis Finishing Toolpaths Combined Z-Level Finishing and Optimization 7


Combined Z-Level Finishing and Optimization

This toolpath contains nearly all parameters that can be defined for both the Z-Level Finishing and the Optimized Z-Level Finishing toolpaths. This allows you to define common parameters, like the tool to be used, the tolerance values, the minimum width of the pockets, etc.

1. Define the standard and specific parameters as in the above picture.

2. Click on the button in the Min/Max Slopes section. Here, you can define the minimum slope limit to be taken into account for Z-Level Finishing and the maximum slope limit not to be exceeded by Optimization.

Slope Limit Option in the Combined Z-Level Finishing and Optimization Toolpath

3. Define a minimum slope of 30° for Z-Level Finishing and a maximum slope of 35° for Optimization.


5. If you want to machine flat surfaces, activate the corresponding option. For our example, deactivate the Machine Flat Surfaces option.

6. Click OK to validate the parameters and run the toolpath calculations.


7 3-Axis Finishing Toolpaths Practicing: 3-Axis Finishing Toolpaths


Combined Z-Level Finishing and Optimization

7. Simulate the toolpth with the Progressive Display mode.

Some areas are machined by the Z-Level Finishing step...

... while others are machined during the Optimization step.

7.5 Practicing: 3-Axis Finishing Toolpaths

7.5.1 Deleting Passes on Vertical Areas When programming a Planar Finishing toolpath, large scallops may be generated with the passes that are executed on the vertical areas which are orientated in the toolpath direction.

Although these scallops can be remachined with a similar toolpath calculated in the perpendicular direction, you may consider these passes unnecessary.

The specific parameters of this toolpath contains an option which allow you to delete these passes.

To illustrate this, we are going to use the Pumpe workzone.

1. Create a new Planar Finishing toolpath with the following parameters:

Ball cutter, Body Radius: 2 Box machining cycle, Parallel to Y direction Stock Allowance: 0 Tolerance: 0.10 Stepover: 0.5 Vertical Lead-ins Corner Smoothing Radius: 0

3-Axis Finishing Toolpaths Practicing: 3-Axis Finishing Toolpaths 7



Planar Finishing with Passes on Vertical Areas

With the defined Stepover value, the distance between the passes on vertical areas increases.

2. Open the Toolpath Parameters menu of this toolpath.

3. Click on the button of the Pockets/Flats Selection section.

The Pockets/Flats Selection dialog box is displayed.

4. Activate the Limit Distance between Passes option.

The Maximum Distance as Multiple of Stepover field is displayed.

Pockets/Flats Selection: Distance between Passes

5. Keep the default value in this field.

When the distance between the passes exceeds 1.5 times the defined Stepover value, the corresponding passes will be removed from the toolpath.




7 3-Axis Finishing Toolpaths Practicing: 3-Axis Finishing Toolpaths


Planar Finishing: Removed Passes

This time, the toolpath has not generated passes on the vertical areas.

7.5.2 Exercise: 3-Axis Finishing

OBJECTIVES

In this exercise, you are asked to use what you have learned in the 3-Axis Finishing Toolpaths section to program finishing toolpaths on the Plate_cover part that you used in the 3-Axis Roughing exercise.

INSTRUCTIONS

1. Program a Flat Surface Finishing toolpath.

2. Program a Planar Finishing toolpath. Make sure that it executes stepovers on the surfaces of the part.

3. Program a Z-Level Finishing toolpath.

Solution: 3-Axis Finishing Toolpath The following parameters are given as an example.

1. Flat Surface Finishing toolpath.

Expand Window by Radius+Stock: activated Flat cutter, Body Radius: 16 Tolerance: 0.010 Stepover: 10 Z-Step: 2 (fixed) Vertical Lead-ins Corner Smoothing Radius: 0

2. Planar Finishing toolpath.

Expand Window by Radius+Stock: activated Bull-nose cutter, Body Radius: 10 – Corner Radius: 4 Lace machining cycle, Parallel to X direction Tolerance: 0.010 Stepover: 10 Vertical Lead-ins Corner Smoothing Radius: 0 For this toolpath, make sure that the stepovers are executed on the surfaces of the part:

3-Axis Finishing Toolpaths Practicing: 3-Axis Finishing Toolpaths 7


Stay on Surface

3. Z-Level Finishing toolpath.

Expand Window by Radius+Stock: activated Bull-nose cutter, Body Radius: 5 – Corner Radius: 1 Stock Allowance: 0 Tolerance: 0.01 Z-Step: 2 (fixed) Vertical Lead-ins Corner Smoothing Radius: 0

Stock Simulation Running Stock Simulation 8


8 Stock Simulation The Stock Model Simulation function allows you to:

Run toolpath simulations on selected stock models. Create and save the Stock Model for each toolpath, or generate a stock model based on

several toolpaths. Visualize multiple toolpath trajectories on a given stock model.

The Stock Model used for simulation is different from the Stock Model that you initialize to calculate toolpaths.

8.1 Running Stock Simulation To give you an example of stock simulation, we are going to run stock simulation for the roughing toolpaths of the Training_test worlzone.

1. In the Workzone Manager, click on the first roughing toolpath.

2. Click on the icon located on the left side of the user interface.

Global Roughing Toopath: Simulate Toolpath

The Progressive Display dialog box is displayed.

3. Click on the drop-down list at the top of the dialog box to select the type of stock model.

Progressive Display: Stock Selection

There are 4 types of stock models to be used for simulation: New 2D Stock for Toolpath: creates a 2D stock model large enough to display the stock for the selected toolpath. New 3D Stock for Toolpath: creates a 3D stock model large enough to display the stock for the selected toolpath. New 2D Stock for whole Part: creates a 2D stock model large enough to display the stock for the part but not necessarily for the toolpath. New 3D Stock for whole Part: creates a 3D stock model large enough to display the stock for the part but not necessarily for the toolpath.

4. For our example, select the New 2D Stock for whole Part option.

8 Stock Simulation Running Stock Simulation


5. Click on the button.

You can see the progressive simulation of the toolpath in the Viewing Area.

Toolpath Simulation

6. Once the simulation finished, click on the icon in the Progressive Display dialog box to save the stock modifications.

7. Click on the Close button to exit this dialog box.

The stock modification has been added to the Simulation element in the CAM Entities section of the Workzone Manager.

Stock Simulation Display

TOOLPATH COLOR

Before running stock simulation, you can change the color of the toolpath. This color will be applied to the stock simulation. You can change the color of toolpath by using the toolpath context menu in the Workzone Manager or by using the color button in the Toolpath menu.

NOTE

8. Open the Toolpath Parameters menu of the second toolpath: Click on the icon of the corresponding toolpath in the Workzone Manager.

Stock Simulation Running Stock Simulation 8


Or click with the mouse wheel button on the name of the corresponding toolpath in the Workzone Manager.

9. Click on the Color button and select a new color for the toolpath.

Toolpath Color Selection


11. Run the stock simulation for the second toopath.

STOCK MODEL SELECTION

When running stock simulation for another toolpath, you can select the previous stock model in the Progressive Display dialog box so that you can view the modifications. NOTE

Progressive Display: Stock Selection

Below is the result of the second toolpath stock simulation:

8 Stock Simulation Running Stock Simulation


Stock Simulation after 2 Toolpaths

3-Axis Optimization Toolpaths Optimized Z-Level Finishing 9


9 3-Axis Optimization Toolpaths The Optimization toolpaths in WorkNC are designed to be used in conjunction with the Finishing toolpaths in order to complete the machining of the part.

There are two optimization toolpaths in WorkNC:

Optimized Planar Finishing Optimized Z-Level Finishing

They are available in the 3-Axis Finishing tab of the Toolpath Strategy dialog box:

Optimization Toolpaths in the Toolpath Strategy Dialog Box

Optimized Planar Finishing is intended for use with the Planar Finishing toolpath and Optimized Z-Level Finishing is intended for use with the Z-Level Finishing toolpath.

Because of the machining strategy used by the Planar Finishing toolpath and the Z-Level Finishing toolpath, certain areas of the part will not be machined. The optimization toolpaths automatically machine only those areas not machined by the finishing toolpaths.

9.1 Optimized Z-Level Finishing The Optimized Z-Level Finishing toolpath is generally used in conjunction with a Z-Level Finishing toolpath. These 2 toolpaths are complementary, although they use completely different machining strategies. The Optimized Z-Level Finishing toolpath is intended for use after the Z-Level Finishing toolpath to machine the relatively flat areas of the part.

As with the Z-Level Finishing toolpath, the areas to be machined are determined in relation to a Machining Slope Angle you specify when you create the toolpath. However, with the Optimized Z-Level Finishing toolpath machining will be performed on slopes with an angle less than the specified Maximum Slope and there is also an option which determines if flat surfaces will be machined or not. For those areas to be machined, machining is performed in the parallel plane or by contouring.

9 3-Axis Optimization Toolpaths Optimized Z-Level Finishing


You will normally use the Optimized Z-Level Finishing toolpath after the Z-Level Finishing toolpath, since stock will have been removed from the vertical walls, making tool access easier.

All the standard cutters supported by WorkNC can be used with the Optimized Z-Level Finishing toolpath. You will very likely use different cutters for the Z-level Finishing and Optimized Z-Level Finishing toolpaths, since with the Z-Level Finishing toolpath you will be machining vertical walls and with the Optimized Z-Level Finishing toolpath you will be machining relatively flat areas.

After an Optimized Z-Level Finishing toolpath, the part may be in a finished state or may require a remachining toolpath.

9.1.1 Programming an Optimized Z-Level Finishing Toolpath 1. Create a new toolpath.

2. Click on the Type button to select your toolpath strategy.

3. In the Toolpath Strategy dialog box, select the Optimized Z-Level Finishing toolpath and validate.

4. Define the standard parameters. Below is an example of standard parameters that you can apply:

Optimized Z-Level Finishing: Standard Parameters


SPECIFY THE START POINT

This parameter allows you to define in which corner of the machining zone machining will start.

3-Axis Optimization Toolpaths Optimized Z-Level Finishing 9


SLOPE LIMITS

The Slope Limits parameter allows you to determine which areas of a part are machined according to the slope angle.


Click on the button in the Pockets/Flats Selection section.

The Pockets/Flats Selection dialog box is displayed.

Pockets/ Flats Selection (Optimized Z-Level Finishing)

Avoid Pockets

Activating the Avoid Pockets option will display 2 parameters which determine how pockets are detected:

Avoid Pockets Option

Minimum Width

Any pockets smaller than the minimum width value specified for this parameter will not be machined. If you activate the Auto option, only pockets which are equal to at least twice the size of the cutter diameter plus twice the value of the Stock Allowance will be machined.

Detection Z Step

This parameter is used by WorkNC to check if a closed contour exists (i.e. a pocket) at subsequent levels starting from the top of the part. When a closed contour is detected, WorkNC will compare the width of the pocket to the Minimum Width parameter value and will not machine the pocket if the actual value is smaller than the Minimum Width parameter value. If the actual value is greater than the Minimum Width value WorkNC will machine that level of the pocket and the process will be repeated at each subsequent level in the pocket.

9 3-Axis Optimization Toolpaths Optimized Z-Level Finishing


A Cut Link Distance option is also available when activating the Avoid Pockets option:

Cut Link Distance Specifying a Cut Link Distance value can have an effect on the machining strategy of flat surfaces and pockets.


For detailed information about these parameters, press the [F1] key to open the Online Help and refer to the Pockets/Flats Selection section. NOTE

Avoid Material Left by Previous Smoothing Radius

This option is used to avoid areas with material left due to corner smoothing in the previous toolpaths. This option has been designed to prevent potential tool breakage.

Material Left by Previous Smoothing Radius Option

You can specify the smoothing radius used in the previous toolpath (if any) or the smoothing radius defined in the specific parameters of the current toolpath (activate the Use the Smoothing Radius of the Current Toolpath option). You cannot activate this option if the smoothing radius of the current toolpath is set to 0.

1. For our example, do not activate the Pockets/Flats Selection parameters.

2. Set the Maximum Slope to 10. This will make the toolpath machine relatively flat surfaces only.

3. Set the Corner Smoothing Radius to 0.



Optimized Z-Level Finishing Toolpath

3-Axis Optimization Toolpaths Optimized Planar Finishing 9


9.2 Optimized Planar Finishing The Optimized Planar Finishing toolpath is generally used in conjunction with a Planar Finishing toolpath. These 2 toolpaths are complementary although they use completely different machining strategies.

The Planar Finishing toolpath follows the surface profile with a constant Stepover in the plan view. For parts with vertical or near vertical walls, large scallops will be left on walls because of the constant Stepover and the Machining Direction. The Optimized Planar Finishing toolpath provides an automatic facility for locating and removing the large scallops left on walls, without machining the whole part.

The Planar Finishing and Optimized Planar Finishing toolpaths may be used in any order. The Optimized Planar Finishing toolpath may follow the Planar Finishing toolpath or you may use it before the Planar Finishing toolpath in order to remove stock on the vertical walls, thereby preparing the part for the Planar Finishing toolpath.

The Machining Direction used for the Optimized Planar Finishing toolpath should be perpendicular to the machining direction used for the Planar Finishing toolpath.

All the standard cutters supported by WorkNC can be used with the Optimized Planar Finishing toolpath. You will typically use the same cutter as for the Planar Finishing toolpath.

After an Optimized Planar Finishing toolpath, the part may be in a finished state or may require one or more Remachining toolpaths in order to remove Rest Material.

9.2.1 Programming an Optimized Planar Finishing Toolpath To illustrate this toolpath, we are going to use the plate_cover workzone.

Since we already executed a Planar Finishing toolpath oriented in the X direction, we will run an Optimized Planar Finishing toolpath oriented in the opposite direction (Y) in order to avoid witness marks on the part left by cutter deflection.

TOOLPATHS SEQUENCE ORDER

For practical reasons, the optimization toolpaths are presented and executed after the finishing toolpaths in this training guide. Nevertheless, we recommend you to run Optimized Planar Finishing toolpaths before Planar Finishing toolpaths.

NOTE

To define an Optimized Planar Finishing toolpath, proceed as follows:

1. Create a new toolpath.

2. Click on the Type button to select your toolpath strategy.

3. In the Toolpath Strategy dialog box, select the Optimized Planar Finishing toolpath and validate.

4. Define the standard parameters.

Below is an example of standard parameters that you can apply:

9 3-Axis Optimization Toolpaths Optimized Planar Finishing


Optimized Planar Finishing: Standard Parameters

In the example above, we have defined a Parallel to X machining direction since the previous Planar Finishing toolpath was run in the Y direction.

We have also chosen the Box machining cycle. With this cycle, the part will be machined from top to bottom in order to prevent the body of the cutter from touching the stock. We recommend that you use this cycle if you machine vertical walls with the Optimized Planar Finishing toolpath before the Planar Finishing toolpath.


SLOPE LIMIT

This parameter allows you to determine the areas that will be machined. All areas with an angle greater than the value defined in the Maximum Slope field will be machined.

1. For our example, keep the default value in the Maximum Slope field.



Optimized Planar Finishing Toolpath

3-Axis Optimization Toolpaths Practicing: 3-Axis Optimization Toolpaths 9


9.3 Practicing: 3-Axis Optimization Toolpaths

9.3.1 Optimized Z-Level Finishing: Material left by Previous Smoothing Radius This specific parameter is used to avoid areas with material left due to corner smoothing in the previous toolpaths. It has been designed to prevent potential tool breakage.

The operating mode of this prameter is based on the smoothing radius used by the previous toolpath and on the detection tolerance depth.

To illustrate this, we are going to create a workzone with the corner_smoothing.xdw file.

Part for Corner Smoothing

1. Program a Global Rough/Rerough toolpath with the parameters given in the above table.

Expand Window by Radius+Stock: activated Bull-nose cutter, Body Radius: 5 – Corner Radius: 0.5 Stock Allowance: 2 Tolerance: 0.1 Stepover: 5 Z-Step: 5 (fixed) Rough Flat Surfaces: activated Corner Smoothing Radius: 5

2. Initialize the Stock Model (3D Solid Block) and run calculations.

3. Update the Stock Model. You should obtain the following result:

Corner Smoothing Part - After Roughing

4. Program a Z-Level Finishing toolpath with a smaller tool (Flat, Body Radius: 4) and a Corner Smoothing Radius (4).

5. Program an Optimized Z-Level Finishing toolpath with the following parameters:

Flat cutter, Body Radius: 4 Stock Allowance: 0.1 Tolerance: 0.1

9 3-Axis Optimization Toolpaths Practicing: 3-Axis Optimization Toolpaths


Stepover: 1.045 (auto) Vertical Lead-ins Minimum Slope: 45 Corner Smoothing Radius: 0


Resulting Optimized Z-Level Finishing

In the few areas highlighted in the above picture, the tool comes and machines the material which was left because of the Corner Smoothing Radius of the Z-Level Finishing toolpath. In some cases, e.g. when the remaining quantity of material is important, this may lead to tool breakage. To avoid this, you can program the Optimized Z-Level Finishing toolpath in such a way that the left material remains unmachined.

6. Create a new Optimized Z-Level Finishing toolpath and click on the button of the Pockets/Flats Selection section.

7. Define the specific parameters as in the picture below to make sure that the remaining material is not machined:

Pockets and Flats Selection Parameters

You have to enter the value of the Corner Smoothing Radius which was used in the Z-Level Finishing toolpath, i.e. 4 mm in our example. Make sure that the Auto. option is activated.

8. Validate the parameters and run the toolpath calculations


3-Axis Optimization Toolpaths Practicing: 3-Axis Optimization Toolpaths 9


Resulting Optimized Z-Level Finishing with Avoid Left Material

If you look at the same areas as the ones we highlighted before, you can note that the tool does not machine the material that was left by the Z-Level Finishing toolpath.

9.3.2 Optimized Z-Level Finishing: Pocket Detection And Flat Surface Machining To illustrate this, we are going to use the workzone that you created for the Corner Smoothing option with the corner_smoothing.xdw file.

1. Program a new Optimized Z-Level Finishing toolpath with the following parameters:

Expand Window by Radius+Stock: activated Flat cutter, Body Radius: 4 Lace machining cycle, Parallel to X direction Stock Allowance: 0.1 Tolerance: 0.1 Stepover: 2 (fixed) Minimum Slope: 45 Machine Flat Surfaces: deactivated Corner Smoothing Radius: 0

2. Click on the button in the Pockets/Flats Selection section.

3. Make sure that the Avoid Pockets option is deactivated.



Optimized Z-Level Finishing with Pocket Machining

9 3-Axis Optimization Toolpaths Practicing: 3-Axis Optimization Toolpaths


Note the toolpath has only machine the red surfaces: these surfaces are not flat surfaces (Draft Angle: 89.7000). It has ignored the gray surfaces which are flat surfaces.

Note also that the pocket has been machined.

5. Create a new toolpath, keep the same parameters but this time, activate the Avoid Pockets option in the Pockets/Flats Selection dialog box. Activating the Avoid Pockets option enables the Minimum Width parameter. Any pockets smaller than the minimum width value specified for this parameter will not be machined. If you activate the Auto option, only pockets which are equal to at least twice the size of the cutter diameter plus twice the value of the Stock Allowance will be machined.

In our example, the pocket width is 35 mm. For the pocket not to be machined, you must enter a minimum width value that is superior to 35. Let’s say 37mm.

Avoid Pockets Parameters



Optimized Z-Level Finishing: Pocket avoided

The pocket has not been machined.

Editing Toolpaths Practicing: 3-Axis Optimization Toolpaths 10


10 Editing Toolpaths Sometimes you may want to edit your toolpaths and save time when machining:

By removing sections and therefore unnecessary paths when machining corners. By isolating sections of the toolpath and reorder them. By adding an offset value to the toolpath (or a section of the toolpath) in order to protect the

part in case of further modifications of the CAD model. By inverting the machining direction of the toolpath (or sections of the toolpath) to improve

the machining strategy. By defining new rates for portions of the toolpath.

To illustrate this function, we are going to use the toolpaths that you have programmed in the Training_test workzone.

To use the Toolpath Edtion function proceed, as follows:

Display the toolpath that you want to modify in the Workzone Manager.

Click on the icon in the toolbar on the left side of the user interface. Or click on Edit in the text menu bar and select Multiple Edition in the Toolpath Modification menu.

You can also right click on the toolpath and select Multiple Edition in the Toolpath Modification menu.

The Toolpath Edition dialog box is displayed:

10 Editing Toolpaths Removing Toolpath Sections


Toolpath Edition Dialog Box

The selected toolpath is displayed in the Viewing Area, the Remove function is activated by default.

COLLISION DETECTION

You can click on the Select Tool Point button and place the cutter at any point on the toolpath and detect collisions at this point by activating the Check Collisions at Selected Point option. You can deactivate the Tool Point Selection Moves the Machine option so that the machine does not move when selecting points. This allows you to have better visibility, but in this case collisions with the machine are not detected.

NOTE

For this training session, we are going to see how to remove, isolate, offset and invert portions of a toolpath.

10.1 Removing Toolpath Sections We are going to remove sections on the Z-Level Finishing toolpath.

1. Select the toolpath and start the Toolpath Edition function.

2. Make sure that the Remove function is activated. If not, click on the Remove button in the Command section of the dialog box.

The dialog box offers you various possibilities to remove sections of toolpath. You can delete segments, a section between 2 points or a complete pass of the toolpath. You can also draw rectangles or polygons to remove the segments contained in them. Let’s see how to remove segments contained in a polygon. Let’s suppose that you want to remove the sections on the small boss of the part:

Editing Toolpaths Removing Toolpath Sections 10


Toolpath Sections to be Removed

3. Click on the icon to show a top view of the part and zoom in using the mouse wheel button

4. Click on the Polygon button in the dialog box and click on points around the passes to be removed in the Viewing Area:

Polygon Selection

CANCELLING SELECTION

In the dialog box, click on the Del Last button to cancel the last point selection or click on the Clear button to cancel all point selections. NOTE

5. Click on the Preview button to obtain a preview (in blue) of the toolpath sections that are going to be removed. You can also activate the Auto option to automatically obtain previews of your selection as long as the Toolpath Edition dialog box is opened.

Removed Sections Preview

10 Editing Toolpaths Removing Toolpath Sections


When you change the orientation of the part after having made a selection, you can restore the previous orientation by clicking on the Clip Plane in +Z button.

You can invert your selection by activating the Invert Clipping option.

6. Click on the Apply button in the dialog box or right click in the Viewing Area to apply the modification.

Remove Function Applied

The dialog box remains opened, allowing you to apply other modifications.

CANCELLING MODIFICATIONS

Once you have applied several modifications, click on the Undo button to cancel the last modification or click on the Undo all button to cancel all the modifications. NOTE

7. Click OK to validate and exit the function.

The Workzone Manager now displayed a E- status symbol to indicate that the toolpath edition requires calculations. In fact, it requires the calculation of the new retracts and lead-in movements.

Toolpath Edition waiting for Calculation

8. Run the calculation.


Editing Toolpaths Isolating Toolpath Blocks 10


Toolpath with Removed Sections

10.2 Isolating Toolpath Blocks You can isolate some sections of the toolpath to insert them again but in a different order. To illustrate this function, we are going to use the Optimized Z-Level Finishing toolpath.

We are going to divide the toolpath into blocks. We are going to create a block for each Z level of the toolpath.

1. Activate the toolpath display and start the Toolpath Edition function.

2. Click on the Isolate button in the Command section of the dialog box.

Toolpath Edition: Isolate Function

3. Show a right view of the part so you can identify the different levels of the toolpath.

4. Click on the icon in the toolbar on the right side of the user interface to hide the part.

We are going to make rectangular selections to select the different sections of the toolpath.

5. Click on the Rectangle button in the dialog box.

We are going to select the upper level of the toolpath.

10 Editing Toolpaths Isolating Toolpath Blocks


6. Click on 2 points around to toolpath sections in the Viewing Area, as illustrated below:

Rectangular Selection

7. Click on the Apply button or right click in the Viewing Area to validate your selection.

8. Click on the separator button in the middle of the dialog box:

Block List

The Block List is displayed. The Original Block contains the sections of the toolpath that you have not isolated yet. The Isolated Block 1 contains the toolpath sections you have just selected.

9. Create the other isolated blocks using rectangular selections.

Editing Toolpaths Isolating Toolpath Blocks 10


Isolated Blocks Created

10. Click on the various blocks in the dialog box. The corresponding toolpath sections are highlighted in blue.

The Original Block should be empty : if you click on it in the Block List, there should be no highlighted element in the Viewing Area.

REORGANIZING THE BLOCKS

The order in which the blocks appear in the list indicates the machining order of the modified toolpath. You can move the isolated blocks in the list to change that order.

Drag and drop the blocks in the list until you obtain the desired order.

Drag and Drop Isolated Block 5

In our example, we want the toolpath to machine the lower levels first:

Isolate: Drag and Drop

Click on the Apply button to validate the new order.

10 Editing Toolpaths Offsetting Toolpath Sections


EDITING AN ISOLATED BLOCK

The Isolate function also offers you the possibility to offset, invert or remove a selected block.

1. Right click on the block.

2. Select the modification that you want to apply.

Isolated Block: Context Menu

If you want to offset a block, first enter the value in the corresponding field, then right click on the block and apply the offset.

Click OK to validate the Isolate function.

Run the calculations.

If you simulate the toolpath, you will see that it machines level by level, starting from the bottom of the part.

10.3 Offsetting Toolpath Sections You can add an offset to some sections of a toolpath. To illustrate this function, we are going to use the Flat Surface Finishing toolpath.


2. Click on the Offset button in the Command section of the dialog box.

Toolpath Edition: Offset Function

Editing Toolpaths Inverting Toolpath Sections 10


We are going to offset the pass on the flat surface at the top of the part.

3. Click on the Pass button in the dialog box.

4. Click on the pass to offset.

Pass to Offset

5. Enter the offset distance in the Value field of the dialog box, for example 2 mm.

6. Click on the Apply button or right click in the Viewing Area to validate the offset.

Before Offset After Offset

Click OK to validate and exit the function.

Run the calculations.

10.4 Inverting Toolpath Sections You can invert the machining direction of sections or complete toolpaths. To illustrate this, we are going to use the Optimized Planar Finishing toolpath.


2. Click on the Invert button in the Command section of the dialog box.

Toolpath Edition: Invert

10 Editing Toolpaths Inverting Toolpath Sections


We are going to invert the machining direction for the last portion of the toolpath, in order to reduce the

distance between the retract point of the previous portion (see below) and the lead-in point of the

last portion (see below):

Section to Invert

3. Orientate the part to obtain the following display:

Part Orientation

4. Click on the Rectangle button in the dialog box.

5. Make the following rectangular selection:

Rectangular Selection

6. Click on the Apply button or right click in the Viewing Area to validate the operation.

7. Click OK to validate and exit the function.

8. Run the calculations.

Editing Toolpaths Validating or Cancelling Modifications 10



New Machining Direction

The distance between the retract point of the previous section (see above) and the lead-in point of the

last portion (see above) is shorter. The machining direction of the last portion (see arrow above) has been inverted.

10.5 Validating or Cancelling Modifications Once you have made modifications to a toolpath with the Toolpath Edition function, you can cancel the modifications or validate the modified toolpath.

There are 2 ways of activating these commands:

Right click on the icon or on the E+ status symbol of the modified toolpath in the Workzone Manager.

Toolpath Context Menu: Validate/Cancel Modifications Commands

Or...

10 Editing Toolpaths Validating or Cancelling Modifications


Select the toolpath in the Workzone Manager.

Click on Edit in the text menu bar and select the appropriate command in the Validate/Cancel Modifications menu.

Validate/Cancel Modifications in the Edit Menu

RESTORE INITIAL TOOLPATH

This command is available when toolpath modifications have been calculated on the selected toolpath (E+ status symbol). If you activate this command, the E+ status symbol disappears and the initial toolpath is restored.

ACCEPT MODIFICATION

This command is available when toolpath modifications have been calculated on the selected toolpath (E+ status symbol). If you activate this command, the E+ status symbol remains displayed, the Validate/Cancel Modifications commands are no longer available. The only way to restore the initial toolpath is to recalculate the toolpath. To do so, right click on the toolpath and select Recalculate.

CANCEL MODIFICATION

This command is available when toolpath modifications have been applied but not yet calculated (E- status symbol). If you can activate this command, the E- status symbol disappears and the pending calculations are cancelled.

For our example, restore all the initial toolpaths.

Calculating the Recommended Safe Tool Length 11


11 Calculating the Recommended Safe Tool Length This function allows you to detect any collision between the tool holder, the cutter (under certain conditions), the part surfaces or Machining Context surfaces and clamps for a given calculated toolpath.

In case of collision detection, the function will inform you of the Recommended Safe Tool Length that is required to avoid any collisions between the selected tool holder and the part.

This function is available in the Tool Holder Collision Detection Parameters dialog box.

To illustrate this function, we are going to use the Planar Finishing toolpath that we created for the Training_test workzone.

To activate the function, proceed as follows:

1. Select the corresponding toolpath in the Workzone Manager

2. Click on the icon in the toolbar on the left side of the user interface.

The Tool Holder Collision Detection Parameters dialog box is displayed.

Tool Holder Collision Detection Parameters Dialog Box

3. Select the tool holder that you want to use: If you want to use a simple, cylindrical holder, activate the Cylindrical Holder option and indicate the radius and the length of your tool holder. If you want to use an existing tool holder in your library, activate the Holder Profile File Name option and click on the None button. Double click on the relevant tool holder in the WorkNC Tool Holder Library.

11 Calculating the Recommended Safe Tool Length


For our example, select Cylindrical Holder and enter 15 in the Holder Radius field. Keep the default Holder Length value. A preview of the tool holder with the cutter is displayed on the right side of the dialog box.

4. Enter the Effective Tool Length of the cutter that is to be used for the collision detection calculations i.e. the distance between the tip of the cutter and the lower face of the tool holder.

For our example, keep the default tool length.

5. In the Collision Detection section, activate the Calculate Recommended Safe Tool Length only option.

Collision Detection Parameters Defined


A H- status symbol is now displayed on the toolpath line in the Workzone Manager and the icon appears in the Viewing Area.

7. Run the collision detection calculations.

A Calculation Report is displayed. If collisions have been detected, it indicates the Recommended Safe Tool Length.

8. Click OK to close the Calculation Report.

A H+ status symbol, indicating that the collision detection has been calculated is now displayed on the toolpath line in the Workzone Manager. This status symbol as well as the ball of the toolpath appear in red, which means that the application detected collisions between the part and the tool holder.

Calculating the Recommended Safe Tool Length 11


Workzone Manager: Tool Holder Collisions Status Symbols

You can simulate the toolpath in the Progressive Display mode to visualize the collisions between the tool holder and the part:

Tool Holder Collision With the Part

The tool holder that we defined is displayed in the Viewing Area. You can activate or deactivate the tool holder

display by clicking on the icon on the right side of the user interface.

As there are collisions between the holder and the part, the cutter used by the toolpath is too short. The Tool Holder Collision Detection function allows you to determine the recommended tool length:

1. In the Workzone Manager, select the toolpath for which you have executed the collision detection.

2. Click on the icon again.

In the dialog box, the Recommended Safe Tool Length field is displayed, indicating the minimum cutter length to avoid collisions:

3. Enter this recommended tool length in the Effective Tool Length field.

11 Calculating the Recommended Safe Tool Length


Effective Tool Length Modified


The H+ status symbol is displayed in black and the ball of the toolpath is displayed in green.

No More Collision

Repeat the procedure for all the finishing and optimization toolpaths.

Since these toolpaths use the same cutter, it may be useful to apply the same configuration before postprocessing them.

Postprocessing Toolpaths 12


12 Postprocessing Toolpaths Once you have programmed toolpaths in the CAM mode, you need to postprocess the toolpath data. Postprocessing allows the user to convert toolpaths data into the correct format before transferring it to the target machine NC.

Let’s postprocess the toolpaths that we created in the Training_test workzone:

SELECTING THE POSTPROCESSING METHOD

1. In the Workzone Manager, select all the toolpaths. To do so, press and hold the [Shift] key, click on the first toolpath of the list and then on the last toolpath.


Since you have selected more than one toolpath, the application asks you to select the postprocessing method: Separately or Concatenated.

SEPARATE OUTPUT FILES OR CONCATENATED OUTPUT FILES

The Separately option will generate postprocessed toolpath files containing individual toolpaths, whereas the Concatenated option will generate a postprocessed toolpath file that contains multiple toolpaths. NOTE

3. Click on the Concatenated button for our example. The Concatenated Postprocess dialog box is displayed.

Concatenated Postprocess Dialog Box

TOOLPATHS TO BE POSTPROCESSED

You can add or remove toolpaths by clicking on the Add or Remove buttons below the Toolpaths field. You can also change the order of the toolpaths by selecting one toolpath and clicking on the Up or Down buttons.

NOTE

12 Postprocessing Toolpaths


SELECTING THE POSTPROCESSOR

1. Click on the Select button in the Parameters field to select your postprocessor.

The Select Postprocessor dialog box is displayed.

Select Postprocessor Dialog Box

As you can see, this dialog box contains the list of available postprocessors. In the above example, you can see columns with colored symbols next to the name of the available postprocessors. These columns represent the types of machining for which the various postprocessors can be used or not.

The symbol indicates that the postprocessor is recommended for the corresponding type of machining.

The symbol indicates that the postprocessor cannot be used for the corresponding type of machining.

The symbols on the left side of the list indicate the postprocessors that cannot be selected for the current toolpaths. In the above example, the selected toolpaths are 3-axis toolpaths, and we cannot select the postprocessors that have been specifically defined for 2D and 5-axis machining. However, note that a postprocessor can be defined for 2 types of machining. This is done in the postprocessor file.

2. Click on the Select button to select your postprocessor file.

A new dialog box pops up to allow you to select your directory and postprocessor file.

Postprocessing Toolpaths 12


Postprocessor File Selection

POSTPROCESSOR FILE SELECTION

In the above example, we have selected the disk D and corresponding pospro directory.

The standard postprocessor directory is C:\WorkNC**\Postpro. NOTE

3. Once you have selected the directory and the postprocessor file (wncpos.lis), click on the OK button.

4. For our example click on the Postprocessor without Transformation in the Select Postprocessors dialog box and click OK to validate.

The selected postprocessor and its compatibility is now displayed in the Concatenated Postprocess dialog box.

5. Click on the (Re)Postprocess button.

6. Run the calculations.

Once the calculations are completed, a Concatenated Postprocess line with C+ status symbol is displayed in the Workzone Manager to indicate that the postprocess has been executed:

Concatenated Postprocess in the Workzone Manager

POSTPROCESSING PARAMETERS

For more details about the parameters, press the [F1] and look for Postprocessor in the Online Help. NOTE

Exercise: Basic Functions Validating or Cancelling Modifications 13


13 Exercise: Basic Functions For this exercise, you are asked to practice the basic operations that were explained throughout this training guide.

Read the whole exercise before starting to carry out the task.

Create a workzone from the plate_wing.xdw CAD File.

Create the following toolpaths and define the parameters as proposed in the table below.

Calculate the toolpaths one by one, update the Stock Model after the first roughing toolpath.

1. Global Rough / Rerough

2. Flat Surface Rough / Rerough

3. Optimized Planar Finishing

4. Planar Finishing

5. Z-Level Finishing

Machining Zone Expand Window by is deactivated

Expand Window by is deactivated




Cutter Details Tool: Bullnose Body Radius: 16 Corner Radius:8

Tool: Flat Body Radius: 18

Tool: Bullnose Body Radius: 10 Corner Radius: 4


Tool: Ball Body Radius: 8

Machining Parameters

Method: Climb Cycle: Spiral


Cycle: Lace Direction: X


Method: Mixed

Tolerances Stock Allowance: 2 Tolerance: 0.1 Stepover: 16

Stock Allowance: 2 Tolerance: 0.1 Stepover: 18



Stock Allowance: 0 Tolerance: 0.03

Z-step 5 5 None None 5

Specific parameters

Reroughing Area option is deactivated Rough Flat Surface option is deactivated

Reroughing Area option is deactivated

Minimum Slope:60 Machine Base of Walls is deactivated

Corner Smoothing

2 2 0 1 1

Simulate the toolpaths by using stock simulation. Use the same 3D Stock Model for the whole part.

Some parameters need to be modified and there is a lot of stock remaining on the part. For example, deactivating the Expand Window by option prevent the cutter from fully-machining all surfaces of the part. The cutter details and the Z-level for the Z-Level Finishing toolpath need to be improved because there is a lot of rest material on the vertical surfaces of the part. The machining direction for the Planar Finishing has to be changed because it is the same as for the Optimized Planar Finishing toolpath. The stepover for the Planar Finishing toolpath needs to be reduced.

That is why you are asked to redefine some parameters and to create one more toolpaths to optimize your finishing toolpaths.

13 Exercise: Basic Functions Validating or Cancelling Modifications


Redefine parameters and create 1 more toolpath as proposed in the table below:

1. Global Rough / Rerough

2. Flat Surface Rough / Rerough

3. Optimized Planar Finishing

4. Planar Finishing

5. Z-Level Finishing

6. Optimized Z-Level Finishing

Machining Zone

Expand Window by is activated (36)

Expand Window by is activated





Cutter Details Tool: Bullnose Body Radius: 16 Corner Radius:8

Tool: Flat Body Radius: 16





Machining Parameters




Cycle: Lace Direction: Y

Method: Mixed


Tolerances Stock Allowance: 2 Tolerance: 0.1 Stepover: 10

Stock Allowance: 1.5 Tolerance: 0.1 Stepover: 10

Stock Allowance: 0 Tolerance: 0.01 Stepover: 0.332 (auto)


Stock Allowance: 0 Tolerance: 0.01

Stock Allowance: 0 Tolerance: 0.01 Stepover: 0.288 (auto)

Z-step 5 5 None None 1 None Specific parameters

Rough Flat Surface option is activated (tolerance: 0.01)

Machine Base of Walls is activated Minimum Slope: 10

Corner Smoothing

1 1 0 0 0 0

Simulate the toolpaths by using stock simulation.

Postprocess the toolpaths separately.

Exercise: Basic Functions Solution: Basic Functions 13


13.1 Solution: Basic Functions

TOOLPATH: GLOBAL ROUGH/REROUGH Expand Window by option deactivated: Expand Window by option activated:

TOOLPATH: Z-LEVEL FINISHING Initial Toolpath New Toolpath

STOCK SIMULATION Inital Toolpaths New Toolpaths

POSTPROCESSING

Toolpaths Postprocessed Separately

Index

Copyright 2014 © Sescoi International i SESINT_EN_WNCBAS1 240414 - CAM Basic 1

Index

3

3-Axis Finishing Toolpaths, 7-1 3-Axis Optimization Toolpaths, 9-1 3-Axis Roughing Toolpaths, 6-1, 6-46

A

Analyzing Altitudes, 4-17 Analyzing Borders, 4-22 Analyzing Curvature, 4-15 Analyzing Draft Angles, 4-19 Axis Rotation Toolbar, 4-6

C

Calculating the Recommended Safe Tool Length, 11-1 Combined Z-Level Finishing and Optimization, 7-19 Corner Smoothing, 6-21 Creating a New Workzone in the CAM Mode, 3-1 Creating a Workzone in the CAD Mode, 3-9, 6-46 Creating Toolpaths, 5-1 Cusp Height, 6-21 Cut Link Distance, 6-19 Cutter Details, 6-2 Cutter Movements, 6-14

D

Defining an Initial Lateral Step on the Global Roughing Toolpath, 6-44 Deleting Passes on Vertical Areas, 7-22 Displaying Toolpaths, 6-28 Dynamic Rotation, 4-2 Dynamic Sectioning, 4-13 Dynamic Viewing, 4-7

E

Editing Toolpaths, 10-1

F

Flat Surface Finishing, 7-1 Flat Surface Rough/Rerough, 6-36 Flat Surface Roughing, 6-20

G

Global Rough/Rerough, 6-1

I Initial Step, 6-23 Initializing the Stock Model and Calculating the Roughing Toolpath, 6-23 Inverting Toolpath Sections, 10-14 Isolating Toolpath Blocks, 10-7

M

Machining Order, 6-22 Machining Parameters, 6-6 Machining Zone, 6-2 Manipulating Parts, 4-1 Measurements, 4-8

N

NC Machining Parameters, 6-11

O

Offsetting Toolpath Sections, 10-12 Opening the Toolpath Parameters Menu of a Toolpath, 6-31 Opening/Closing Workzones and CAD Files, 3-15 Optimized Planar Finishing, 9-6 Optimized Z-Level Finishing, 9-1 Optimized Z-Level Finishing: Material left by Previous Smoothing Radius, 9-8 Optimized Z-Level Finishing: Pocket Detection And Flat Surface Machining, 9-13

P

Part Analysis, 4-12 Part Geometry Preparation, 2-1 Planar Finishing, 7-13 Pocket Selection, 6-17 Postprocessing Toolpaths, 12-1 Practicing: 3-Axis Finishing Toolpaths, 7-22 Practicing: 3-Axis Optimization Toolpaths, 9-8 Practicing: 3-Axis Roughing Toolpaths, 6-40 Predefined Orientations, 4-1 Programming a Combined Z-Level Finishing and

Index

SESINT_EN_WNCBAS1 240414 - CAM Basic 1 ii Copyright 2014 © Sescoi International

Optimization, 7-19 Programming a Flat Surface Finishing Toolpath, 7-1 Programming a Flat Surface Roughing Toolpath, 6-36 Programming a Global Rough/Rerough Toolpath: Specific Parameters, 6-17 Programming a Global Rough/Rerough Toolpath: Standard Parameters, 6-2 Programming a Planar Finishing Toolpath, 7-13 Programming a Reroughing Toolpath, 6-34 Programming a Z-Level Finishing Toolpath, 7-4 Programming an Optimized Planar Finishing Toolpath, 9-6 Programming an Optimized Z-Level Finishing Toolpath, 9-2

R

Removing Toolpath Sections, 10-2 Reroughing, 6-34 Reroughing Areas, 6-20 Running Stock Simulation, 8-1

S

Selecting a Strategy, 5-2 Starting WorkNC, 2-2 Stock Parameters, 6-17

Stock Simulation, 8-1

T

Tolerances, 6-12 Tool Holder Collision Avoidance, 6-17

U

Updating the Stock Model, 6-31 User Interface in the CAM Mode, 3-5 Using the Final Allowance Parameter, 6-40

V

Validating or Cancelling Modifications, 10-18

W

Workzones, 3-1

Z

Z-Level Finishing, 7-4 Zoom Functions, 4-5 Z-Step, 6-14

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