ESPRIT 2009 Get Started Guide

Get Started with ESPRIT

Get Started with ESPRIT 2009

Copyright © 2008 DP Technology Corp. All rights reserved. U.S. Patent No. 6,907,313. Other U.S. patents pending.

Information is subject to change without notice.

No part of this manual may be reproduced, transmitted, translated in any form or by any means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any information storage or retrieval system, without written permission from DP Technology Corp.

The software described in this document may only be used or copied in accordance with the terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the software onto any medium except as specified in the license or non-disclosure agreement.

All DP Technology Corp. software products contain integrated security programs and/or plug-in modules that are required for the software license to properly operate. It is a violation of the DP Technology Corp. copyrights and U.S. Copyright law to disable or attempt to disable or remove or otherwise operate the software without the security programs and/or modules installed. Any software not supplied by DP Technology Corp. which is intended to allow the operation of the software without the required plug-in security module and/or integrated security programs is a copyright violation.

ESPRIT is a registered trademark of DP Technology Corp.

All brand or product names or proprietary file types mentioned in this document are trademarks or registered trademarks of their respective holders. Contact the appropriate companies for more information regarding trademarks and registration.

DP Technology Corp. 1150 Avenida Acaso Camarillo, California 93012 USA

Phone (805) 388-6000 Fax (805) 388-3085 www.dptechnology.com

Printed in the United States of America

Contents

Welcome to ESPRIT 2009. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Installing ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Getting Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5ESPRIT Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ESPRIT Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9The ESPRIT Work Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Opening and Storing Files in ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Selecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Controlling the Display of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Using Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20ESPRIT Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24ESPRIT KnowledgeBase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Create Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Create Milling Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32Create Turning Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Create Wire EDM Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Mill a Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Cut the Pockets and Slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Mill and Drill Holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Create a Shop Floor Report. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Mill on a Rotary Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Cut Along a Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86Rough and Finish the Pocket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91Copy and Rotate Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Mill a Mold Core . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98Pre-Finish All Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102Finish Near-Flat Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106Finish the Blend Fillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Mill 5-axis parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111Create 5-axis swarf operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112Create a 5-axis contouring operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123Create 5-axis composite operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Turn a Standard Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145Remove Excess Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146Finish and Groove the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154Finish and Thread the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157Perform the Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Turn an Advanced Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165Create a Balanced Rough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166Drill and Groove Simultaneously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169Mill/Turn a Face Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172Transfer the Part to a Sub-Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174Drill on a Rotary Axis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177Mill with the B-Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Wire EDM a Die Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181Create Draft Conic Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182Contour the Die Openings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191Sort EDM Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198Simulate the Slug Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Wire EDM a 4-Axis Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205Contour a Multi-Axis Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Welcome to ESPRIT 2009 | 1

Welcome to ESPRIT 2009

ESPRIT has all the power you need to machine any part...

ESPRIT is a high-performance computer-aided manufacturing (CAM) system for a full range of machine tool applications. ESPRIT delivers powerful full-spectrum programming for 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turn machining, and B-axis machine tools.

ESPRIT’s high-performance capabilities include machining any part geometry (solid, surface, or wireframe), universal post processing to format G-code for virtually any machine tool, and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency.

ESPRIT’s multitasking component provides powerful capabilities for driving mill-turn machines, multi-axis lathes, and Swiss-style machine tools. ESPRIT provides synchronization of simultaneous cutting cycles using any combination of turrets and spindles for milling or turning, factory-certified post processors for all the leading multitasking machine tools, and dynamic solid simulations for dry run verification of the machining processes.

Get Started with ESPRIT will teach you all the basics of how to machine your parts, plus show you advanced techniques to help you get the most out of ESPRIT 2009.

Installing ESPRIT ............................... 2

Getting Help ......................................... 5

ESPRIT Support .................................. 7

2 | Get Started with ESPRIT 2009

Installing ESPRITPrerequisites for ESPRIT 2009The installation program verifies all requirements before proceeding. If the system does not meet requirements, the installation will abort until the system complies. Existing users should review their computer systems to be sure that they comply with the latest ESPRIT installation and system requirements.

The following operating systems are supported by ESPRIT 2009:Microsoft® Windows® XP SP2 x32 or x64 or Windows® Vista™ x32 or x64•

The following operating system components are required by ESPRIT 2009:Microsoft® Internet Explorer version 6.0 or greater• Microsoft® .NET Framework version 2.0.50727*• Microsoft® SQL Server 2005 Express edition*• SafeNet Sentinel drivers version 5.39 or greater*•

The following are minimum hardware requirements for ESPRIT 2009:800 MHz 32-bit (x86) processor or greater• RAM requirements of a minimum of 512 MB, 1 GB or more recommended• 32 MB video card capable of 16-bit color at 1024 x 768 and OpenGL rendering• 20 GB hard disk drive• 1 GB of free hard drive space• CD-ROM or DVD-ROM drive• Mouse• Parallel or USB port (required for ESPRIT security)•

* Microsoft® .Net, Microsoft® SQL Server 2005 Express and the SafeNet Sentinel drivers are all included on the ESPRIT 2009 CD for your convenience; you will find them in the Prerequisites folder. Components are provided in English only. For other languages, visit the download center at the Microsoft website (www.microsoft.com) for your country or visit Sentinal Support at the SafeNet website (www.safenet-inc.com).

Note: Older machines will run ESPRIT 2009, but the results will be less than ideal. The use of additional memory or faster processors will directly improve performance and capacity. Sufficient swap space is required to handle installation of ESPRIT 2009 as well as any files saved.

Security ModulePlug your Security Module into the appropriate port on your computer. If you have a parallel Module, plug it into the primary parallel port (LPT1) at the back of your computer. Do not plug it into a serial port. ESPRIT is not fully functional if the Module is not inserted correctly. Without the Module, ESPRIT runs in “demonstration mode”. You can use ESPRIT, but you will not be able to create NC code or store any files.

Take special care to protect your security module from loss or damage. It is an integral component of the software and your license.

The only device you may attach to the back of a parallel Security Module is a parallel printer.


Important: Do not plug any tape backup systems, portable CD-ROMs, DVD players or recorders, Zip drives, multi-function office systems (all-in-one printer/fax/scanner/copier devices) into a parallel Security Module. These will damage your module.

If your Module becomes damaged, your ESPRIT software will not work until a replacement Security Module and new password can be shipped to you at your expense. Module replacement is not covered by Software Maintenance Contracts.

Lost or stolen Modules are your responsibility. Please check with your insurance carrier to be sure your business insurance has them covered for the full value of your ESPRIT software.

Install ESPRIT from the CDPlease set your computer’s date correctly before installing ESPRIT and do not change the date thereafter.

Important: An incorrect date can damage the security module and render ESPRIT inoperative. Your ESPRIT software will not work again until a replacement security module and new password can be shipped to you.

If a virus protection software is installed on your computer, you need to disable it before installing ESPRIT. The ESPRIT installation uses scripts that will be automatically blocked by your anti-virus software unless virus protection is disabled. Make sure to turn the virus protection back on after you install ESPRIT.

Note: Your system must meet the prerequisites listed on the previous page before you will be allowed to install ESPRIT 2009.

Insert the ESPRIT 2009 CD in the CD-ROM or DVD drive.1.

Open the file ReadThisFirst.doc on the CD.2.

Follow the instructions to perform a new installation of ESPRIT 2009 or to upgrade from a 3. previous version of ESPRIT.


Use ESPRITESPRIT 2009 is a single instance application and does not support multiple instances. ESPRIT does not limit the number of instances running, but you may experience unexpected and undesirable results in choosing to run more than one instance of ESPRIT at the same time.

Select the ESPRIT icon on your Windows desktop

Or,

From the Windows Start menu, select All ProgramsESPRIT 2009ESPRIT.

Other ESPRIT 2009 menu items:

DNC To Machine Tool: For advanced users, DNC customization

License Manager: Updates passwords for product additions and installs

NC Editor: NC file editing tool

Settings Manager: Imports, exports and resets ESPRIT user settings

KnowledgeBase: Database setup and management


Getting HelpThe ESPRIT Help system is HTML-based, making it easy to navigate between topics to find the exact information you need. You can access the online help system several ways:

Press the F1 key at any time• On the Help menu, click ESPRIT Help• From within a dialog, click the Help button for specific help about that topic•

To print any topic, select the Print button at the top of the Help window. To return to the main topic window (displayed above), select the Home button. Use the Forward and Back buttons to move back and forth through the topics you’ve already viewed.

There are four tabs in the navigation pane of the Help window that help you find the information you need. If you do not want to view the tabs, select the Hide button. To display them again, select Show.

Contents. • Displays information in a chapter format. Help topics are grouped logically by subject area. Each time you select a topic in the list, it opens automatically in the right pane of the Help window.

Index. • Displays topic information in alphabetical order. You can scroll through the list or type the first few letters of the keyword you are looking for. To open a highlighted entry in the index, simply press Enter or select the Display button. Or, you can double-click on an entry to open that topic.

Search. • Lets you search through every topic in the help file for a specific word or phrase. Type a word or phrase (enclose the phrase in quotes to find that exact phrase), then select List Topics or simply press Enter. Every help topic that contains that word or phrase is listed.


Favorites. • Lets you save a list of help topics that you commonly refer to. To add a topic to the Favorites list, open the topic (from the Contents tab, the Index, or from a Search), place the cursor in the Current Topic field and press Enter.

ESPRIT Help on the WebGet the most current information about ESPRIT, new product features and enhancements, latest releases, post processors, advanced tips, and creative solutions. The ESPRITWeb is a family of four websites dedicated to serving the needs of the ESPRIT community. Register for the ESPRITWeb at: http://www.dptechnology.com/ew

The ESPRITWeb home page is the central point for the ESPRIT online user community. It contains • up-to-date information on all ESPRIT products and includes links to all other ESPRIT online areas.WebBoard is a discussion group that provides you with an open forum for discussion on any • topic related to ESPRIT. Ask questions and share your ideas, solutions, and experiences with other ESPRIT programmers.SupportWeb is a web-based three-step technical support system. Start by using the Frequently • Asked Questions (FAQs) to find a solution to your problem. If your initial FAQ search does not answer your question, search the solution database for answers. Finally, if you have not found your solution in either of these places, you can submit your question to our technical support engineers directly from the web and subsequently via e-mail.FileLibrary is a web-based library of post processors, macros, and other data files useful to • ESPRIT programmers.

The ESPRITWeb is only available to registered ESPRIT users who have an active Software Maintenance Contract (SMC).

For more information on SMC, go to http://www.dptechnology.com and click on the link to Professional Services. We look forward to hearing your comments and suggestions on how we can improve your website. Send your comments via e-mail to [email protected] or even better, post your message on the WebBoard discussion group.

General Windows® HelpFrom the Windows Start menu, select “Help and Support”. Microsoft provides general information about the Windows operating system.


ESPRIT SupportThe DP Technology web site provides a wide variety of information about the company and its products.

You can access the web site at: http://www.dptechnology.com

For support issues, please send an e-mail to: [email protected]

Phone SupportContact your reseller first. Resellers of ESPRIT give specialized information related to the custom solution they provided to you. This is the best place to start.

If you don’t have a reseller, contact the nearest DP Technology office.

Corporate Office Midwest USA Eastern USADP Technology Corp.1150 Avenida AcasoCamarillo, CA 93012

DP Technology Corp.1001 E. Touhy AvenueSuite 300Des Plaines, IL 60018

DP Technology Corp.8535 Cliff Cameron DriveSuite 112Charlotte, NC 28269

Toll Free: 800.627.8479Tel: 805.388.6000Fax: 805.388.3085

Toll Free: 800.627.8479Tel: 847.297.8100Fax: 847.297.8107

Toll Free: 800.627.8479Tel: 704.594.9551Fax: 704.594.9802

dptechnology.com

DP Europe DP Germany DP Italy“Le Thèbes”68 Allée de Mycénes34000 MontpellierFrance

Sommerleite 1D-96 148 BaunachGermany

Via Iacopo Nardi 250132 FlorenceItaly

Tel: +33 4 67 64 99 40Fax: +33 4 67 64 99 41

Tel: +49 9 54 49 80 3 53Fax: +49 9 54 49 80 3 54

Tel: +39 055 2342286Fax: +39 055 2347858

dptechnology.fr dptechnology.de dptechnology.it

DP Japan DP ChinaLevel 28, Shinagawa InterCity Tower A2-15-1 Konan, Minato-kuTokyo 108-6028Japan

458 North Fu Te RoadBuilding No. 36, 1FWaigaiqiao F. T. Z.Shanghai 200131China

Tel: +81 3 5485 1884Fax: +81 3 5469 1885

Tel: +86 21 5868 3696Fax: +86 21 5868 2803

dptechnology.jp dptechnology.cn


Software Maintenance Contract (SMC)Our goal is to build successful ESPRIT users. We believe the best way to do this is through the SMC program. Participants receive...

Unlimited phone support• Continuous ESPRIT software and documentation upgrades• ESPRIT de Corps Newsletter, our informative and technical newsletter• Opportunity to participate in and gain from cutting edge field testing• 24-hour web access to the DP Help Center and FTP site•

For more details on the DP Technology SMC, please call 1+(805)388-6000.

ESPRIT Fundamentals | 9

ESPRIT Fundamentals

Before you begin the projects in this guide, you should familiarize yourself with how to work with part files in ESPRIT. As a native Windows-based application, the ESPRIT interface and its menus and toolbars should look familiar to you.

This chapter explains how to work with ESPRIT part files as well as how to open files from other CAD systems. You will also learn about the ESPRIT work environment and how to customize it to the way you work. In addition, you will gain a working knowledge of how the ESPRIT KnowledgeBase works.

Note: Before beginning to use ESPRIT, you should have a working knowledge of your computer’s operating system and its conventions. You should know how to use a mouse and standard menus and commands. To review these techniques, refer to the documentation for Microsoft® Windows®.

The ESPRIT Work Environment 10

Opening and Storing Files in ESPRIT ...................................................... 12

Selecting Elements ......................... 14

Controlling the Display of Elements ................................................. 17

Using Features ................................. 20

ESPRIT Machining Technology 24

ESPRIT KnowledgeBase .............. 26

10 | Get Started with ESPRIT

The ESPRIT Work EnvironmentLet’s take a quick look at the ESPRIT screen. This window is displayed when you create a new file or open an existing one.

The ESPRIT window contains menus and default toolbars along the top of the screen, a graphic work area where you can view your work, and a status area along the bottom of the screen that displays dynamic information about your part environment and the current command or action.

Menus and ToolbarsYou can select commands from the menus or from toolbars. Use the Smart toolbar to quickly display and hide ESPRIT toolbars based on the type of work you want to do.

For example, if you want to create features, just activate the Features group of toolbars. All other toolbars are automatically hidden. All visible toolbars activated from the Smart toolbar will always be shown in the same position so you never have to hunt for a command.

Graphic Work AreaBy default, the initial view orientation is set to the Top view with the XYZ axes displayed. The X-axis is horizontal, Y is vertical, and Z points out towards you. To change to a different view, use the View pulldown near the upper right of the screen. To show or hide the XYZ coordinates, select XYZ Axis on the View menu.

Prompt AreaThe Prompt area is perhaps the most important area on the ESPRIT screen. The prompts tell you what to do next. Always pay attention to what the prompt is telling you.

Status AreaThe Status area, at the bottom of the ESPRIT screen, provides dynamic information about the current work environment. As you select commands or move the cursor, the information is constantly updated.

Specialized WindowsESPRIT also provides two specialized windows that provide additional information about the parts you are working on and provide an excellent way to manage your work.

Project Manager

The Project Manager consists of a set of windows that list every operation, feature, and cutting tool in the current session and lets you manage, sort, and reorder these items. The Tools window does not display for wire EDM files. To view the Project Manager, press the F2 key or click Project Manager on the View menu.

Property Browser

The Property Browser displays information about any item selected in the graphic work area or the Project Manager. You can view and change individual properties for the selected item. To view the Property Browser, click Properties on the View menu or hold down the Alt key as you press Enter.


Menus and ToolbarsLocated at the top of the screen, menus and toolbars give you

quick access to the functions you can perform in ESPRIT.

The Graphic Work AreaThe largest area of the screen,

this is where your part is displayed.

The Status AreaLocated at the lower right of the

screen, this area provides dynamic information about the current

work environment.

Project Manager

Property Browser

The Prompt AreaLocated at the lower left of the

screen, this area is where ESPRIT prompts to tell you what to do

next.

Operations

Features

Tools


Opening and Storing Files in ESPRITWhen you start a new session in ESPRIT or create a new file, you are given the choice of starting with a blank file or basing your new work session on a predefined template.

The <Blank Document> option opens a new file that uses the ESPRIT defaults. A template file contains user-defined elements and settings for the way you machine parts at your company.

You can create templates that include regularly used tools, machine setup configurations, simulation settings, repeated geometry, and KnowledgeBase settings. As you become more

familiar with ESPRIT, you can create templates that make it easier and faster to work on similar types of jobs.

As a new user, select <Blank Document> and click OK.

The display of the template dialog is controlled by the “Display Template Dialog” option on the Input page of the Options dialog, available on the Tools menu. By default, the template dialog displays.

For more information about how to create and use template files, please refer to the ESPRIT online help.

Creating New FilesClicking the New command closes the current file so that you can begin work on a new file. If changes have been made to the current file, ESPRIT will prompt you to save those changes before the file is closed.

The commands on the File menu or the icons on the Standard toolbar (located near the upper left of the ESPRIT screen) are used to manage part files.


Opening Exist ing FilesESPRIT lets you open native ESPRIT files (.esp extension), native 2D and 3D files from other CAD systems such as SolidWorks or Pro/E, stereolithograhpy (STL) files, and translated files such as IGES and STEP.

Since ESPRIT is based on the Parasolids kernel, it is adept at opening a variety of solid model files.

Use the Open command to open a previously saved file. Use the “Files of type” pulldown to list only files with a specific extension. This makes it easier to browse for the file you want. If the file you’re looking for has an unlisted extension, select “All Files”.

Note: The list of available file formats is based on the licensed options. For example, if your license does not allow you to open Catia files, this option will not display in the “Files of Type” pulldown.

Opening CAD Files from Another System

You can import a CAD file or merge a CAD file into an existing ESPRIT file.

On the 1. Standard toolbar, click Open or press Ctrl+O.

Click the 2. Options button.

Select an option on the 3. File Type pulldown to set the options for each type of CAD file. Specific import options are provided for each type of CAD file. For example, if you are importing a Parasolid, SolidWorks, or Solid Edge file, remember to select either “Import as solid” or “Surfaces”. When “Wireframe” is checked, wireframe elements are created along surface edges

After setting the options, click 4. OK to return to the Open dialog box.

Select the file you want to import. 5. To make it easier to find the file you want, use the “Files of type” pulldown to select a file extension.

If you want to preserve elements created in ESPRIT and merge the CAD file elements with 6. them, check the Merge option.

Click 7. Open to import the CAD file into ESPRIT.

Saving FilesAfter working in ESPRIT, you’ll want to save your work so you can retrieve it later.

The Save command stores the current file as a native ESPRIT file or as another type of CAD format. ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file format, select the “Save as type” pulldown and then select a file extension.


Selecting ElementsOne of the most important tasks in any CAD/CAM system is the ability to select a variety of elements in the part file. A single part file may include one or more solid models, wireframe geometry, surfaces, and toolpath,

In addition, you must have the ability to select individual components of an element, such as edges on a solid model or the endpoint of a line.

Selecting Elements in the Work AreaElements in the work area can be selected individually, as a group or by type of element.

Use your mouse to select an individual element in the work • area. To select more than on element, hold down the Ctrl key as • you select elements or drag a selection box over a group of elements. To select a group of connected elements, hold down the Shift • key as you select an element.

Use the Selection list to select elements by type. If Geometry is chosen, you will only be able to select geometry elements in the work area. When you are finished, remember to set the Selection type back to All.

The Group CommandIf you want to select all elements that fit specific selection criteria, you can use the Group command on the Edit menu.

The Group command lets you select all elements using the following criteria:

Element type• Color• Layer• Work Plane•

After you identify the selection criteria, click OK to automatically select all elements that meet those criteria.

Selection List

Group Dialog


Selection ModesFour selection modes are provided in the status area at the lower right of the screen:

HI (highlight) mode• SNAP mode• SUB-ELEMENTS mode• INT (intersection) mode• GRID mode•

When a mode is grayed out, that means the mode is disabled. Click on a mode to enable or disable it.

HI Mode

When HI mode is enabled, ESPRIT always asks you to confirm element selections. This allows you to select from elements that are close to, or even on top of, each other. For example, you can use HI mode to select a solid model, an edge on that model, or feature created from a solid model.

When HI mode is enabled, ESPRIT will prompt “Is this the correct choice” and highlights an element near the selection point.

If this is not the correct element, answer No by pressing the right mouse button. ESPRIT

will highlight the next closest element. In this example, you want to select the feature but a segment is highlighted instead. You would click the right mouse button until the feature highlights.

When the correct element is highlighted, answer Yes by pressing the left mouse button.


SNAP Mode

When SNAP mode is enabled, the cursor recognizes the midpoints and endpoints of lines and segments and the centerpoints of circles and arcs as valid point selections.

With SNAP enabled, the cursor changes to:

when you hover over the end of a segment or arc

when you hover near the midpoint of a segment or arc

when you hover over the centerpoint of a circle or arc

SUB-ELEMENTS mode

When SUB-ELEMENTS mode is enabled, you can select the individual sub-elements of solid models or EDM features in the work area. For example, you can select the faces, faces loops, or edges of a solid model. You can also select the sub-elements of draft conic features.

The selection of sub-elements is extremely useful for selecting the individual faces on a solid model that you want to machine. The Grouping Properties command relies on the selection of sub-elements to automatically group faces for several types of features: Holes, Draft Feature Recognition, Turning Profiles, and FreeForm features.

INT Mode

When INT mode is enabled, the cursor recognizes the intersections of segments, lines, arcs, and circles as valid point selections.

With INT set on, the cursor changes immediately to and remains as the INT cursor until an intersection is chosen. The cursor exits INT mode immediately after an intersection is chosen.

GRID Mode

ESPRIT uses the grid configuration settings from the Options dialog box (from the Tools menu,

select Options and then the Input tab). This lets you select from a defined invisible array of screen locations in response to prompts for points, angles, distances, and so on.

You may want to set the grid spacing to match your part drawing values.

Deselecting ElementsTo deselect all items simply click anywhere in a blank area of the work area.

Selecting Items in the Project ManagerFeatures and machining operations can be selected directly in the Project Manager. Most of the time, this is much easier than selecting these items in the work area.

When a feature or operation is selected within the Project Manager, the same item highlights in the work area.


Controlling the Display of ElementsESPRIT provides a variety of methods that let you control how your parts are displayed.

Shaded and Wireframe DisplaysFor solids and surfaces, you can set the display to shaded or wireframe mode.

Shaded Wire: Creates a shaded image with wireframe. The display of the wireframe is light source dependent. Wireframes will appear in different colors and/or disappear depending on the part orientation with respect to the light. Silhouettes are not supported, only true edges.

Shaded: Creates a shaded image. Has no effect on geometry elements. You can also shade the simulation of cutting operations.

Hidden Wireframe: Displays visible solids, surfaces, and geometry as wireframe depending on the orientation of the part. Elements that would normally be hidden by a shaded view are not displayed.

Wireframe: Displays all solids, surfaces, and geometry as wireframe.

ViewsESPRIT provides several standard view orientations.

When you change from one view plane to another, the display in the work area rotates to the new view orientation and the display automatically zooms to fit all elements within the screen. You can control the rotation animation speed on the Workspace tab of the Options dialog (available on the Tools menu).

You can also store your own view orientations, Pan, rotate or zoom the view to the orientation you prefer and then store the view for later use.


Storing a ViewClick View Planes from the Layers and 1. Planes toolbar.

Click the New... button.2.

Type a name and click OK.3.

You can then choose that view at any time from the pulldown list.

Panning, Zooming, and RotatingCommands on the View toolbar let you fit, zoom, pan and rotate the display of your part in the work area.

Redraw: Repaints the screen. Use Redraw when graphics become temporarily obscured. For example, if you delete an element that was on top of another element, you may need to redraw the screen.

Zoom to Fit All: Fits all visible graphic elements in the screen. You can also press F6 to execute this command.

Zoom: Magnifies a particular area. Select Zoom, then drag a box over the area you want to magnify.

Zoom Previous: Zooms out to a smaller view or jumps back to the previous view after using Zoom.

Zoom Dynamic: Dynamically zooms the view in or out depending on the direction of the mouse movement. Moving the mouse forward causes the view to zoom in; move the mouse back to zoom out.

Rotate: To dynamically rotate your drawing view in three dimensions about a selected element, select Rotate View then hold down the left mouse button over any line (including the x, y, and z axes), segment, circle, arc, or point and drag the mouse in the direction you want to rotate the view.

Or, you can hold down the left mouse button on an open space in the work area and drag the mouse to freely rotate the view.

Pan: Shifts the view. Select Pan, then drag your mouse in the direction you want to move the view.


MasksThe Masks command on the View menu lets you hide the display of specific element types.

Press Ctrl+M to display the dialog and uncheck any items you want to hide. All elements of that type will be hidden in the work area. To display the elements again, check the item in the dialog.

LayersLayers are very useful for controlling the display of different types of elements in a complex part file. For example, you can set up different layers for machine components, the initial part stock or casting, the finished part, roughing toolpaths and finishing toolpaths, or any other type of geometry.

Once an item is placed on a particular layer, you can turn the layer on or off to hide or show the different aspects of your part. Place elements of any type in a named layer, then turn that layer off to hide all items in that layer. The elements are not deleted, just temporarily hidden. You can turn a layer back on at any time.

Setting the Display of Items on LayersSelect Layers from the Layers and Planes toolbar.1.

Place a check next to the layers you want to show and uncheck layers you want to hide.2.

Note: Do not uncheck the active layer because this will cause all new elements you create to be invisible.


Using FeaturesFeatures serve several purposes in ESPRIT. First, they describe the shape of the parts you want to machine. ESPRIT uses standard manufacturing terms for features such as pocket, hole, profile, face, and so on. In this way, a set of features can describe the shape of an entire part.

Features also contain machining properties that control where material removal should occur. These properties include cutting depths, draft angles, cut direction, entry and exit points, and lead-in/lead-out points to name a few.

When NC operations are created, ESPRIT typically prompts you to select a feature. You can select a feature before or after the operation technology is defined. It is recommended that you select the feature first because then the machining operation automatically adopts the machining properties from the selected feature.

Features are created using the commands on the Features toolbar. To display the toolbar, click Features on the Smart toolbar. A feature can be created from wireframe geometry, solid models, surfaces, or NURB curves.

When a feature is created, it is classified as one of the following:

Chain FeatureAn individual feature is considered to be a chain feature. A chain feature could be the boundary around a part, a simple pocket, or a path constructed of wireframe geometry. A chain feature defines the start location, direction, and end location for a cutting path.

Chain features are quite simple and are used when you want the cutter to follow a defined path. Typically, these are contouring or profiling operations. In most cases, the tool can be centered on the chain feature or offset to the right or left.

PTOPA PTOP (point-to-point) feature defines a path connecting a series of holes or points.

PTOP features are typically used for drilling operations and can also be used for manual milling. The tool will follow this path to drill each hole. PTOP features contain information about the depth and diameter of holes along the path as well as information about chamfers and counterbores.

FeatureA collection of individual features that comprise an area to be machined is considered a feature.

Features are represented by a folder in the Feature Manager. A feature is typically a pocket containing sub-pockets or islands or a part feature containing all features found within a part boundary.


Feature Recognit ionESPRIT has the ability to recognize different types of features automatically. The Pocket, Face Profiles and Holes commands will automatically recognize milled types of features such as pockets, holes, faces, and boundaries. For wire EDM parts, the Draft Features command will automatically recognize a part as a 2-axis or 4-axis feature.

When the Pocket or Face Profiles command is used, every feature within the selected boundary or face is recognized. The Holes command will recognize every hole within a specified range of diameters.

The ESPRIT KnowledgeBase extends this feature recognition ability by letting you create additional classifications for features. For example, a chain feature can be further classified as a groove profile. The advantage to this approach is that a specific machining process can be associated with a specific type of feature. For example, that groove feature can be linked to a particular grooving operation. This not only saves a considerable amount of time, it also improves the consistency and reliability of your NC code.

Important: Your security module must be attached to your computer and you must have a valid license in order to use the ESPRIT KnowledgeBase.

A PTOP feature connecting a set of holes

A 3-dimensional chain feature

A feature that includes pockets, faces, holes and profiles


Default Part TypesThe ESPRIT KnowledgeBase includes several standard part types - milled, turned, mill/turn, or wire EDM.

The KnowledgeBase can then be used to apply a specific type of machining based on which type of part you are working on. For example, milling operations can be automatically applied to milled features and EDM operations can be specified for specific wire EDM features.

Feature ManagerESPRIT provides two very useful tools to help you manage features: the Feature Manager and the Property Browser,

The Feature Manager lists every feature in the open part file along with any associated machining operations.

The Feature Manager is a component of the Project Manager. To display the Project Manager, press the F2 key or select Project Manager from the View menu. The Project Manager includes the Operations Manager, the Feature Manager and the Tools Manager.

To view the Feature Manager, click on the Features tab.

Each time a feature is created, it is added to the Feature Manager. When a feature is selected in the list, the same feature highlights in the work area. As you create machining operations, it is much easier to select a feature from this list than in the work area, especially when a part file contains multiple features.

Several operations can be associated with a single feature and operations can be copied from one feature to another.


Property BrowserThe Property Browser displays all the properties of a selected item. These include general properties such as color, layer, and element type plus any machining properties.

Features always have machining properties.

To display the Property Browser, hold down the Alt key as you press the Enter key (Alt+Enter) or select Properties on the View menu.

To edit a feature property, click on the property’s value in the right column and make your change. In this way, you can create a feature from 2D geometry and quickly give it 3D properties by adding depth and draft angles.

Work Planes Assigned to FeaturesEach time a new feature is created, a work plane is assigned to it automatically. The assigned work plane property affects the orientation of the tool for cutting operations placed on that feature. You can view the work plane property in the Property Browser.

ESPRIT assigns only one work plane to each feature, regardless of the complexity of the feature. If you try to delete a work plane associated with an existing feature, ESPRIT protects you from accidentally deleting the work plane by displaying a warning that your action is not allowed.


ESPRIT Machining TechnologyUse ESPRIT to create a wide variety of machining operations for milling, turning, mill/turn and wire EDM.

Machining ModesOn the Machining menu, individual cutting operations are organized into three primary modes: SolidMill, SolidTurn, and SolidWire. Selecting a command on one of these menus places you in that mode. You can be in only one mode at a time. For example, if you have the SolidMill FreeForm toolbar displayed and then open the SolidTurn toolbar, the SolidTurn toolbar replaces the SolidMill FreeForm toolbar. Once a part has been programmed with a machining cycle, the mode in ESPRIT is locked. Only one machining mode is allowed per file.

The current machining mode is displayed in the status area.

Technology PagesWhen you select a machining command, the technology pages for that command are displayed. Each technology page lets you choose the machining settings that control how that operation will be performed.

You can save the technology settings for a particular operation by right-clicking inside the technology page and selecting Save. To retrieve those stored settings later, right-click inside the technology page and select Open.

Post ProcessingAfter you create an operation, it is added to the Operations Manager in the Project Manager. You can convert any or all of those operations to NC code.

To convert selected operations, open the Project Manager (press F2). Hold down the Ctrl key to select individual operations or hold down the Shift key and then select the first and last of a block of operations.

You can access the NC Code command in a number of ways:On the Common Machining toolbar, click NC Code• Press the F9 key• On the File menu, click NC Code• Right-click inside the Operations page of the Project Manager and select NC Code from the menu•

Important: To generate NC code, your security module must be attached to your computer and you must have a valid license. You cannot save files or generate NC code if you are running ESPRIT in “demo” mode.


Technology Pages

Operation settings are logically grouped on separate tabs

Context-sensitive help is available for all machining

commands

Enter values directly or use the selection arrow to gather information from elements in

the work area

Click the pulldown to view all available

options

Right-click to save, open or

reset technology defaults


ESPRIT KnowledgeBaseThe ESPRIT KnowledgeBase includes a comprehensive database that lets you store information about feeds, speeds, material, cutting tools and standard machining processes, providing you with optimum feedrates and tools for machining your parts. The information stored in the KnowledgeBase can be accessed by anyone in the shop during an ESPRIT session.

This guide primarily focuses on the following KnowledgeBase commands on the Common Machining toolbar:

• KnowledgeBase Document SettingsKnowledgeBase Settings• Process Manager•

For detailed information about the ESPRIT KnowledgeBase, please read the ESPRIT online help.

Important: To access the ESPRIT KnowledgeBase, your security module must be attached to your computer and you must have a valid license. KnowledgeBase commands are disabled if you are running ESPRIT in “demo” mode.

The KnowledgeBase greatly expands the productivity and automation capabilities of ESPRIT. Use the KnowledgeBase to set up and store your most commonly used tools, materials, and parameter settings for operation and tool pages. The KnowledgeBase also offers dramatic improvements in the efficiency, consistency and quality of machining operations. Classify features by part type and then use feature recognition to automatically associate machining processes to a part.

As part of the base license of ESPRIT, the following KnowledgeBase components are included:

• KnowledgeBase Document SettingsKnowledgeBase Settings• Rebuild• Rebuild Options• Process Manager• KnowledgeBase Manager•

The KnowledgeBase Manager includes:Cutting Tools Manager• Speeds Feeds Manager• Default part types• Default technology•

The separate KnowledgeBase Development Environment includes:

All base options• Process Technology Manager• Default Technology Manager•


KnowledgeBase Document Settings

KnowledgeBase Document Sett ingsThe KnowledgeBase Document Settings command lets you select the part type, part material, and default technology settings used for cutting operations.

Part Type

ESPRIT provides several default part types for milling, turning, mill/turn and wire EDM. As you create features, the Part Type determines the feature type associated with that feature based on pre-defined rules. Feature types are typically associated with automated machining processes. Part types are defined in the Part/Feature KB Manager.

Speed Feeds

The Speed Feeds settings for material and class determine the feedrate and speed for machining operations. Materials are defined in the Speeds Feeds Manager.

Default Technology

The Default Technology determines the technology settings used for new cutting operations and tools. Default technology is defined in the Default Technology Manager.


KnowledgeBase Sett ingsThe KnowledgeBase Settings command is used to configure the colors displayed on technology pages and for items linked to the KnowlegeBase in dialogs and the Property Browser. You can also set up options for the Process Manager and global KnowledgeBase settings.

The option “Apply selected processes to all features” controls how a machining process is applied to features when you use the Process Manager.

When this option is checked, the same process is applied to all the selected features. This is useful when you want to machine several similar features at one time.

When “Apply selected processes to all features” is unchecked, you can select several features at once and apply a separate machining process to each one.

The Reset Technology Last User Defaults button lets you reset all the technology page defaults to the ESPRIT system defaults.

You can learn more about KnowledgeBase Options in the ESPRIT online help.

KnowledgeBase Settings


Process Manager

Process ManagerThe Process Manager command lets you create and save a collection of machining operations as a Machining Process (.prc) file for future use on similar projects. Or, you may want to use the Process Manager simply as a convenient way to create and apply several operations to a feature at once. When the KnowledgeBase is used to automatically link machining processes to features, you only need to create features and then apply the associated process.

A machining process can be created to perform a complex set of operations. However, you can also create machining processes to save time on relatively simple tasks. For example, if you always create Center Drill, Drill, Countersink, and Tap cycles for certain types of holes, you can create a single machining process that consists of all these drilling operations and then open and apply that machining process whenever you need it. Or, if you commonly perform face milling and contouring to most jobs, you can create a machining process with only Facing and Contouring operations.

The Process Manager has a toolbar of commands along the top of the dialog and three main list areas: “Features”, “Process”, and “Process Steps”.


Project 1: Create Features | 31

Pr

o

ject

1Create Features

Features provide the basis for most machining operations in ESPRIT. The machining properties contained within a feature provide a single source of information about how to cut the part regardless of which type or how many operations are associated with the feature. This allows for better automation capabilities because the associated toolpaths are automatically updated whenever a feature is modified.

In summary, features:Describe the shape of the part you want to cut• Contain machining properties that control how the shape • is cutAllow you to automate machining processes•

This project shows you how to create features for use with milling, turning, and wire EDM operations.

Before you begin, please review how to select elements using SNAP mode and HI mode in the “ESPRIT Fundamentals” chapter.

The files for this project are available for download from ESPRITWeb » File Library » ESPRIT 2009 and from the ESPRIT CD.

All dimensions in this tutorial are in millimeters. Make sure System Unit on the Tools menu is set to Metric.

Create Milling Features ..............32

Create Turning Features ............39

Create Wire EDM Features ...... 50


Create Milling FeaturesMilling features typically include features that have depth such as pockets, holes, and faces. These features can be created from 2D or 3D wireframe geometry or created directly from a solid model.

In this project, you will import a solid model and quickly create an entire set of features by simply selecting the top face of the part.

Face ProfilesThe Face Profiles command lets you create a feature by selecting a face or individual face edges on a solid model. The feature recognition capabilities in the Face Profiles command will create a feature for the face boundary and additional features for any pockets, holes, or bosses associated with the selected face.

Holes associated with the selected face are processed using the settings in the Feature Parameters command. Face Profiles can handle compound holes such as chamfered, counterbored, and countersunk. For complex holes you must use the Holes command on the Features toolbar. To learn more about Hole features, please review the online help in ESPRIT.

Feature ParametersThe Feature Parameters command lets you define the parameters for how holes and pockets are created when the Face Profiles or Pocket commands are used.

When the diameter of a hole lies within the minimum and maximum range, a Hole feature is created. Drilling operations are typically applied to hole features. You can also choose to create a single PTOP feature that connects all the holes when ESPRIT recognizes the features.

Otherwise, a pocket or a profile feature is created for any hole with a diameter outside the defined range. Face Profiles will create a profile. Pocket will create a pocket. You can then apply a pocketing or spiraling operation to mill these types of holes.

To learn how to machine the features in this lesson, complete the project called “Mill a Standard Part”.


Open a Typical CAD File

On the 1. Standard toolbar, click Open.

Locate the following file: Features\2. mill_part.x_b

Click 3. Open.

Change view to IsometricClick View Shaded Wire

Enable HI Mode

Press Alt+Enter to display Property Browser

Press F2 to display

Project Manager

Change the Display in the Work Area

Before you begin working on this file, set up the display so that you can easily access the Feature Manager, the Property Browser and the Features toolbar. You can perform the following steps in any order.


Define the Parameters for Hole Recognit ion

This part contains one set of holes with a countersink, another set with a counterbore and a single large hole that should be milled instead of drilled. Since hole features are used for drilling operations, you need to specify the maximum diameter allowed for a hole feature so that the milled hole will be considered a pocket feature during feature recognition.

When you click a selection arrow in any dialog, you can select an element in the work area and ESPRIT will read the data directly from the part.

Step 2Click Feature Parameters

Step 3Click Selection

Arrow

Step 4Select the edge of one of the larger

corner holes

Step 5Click OK

Step 1Click Features

Set the Part Type in the KnowledgeBase

It is important that you set up the document before you create any new features so that the KnowledgeBase can assign the appropriate feature type as features are created.

On the 1. Smart toolbar, click Common Machining and then click KnowledgeBase Document Settings.

Set 2. Part Type to Milled Part - Std Metric.

Click 3. OK.


Step 1Click Face Profiles

Step 2Select the top

face of the part

Step 3Click OK

In this case, the new Max Diameter should be 21.48. From now on, hole features will be created for any holes with a diameter between 0 and 21.48. Any hole with a larger diameter will be treated as a milled feature.

Let’s take a look at the new features in the Feature Manager.

Create an Entire Set of Features at One Time


Select any feature in the features list and then take a look at its properties in the Property Browser. Pay particular attention to the KnowledgeBase properties.

Notice that two hole features have been created, with each one being recognized as either a Countersink or a Counterbore feature type.

The three pocketed areas have been individually recognized as either a Small Pocket, Medium Pocket, or Slot.

The largest hole has been recognized as a milled hole.

Feature types in the KnowledgeBase are important because specific machining processes can be linked to each type.


Rename Features

It can be very useful to give meaningful names to features. They are easier to select later when you create operations and are helpful to other people who use the file.

Step 2Right-click on the feature, then click Rename on the

menu

Step 1In the Features list, select to

highlight the slot feature

Step 3Type Slot and press Enter

to rename the featureStep 4

In the Feature Manager, find the highlighted feature shown and

rename it ‘Face Island’

Step 5Optionally, rename the other

features as shown


Create a Hole Feature for the Milled Hole

It is more efficient to pre-drill the milled hole before applying a spiraling operation. To do this, you can create a simple Hole feature that matches the size of your largest drill.

You can now adjust the diameter of the hole feature to match your drill and the depth to match the full depth of the part.

In the Feature Manager, select the new Hole feature.1.

In the Property Browser, change the 2. Depth value from 23.1 to 38.1.

Change the 3. Diameter value from 42 to 30.

Step 1Click Holes

Step 2Set the Max and Min

Diameter to 42

Step 4Click OK

Step 3Select the top face of

the part

Adjust the Height of the Face Island

When the feature around the island on the face was created, the feature depth was determined by the height of the vertical walls. You need to increase the height of the feature to make it parallel with the top of the island.

In the 1. Feature Manager, select the Face Island feature.

In the 2. Property Browser, click the Depth value of -10 and change it to -15.

You’re probably wondering why you need to enter a negative value to increase the height of the feature. When a top face is selected, Face Profiles assigns a positive depth pointing downward. For a bottom face, a negative depth is assigned pointing upward.


Create Turning FeaturesStandard turning operations use chain features and PTOPs to define the cutter path. Mill/turn operations also let you choose typical milling features such as face profiles and pockets.

For simple 2-axis work, you only need to create chain features on the inner and outer part profiles. For multiple-axis work, you must create chain features on the upper and lower sides of the part profile because they correspond to upper and lower turrets.

In this project, you will use the Turning Profile command to identify features for turning operations and then use the Face Profile and Holes command to identify milling features for mill/turn operations.

Turning ProfilesThe Turning Profile command analyzes the shape of a selected solid model, surface, surface composite, or STL model to find internal and external profiles. ESPRIT rotates the part around the x-axis to find the OD profile, ID profile or projections of the front face or back face. The calculated profile can be created as a chain feature or as individual geometric elements.

Chain FeaturesESPRIT provides two general ways to create chain features. The Auto Chain command will create a chain feature automatically from existing geometry. All of the geometry between the start and end locations you select are added to the chain feature.

The Manual Chain command lets you create a chain feature by manually selecting existing elements and, if SNAP mode is on, you can also select SNAP locations.

Chain features can also be created from surface curves, surface edges and text, but that does not apply to this lesson.

To learn how to machine the features in this lesson, complete the project called “Turn an Advanced Part”.


Open an ESPRIT File Containing a Mil l /Turn Part


Locate the following file: Features\2. turning_part.esp

Click 3. Open.

Create Turning ProfilesIn this lesson you will be extracting geometry from the part and creating multiple features. In this type of situation, your job will be much easier if you place the different types of elements on different layers so that you can turn off each layer as you finish each task.

This part file already includes layers for the part and the two types of features you will create: chain features for turning operations and milled features for mill/turn operations.

Set Up the KnowledgeBase


Set 2. Part Type to MillTurn Part - Std Metric.

Click 3. OK.


You now have geometry that defines a complete profile of the part. Now you will create a chain feature that passes over the groove area. First you need to turn off the ‘Part’ layer to make it easier to see the geometry.

Step 3Click Turning

Profiles

Step 4Select the solid

model

Step 5Set Profile Type to Full

Set Create to GeometrySet Profile Location to Top

Click OK

Step 1Set the layer to

Geometry


Create OD and ID Profi les

First you will create a turned profile of the entire solid. ESPRIT gives you the choice of creating the profile as geometry or as a feature. For this example, you will create geometry and then use that geometry to create a chain feature that passes over the OD groove and a chain feature for the ID at the back of the part. You do not want to cut the groove during the initial OD roughing operation. The groove should be cut with a separate grooving operation. You will create a profile of the OD groove in the next step.


Step 6Click Layers to display the

dialog

Step 7Uncheck ‘Part’

Select ‘Chain Features’Click Current

Close the Layers dialog

Step 8Click Auto Chain

Step 9Select the start

point of the feature as shown

Step 10Select the segment to the left to indicate the

feature direction

Step 11Select the end point of

the long segment


Step 12Select the end point

shown

Step 13Click Cycle Stop to create the feature


Step 15Create a chain on the ID

profile as shown

Step 16Click Cycle Stop

Step 17Click Layers, then check ‘Part’ to

display the solid model again


Create the OD Groove Profi le

In addition to selecting the entire solid model, ESPRIT provides the ability to select individual faces. You will create a profile feature of the OD groove by selecting only three faces. The feature will be created below the turning axis because the groove will be cut with the lower turret.

Before you can select individual faces, you must allow the grouping of sub-elements. Otherwise, the entire solid will always be grouped.

Step 2Click Turning Profiles

Step 3Zoom in on the groove

Step 1In the Status area, make sure

SUB-ELEMENTS is active


Step 6Set Profile Type to ODSet Create to Feature

Set Profile Location to BottomClick OK

Step 4Using HI mode, select the face on the

chamfer as shown

Step 5Select the other chamfer face and the

face between them


Create a Face Profi le Feature

In the following examples, you will learn how to create face profile features by selecting edges. Since the milled areas around the circumference of the part are positioned at an angle, ESPRIT will create a new work plane automatically when each feature is created. You can then view the work plane property in the Property Browser.

In the Layers dialog, turn on the ‘1. Part’ layer to display the solid model and make Milling Features the current layer.

Set the view plane to ‘2. Rotated’.

On the 3. Features toolbar, click Face Profiles.

Select the edge loop shown below. You may need to right-click a few times to select the 4. correct loop.

5. Click OK.

Step 8Click Layers, then uncheck ‘Part’ and

‘Geometry’ so you can see only the chain features


Click 6. Face Profiles again.

Select the two edges shown.7.

8. Use the Rotate command on the View toolbar to rotate the part and then select the third edge as shown.

9. Click OK.

Notice that you do not need to select a closed loop of edges to create a face profile feature. You have now created an open feature that can be milled with a contouring operation.

Because this feature is not parallel to the current work plane, ESPRIT has created a new work plane and assigned it to the feature. You can see the new work plane on the work planes drop down list.

Copy and Rotate the Face Profi le Feature

Now that you have one of the face profile features, you can rotate copies of that feature around the part to the other two locations.

On the View menu, click 1. UVW Axis. Seeing the orientation of the axis will make it easier to understand which plane you should use for the rotation. Elements are typically rotated around the W axis of the current work plane, but you can also use a geometric element to define the rotation axis.

Set the view plane to 2. ‘Right’ and set the work plane to ‘YZX’.


Create Hole and PTOP Features

The holes on this part are not planar so you cannot use the feature recognition capabilities in ESPRIT. You can, however, create hole features by manually selecting each hole or by selecting the face that contains the holes. First you will create features for the holes located around the perimeter of the part, then you will create a PTOP feature for the drilled hole on the front face of the part.

Set the view plane to ‘1. Isometric’ to get a better view of the part.

On the 2. Features toolbar, click Holes to display the dialog.

Select the face profile feature you just created.3.

4. Press Ctrl+C to display the Copy dialog.

Set Transformation Type to 5. Rotate, select Copy and set Number of Copies to 2.

Set Total Angle to 6. 360 and press the Tab key. The Angle Between Copies value will be automatically calculated as 120°. Make sure Use Origin for Rotation Axis is checked.

7. Click OK.


Step 4Check ‘Connect all

holes with one Ptop’

Step 5Check ‘Manual

Selection’

Step 6Select the OD face that

contains the holes

Step 7Click OK

Step 8Click Manual PTOP

Step 9Select the point at the

origin


Step 3Set Max Diameter to 20Set Min Diameter to 0


Create Wire EDM FeaturesESPRIT provides features that are designed specifically for the needs of wire EDM operations. These features are used for no other purpose than to make EDM programming as quick and easy as possible.

EDM features contain machining properties such as taper, land height, and lead-in/lead-out points. When an EDM feature is selected for a machining operation, ESPRIT uses this information to automatically populate the SolidWire technology pages. If you make any changes to the feature, the machine technology will recognize those changes and update the appropriate settings upon rebuilding the technology.

Draft Feature Recognit ionThe Draft Features command will automatically create the appropriate 2-axis or 4-axis wire EDM feature based on the type of geometry you select. For 2-axis geometry, ESPRIT will create a Draft Conic feature. When 4-axis geometry is selected, a Ruled feature is created.

ESPRIT’s EDM feature recognition lets you define rules in the Draft Features dialog that will automatically calculate the feature start point, lead-in and lead-out points, corner types, and taper angles. Open profiles and closed profiles can both be used in EDM feature recognition.

Draft Conic FeaturesWhen ESPRIT recognizes a 2-axis part, a Draft Conic feature is created. You can select 2D or 3D geometry for a draft conic feature. When 2D geometry is selected, you can add 3D properties through the Property Browser.

When 3D geometry is selected, you must have an upper profile, a lower profile and at least one element connecting the upper and lower profiles. The feature will automatically include properties for the land depth of vertical walls,

the draft angle for tapered walls, and corner styles such as sharp, conical or isometric based on the selected model. Any of these properties can be easily changed after the feature is created.

Ruled FeaturesWhen ESPRIT recognizes a 4-axis part, a Ruled feature is created. 4-axis EDM operations require the use of a ruled feature. This type of feature contains properties for the XY-profile, the UV-profile, and synchronization (match) lines between the two profiles.

To edit the match lines of a ruled feature, you must use the Add Match Line and Remove Match Line commands on the Edit Features toolbar.

Chain FeaturesESPRIT also allows the use of traditional chain features for 2-axis wire EDM operations. The disadvantage to using chain features is that machining information such as depth, land height, taper and so on must be defined on the machine technology pages each and every time an operation is created. Another disadvantage to using chain features is that you cannot create advanced conics—including taper changes and corner styles.

Note: Chain features cannot be used for 4-axis operations


Create a 3D EDM Feature from 2D Geometry


Locate the following file: Features\2. EDM_part_2D.esp

Click 3. Open.

Create a Draft Conic Feature

You will now create an EDM draft feature from the simple 2D geometry in this file. After the feature is created, you will use the Property Browser to add 3-dimensional properties like taper and corner styles.

A fast way to select all the geometry in a profile is to hold down the Shift key as you select only one element in the profile.

Note: Never use Ctrl+A to select geometry for an EDM feature. Ctrl+A will select all geometry in the work area, including overlapping geometry or geometry that is not visible on the screen. EDM feature recognition will fail when disconnected or inappropriate geometry is selected.

Choose an EDM Machine Type

Before you can use EDM feature recognition, ESPRIT must be in SolidWire mode. An easy way to do this is to specify an EDM machine type for the work session. You can also activate SolidWire mode by displaying the toolbar for SolidWire Gold or SolidWire Platinum.

On the 1. Tools menu, click EDM Machine Types.

Select 2. Sodick and click OK.

Note: You must actually select a machine type in the dialog to activate SolidWire mode. You cannot simply open the dialog and then click OK. This prevents accidentally activating SolidWire mode by simply opening the dialog.


Step 1Hold down the Shift key and select an element in

the profile

Step 3Click Draft Features

Step 4Set Part Type to Punch

Set Approach Type to MiddleSet the UV plane height to 15

Approach Type is used to locate the element where the feature will start based on the location of the thread point. In this example, the start point will be created at the midpoint of the element closest to the thread point.

The lower edge of this profile is actually comprised of two separate line segments. ESPRIT gives you the option to retain them as separate elements when the feature is created or combine them into a single element.

In this project, a different draft angle will be applied to each segment so you will not want to combine them.

Step 2Hold down the Ctrl key and select the thread

point


Step 7Click OK to create the feature

Step 6Click the Rules tab and set Combine Elements to No

Step 8In the Feature Manager, select the new

feature

Step 9In the Property Browser, click on the value for Draft, change it to 10 and press Enter

Notice that the depth in the positive Z direction is a negative value in the Property Browser. This is to keep consistency throughout the software because, in the milling world, a positive depth means moving the end mill in the negative Z direction.


Step 1In the Feature Manager, select the draft

conic feature

Step 2Use the sub-element arrow buttons to

select the upper right corner of the feature

Step 3Change the Corner Radius Mode to

Isometric and press Enter to confirm

Customize the Draft Conic Feature

Now that the draft conic feature has a uniform depth, draft angle and corner styles, you will begin to customize the feature by changing the properties of specific sub-elements. This is accomplished by using the sub-element selector in the Property Browser.

The Sub-Element forward and back arrow buttons let you quickly move through and select sub-elements in an EDM feature. The feature in this lesson has 10 sub-elements, which include segments and arcs. As each sub-element is selected, the start and end locations are highlighted in the work area.


Step 4In the same way, select the lower right

corner of the feature

Step 5Change Corner Radius Mode to Programmable and press Enter

Step 6Change Program Radius to 2.0 and press

Enter

Step 7Use the same techniques to update

the rest of the feature


Change the Taper of a Group of Draf t Conic Sub-Elements

Now that you have learned how to modify the properties of individual draft conic sub-elements, you will practice modifying a group of sub-elements. In this example, you will make a taper change to a group of sub-elements.

Open the following file: Features\1. EDM_part_subelements.esp This draft conic feature currently has depth but no taper. You will add a 5° taper along the bottom edge of the part.

In the Status area, make sure 2. SUB-ELEMENTS mode is active.

3. On the View menu, click Mask and then uncheck Geometry. This will hide the display of all geometry so that you won’t accidentally select geometry instead of feature subelements.

Make sure 4. HI mode is active.

Note: When you use HI mode, ESPRIT will first highlight the entire feature. Right-click to respond No, then respond Yes with a left-click when the sub-element highlights.

Note: The color for sub-elements in a draft conic feature is controlled in the Options dialog (available on the Tools menu). This makes it easier to see at a glance the difference between each type of sub-element that makes up a draft conic feature.


Step 7While holding down the Ctrl and Shift keys simultaneously, select any sub-element between the

first and last

Step 8Click Taper Change

Step 9Set Starting Taper and Ending Taper to 5, then

click OK

When a taper is applied to sub-elements, the feature direction determines the location of the starting taper. The selection of the first sub-element in a group has no effect. This becomes apparent when a gradual taper is applied as you can see below.

Tip: Draft Conic features are always created in a counter-clockwise direction.

Step 5Select the first sub-element

Step 6Hold down the Ctrl key and select the

ending sub-element


Create a Ruled Feature from a Solid Model

In this example, you will automatically select faces on the solid model to create a ruled feature. You will select an edge along one face and use ESPRIT’s propagation capabilities to select all the faces around the outside of the solid model. The face sharing the selected edge is grouped along with the next face that shares the opposite edge. Each face that shares an opposite edge is then propogated until all faces sharing opposite edges are added to the group.

Open the file: Features\EDM_part_4axis.esp

Step 1Hold down the Shift key and

use HI mode to select an edge

Step 2Hold down the Ctrl key and

select the thread point



Step 4Set Part Type to Punch

Set Priority to Ruled OnlySet Approach Type to Single Direction

Set Angle to 60Set the UV plane height to 30

Click OK


As you can see in the Property Browser, the ruled feature has properties for the XY profile, the UV profile, and the match lines between them.

Step 5Change the view to

Isometric

Project 2: Mill a Standard Part | 61

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Mill a Standard Part

ESPRIT has very strong capabilities in 2.5D milling, providing both ease-of-use and a high level of control over every aspect of a milling operation.

The intent of this project is to teach you the process for creating standard milling operations using ESPRIT’s SolidMill Traditional machining technology.

ESPRIT gives you several options for accessing standard milling commands.

Menus and Toolbars. • Traditional milling commands are located on the SolidMill Traditional submenu on the Machining menu. You can also use the SolidMill toolbar.

Process Manager. • You can also select SolidMill commands from a single menu within the Process Manager. The Process Manager lets you apply several machining operations to a single feature at one time.

For this project, you will learn how to use the commands on the SolidMill Traditional toolbar to create standard milling operations and how to create a machining process using the Process Manager.

2Remove Excess Material ........... 62

Cut the Pockets and Slot ......... 70

Mill and Drill Holes .......................77

Create a Shop Floor Report ... 82



Before you start this lesson, you can review and simulate the cutting operations in the following file:

Milling - Standard\standard_milling_complete.esp.


Remove Excess MaterialAt the beginning of any milling job, it is critical to remove as much excess stock as possible before you begin cutting the finish passes.

In this project, the part is cut from standard rectangular stock. The first thing you need to do is remove the excess material from the top and around the sides of the part.

To do this, you will first create a facing operation to quickly remove as much stock as possible from the top of the part. Then you will create a 3D contour around the island on the top face. You will finish by roughing and finishing the outer profile of the part.

FacingThe Facing command is ESPRIT has multiple options to make facing as fast and effective as possible. You have full control over depths of cut, optimized cutting angle, stock allowance on floors and walls, and how far you want the tool to travel when it reaches the edge of the stock.

The Facing operation also automatically creates a final pass around any islands. This guarantees a consistent amount of stock on floors and walls.

Wire Frame Mill ingThe Wire Frame Milling command lets you create a basic 3D milling operation from simple 2D geometry. The profile of the shape you want to cut is called the drive curve. This profile is driven along a path called the basic curve. Each curve must be created on a separate plane and the end point of the drive curve must lie along the basic curve. When constructing the tool path, the drive curve will be placed perpendicular to the basic curve at the start point of the basic curve.

ContouringThe Contouring command creates cutting passes that follow the shape of a selected feature. You can center the tool on the feature or offset it to the left or the right. You can enter an offset distance or use the radius of the tool.

The Contouring command lets you combine rough and finish passes in a single operation or you can create separate rough and finish passes. When roughing and finishing passes are combined in one Contouring operation, the same tool is used for both phases of the operation. To use different tools, you must create separate contouring operations. It is recommended that you use separate operations for roughing and finishing.

Technology FilesMachining technology settings can be easily saved as a separate file and used over and over for the machining of similar parts. For this project, you will load pre-existing technology files that are located in the following folder:

Getting Started\Milling - Standard\Technology

After loading the technology for an operation, you can click on the various tabs to review the individual settings. For more detailed information, click the Help button located at the lower right corner of the technology page.


Open the Part File

Make sure 1. HI mode is enabled.

Locate and open the following file: Milling - Standard\2. standard_milling.esp

On the 3. Smart toolbar, click SolidMill Traditional - SolidMill Production to display the toolbar.

If you completed Project 1: Create Features, these milled features should look familiar to you.

Create a Facing Operation

For this facing operation, there is an island on the face that must be avoided. The Facing command lets you select and avoid islands and pocketed areas when the Include Islands option is set to Yes.This operation will start slightly below the selected feature and cut at incremental depths of 8mm in a simple back and forth tool motion. A stock allowance of 0.5mm will remain on the walls of the island after the operation is complete. No stock allowance will remain on the floors.

Typically, you would select the feature first and then define the operation technology. Because there is an island on the face, you must first define the facing technology and select the Include Islands option. ESPRIT will then prompt you to select features for the boundary, any islands and any pockets you want to avoid. You will select the stock profile feature and the island profille. You want to face across the tops of the pockets on this part, so you will simply answer No when ESPRIT prompts you to select pockets to avoid.


Step 1Click Facing

Step 2Right-click inside the

technology page and click Open

Step 4Click OK

Step 3Open the file:

Milling - Standard\Technology\1-Facing.prc

Step 5In the work area, select the

Stock Profile feature


Step 6Select the Facing Island

feature

Step 8When prompted to select non-cross

pockets, right-click to answer No.A non-cross pocket designates an open

area where the tool cannot rapid across.

Step 7This is the only island to avoid, so right-click to

continue to the next step

Step 9When prompted to select cross pockets,

right-click to answer No. A cross pocket designates an open area

where the tool can rapid across.


Create a Wire Frame Mill ing Operation

For this operation, you will use two existing features. The Wireframe Drive Curve defines the curved profile for the walls around the island on the face. The Wireframe Basic Curve feature is located on the top face of the island and defines the path the profile will follow.

For Wire Frame Milling, you first define the machining technology and then select the features. The Machine Along option controls which curve is used to control the direction of the cutting passes. In this case, the tool will follow the direction of the basic curve.

Step 1Click Wire Frame

Milling


2-Wire Frame Milling.prc

Step 3Click OK


Step 4In the work area, select the Wireframe Basic Curve feature located on the top

of the island

Step 5Select the Wireframe Drive Curve feature located on the island wall


Create Rough and Finish Contouring Operations

To cut the external profile of the part, you will first rough the profile with a 30mm end mill that will leave 0.5mm stock on the walls and then finish with a 20mm end mill. Because the roughing and finishing operations use very different settings, you will create two separate Contouring operations.

Step 1Select the External

Profile feature


3-Contouring Rough.prc

Step 4Click OK

Step 2Click Contouring


Step 5With the feature still

selected, click Contouring


4-Contouring Finish.prc

Step 7Click OK


Cut the Pockets and SlotThe part in this project contains two pockets and a slot. ESPRIT offers two types of pocketing operations that you will use to cut each pocket.

Trochoidal PocketingThe Trochoidal Pocketing command is used to quickly rough parts at a constant material removal rate. Trochoidal Pocketing provides multiple levels of control over tool motion pattern, feedrates, and cutter load.

Trochoid tool motion is well suited for high-speed machining (HSM) because it uses the biggest possible curve based on the shape of the pocket, allowing for the fastest possible feedrates. Although developed for high-speed machining, Trochoidal Pocketing brings benefits to any type of machine by providing a more constant tool load and a better surface finish.

The Trochoid tool motion pattern creates a spiral in the largest area of the pocket to maintain a constant level of tool loading. When the trochoid pattern reaches the maximum radius that will fit, the rest of the tool path uses an adjustable curve that adapts to the shape of the pocket.

PocketingThe Pocketing command removes material within a closed boundary. Within a single pocketing operation, you have the option to create separately definable phases for roughing, wall finishing, and floor finishing passes that each let you use a different tool.

For example, you can use a standard end mill on the floors to provide the required finish and use a ball or taper end mill on the walls. If you do not want all of these phases combined in a single operation, you can create each phase independently. You can choose to create only roughing passes, only wall finishing or floor finishing passes, or a combination of your choice. This gives you the flexibility to create

pocketing operations with full control over the process.

Rest MachiningThe Rest Machining command is used to remove material in areas and corners that previous operations left behind. You can create rest machining operations for several parent operations at one time or you can create rest machining operations for all operations associated with a single feature. The previous operation becomes the “parent” operation and the rest machining operation applied to it becomes the “child” operation. The child operation inherits many of the settings from the parent operation, such as total depth, stock allowance, clearance settings, and so on. If a parent operation is modified, the rest machining operation is automatically recalculated and updated.

Machining ProcessesA machining process is a convenient way to create and apply several operations at once. The Process Manager lets you create any number and type of machining operations and apply them to any number of features.

Important: To use the Process Manager, your security key must be attached to your computer and you must have a valid license. If you are running ESPRIT in demo mode, use the commands on the SolidMill Traditional toolbar to cut the pockets.


Set Up the KnowledgeBase


Set 2. Part Type to Milled Part Std - Metric.

Set 3. Default Technology to Default Technology - Inch / Metric.

Click 4. OK.

Click 5. KnowlegeBase Settings.

Make sure ‘6. Apply selected process to all features’ is checked and click OK.

Step 1Select the Medium Pocket

feature and then click Process Manager

Step 2A process already exists in the

KnowledgeBase. Click New Process to create your own process.

Step 3Select SolidMill Traditional -

Trochoidal Pocketing

Create a Process to Mil l the Medium Pocket

To mill the medium pocket, you will first remove as much material as possible as quickly as possible with a Trochoidal Pocketing operation. A stock allowance of 0.5mm will remain on the walls and floors of the pocket. A traditional Pocketing operation will then be applied to first finish the walls and then the floors. To remove any material remaining in the corners, you will then apply a Rest Machining operation. You will create a machining process to perform all three operations.



Traditional Pocketing


5-Pocket1 Trochoidal Pocketing.prcand click OK


6-Pocket1 Finish Pocketing.prcand click OK



Rest Machining


7-Pocket1 Rest Machining.prcand click OK

Step 9Click Apply

Do not click Exit yet


Create a Process to Mil l the Small Pocket

The process to machine the small pocket is similar to the medium pocket, except that a Rest Machining operation is not required.

Step 1Select the Small Pocket feature

Step 2Click New Process


Trochoidal Pocketing


8-Pocket2 Trochoidal Pocketing.prcand click OK



Traditional Pocketing

Step 7Click Apply

Step 8Click Exit


9-Pocket2 Finish Pocketing.prcand click OK


Cut the Slot

To cut the slot, you will use a traditional Pocketing operation using a tool with a diameter the same width as the slot. The tool will enter the material using a long ramping move and then cut the slot with a single pass.

Step 1Select the Slot

feature

Step 3Click Pocketing


10-Slot with Ramping.prcand click OK

Step 2Click SolidMill

Traditional


Mill and Drill HolesThis part has different types of holes, including a milled hole. For this project, you will create drilling and spiraling operations depending on the type and size of the hole.

Drill ingThe Drilling command is applied to hole features or point-to-point (PTOP) features. The drilling order is defined by the path of the PTOP feature. SolidMill Drilling supports several types of drilling, including drill, tap, peck, and bore. The operation drills to a specified depth and you have the option to include the length of the tool tip in the total depth value. You can also use SolidMill Drilling to spot drill holes to the correct depth based on the diameter of the tool and the chamfer diameter.

SpiralingThe Spiraling command creates spiral or helical cutting passes based on the selection of a circle or a feature in the shape of a circle. A spiraling operation is typically used when you want to mill a hole that is too large to drill.

Bottom Up SpiralingSpiraling passes can be created from the top down or from the bottom up. Bottom up spiraling can be used to avoid having to rotate your part using index milling. Bottom up toolpath will be automatically generated when the incremental depth is set to a negative value.

When using bottom up technology, the tool origin is very important. By default, all ESPRIT tools have the origin set on the bottom. The bottom up technology does not shift the tool origin, so you have to be aware of the tool thickness when creating your tool path. However, you can create a custom tool where the tool origin is set on the top of the cutting tool edge.

Pre-Dril l and Mill the Milled Hole

The milled hole has an upper diameter of 42mm and a lower diameter of 50mm. You will cut this hole in three steps. First, you will pre-drill the hole with a 30mm drill. Then, you will create a Spiraling operation to mill the upper diameter to a depth of 30mm. You will then create a bottom up Spiraling operation using a custom tool to mill the lower hole.


Step 1Select the Spiral Rough feature

Step 2Click Drilling


11-Milled Hole Drilling.prcand click OK

Step 4Select the Milled

Hole Upper feature

Step 5Click Spiraling


12-Milled Hole Spiraling.prcand click OK


Step 7Select the Milled Hole

Lower feature

Step 8Click Spiraling


13-Milled Hole Bottom Up Spiraling.prcand click OK


Apply Exist ing Processes to Dril l the Holes

The ESPRIT KnowledgeBase provides several standard machining processes. Based on the type of feature you select, the ESPRIT KnowledgeBase will search for the most appropriate machining process.

You will select the two hole features and use standard processes in the KnowledgeBase to drill them. The KnowledgeBase will find one process for the countersink holes and another process for the counterbore holes. The order in which you select the features controls the order of the operations in the operations list.

To make sure the correct drilling process is created for each feature, you must use KnowledgeBase Options to specify that you do not want the same process applied to all features. Otherwise, the first process found will be applied to all the selected features.

On the 1. Common Machining toolbar, click KnowledgeBase Settings.

Uncheck ‘2. Apply selected process to all features’.

Click 3. OK.

Step 4Hold down the Ctrl key and select the Countersink and Counterbore

features

Step 5Click Process

Manager

Step 6Click Apply

Step 7Click Exit


Simulate

Step 1On the Smart toolbar, click

Simulation

Step 2Click Run to start the

simulation

Step 3Click Stop to exit

the simulation


Create a Shop Floor ReportThe Report Generator creates HTML and PDF reports that detail the tools and operations for any of your part files. The preformatted reports are an important NC post processing tool and invaluable shop floor resource. They provide the machining details required to correctly set up a machine and perform the required machining operations.

Reports contain information about the machine, the tools, the part, operations, and the NC program. In addition, each page in the report displays a full-color image showing how the part should look at each stage of the machining process.

Two types of standard reports are available: Summary and Detailed.

Summary ReportBasic information about the machining process is provided on a single summary page. The summary report contains a header with general information about the program and an operation list with one row per operation. Each row displays the main information about the operation like the operation name, the tool name, the tool ID, feeds and speed, and so on.

Detailed ReportThis report provides the same summary page along with detailed pages for each operation and a complete tool list. Click on an operation hyperlink in the summary page to access the operation details. Click on a tool hyperlink to access the tool details. Operation report pages provide detailed operation-specific information such as the tool details and available cutting parameters.

Default Folders for Report FilesBy default, report files are saved to your user folder under the ESPRIT\Data\ReportGenerator\Reports directory, but you can change it to any other location by clicking the Options button on the Report Generator dialog.

Generated reports are saved to a subfolder in the distribution location. The subfolder is always named the same as your part file. If you regenerate any report, all files in the subfolder, including any output from a previous report, are deleted. If you intend to save any previous version of a report, copy it from the distribution folder before you regenerate the report.

Important: To use the Report Generator, your security key must be attached to your computer and you must have a valid license. If you are running ESPRIT in demo mode, the Create Reports... command is not available on the File menu.


Step 1On the File menu, click

Create Reports...

Step 2Select Milling-Detailed, then click

Create Reports

Step 3Right-click on OpSummary.htm

and click Open

It will take several moments to generate a detailed report of all the operations and tools used in this part file. After the report is generated, Windows Explorer will launch and open to the folder where the report files were generated.


Step 4Click on a hyperlink to view the

operation or tool details

Project 3: Mill on a Rotary Axis | 85

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Mill on a Rotary Axis

ESPRIT’s 4-axis wrap milling is used for cutting while the NC machine axis rotates. Wrap milling is designed to be used with a barrel stock rotating about an axis. For a standard milling machine, the rotation axis can be parallel to the x-axis (A-axis), y-axis (B-axis) or z-axis (C-axis). For a mill/turn machine, the rotation axis is typically the C-axis.

Wrap milling should not be confused with index milling. Indexing, or 4/5-axis milling, refers to the situation where the NC machine axis (or axes) rotates to a new orientation, then cuts after the NC machine stops rotating.

This project will show you how to set up rotary axes in ESPRIT and create rotary milling operations to contour and pocket the OD of a part. Wrap milling operations can also be performed on the ID and the face of a part.

3Cut Along a Contour .................... 86

Rough and Finish the Pocket ..91

Copy and Rotate Operations ...94




Milling - Rotary\rotary_milling_complete.esp.


Cut Along a ContourYou will begin this project by creating a contouring pass on the OD of the part.

Wrap ContouringThe Wrap Contouring command lets you easily cut solids and 3-dimensional geometry while the stock rotates on the NC machine. You can create as many contouring passes as needed — a single finishing pass along the outline of the feature or multiple roughing passes offset incrementally from the feature. You can also define separate stock allowance values for the walls and floors. Entry and exit moves can be created while the stock is rotating or the tool can approach and exit the part without rotary motion.

Wrap Contouring is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face Contouring is used.

Machine Setup for Rotary Mill ingTo enable rotary milling, you need to define at least one rotary axis and set the angle limits for the NC machine. Wrap milling operations can be defined on any rotary axis or combination of two rotary axes. If available, the secondary axis will be used as the rotary axis. Otherwise, the primary axis is used.

Creating a new rotary axis in ESPRIT is quite simple using the Machine Setup command on the Common Machining menu.

Machine Setup lets you configure any type of 2-axis through 5-axis milling machine. You can define separate linear motion in X, Y, and Z for your machine components as well as rotary movement in A, B, and C. This allows you to customize the configuration of the machine in ESPRIT to match your milling machine exactly and provide an accurate display of all machine motion, including rotary and index milling, during simulation.

Open the Part File

On the 1. File menu, click Open.

Locate and open the following file: Milling - Rotary\2. rotary_milling.esp This file contains all the features, cutting tools and machine parameters needed for this project.

On the 3. Smart toolbar, click Common Machining to display the toolbar.


Let’s take a look at the machine parameters in ESPRIT.

On the 1. Common Machining toolbar, click Machine Setup.

Click the 2. Assembly tab.

Define Rotary Axes in Machine Setup

The NC machine for this project uses standard X, Y, and Z linear motion on the machine head. The table has a rotary C-axis mounted on the A-axis.


Open the assembly tree for 3. Head and then open the tree for Axes. (Click the plus sign to open a tree)

If you click on the X, Y, or Z axis you will see that they all have linear motion and that each has its own axis vector that defines the direction of the axis.

Open the assembly tree for 4. Table and then open Axes.

The order of the axes listed in Machine Setup is important. The first axis in the list is the primary axis. The second axis is the secondary axis and so on. In this case, the C-axis is mounted on the A-axis. Movement will first occur on the A-axis, followed by movement on the C-axis. Notice that the maximum rotation allowed for the A-axis is 90 degrees.

The maximum rotation allowed for the C-axis is a full 360 degrees.

Click 5. OK to close the Machine Setup dialog.


Step 1Select the chain feature around the contoured

shoulder

Step 3Click Wrap Contouring

Create a Wrap Contouring Operation

This operation will cut the contoured shoulder on the OD of the part with a single pass using a 25mm end mill. The diameter of the stock is 25mm. The entry and exit moves are performed while the part is stationary. The lead-in and lead-out distances are both set to 20mm.

The Move Type setting on the Wrap Contouring technology page controls the position of the tool during the cutting moves. In this case, the tool axis is positioned on the radial axis. Since the wall you are cutting is parallel to the radial axis, you do not need to use the Preserve Radial Wall option to prevent any possible gouging.

Step 2Click SolidMill Traditional -

SolidMill Production


Step 6Click OK to create the

operation


Milling - Rotary\Technology\1-WrapContouring.prc

Step 4Right-click inside the technology

page and click Open


Rough and Finish the PocketThis part has four pockets on the OD. To save time, you will create operations to rough and finish one of the pockets then simply copy those operations to the other three pockets.

Wrap PocketingWrap Pocketing lets you easily cut solids and 3-dimensional geometry while the stock rotates on the NC machine. Roughing passes, wall finish passes and floor finish passes can be combined in a single operation and each type of cutting pass allows the selection of a different tool. Tool path can be produced on the OD or the ID of cylindrical stock and all tool paths are drawn in 3D for better visualization.

With the exception of specific rotary options, the settings for Wrap Pocketing are identical to the SolidMill Pocketing technology pages.

Wrap Pocketing is used for milling on the OD or the ID of a part. To cut on the face, Rotary Face Pocketing is used.

Rough the Pocket

You will first create an operation to rough the pocket using concentric cutting passes that start in the middle of the pocket and move outward. A rough stock of 0.20 mm will remain on the walls only. A second Wrap Pocketing operation will be used to finish the walls.

The roughing tool is defined in the General technology page and the cutting strategy is defined on the Rough page.

Step 1Select the chain feature

around the pocket

Step 2Click Wrap Pocketing



2-WrapPocketing_Rough.prc

Step 4Click OK

Finish the Pocket Walls

Next, you will create an operation that only outputs a single wall finish pass using a 10mm finishing tool. The tool and cutting strategy are defined on the Wall Finish technology page.

Step 1With the chain feature

still selected, click Wrap Pocketing



3-WrapPocketing_Finish.prc

Step 3Click OK


Copy and Rotate Operations

Step 1Hold down the Ctrl key

and select the two Wrap Pocketing operations

Step 2On the Edit menu,

click Copy

Step 3Set Transformation Type to

Rotate and click Copy

Step 4Set Number of Copies to 3

and press the Tab key

Step 5Check Use Origin for

Rotation Axis

Step 6Click OK

You now have rough and finish operations for one pocket. You will quickly copy those operations to the other three pockets. In this case, the default UVW axis will be used as the rotation axis.


Simulate


Project 4: Mill a Mold Core | 97

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Mill a Mold Core

The mold insert in this project is part of a mold assembly used to manufacture a 2-button computer mouse. This part will give you a good overview of surface roughing and finishing techniques in ESPRIT. Not all surfaces of this sample part will be machined completely.

The intent of this project is to teach you the process for milling complex surfaces. By the end of this lesson you will know how to use the more advanced milling techniques offered by ESPRIT that let you optimize your toolpaths and cut your parts the way you want to.

4




Milling - Surfaces\mold_core_complete.esp.

Remove Excess Material ........... 98

Pre-Finish All Surfaces ............ 102

Finish Near-Flat Surfaces ...... 106

Finish the Blend Fillet.............. 108


Remove Excess MaterialWhen complex surfaces are milled, the maximum amount of stock material must be quickly and evenly removed before the pre-finishing and finishing passes can begin. It is critical that the roughed part have a constant stock so the finishing tools can cut as effectively as possible.

Variable-Z RoughingTypical surface roughing operations use a standard cutting pattern, such as a back and forth motion, to remove material at specified incremental depths. This can cause multiple tool repositioning moves and a tool motion that does not follow the curves of the part.

The Variable-Z Roughing command creates an optimized roughing operation with cutting passes that adapt to the shape of the part. At each incremental depth of the operation, ESPRIT calculates the part boundaries so the tool follows a more intelligent pattern with fewer repositioning moves.

Trochoidal Tool MotionTrochoidal tool motion lets you quickly rough parts at a constant material removal rate. Although developed for high-speed machining, trochoidal roughing brings benefits to any type of machine by providing a more constant tool load and a better surface finish.

Search FactorComplex surfaces require complex toolpath. The Search Factor setting in ESPRIT lets you increase the analysis of the part geometry to improve the accuracy of the toolpath.

Search Factor is applied to a part based on a grid calculated from the tool size, the tolerance, and the step over specified on the operation technology page. The default value for Search Factor is 1. The operation searches for cutting passes based on the original calculated grid. Setting Search Factor to 2 divides each grid in half (in effect doubling the number of grids), setting it to 3 divides each grid in thirds, and so on.

For surfaces that require high precision machining, use a higher Search Factor value to allow for a more precise scanning of your part.

Hiding OperationsWhen you program surfaces, the complexity of the different toolpaths can make it difficult to see what you are doing on the screen. ESPRIT lets you hide the display of existing operations while you are working and then display them again later. This makes it faster and easier to program your parts by displaying only the operations you are currently working on.

In the Operations Manager, you can right-click on any operation and click Hide to hide the toolpath or click Show to display a hidden toolpath. Hidden operations simulate and post like visible operations.


Open the Part File


Locate and open the following file: Milling - Surfaces\2. mold_core.esp

On the 3. Smart toolbar, click SolidMill FreeForm to display the toolbar.

Create a Variable-Z Roughing Operation

This operation will use a Trochoid tool motion pattern. At each incremental depth of 2mm, ESPRIT will create a spiral in the largest machinable area to maintain a constant level of tool loading. When the spiral reaches the maximum radius that will fit, the rest of the tool path uses an adjustable curve that adapts to the shape of the part. The Search Factor for this operation is set to 2.

The feedrate for the trochoidal cutting movement is about one and a half times faster than the feedrate used for the entry and exit moves. The feedrate for non-trochoidal moves is set on the General technology page. The trochoidal feedrate is set on the Advanced page.


Step 1Click Variable-Z

Roughing


Milling - Surfaces\Technology\1-Variable-Z.prc

Step 4Click OK

Step 5Select the solid model

Step 6Click Cycle Stop to create the

operation

Step 2Right-click inside the technology page and

click Open


Step 7Click the Operations tab

Step 8Right-click on the roughing

operation and click Hide


Pre-Finish All SurfacesThe next step in this project is to pre-finish the surfaces. You will do this by creating two operations: one to pre-finish all the near-vertical areas and one to pre-finish all the near-horizontal areas.

Z-Level FinishingThe Z-Level Finishing command combines two types of machining strategies into a single operation for the best possible surface finish on complex surfaces. Separate machining options are available for vertical and horizontal cutting passes. The appropriate machining strategy is selected based on a user-defined slope angle that indicates whether a surface should be considered vertical or horizontal.

When you create a Z-Level Finishing operation, you have the option to machine the entire part or you can selectively machine vertical or horizontal areas only. When you machine the entire part, you can choose to cut the vertical and horizontal areas with different tools. Options for machining vertical areas are located on the Z-Level Finish technology page, while options for machining horizontal areas are located on the Floor Finish page. Feeds and speeds and entry/exit moves can be defined independently for z-level and horizontal cutting passes.

Acceleration/Deceleration DistanceFor high-speed machining, the Acceleration Distance and Deceleration Distance settings ensure that the machine is at the specified feedrate when the tool reaches the part and starts cutting material.

Entry and exit moves are affected by two feedrate settings: XY Feedrate and Entry Feedrate %. Acceleration Distance and Deceleration Distance give you better control over how these feedrates are applied over the entire length of the entry and exit movement so that the tool can be cutting at the full XY feedrate before it reaches the part.

These distances are measured from the edge of the part along the entry or exit move.

Create Finishing Passes on Near-Vert ical Areas

You will begin by pre-finishing all the near-vertical areas of the part, leaving a stock allowance of 0.4mm. The entry and exit moves are both set to Tangent Radius, which will create a 10mm radiused move tangent to the toolpath. The incremental depth for each z-level is 0.1mm. Horizontal areas will not be cut.


Step 1Click Z-Level Finishing


2-Z-Level_Vertical.prc

Step 3Click OK

Step 4Answer Yes when prompted

to use the previously selected surfaces



Step 1Click Z-Level Finishing


3-Z-Level_Horizontal.prc

Step 3Click OK

Create Finishing Passes on Near-Horizontal Areas

This operation also uses Tangent Radius entry and exit moves except that the radius is now set to 3mm. The same stock allowance of 0.4mm is used. On the Floor Finish page, the Cut Horizontal Areas is set to Only and the Max Slope Angle option is set to 15 degrees. This means that only areas with a slope angle less than or equal to 15 degrees will be cut. When Cut Horizontal Areas is set to Only, the settings on the Z-Level Finish page are disabled.


Step 4Answer Yes when

prompted to use the default surfaces


Step 6Hide the display of the two Z-Level Finishing

operations


Finish Near-Flat SurfacesIn order to provide a good mating surface with the other mold components, you need to finish the flat areas of the mold insert.

FinishingThe SolidMill Finishing command creates finishing passes using either a specified step over distance or an allowable scallop height from the tool you are using. When scallop height is specified, ESPRIT calculates the distance of the step over between each cutting pass. Finishing offers a wide variety of tool motion patterns that give you full control over how your toolpath is created.

Morphing Tool MotionESPRIT offers tool motion patterns that automatically adapt to the shape of an outer boundary and an inner boundary. These tool motion patterns are called Morph and Morph Spiral. Morph moves use bridge movements between cutting passes while Morph Spiral uses gradual spiral passes between cutting passes.

These tool motion patterns typically require the selection of outer and inner boundary features. With Morph In, the toolpath begins by following the shape of the outer profile and then gradually adjusts to the shape of the inner profile. Morph Out produces the exact same toolpath except that the toolpath begins with the inner profile.

Slope MachiningSeveral options are available that let you optimize the machining of localized areas within a part based on a user-defined slope angle. There is no need to create additional toolpath boundaries. In addition to creating a finishing operation for an entire part, individual areas of that part can be defined as flat or steep based on the slope of the surface. Once these areas are identified, separate operations can be created using different milling strategies.

Cut Near-Flat Areas

This operation will use the Morph Out tool motion pattern to cut all flat areas with a slope of less than 10 degrees. To provide clearance, the cutting passes will be offset from any wall by 0.1mm. There is no need to select inner and outer boundaries for the morph movement because ESPRIT will automatically calculate the local boundaries around each flat area.

After the toolpath is created, please notice how the tool motion adapts to the shape of each flat area.


Step 1Click Finishing


4-AreaFinish.prc

Step 3Click OK

Step 4Use the default

surfaces



Step 6Hide the finishing

operation

Finish the Blend FilletNext, you will create an operation to produce a smooth finish on the fillet around the mouse core. This finishing operation will also use a morphing tool motion, except that this time you will use the Morph Spiral In pattern to produce gradual spiraling passes. You will also need to select the outer and inner boundaries since you will not be using slope machining to calculate the boundaries.

You will first define the machining technology and then ESPRIT will prompt you to select first the outer boundary and then the inner boundary.


Step 1Click Finishing


5-FilletFinish.prc

Step 3Click OK

Step 4Select the chain feature for

the outer boundary


Step 6Use the default surfaces and

click Cycle Stop

Step 5Select the chain feature for the

inner boundary

Project 5: Mill 5-axis parts | 111

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Mill 5-axis parts

Functions on the SolidMill Mold 5-Axis toolbar deliver fast, safe, and reliable programming for a variety of 5-axis applications.

In this project, you will:Use 5-axis swarf milling operations to cut the tilted walls • on the inside and outside of a part by utilizing the side of the toolCreate a 5-axis contouring operation to cut a profile on a • formed piece of sheet metal while keeping the tool axis perpendicular to the model surfaces at all timesCreate five different 5-axis milling operations with the • Composite cycle by utilizing a variety of machining patterns and tool orientations

Like other ESPRIT cycles, the SolidMill Mold 5-Axis cycles are feature-based. All Mold 5-Axis cycles must be applied on a FreeForm feature. The FreeForm feature defines WHAT is cut, while the cycle defines HOW it will be cut.

5Create 5-axis swarf operations ..112

Create a 5-axis contouring operation ..............................................123

Create 5-axis composite operations .......................................... 127



Before you start this lesson, you can review and simulate the completed files in the following folder:

Milling - 5-Axis


Create 5-axis swarf operationsIn this lesson, you will start by creating two FreeForm features that define the area to be machined.

Then you will create two Ruled features that will guide the orientation of the tool during the cut. The upper and lower profiles of the Ruled feature set the limits of the wall to be cut while the match lines between the two profiles are used for the tool orientation.

The 5-Axis Swarf cycle utilizes the side of the tool to cut tilted walls. While the flank of the tool is removing material along a wall, the bottom of the tool can be in the air or moving along the “floor” of the part.

Open the part f i le

Open the file 1. SwarfOperation.esp

Two chain features have already been created on the wireframe geometry. You will use these chains to create a Ruled feature. But first, you will create two FreeForm features that define the area to be machined.


Create a FreeForm feature on the inside of the part

Click the Layers icon and select 5 ‘Solid’ to display the solid 1. model. Close the Layers dialog.

On the Smart toolbar, click SolidMill FreeForm.2.

Click FreeForm Feature.3.

Click Grouping Properties and set Face to Tangent Faces. Click 4. the Properties icon and set Maximum Tangent Angle Between Faces to 2 and click OK.

Hold down the Shift key and select any face on the inside of the 5. part. All the inner tangent faces are added to the Part list in the Project Manager.

In the Project Manager, click inside the Check list to activate it.6.

Select the solid model to add it as the check element.7.

Click OK to create the feature.8.


Create a FreeForm feature on the outside of the part

Click FreeForm Feature again.1.

Hold down the Shift key and select a vertical edge on the outer wall of the part. All the outside 2. faces are grouped and added to the Part list.

Click inside the Check list and then select the solid model.3.


Close the Grouping Properties dialog.5.


Create a Ruled feature from wireframe geometry

Click Ruled Feature.1.

Set “Recognize From” to “Wire Frame Geometry”.2.

Click inside “Upper Chain” to activate it, then select the chain called “UpperProfile”.3.

Click inside “Lower Chain” and then select the chain called “LowerProfile”.4.

Click inside “Match Lines” and select all the segments that link the upper profile to the lower 5. profile.

Change “Name” to Inside1.6.

Set “Cutting Side” to Left and click OK.7.


Create a Ruled feature from solid faces

Again, click Ruled Feature.1.

Set “Recognize From” to “Solid Faces”.2.

Click inside “Faces” to activate it and then hold down the Shift key and select a vertical edge 3. on the outside of the part to propagate all the outer faces.

Click inside “Lower Edge” and select one of the edges at the bottom of the outer wall of the 4. part.

Change “Name” to “Outside2”.5.

Set “Cutting Side” to Left and click OK.6.


Create a 5-Axis Swarf operation with f loor sur faces

In the Feature Manager, select the feature “1. 1 FreeForm”.

Click 5-Axis Swarf Milling.2.

On the General tab, select the tool 3. EM6.

Click the Tool Path tab.4.


Set the tool path parameters

Set Tolerance to 0.1 and Stock Allowance to 0.1.

Click the selection arrow next to Ruled Feature and select the feature “2. Inside1”.

Set the following parameters:3.

Cutting Side = Left•

Offset Tool Radius = Yes•

Stop At Floor = • Yes

Stock Allowance Floors = 0•

Single Cut = Yes•

Invert Tool Direction = No•

Loop Around Corners = No•


Set the approach type

Click the Retract tab.1.

In the Approaches list, click Add New 2. Approach.

Add a Radius approach to the list.3.

Set Arc Angle to 45.4.

Set Arc Radius to 5.5.

Click OK to calculate the tool path.6.

Simulate

Simulate to verify the tool path.


Modify the tool path parameters

Double-click on the Swarf operation in the Operation Manager and change the following 1. parameters:

Single Cut = No•

Incremental Depth = 2•

Alternate Cut Direction = Yes•

Click OK and simulate the new tool path.2.


Create a 5-Axis Swarf operation without f loor sur faces

In the Feature Manager, select the feature “1. 2 FreeForm”.

Click 5-Axis Swarf Milling.2.




Click the selection arrow next to Ruled Feature and select the feature “6. Outside2”.



Offset Tool Radius = Yes•

Stop At Floor = • No

Bottom Wall Extension = • 2

Single Cut = No•

Incremental Depth = • 2

Alternate Cut Direction = No•

Adapt Orientation to Curvature = No•

Invert Tool Direction = No•

Loop Around Corners = Yes•


Set the approach type


Add a Radius approach to the Approaches list.2.

Set Arc Angle to 90.3.

Set Arc Radius to 8.4.



Create a 5-axis contouring operationIn this lesson, you will create a continuous 5-axis contouring operation along a selected profile. The profile must lie entirely on the surface to be machined (it must belong to the surface at least within the machining tolerance). As the tool follows the profile, the tool axis is kept parallel with the surface normal on the model.

For this lesson, you will use a chain feature as the drive profile for the tool. However, you can also use a solid edge, solid loop, curve, segment, arc, line, or circle as a drive profile.


Open the file 1. ContourOperation.esp

This file already contains a chain feature that you will use as the drive profile for the tool.


Create a 5-Axis Contour operation

Click 1. 5-Axis Contour Milling on the Mold 5-Axis toolbar.

Because a FreeForm feature was not selected first, ESPRIT starts the creation of a new 2. FreeForm feature.

Select the entire solid body and click OK.3.


Click the Tool Path tab5.


Define the tool path parameters


Click the selection arrow next to Drive Profile and select the feature “2. 2 Chain”.


Drive Feature on Edge = No•

Reverse Tool Direction = No•


Drive Profile Offset = 1 (equal to the tool radius)•

Penetration Distance = 1.5 (a distance bigger than the thickness of the sheet metal)•

Max Angle From Normal = 0•


Define the l inks


Add a Lateral approach to the Approaches 2. list.

Set Lateral Distance to 10.3.

Set Tool Length to 100.4.


Simulate.6.


Create 5-axis composite operationsThe concept of the 5-Axis Composite cycle is that any 5-axis machining function, no matter how complex, can be defined with a few simple steps. Instead of fragmenting advanced 5-axis functionality into a dozen or more separate dedicated functions with a limited set of options, the 5-Axis Composite Milling cycle combines every possible way to machine a complex 5-axis part while presenting the options in the logical steps for machining any type of part.

The 5-Axis Composite Milling function separates the desired shape of the tool path on the area to be machined from the rules that govern the orientation of the tool axis during machining. In this way, users can create their own customized tool path as a combination of available choices. In other words, by choosing from the five different machining patterns and the four different tool orientation strategies, you have twenty different ways to machine the part.

The tool path pattern defines the tool path flow along the part; the tool axis orientation defines the orientation of the tool while machining. Users also have the ability to limit a 5-axis cycle to 4-axis motion by locking an axis.

In the following lessons you will learn to use each type of machining pattern on both milling and mill/turn machines.


Create a composite operation from parallel planesThe Parallel Planes Intersection pattern creates curves by intersection of the part with a set of parallel planes. The tool is then driven along those curves. The plane direction is set from an existing work plane that must be previously saved. This work plane is used to control the direction of the set of planes. The planes will be created in the direction of the W axis.

The position of the first plane in the set is defined by selecting a point or by entering X, Y, Z coordinate values. The position of the last plane is set by a user-defined distance. The distance is measured along the positive direction of the W axis. The user then enters the incremental distance between each plane in the set. The step over of the calculated tool path depends on the distance between the planes.


Open the file 1. Composite_ParallelPlanes.esp

Start by creating a point at: X = 20, Y = 0, Z = 0.2.

This point will be used for the tool orientation.


Create a FreeForm feature

Click 1. FreeForm Feature on the Mold 5-Axis toolbar.

Use the Shift key and grouping properties to group all the internal tangent faces of the part.2.

Select the solid model as the check element.3.



Create a 5-Axis Composite operation

Select the FreeForm feature and click 1. 5-Axis Composite on the Mold 5-Axis toolbar.

Select the tool 2. UN10.




Set Machining Pattern to 2. Parallel Planes Intersection.


Tool Position = Contact Point On Curve•


Work Plane = • YZX (this is an existing work plane in the document)

Start Point X, Y, Z = 0,0,0•

Ending Distance = • -80 (a negative ending distance will go in the opposite direction of the W axis of the selected work plane)

Pass Movement = One Way•

Change Pass Start Position = Yes•

Step Increment = • 3


Define the tool axis orientat ion

Set Orientation Strategy to 1. Through Point.

Click the selection arrow next to Through Point X, Y, Z and select the point in the work area.2.


Toward Through Point = No•

In-Line Angle = 0•

Cross Angle = 0•

Angle Limitation = No Limit•


Simulate

Simulate to verify the tool path.

Define the l inks


Add a Vertical approach with a 60mm Vertical 2. Distance.

Add an Adaptive Cubic feed link and set the 3. Maximum Link Distance to 20mm.



Create a composite operation from planes along a curveThe Planes Intersection With Spine Curve pattern is similar to the Parallel Planes Intersection pattern except that the set of planes are created perpendicular to a spine curve.

The spine profile can be a chain feature, an edge, a face loop, a curve, a segment, an arc or a circle. The first plane in the set is located at a point along the curve. The point should belong to the selected curve, but it does not necessarily need to be the initial point of the curve itself. The last plane in the set is also located at a a point along the curve. Like the start point, the end point should belong to the selected curve, but it does not necessarily need to be the ending point of the curve itself.


Open the file 1. Composite_PlanesWithSpineCurve.esp.

In the Feature Manager, select “2. 1 FreeForm”.

Click 3. 5-Axis Composite.

Select the tool 4. BM20.


Define the toolpath parameters

On the Tool Path tab, set Tolerance to 0.1 and Stock Allowance to 0.1.

Set Machining Pattern to 2. Planes Intersection With Spine Curve.


Tool Position = Contact Point On Curve•


Spine Profile = • 1 Chain

Start Point X, Y, Z = click the selection arrow and digitize the start point of 1 Chain. Then • change the X value to 2.

End Point X, Y, Z = digitize the end point of 1 Chain•

Pass Movement = Optimized Direction•

Change Pass Start Position = No•




Set Orientation Strategy to 1. Perpendicular to Drive Surface.



Cross Angle = 0•

Angle Limitation = • Fixed Angle With

Reference Axis = • X-Axis

Fixed Angle = • 75

The Angle Limitation setting is used to lock the B-axis at -15 degrees. The Reference Axis is set to X-Axis because the reference axis is in the global XYZ system.

Define the l inks


Add a Vertical approach with a Vertical Distance 2. of 10mm.

Add a Fluent Cubic feed link with:3.

Maximum Link Distance = 10•

Start Arc Angle = 30•

Start Arc Radius = 5•

End Arc Angle = 30•

End Arc Radius = 5•



Create a composite operation from a drive sur faceParametric Pattern generates the tool path from the parametric curve of a selected drive surface. When more than one surface is being cut, the curves are propagated side by side to the next surfaces. The propagation tries to keep a fluid flow to the tool path. The drive surface must belong to the model being cut.

After the drive surface is selected, the U and V cutting directions are displayed on the selected drive surface. A white arrow shows the normal direction of the drive surface. The U direction is displayed with a red arrow and the V direction is displayed with a green arrow.

The direction of the cut can be set to either the U direction or the V direction of the drive surface. By default, the tool moves in the same direction as the arrow but an option is provided that lets the user cut in the opposite direction.


Open the file 1. Composite_ParametricPattern.esp.

Select the FreeForm feature.2.


On the General tab, select the tool 4. BM20.




Set Machining Pattern to 2. Parametric Pattern.


Tool Position = Tool Center on Curve•

Drive Surface = click the selection arrow and digitize the face shown on the solid•

Cutting Direction = V Direction•

Reverse Cutting Direction = Yes•

Reverse Step Over Direction = Yes•

Pass Movement = Optimized Direction•








Cross Angle = 0•


Define the l inks


Add a Bridge feed link with:2.

Maximum Link Distance =5•

Vertical Distance = 2•



Create a composite operation from a projected surfaceProject Parametric Pattern is similar to Parametric Pattern except that an auxiliary surface that does not belong to the model is used. The shape of the tool path is created by projection of the parametric lines of the drive surface onto the model. The projection is normal to the drive surface.

After the drive surface is selected, the U and V cutting directions are displayed on the selected drive surface as red and green arrows respectively. A white arrow shows the normal direction of the drive surface.

The direction of projection is, by default, the opposite direction of the natural Normal direction of the drive surface. That means that if the normal of the drive surface is pointing towards the model, points will be projected in the opposite direction.

If the Normal direction arrow is pointing towards the model, check Reverse Projection Side to make sure points are projected onto the model. The projection distance controls the maximum distance that points are projected from the drive surface onto the model. The projection distance can be used to prevent points from being projected onto undesired surfaces behind the target surfaces.


Open the file 1. Composite_ProjectParametric.esp.







Set Machining Pattern to 2. Project Parametric Pattern.


Tool Position = Contact Point on Curve•


Drive Surface = click the selection arrow and digitize • 2 Nurb Surface

Cutting Direction = • V Direction

Reverse Cutting Direction = Yes•

Reverse Step Over Direction = Yes•

Reverse Projection Side = • Yes

Projection Distance = • 10

Pass Movement = • Zigzag




Calculate the toolpath


Simulate.2.

Notice how the tool stays perpendicular to the drive surface and not to the model.





Cross Angle = 0•



Create a composite operation with a constant of fsetThe Contour Offset pattern uses a progressive offset of the boundary of the surfaces to be machined. This produces a somewhat concentric tool path. The progressive offset can start on the inside of the area to be machined, proceeding outward toward the external border, or it can start at the external boundary and proceed inward toward the center of the area to be machined. If the area to be machined contains islands, the offset can be calculated in an alternating inner-outer order.


Open the file 1. Composite_ContourOffset.esp.







Set Machining Pattern to 2. Contour Offset.


Tool Position = Contact Point on Curve•


Use Approach Point = No•

Pass Movement = • Inside Out



Set the following tool axis orientation parameters:4.

Orientation Strategy = • Perpendicular to Drive Surface

In-Line Angle =0•

Cross Angle =0•



Define the l inks


Add an Adaptive Cubic feed link with a Maximum 2. Link Distance of 5mm.


Project 6: Turn a Standard Part | 145

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Turn a Standard Part

A basic lathe permits movement within a single plane defined by the Z and X axes—the Z axis being parallel to the stock and the X axis perpendicular. In order for ESPRIT to accommodate both standard milling and turning operations, the global axis labeled “X” is the spindle axis (the Z axis). The global axis labeled “Y” is the lathe X axis.

The intent of this project is to teach you the process for creating basic lathe operations using ESPRIT’s SolidTurn machining technology.

6




Turning - Standard\turned_part_complete.esp.

Remove Excess Material .......... 146

Finish and Groove the OD ...... 154

Finish and Thread the ID ........ 157

Perform the Cutoff ....................... 161


Remove Excess MaterialThe first step in any machining process is to remove as much excess material as quickly as possible. It is equally important to leave a uniform amount of rough stock so that finishing operations can cut as efficiently as possible. Variations in the amount of rough stock should be avoided to prevent the tool from becoming unexpectedly buried in excess material. A uniform amount of rough stock will also result in a much better surface finish on the final part.

For this project, you will begin wih roughing and drilling operations.

Stock AutomationESPRIT maintains awareness of the state of lathe stock at any moment during the machining process. The current operation calculates the stock material based on any previous turning operations or the initial stock defined in Machine Setup or Simulation. After any turning operation is created, ESPRIT updates the knowledge of the stock. That knowledge can then be used to calculate the stock for any subsequent turning operations. The visibility of the turning stock on the screen is controlled through the Masks dialog. Click Masks on the View menu (or press Ctrl+M), then check Lathe Stock on the Details tab.

RoughingSolidTurn Roughing creates parallel cutting passes between the specified stock and a selected chain feature. Roughing passes can be created on the face, the OD, or ID of a part.

You can choose to create all rough cuts at a specified depth except for the last pass, which will follow the profile to cut the remainder of the material, or you can create evenly spaced roughing passes based on the distance between the stock and the selected feature.

The Roughing command lets you create a finish pass after the roughing passes are complete.

You can define separate rough stock for the roughing passes and the finish pass.

Drill ingThe SolidTurn Drilling command creates a face centerline drilling operation to a specified depth in Z. SolidTurn Drilling gives you several options for your drilling routines: drill, peck, tap and bore.

For off-centerline drilling or to drill on the OD of a part, you must have a live tool (a spinning tool) and you must use the Wrap Drilling command on the SolidMillTurn menu. Mill/turn operations are detailed in Project 6.

Process ManagerYou will use the Process Manager to create a separate process step for the face rough, the OD rough, the OD pocketing and the center drill and then apply all four process steps with the click of a button. You can select as many features as you like in the Feature Manager and then use the Process Manager to create one or more operations for each feature. In this project, you will create a single operation for each feature.

Important: To use the Process Manager, your security key must be attached to your computer and you must have a valid license. If you are running ESPRIT in demo mode, use the SolidTurn toolbar to complete this project.

Technology FilesMachining technology settings can be easily saved as a separate file and used over and over for the machining of similar parts. For this project, you will load pre-existing technology files that are located on the ESPRIT CD in the following folder: Getting Started\Turning - Standard\Technology.

After loading the technology for an operation, you can click on the various tabs to review


Open the Part File


Locate and open the following file: Turning - Standard\2. turned_part.esp This file already contains the features, cutting tools and lathe information you will need to complete this project.

On the 3. Smart toolbar, click Common Machining.

Click 4. KnowledgeBase Settings.

Make sure ‘5. Apply selected process to all features’ is unchecked. You will be creating an individual process step for each feature, so you don’t want the same process applied to all features.

Click the ‘6. Reset Technology Last User Defaults’ button to reset all operation settings to the system default.

Click 7. OK.

the individual settings. For more detailed information, click the Help button located at the lower right corner of the technology page.


Step 5Click Process

Manager

Step 7Select SolidTurn - Roughing

Step 4Hold down the Ctrl key as you select the following features in

the Feature Manager:1 Chain2 Chain7 Chain1 PTOP

Create a Process

This part will be roughed from 60mm bar stock. First, you will rough the face and then the OD, leaving a uniform rough stock of 0.2 mm. You will finish by creating a drilling operation to remove as much stock as possible from the ID.

Step 6Select ‘1 Chain’ in the feature

list

Step 1On the View menu,

click Masks

Step 2On the Details tab, select Lathe Stock

Step 3Close the Masks

dialog


Notice that Type of Work is set to Face and Stock Type is set to Automation. Click the Rough tab and observe the settings for Rough Passes. This operation uses a 2mm depth of cut with a uniform amount of rough stock set to 0.2mm. The setting for Pullout Mode controls the direction of the clearance cuts. In this case, the clearance cut will take place in the same direction as the cutting pass for a distance of 2mm. On the Finish tab, notice that a finish pass will not be performed. The OD will be finished later with a contouring operation.

Step 8Right-click anywhere inside the technology page and click Open

Step 9Open the following technology file:

Turning - Standard\Technology\1-Face Rough.prc


Step 12Right-click in the technology page and click Open

In the same Technology folder, open the file: 2-OD Rough.prc

Step 11Select ‘2 Chain’ in the

feature list, then select SolidTurn - Roughing

Step 10Click OK to create the

Face Rough process step for the first chain feature


Step 13Click OK to create the OD

Rough process step

The OD Rough operation uses the same roughing tool as the Face Rough operation. Type of Work is now set to OD. On the Rough page, the same depths of cut and rough stock are used.


feature list, then select SolidTurn - Roughing


Step 18Click OK to create the Center Drill process

step

Step 16Select the PTOP feature

in the list, then select SolidTurn - Drilling


4-ID Center Drill.prc

This operation will be used to rough the undercut area on the OD using a constant depth of cut. Notice on the Advanced tab that Undercutting Mode is set to Below. ESPRIT will recognize and cut any undercut areas located below the tool while undercut areas in front of the tool will be ignored.


3-OD Rough Undercut.prcand then click OK


You have now removed most of the excess material from this part.

If you click on the Operations tab in the Project Manager, you will see another view of the four operations you just created. You do not need to be overly concerned about the order in which you create operations, because they can be reordered easily in the Operations Manager with a simple drag and drop.

Step 19Click Apply to generate all

four operations at once

Step 20Click Exit to close the

Process Manager


Step 1Select the following

features:3 Chain8 Chain

Step 2Click Process

Manager

Step 4Select SolidTurn - Grooving


features list

Finish and Groove the ODNow that you have roughed and pocketed the OD of the part, you will create a finishing pass along the OD and then rough and finish the OD groove in a single operation.

ContouringThe SolidTurn Contouring command lets you create a finish pass along the face, OD or ID of a part. You can choose to skip undercut areas where a material violation may occur or cut as much material as possible with consideration for the size of the cavity and the side relief of the tool.

GroovingThe SolidTurn Grooving command gives you multiple options that let you control exactly how you want to cut your grooves. A grooving operation can be applied to the face, OD or ID of a part.

You can create only roughing passes, only finishing passes, or both. When roughing and finishing passes are combined, ESPRIT lets you define exactly when and where the finishing passes will be created in relation to the roughing passes.


Step 6Click OK to create

the OD Groove process step


5-OD Groove.prc


Step 7Select the ‘8 Chain’ feature,

then select SolidTurn - Contouring


6-OD Finish.prc

Step 10Click Apply

Do not click Exit yet

Step 9Click OK


Finish and Thread the IDThe OD of the part is now complete and you are ready to start working on the ID. You will first rough and finish the ID in one step, then cut the ID groove and finish by creating a threading operation.

Roughing and Finishing in One StepWhen you roughed the OD of the part, you created only roughing passes. Now you will create a single roughing operation that will create roughing passes for the ID, followed by a single finishing pass. The same tool is used for all cutting passes.

ThreadingThe SolidTurn Threading command lets you create a threading operation on the face, OD or ID of a part.

During simulation, the actual thread channels can be simulated by setting Simulate Threads to Full Thread in the Simulation Parameters dialog.

Step 1With the Process

Manager still open, Select the feature:

4 Chain

Step 2Select SolidTurn - Roughing


Step 4Click OK

Step 5Click Apply


7-ID Rough Finish.prc


Step 6Select ‘5 Chain’ in the Feature Manager, then select

SolidTurn - Grooving in the Process Manager

Step 9Click Apply

Step 8Click OK

Step 7Open the file:8-ID Groove

Step 10Click Exit


Step 12Select ‘10 Chain’

Step 14Open the file: 9-ID Thread

Step 15Click OK

Step 11Click SolidTurn

Step 13Click Threading


Perform the CutoffA cutoff operation is used to separate the part from the bar stock. It is a very simple operation, with the tool moving only in the X direction along the specified chain feature.

Step 1Select the feature

‘9 Chain’

Step 2Click Cutoff

Step 3Select the Cutoff Tool

Step 4Set Stock Type to

Automation


Step 7Click the Rough tab

Step 8Set the Rough

Passes settings as shown

Step 5Click the General tab

Step 6Set the Entry and

Exit settings as shown

Step 9Click OK


Simulate

The details of the machine, including spindles and turrets, are already defined in Machine Setup. You can now simulate the complete movement of the operations, the part and the machine if you’d like to see how the operations you just created work together.

Click 1. Simulation.

Click 2. Run to start the simulation. The operations are simulated in the same order as they are listed in the Operations Manager.

If you’d like to slow down the simulation, simply drag the speed control to the left. To pause 3. the simulation, click Pause. To show or hide the machine base, turrets, or spindles, click the visibility icons.

When you are finished, click 4. Stop.

Stop

RunSpeed


Shop Floor ReportsThe ESPRIT Report Generator creates HTML and PDF reports that detail the operations and tools used for any of your turning part files. The preformatted reports are an important NC post processing tool and invaluable shop floor resource. They provide the machining details required to correctly set up a machine and perform the required machining operations.

You can learn more about shop floor reports in the “Mill a Standard Part” project.

Project 7: Turn an Advanced Part | 165

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Turn an Advanced Part

In the previous project, you learned how to turn a part on a basic lathe. Now, you will learn how to mill/turn a part on a multi-axis lathe with two spindles and two turrets.

A basic lathe permits movement within a single plane defined by the Z and X axes. However, to perform livetool milling operations, additional axis combinations are required.

The first addition is a rotational axis along the stock, often referred to as the C axis. The next step is to add an axis normal to the ZX machining plane, often referred to as the Y axis. A rotational axis along the Y axis is called the B axis. A specific machine tool manufacturer may refer to an additional axis by another name, but all mill/turn machines support these axis combinations in one form or another.

The intent of this project is to teach you the process for creating multi-axis lathe operations. You will perform several operations on the main spindle, then transfer the part to the sub-spindle where you will complete the machining.

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Turning - Advanced\advanced_turning_complete.esp.

Create a Balanced Rough ........ 166

Drill and Groove Simultaneously 169

Mill/Turn a Face Profile .......... 172

Transfer the Part to a Sub-Spindle ...................................................174

Drill on a Rotary Axis ................ 177

Mill with the B-Axis .................... 178


Create a Balanced RoughThe Balanced Roughing command uses two tools to let you rough a part about twice as fast as a normal roughing operation. One tool stays behind the other and cuts at the next depth according to the specified turret trailing distance.

Balanced Roughing also lets you perform pinch turning, where two tools cut simultaneously. The main tool and the trailing tool cut at the same depth and at the same speed. Because the two tools are cutting simultaneously, the feedrate can be doubled while maintaining the same tool load.

Open the Part File

The part file for this project already contains the features, cutting tools and machine setup information you will need to complete this project.


Locate and open the following file: Turning - Advanced\2. advanced_turned_part.esp

On the 3. Smart toolbar, click SolidTurn.

If you completed the lessons in the “Create Features” project, this part should look familiar to you.


Create a Balanced Roughing Operation

For this operation, two different tools are used; one for the upper turret and the other for the lower turret. The tool on the lower turret will trail behind the first by 5mm. A 2mm depth of cut is used and rough stock is set to zero.

After you load the Balanced Roughing technology file, take a look at the settings on the Strategy page for the definition of the trailing turret and trailing tool. The settings for the roughing passes and the trailing distance are defined on the Balance Rough page.

Step 1Open the Layers

dialog and turn off the Part layer

Step 3Select the chain feature for the

OD profile

Step 4Click Balanced

Roughing


Turning - Advanced\Technology\1-Balanced Rough.prc

Step 7Click OK

Step 5Right-click inside the technology page and

click Open

Step 2Press Ctrl+M and

check Lathe Stock on the Details tab


Two operations have been created, one for each turret. You can click on each operation to highlight it in the work area.

Add a Sync Code

Next, you will add a sync code after these roughing operations to make sure that these operations are completely finished before machining can begin on the next operation.

There are two methods for syncing operations. You can use the sync commands located at the top of the Operations Manager or you can use drag and drop. For these operations, you will use the sync commands. For the next set of operations, you will learn to use drag and drop. Then you can decide which method you prefer.

Step 2Select either of the Balanced

Roughing operations, then hold down the Shift key as you select

the other operation

Step 3Click ‘Create Sync Below Selected

Operations’

Step 1Click the Operations tab to view the

Operations Manager


Drill and Groove SimultaneouslyNext, you will use the top turret to perform a drilling operation as you groove the OD with the lower turret. When simultaneous operations are created, only one spindle speed can be used. Spindle priority must be specified for one of the operations so that ESPRIT knows which operation controls the spindle speed.

Spindle priority should be designated for the operation with the longest cycle time to make sure that only one spindle speed is used for the entire cycle. After the operations are created, you can see which one has the longest cycle time by looking in the Property Browser or by launching a simulation in real time mode.

Step 1Select the PTOP feature on

the face of the part

Step 2Click Drilling


2-Face Drilling.prc

Step 4Click OK

Create a Dril l ing Operation with the Upper Turret

For this operation, you will drill to a depth of 40mm. For this reason, the Drill Type on the Drill technology page is set to Peck with a peck increment of 5mm.


Create a Grooving Operation with the Lower Turret

For this operation, you will be cutting the groove below the center line. For this reason, the X Clearance Absolute value for the entry and exit moves must be negative. You can view the Entry and Exit settings on the General page. On the Groove page, you will see that this grooving operation includes roughing passes that leave 0.2mm rough stock followed by a final finishing pass.

Note: The Drilling and the Grooving operations both have Spindle Priority set to Off. You will complete the operations and then use the Spindle Priority command in the Operations Manager to set the Spindle Priority.

Step 1Select the chain

feature for the lower groove

Step 2Click Grooving


3-OD Groove.prc

Step 4Click OK

Set the Spindle Priority and Sync the Operations

You can set Spindle Priority on the machining technology pages or you can set it in the Operations Manager. Unless you know for certain that one operation will have a longer cycle time than the other, it is better to first create the operations, compare the cycle times in the Property Browser and then set the spindle priority for the longest operation in the Operations Manager.

You also need to add sync codes after the drilling and grooving operations. The next operation is a milling operation so all turning operations must be complete before you can start milling.


Step 1In the Operations Manager, select the Grooving operation. The cycle time is

displayed in the Property Browser.

Step 2Click Spindle Priority

Step 3Select near the bottom of the Drilling

operation

Step 5Release the mouse to create a sync code below the selected operations

To show you which operation has spindle priority, the name of the grooving operation is highlighted in yellow and the background is a dark gray.

Note: Selecting above or below an operation has an affect on where the sync code is created. When you select above an operation, the sync code is added above that operation. A bright red line above or below the selected operation highlights where the sync code will be located.

Step 4Hold down the mouse button as you drag the cursor to the bottom of the Grooving operation. You should see a bright red line below both operations.


Mill/Turn a Face ProfileThe profile feature on the face of the part needs to be milled. For milling a face on a rotary axis, you can use the Rotary Face commands on the SolidMillTurn menu. Whether the tool is positioned above or below the center line for a rotary face milling operataion depends on the X Axis Limit in Machine Setup.

For the next operation, the tool is positioned below the center line. The illustration below shows the settings used in Machine Setup to accomplish this.

Set a negative axis limit in X to position the tool below the center line. A positive limit positions the tool above the center line. Machine Setup is available on the Common Machining menu.

Create a Rotary Face Operation

The technology settings for Rotary Face Contouring are identical to the standard Contouring command on the SolidMill Traditional menu, except that the NC output combines rotary motion with tool motion.

For this operation, the tool is positioned below the center line with a lead-in/lead-out distance of 10mm. You can view the entry and exit move settings on the Common page. The flat areas on this profile are cut with a single roughing pass that leaves no rough stock. The profile is cut with a combination of tool movement and rotary movement of the part.


Step 1Click SolidMillTurn

Step 2Select the profile

feature on the face of the part

Step 3Click Rotary Face

Contouring


4-Wrap Face Contouring.prc

Step 5Click OK

Step 6Add a sync code after the milling operation and the last sync code

Note: A sync code can be added to a machining operation, another sync code or to a tool


Transfer the Part to a Sub-SpindleNext, you need to transfer the part from the main spindle to the sub-spindle to that you can perform additional operations on the back of the part. To do this, you must first instruct the machine to pick up the part with the sub-spindle, pull the bar stock forward and then perform a cut off to separate the part from the bar stock.

The bar feed distance should be calculated as follows:

Bar Feed Distance = Final Part Length (A) + Cut Off Tool Width (B) + Back Stock Allowance (C1) + Front Stock Allowance (C2)

After the cut off, the front face of the bar is positioned at the same location as the front face of the bar at the beginning of the program. This makes it possible to loop the program in order to cut several parts using the automatic bar feeder of the machine.

Create a Pickup Operation with the Sub-Spindle

You will now instruct the sub-spindle to pickup the part on the front face using a designated pickup point.


Step 2Click Pickup

Step 4Select the reference

point on the face of the part

Step 3Open the file: 5-Pickup.prc

Click OK

Create a Bar Feed Operation

Next, the sub-spindle needs to pull the bar stock forward so that the cutoff can be performed. The calculated distance for this bar feed operation is 84mm.

Part Length = 80mm•

Front and Back Stock Allowance = 0•

Tool Width = 4mm•

You then need to specify a point from which this distance will be measured. You will select the same reference point on the face of the part that you used for the pickup operation.

Step 1Click Bar Feed


6-Barfeed by Spindle.prcClick OK

Step 3Select the reference point

on the face of the part

Step 1Click SolidTurn


Step 2Click Cutoff

Step 3Open the file: 7-Cutoff.prc

Click OK

Step 1Select the chain feature at the

back of the part

Step 4Add a sync code after

the Cut Off Cycle

Create a Cutof f Operation

Finally, you will use a cutoff tool on the upper turret to perform the cutoff. You then need to add a sync code to make sure all operations are complete before you begin the operations on the sub-spindle.


Drill on a Rotary AxisYou will now use the Wrap Drilling command to create a rotary drilling operation on the sub-spindle. Wrap drilling operations are created from PTOP features. You can create wrap drilling operations on the diameter of the stock or on an end face. The drill points should be located directly where they will be drilled. These holes will be drilled to a depth of 10mm.

Step 2Select the PTOP feature

for the holes on the OD of the part

Step 3Click Wrap

Drilling


8-Wrap Drilling.prcand click OK

Step 1Click SolidMillTurn


Mill with the B-AxisYou will now mill the profile features that are located on the OD of the part. Since the three milled areas are the same, you will create a contouring operation for one of them, then copy and rotate that operation to the other two.

Note: The orientation of the B-axis is automatic in ESPRIT. The tool axis is always positioned parallel with the feature work plane.

Step 1Select the profile feature on the OD

of the part



9-Baxis Milling.prcClick OK

A sync must be added after the wrap drilling operation and before the B-axis contouring operation. Wrap Drilling rotates the part as it drills. The B-axis contouring operation requires that the part remain stationary while only the tool moves.

Adding a sync code after a tool change saves time because the tool for the contouring operation will be loaded on the top turret while the drilling operation is being performed on the lower turret.

Create a Mil l /Turn Contouring Operation

This operation will use the top turret of the sub-spindle and will cut directly to the feature depth with a single roughing pass.


Step 4Add a sync code after the Wrap

Drilling operation and the 10mm end mill tool

Step 6Select the B-axis Milling

Operation

Step 7Press Ctrl+C

Step 8Set the dialog as shown and

click OK to copy and rotate the operation

Step 5Change the view orientation to

‘Right’


Simulate

The details of the machine, including spindles and turrets, are already defined in Machine Setup. You can now simulate the complete movement of the operations, the part and the machine if you’d like to see how the operations you just created work together.

Click 1. Simulation.

Click 2. Run to start the simulation.

If you’d like to slow down the simulation, simply drag the speed control to the left. To pause 3. the simulation, click Pause. To show or hide the machine base, turrets, or spindles, click the visibility icons.

When you are finished, click 4. Stop.

Project 8: Wire EDM a Die Plate | 181

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Wire EDM a Die Plate

ESPRIT offers a complete tool set for your make/model of EDM machine. Each manufacturer’s unique cutting technology and methodologies are integrated into specialized technology pages. This gives you full control over the advanced features and unique functionality of the leading machines on the market.

Before creating SolidWire operations, you must first let ESPRIT know which type of wire EDM machine you are using. The machine type you choose determines the options that are available on the operation technology pages.

The intent of this project is to teach you the process for creating 2-axis wire EDM operations using ESPRIT’s SolidWire Gold machining technology.

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Wire EDM\die_plate_complete.esp.

Create Draft Conic Features . 182

Contour the Die Openings ....... 191

Sort EDM Operations ................. 198

Simulate the Slug Removal .... 201


Create Draft Conic FeaturesWhen you have a large number of shapes to cut, you can save time by creating features as a group and then applying a machining operation to all of them at once.

2-Axis ContouringContouring operations are used to remove material along tapered and vertical walls (lands). SolidWire Contouring operations can be applied to features with closed or open shapes. Draft conic features as well as chain features can be used for 2-axis contouring.

A chain feature defines a simple 2-dimensional path for the wire to travel along. Workpiece thickness, land depth, taper and corner styles must all be defined in the cutting operation. A draft conic feature represents a 3-dimensional shape that already contains information about tapers, land depth, corner types, and so on.

Feature GroupsAlthough you can create wire EDM operations one at a time, it is much faster and easier to select a group of similar features and apply the same operation to the entire group at one time.

When several features are selected first and then a technology applied, ESPRIT will automatically create a folder in the Feature Manager that contains all the selected features, a ‘parent’ operation, and a ‘child’ operation for each feature.

Each child operation has the exact same technology settings as the parent operation. If you change the parent operation, the child operations will be updated automatically.

You can also treat the child operations as independent operations by changing some of the technology settings. However, if any of those settings are updated later in the parent operation, the parent will override the children.

Shop Floor ReportsThe ESPRIT Report Generator creates HTML and PDF reports that detail the operations for any of your wire EDM part files. The preformatted reports are an important NC post processing tool and invaluable shop floor resource. They provide the machining details required to correctly set up a machine and perform the required machining operations.

You can learn more about shop floor reports in the “Mill a Standard Part” project.


Open the Part File

The part file for this project contains a solid model of a die plate.


Open the following file: Wire EDM\2. die_plate.esp

Change the view to 3. Shaded.

This part has several types of die openings. There is a group of 10mm diameter holes, a triangular opening with a 2° taper and several rectangular openings with a land depth of 2mm and a 1° taper.

Set the EDM Machine Type

It is important to define the type of EDM machine you are using so that ESPRIT will display the correct machining technology pages.

On the 1. Tools menu, click EDM Machine Types...

Make sure 2. Generic is selected and click OK.


Step 3Select the solid

model

Step 1On the Smart toolbar,

click Features

Step 2Change to an

Isometric view

Create Draft Conic Features

You will create draft conic features for the die openings and the holes. Instead of creating features one at a time for the die openings, you can create all the features at once using ESPRIT’s face propagation capabilities. After the features are created, you will create Contouring operations to cut all the holes and then all the rectangular openings. Then you will create a Contouring operation for the triangular opening.

Draft Conic features are ideal in the following situation:You want to create features from 3-dimensional geometry.• The geometry has tapers, tapers and lands, or advanced conics.•


First you will use Draft Feature Recognition to create the hole features. Draft Feature Recognition will automatically recognize any holes in the solid model and create specialized features with the thread point automatically placed at the center of each hole. You will also automatically place the new features into a feature group.

Step 5Set Part Type to Hole


Step 6Click the selection arrow next to

Maximum Diameter

Step 7Select an edge of one of the holes to automatically load the value on the

technology page


The Feature Recognition Report dialog displays a message that the positions of the thread points was calculated by ESPRIT. The display of this dialog is controlled on the Rules page with the ‘Display Error Messages’ setting.

Step 11Click OK

Step 8Click the Rules tab

Step 9Set Group to Folder to Yes

Step 10Click OK

Note: Full descriptions of the draft feature dialog settings are available in ESPRIT Help (press F1).


The hole features are added to a folder in the Feature Manager. The features are named according to the selection for Part Type to make them easier to identify later.


Step 2Set Face to

Tangent Faces

Step 3Hold down the Shift key and

the Ctrl key as you select a face from each opening

Next you will select all the thread points. These points will be used to define the lead-in/lead-out and start points for each feature.

Next you will select all the faces that belong to the die openings using the Tangent Faces option in the Grouping Properties dialog. All faces will be selected that are tangent to the first face you select.

When you hold down the Shift key, you can select a solid or a single solid face and ESPRIT will automatically select faces based on the settings in the Grouping Properties dialog. When you hold down the Ctrl key as well, you can continue to add more elements to the group.

Step 1Click Grouping

Properties


Step 4Set the Selection Filter to Point

Step 5Hold down the Ctrl key as you

draw a selection box around all the points


Step 7Set Part Type to Die

Set Approach Type to NormalSet UV to 20

Step 8Click the Rules tab

Step 9Set Group to Folder to Yes

Step 10Click OK


You have just created 7 features in one step. The feaures are created in the same order as the faces were selected.

Step 11Set the Selection Filter

back to All



Since most of the machining information is extracted directly from the selected features, you only need to define the cutting strategy on the Contour page and how many cutting passes to create on the Contour page.

Contour the Die OpeningsFirst you will create a single contouring operation and apply that operation to all the holes.

Step 1Click SolidWire

Step 2Select all the

features in the Hole Group


Step 5Click the Contour tab and set Strategy to Rough

and 1 Skim, then click OK

Step 4Make sure Strategy is set to [Rough][Skim]


You will again create a Contouring operation to cut all the rectangular openings. Then you will create a Contouring operation for the triangular opening.

Step 1Drag the feature for the triangular opening to the XYZ coordinate to

move it out of the Die Group


Step 4Set Strategy to [Rough][Skim]

Step 2Select all the features

in the Die Group

Step 3Click

Contouring


Step 5Click the Contour tab

Step 6Set the Primary Cut Strategy to

Rough

Step 7Set the Land Cut Strategy to

Rough and 2 Skims

Step 8Click OK


Step 9Select the triangular

feature


Step 11Make sure Strategy is set to [Rough][Skim]

Notice that this time there is no reference plane for the land height



Step 13Set the Primary Cut Strategy to Rough and 1 Skim

Notice that the Land Cut Settings are disabledClick OK


Sort EDM OperationsSolidWire operations are added to the Operations Manager in the same order as they are created. This is typically not the optimum order in which you will want to cut the final part.

The Advanced Operations Sorting command gives you plenty of options for sorting operations to optimize cutting time. You can sort operations by type of cut or by cavity and then optimize the cutting path between operations.

The operations you created in this project are currently sorted by feature.

You will use Advanced Operations Sorting to sort the operations by type so that all the roughs are performed first, the cutoffs second and the skims last. Then you will practice optimizing the cutting path using different optimization methods.

Note: You can also manually reorder individual SolidWire operations by dragging and dropping them anywhere in the Operations Manager.


Step 1Click Advanced Operation Sorting

Step 2Set Sort By to [Rough][Cut-Off][Skim]

Step 3Set the Path Optimization Routine to Shortest Path, then click the selection arrow and select

the lower left feature as shown

Step 4Click Apply to see the results


Step 5Set Routine to Zigzag and Zigzag Type to

Horizontal

Step 6Set Band Width to 10 and then click Apply to

see the results

Step 7Click OK


Simulate the Slug Removal

Step 1Hold down the Shift key and select a

segment in the outer profile

When SolidWire operations are simulated, you have the option to display the slug removal automatically while the operations simulate or you can wait until the simulation is complete and then remove the slugs manually. For this project, you will manually remove the slugs.

Create the Simulat ion Stock

Before you start the simulation, you will create a solid that represents the initial stock for this part. You will do this by creating a chain feature of the outer profile and then use the Simulation Parameter command to extrude that profile to create the simulation stock.

To automatically select all the connected segments that form the profile of the part, you will hold down the Shift key during the selection process.


Step 6Uncheck Automatic Slug

Removal



Step 4Click Simulation

Step 5Click Simulation

Parameters


Step 8Set Type to Stock

Set Create From to Extrusion

Step 9Set Z+ to 0 and Z- to 20

Click the Selection Arrow and then select the chain feature

Step 10Click Add

Step 7Click the Solids tab

Step 11Click OK


Simulate

Step 1Click Run to simulate all the

cutting operations

Step 2Click Slug Removal

Step 3Select different stock items in the list and click

Move Down or Move UpESPRIT will prevent you from moving the tapered stock above the block because this is not possible

Step 4Click Stop to exit the

simulation

Project 9: Wire EDM a 4-Axis Part | 205

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Wire EDM a 4-Axis Part

What distinguishes 4-axis wire EDM from 2-axis is that the shapes of the top profile and bottom profile can be different, which requires a constantly changing taper as the wire moves around the part.

In ESPRIT, consistency is maintained between 2-axis and 4-axis wire EDM machining technology to make it extremely easy to transition from standard 2-axis EDM operations to more complex 4-axis machining.

This project will show you how easy it is to apply the knowledge you already learned in Project 7: Wire EDM a Die Plate to 4-axis wire EDM operations.

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Wire EDM\advanced_4axis_complete.esp


Contour a Multi-Axis PartFor this project, you will quickly create a ruled feature from an imported solid model and just as easily apply a 4-Axis Contouring operation to that feature.

4-Axis ContouringThe 4-Axis Contouring command on the SolidWire Platinum menu is very similar to the Contouring command on the SolidWire Gold menu, except that you will be cutting separate UV and XY profiles.

The biggest difference between 2-axis and 4-axis contouring in ESPRIT is that you cannot use chain features for 4-axis cutting operations. ESPRIT provides a specialized EDM feature called a Ruled feature for 4-axis wire EDM operations. Ruled features are described in greater detail in Project 1: Create Features.

Cut OffsESPRIT lets you perform a cut-off in two steps. When cutting a punch, a large cut-off distance is sometimes necessary in order to retain rigidity and stability of the punch while roughing and skimming. However, a smaller glue distance is required to allow the operator to make arrangements for the punch that will fall free. Using a secondary cut off frees the operator from standing at the machine while a large glue stop is being cut.


Create a 4-Axis Contouring operation

The machining properties for this feature contain most of the information ESPRIT needs to create a 4-axis contouring operation. You simply need to define the order for cutting passes and how many rough and skim passes to create.

ESPRIT offers standard machining strategies for dies and punches that provide a quick and easy mechanism to generate highly efficient machining, especially important when you are cutting multiple work pieces or work pieces that require multiple cuts. The Punch strategy will perform all the rough cuts first, followed by all the skim cuts, finishing with the cut-offs.

You will specify one rough cut, two skim cuts, a primary cut off and a secondary cut off. The two skim cuts will also be applied to the cut off.

Open the Part File


Open the file: Wire EDM\2. advanced_4axis.esp If you completed Project 1: Create Features this part should look familiar to you.

Click 3. SolidWire.

On the 4. Tools menu, click EDM Machine Types...

Select 5. Generic and click OK.


Step 1Select the Ruled feature

Step 2Click 4-Axis Contouring

Step 3Set Direction to CW

Set Strategy to [Rough] [Skim] [Cut-Off]

Step 4Set Retract Length to 2.0


Step 6Set Strategy to Rough and 2 Skims

Step 7Set the offsets as follows:

Rough: 0.19Skim 1: 0.125Skim 2: 0.106


Step 8Click the Cut Off tab

Step 9Set the Cut-Off settings as

shown

Step 10Click OK


Documents

ESPRIT 2009 Get Started Guide