Workshop 4-5 Axe Frezare - Odp

Your Partner
for CAD/CAM/CAE
solutions and services
Multi-axis hands-on
session workshop
Ionut Nanau
CAD/CAM Engineer
Introduction & Agenda
The goal of this session is to exercise multi-axis capabilities of Pro/NC
Exercise 1 : Retract surface setup
Exercise 2 : LINTOL command and effect on NC code output
Exercise 3 Surface machining
Compare Conventional , Isoline and Cutline
Exercise 4 : Cutline and curve containment
Approach / Exit macro
Exercise 5 : Cutline and pivot point
Exercise 6 : 5 Axis surface milling Cutline and tool axis control
Exercise 7 : 4 Axis surface milling with cutline
Exercise 8 : 4 axis roughing surface milling
Exercise 9 : 4 axis surface milling Tool contaiment
Exercise 10 : 4 axis surface milling Alternate surface for cutlines
Introduction & Agenda
Exercise 11 : 4 Axis surface milling roughing, finishing techniques
Exercise 12 : 4 Axis surface milling 3d helix cut
Exercise 13 : Impeller machining turning & 5 axis surface milling
Exercise 14 : Swarf milling - cutline
Exercise 15: 5 axis holemaking
Exercise 16 : 4 axis trajectory : CURVE, SURFACE & 2 CONTOURS
Exercise 17 : 5 Axis surface machining, trajectory, connection and entry/exit control
Exercise 18 : 5 axis curve trajectory with AXIS_LINEAR_INTERPOLATION
Exercise 19 : 4 Axis trajectory , multi-passes and customize
Exercise 20 : Trajectory and AXIS_DEF_CONTROL options
Exercise 21 : Blade machining Trajectory leading edge
Exercise 22 : 5 axis holemaking
This exercise will demonstrate the impact in the choice of a

retract surface for a 5 axis holemaking toolpath
Sphere
Cylinder
Cone
Open 5ax_cap_nc.mfg model
Edit holemaking NC sequence
and test toolpath with the three
possible retract surfaces
Change the tolerance in Operation Setup for the retract

surface and see the impact on toolpath
Open 5ax_cap_nc.mfg model

Play path, current retract surface
is a cone matching the geometry
of the model
Tool retract along tool axis up
to cone and connect to next hole
by following the cone
Edit NC sequence holemaking
Change retract surface to
be a cylinder, centered on
ZERO Csys, along Z axis
with diameter 7 inches
Play path
Tool retract along tool axis
to intersect with cylinder,
then move along cylinder
Change retract surface to

be a sphere, centered on
ZERO Csys, with diameter
7 inches
Play path
Tool retract along tool axis
to intersect with sphere,
then move along sphere
Edit Operation
Change retract tolerance to 0.01
Play path to see differences
(more connection moves)
Exercise 2 : LINTOL effect
This exercise will demonstrate the effect of the LINTOL command on a 4 axis
toolpath. We will use a MAZAK VARIAXIS post to demonstrate the NC code
output
Open lintol_traj.mfg model
Current LINTOL is 0
Output CL file and run
post-processor UNCX01
(MAZAK VARIAXIS)
Be sure that gpostpp_dir
config.pro options is
set to your current directory
Rename tape file lintol_test.eai
to lintol_test.no
Change NC parameter LINTOL
value to 0.001
Output CL and Rerun post-processor
Compare lintol_test.eia
and lintol_test.no . Note the extra motions
This exercise will allow you to explore the
differences between Conventional surface milling,
isolines and cutlines
Open 5axis_sample.mfg model

Create a mill surface for the floor
of the pocket
Create a conventional surface milling
Create an isolines surface milling
Create a cutline surface milling
Compare toolpaths
Save manufacturing model
Open 5axis_sample.mfg model
Create mill surface for floor of the pocket

call it TOP_SURF_NO_HOLE
Manufacturing tab / Mfg geometry / Mill Surface
From Creo use

New surface, name it
TOP_SURF_NO_HOLE

Create by COPY, select
floor of pocket, fill all loops
to remove the holes

Hide surface for better look !
Create 5 axis conventional surface milling
Create new NC sequence,
surface milling, 5 AXIS
Use BALL12 solid tool
Set NC parameters
Use Mill Surface TOP_SURF_NO_HOLE
In define cut, select Straight Cut
Play path and look at CL file
Rename NC sequence
CONVENTIONAL_SURF
Create 5 axis isoline surface milling
surface milling, 5 AXIS
Alternatively CTRL C and V
to copy, then redefine sequence

Set NC parameters
Use Mill Surface
TOP_SURF_NO_HOLE
In define cut, select Isoline
Check orientation
Play path and look at CL file
Rename NC sequence
ISOLINE_SURF
No real difference with

conventional in this case
Create 5 axis cutline surface milling
surface milling, 5 AXIS cutline
Set NC parameters
Use Mill Surface
TOP_SURF_NO_HOLE
Define two open cutline from edge
at each side of the surface
You will need to
un-hide the surface
to select the vertex
Play path
Look at how the toolpath follow the
shape of the pocket
Look at how the tool is degauged
against the reference model
Save model for
future exercise
This exercise will cover a typical

5 axis machining for powertrain
(cylinder head or throttle bodies )
using cutline machining
We will use a lolipop tool
supported with the hidden
config.pro 5_axis_side_mill
Create mill surface inside of the
throttle body
Create 5 axis cutline machining
with close curve containment
with open curve containment
with large tilt angle
Test Tool / Holder degauging
Set hidden config.pro 5_axis_side_mill to yes

This will allow you to use side mill in
surface milling .. In this case for
a lollipop tool(config.pro->add and write 5_ axis_side_mill; yes)
Open 5ax_curve_containment.mfg model
Create mill surface for inside
of throttle body (inside_surf)
Use surface copy and fill loops
Create 5 axis surface milling using cutlines

Use LOLIPOB_D12_S8 tool
Set NC parameters
Select mill surface inside_surf
Create two closes cutlines
top and bottom of surface
Define containment curve
Axis Def / Pivot Curve
select close curve top
of model
Use Adjust Tool / Preview
to visualize the tool axis
containment
Play path
Change tool to
LOLIPOB_D12_S8_SHORT
Redefine pivot curve
Add Tool parameter for
HOLDER_LENGTH (50)
HOLDER_DIAMETER (40)
Play path to see degauging
toolpath stops before end
of surface

Set NC parameters
(use previous for example)
Come back to NC parameters to setup
helical scan type (available only with cutlines)
select Line at top
of model
Play path

in the direction of the flow
Set NC parameters
(use previous, for example)
Create vertical cutline using
surface curves .. Be careful
define in the order of machining !
select Line at top
of model
Play path
Finally a solution for this machining without

containment, using tilt angle
Set NC parameters ..
Set TILT_ANGLE to -85
Come back to NC
parameters to setup
helical scan type
(available only with cutlines)
Play path
Simulate in VERICUT the first NC sequence.
Tool enter material in rapid
There is a gauge during retract
. We are going to see how to fix this
using a custom approach / exit macro
Select Seq Setup / Approach Exit
Select CUSTOM_ENTRY for first cut
Define a custom strategy, right hand
helix entry with radius 5, ramp
angle 45 and height 5
Select CUSTOM_EXIT for last cut
Define a custom strategy,
left hand helix exit
with radius 5, ramp
angle 45 and height 5
Play path
Run VERICUT
This exercise will demonstrate the benefit of too axis

containment using pivot point
Create 5 axis cutline toolpath
Play path check tool
position
Define pivot point control
Play path
See difference
in tool position
Open cutline_pivot_point.mfg model

Create 5 axis cutline toolpath
Setup NC parameter
Select all surfaces from
protusion on model
Define closed cutline
First one on top of the part
as a sketch circle
Second one represent limit
of surface
Go back to parameter to
define SCAN_TYPE to
HELICAL
Play path
Define pivot point

Seq Setup / Axis Def / Pivot point
Select datum point APNT0
Check mark Flip Axis because the
pivot point in under the surface
Play path note tool
orientation on steep
surface
Change point location ..
Play path
This exercise demonstrates how to use tool axis control to
machine an undercut .
Use walls_axis.mfg model
Create 5 axis surface
machining using cutline
for the flat surface
Check tool degauged
Use tool axis control to
machine the undercut
and better follow the
wall of the part
Play path
Open walls_axis.mfg model
Create a 5 axis surface machining toolpath

Use 0_0625_DIAMETER_BALL_ENDMILL
solid tool
Set NC parameters
Select flat surface from model
Create two open cutlines
Play path
Note how tool is
degauged against the wall
The toolpath is also a 3 axis
toolpath because the part surface is flat
Lets take control of this toolpath. Create a tool axis
control
Select Seq Setup / Axis Def / Pt on Surf / Along Cutline
Define at each extremity of the
cutline a axis orientation using
the datum axis defined at each point
Add an axis def, in the middle
of the second cutline using the axis
defined at this position
Play path
To understand how the toolpath is
computed, unselect the ref model
as a check surface (Seq Setup / Check Surfs)
and play path
think of a way to do better toolpath
Exercise 7 : 4 Axis Cutline milling
This exercise will demonstrate 4 axis surface milling with cutlines
Open spiral_nozzle.mfg model

Create a 4 axis surface
machining
Use open cutline
Define 4 axis plane
Define pivot axis
(rotation axis)
Play path !
Exercise 7 : 4 Axis Cutline milling
Open spiral_nozzle.mfg model
Create 4 axis Cut Line milling toolpath

Use BALL4_5 solid tool
Set NC parameters
Select surface model
inside of groove
Select 4 axis plane
Define cutlines : use two edge
chain indicated,
Define axis control
( Pivot about a point/ Axis)
center of rotation of the part
Play path !
Exercise 8 : 4 Axis roughing with surface milling
Volume milling is only a 2 acis type NC sequence

4 axis roughing can be done using
The reference model as a check surface (default)
A 4 axis milling NC sequence
Isolines of cutlines machining
Use NUMBER_CUTS and
OFFSET_INCREMENT
A dummy part surface
A pivot axis
This exercise will demonstrate the method

to do a 4 axis rouhging.
Exercise 8 : 4 Axis roughing with surface milling
Open 4 axis_rouhging.mfg model

Create a surface using Copy / Paste of the top
of the workpiece
Offset inside part of 38 mm .. The goal is to
have a small part of the surface (as small as
possible) still visible .. This will be our part surface
Create a 4 axis surface milling
Use BEM25 tool
Set NC parameters
Select the offset surface
you have created
Define Cutlines for this surface
Go back to NC parameters to setup
Scan type to TYPE 1
NUMBER_CUTS to 9 and OFFSET_INCREMENT to 4.23
Axis Def / Pivot Axis and select axis of rotation
Play path
Run VERICUT
Exercise 9 : 4 Axis surface milling Tool containment
This exercise demonstrate the impact of tool

containment in a 4 axis surface milling toolpath
Use 4AX_DRIVE_CURVE.mfg model
Create 4 axis NC sequence
with no containment
with pivot axis
with pivot curve
with tool axis control
Play path an compare tool
orientation during toolpath
Create 4 axis surface milling NC sequence
Use BALL25 tool
Set NC
sequence
parameters
Select top
surface
Select 4 axis
plan (VORNE)
Use Straight
cut
Play path
View toolpath in VORNE view
Use BALL25 tool
Set NC
sequence
parameters
Select top
surface
Select 4 axis
plan (VORNE)
Use Straight
cut
Select Axis Def / Pivot Axis /
create and select Axis on CSYS
Play path

Use BALL25 tool
Set NC
sequence
parameters
Select top
surface
Select 4 axis
plan (VORNE)
Use Straight
cut
Select Axis Def / Pivot Curve /
select edge of bottom surface
Play path

Use BALL25 tool
Set NC
sequence
parameters
Select top
surface
Select 4 axis
plan (VORNE)
Use Straight
cut
Select Axis Def / Pnts Srf / Edge
Select surface edge and create and
select datum axis at each corner of the
surface. Axis defined from top surface corner to bottom surface corner
Play path
Exercise 10 : 4 Axis surface milling Alternate Surface
This exercise will demonstrate how surface machining can

used with a alternate surface as the base for the cutlines
Model used is 4x_leg.mfg

Create 4x surface milling
sequence using cutline with NC_ASM_DEf
Use mill-surface to select cutlines from
Play path
Copy the first sequence with
CTRL C and CTRL V
Redefine copied sequence and
use a cylindrical surface to
select the cutlines from
Play path
Compare the 2 tool pathes in right view
Create 4 axis surface cutline milling NC sequence

Use tool Scheibe_d100
Set NC sequence parameters
(Info:you need to go back to the params after selecting cutline)
Select top surface as 4x surf

Use Cut Line and select the two cutlines
Check Cut direction see red arrow
Parameters to check
STEP_OVER 10
SCAN_TYPE TYPE_HELICAL
4X_TILT_ANGLE 75
LEAD_RADIUS 20
INITIAL_ENTRY_EXT LEAD_IN / FINAL_EXIT_EXT LEAD_OUT
Play path
View toolpath in right view and also check with Vericut
Spiral move follows the milling surface
Create 4 axis surface cutline milling NC sequence using a

alternate surface
Copy first sequence with CTRL C and V
Redefine Sequence
Define Cut and select alternate
surfaces
Create a cylindrical mill surface

diameter = 500 /
same length as ref-part
Select the top and bottom edge from the

cylinder for cutlines
Check Cutdirection see red arrow

Play path
View toolpath in right view alternate surface same surface
and also check with Vericut
Spiral move follows the alternate,
cylindrical surface
Compare the two tool pathes
Advantage of the alternate surface one is, that
the tool load is more continous. Feedrates can be
higher
This exercise will demonstrate the roughing and finishing of the

helix channel
Model used is
4_axis_mudway.mfg
Create pivot curve
Create mill surface
Surface milling with axis_shift
for roughing
Rough walls with 4x trajectory milling
using Taper Mill cutter
Finish bottom with 4x surface milling
and pivot curve
Finish walls with 4x trajectory milling
using Taper Mill cutter
Create Pivot Curve

Open modell 4_axis_mudway.mfg
Unhide Layer FLAECHEN in mudway.prt
Reveals helix middle surf
And channel
Create cylindrical surface diam = 18
Copy helix middle surface

Intersect the two surfaces to get the pivot curve
Hide the two construction surfaces

Create milling surface (for a more continous tool path)

Use to create mill surface
CTRL C and CTRL V to copy the quilt surface (F33) from ref-part
Trim this surface at each side with

TRIM_PLANE 1 and 2
and keep inside
Close mill-surface at its ends with two boundary blends

Create milling surface (for a more continous tool path)

Use to merge the 3 surfaces into one
Use option join under RMB menu.
Create rounds on vertical edges r = 0.75
Create round on bottom of

mill surface r = 0.75
(radius equal to ref-part geom)
Finish up mill-surface
Create 4x Cut Line milling sequence to rough the center

Tool: BULLNOSE_1
Parameters
SCAN_TYPE TYPE_3 or TYPE_SPIRAL
STEP_OVER 0.35
PROF_STOCK_ALLOW 0.05
CUT_FEED 12
SPINDLE_SPEED 1200
CLEAR_DIST 0.5
LEAD_RADIUS 0.1
CUT_ENTRY_EXT / CUT_EXIT_EXT ARC_TANGENT

INITIAL_ENTRY_EXT / FINAL_ENTRY_EXT ARC_TANGENT
Select mill surface

Select correct side
Select only bottom surf to be milled

Create 4x surface milling sequence to rough the center

Select 4x plane
Select cut type cutline and select the two

edges as start- end cutlines
The tool path shows some strange connections

at one end.
Ref-part would allow to do this additional short cut
Add complete mill-surface as check-surface .. to get correct tool path

Create 4x surface milling sequence to rough the center (cont.)

Compare two methods for roughing with cutline
a). Using parameters
OFFSET_INCREMENT 0.75
NUMBER_CUTS 3
Check result with PLAY PATH


b.) Add additional roughing slices by using multiple cut_motions and AXIS_SHIFT parameter
Reset params OFFSET_INCREMENT 0 / NUMBER_CUTS 1
Copy 1.Cutline milling and inset 2 additional Cutline milling
Go back to parameters and set a different AXIS_SHIFT for each cut


b.) Add additional roughing slices by using multiple cut motions with AXIS_SHIFT
PLAY PATH and compare new tool path
Finish up sequence by Done Sequence
Create 4x Trajectory milling sequence to rough walls

TOOL: CONIC_3DEG
Parameters
CONNECTION_TYPE SIMULTANOUS
STEP_DEPTH 0.3
AXIS_SHIFT -0.03
NUM_OF_CUTS 5
CUT_FEED 12
TRAVERSE_FEED 8 (for connection)
SPINDLE_SPEED 1200
CLEAR_DIST 0.5
In tool_motions select Drive surface cut

Create 4x trajectory milling sequence to rough walls

Select Mill Surface (only top loop)
. and select loop shown below as trajectory
and HEIGHT surface
Resulting tool path should look as follows

Create 4x Cut line milling with pivot curve to finish bottom

surface(copy-paste first sequence)
TOOL: BALLEND_D1_5
Paremeters (Use params from first sequence)
STEP_OVER 0.1
PROF_STOCK_ALLOW 0
Select bottom surface from mill surface
Select tab cut lines and select the two

open cutlines like in first sequence
Create 4x Cut line milling with pivot curve to finish bottom surface
PLAY PATH -> We see a non- continous tool path
Tool is degauged
We need a Pivot Curve !

Select Axis Control and Type -> Pivot about a Curve
and Pivot Curve select curve Intersect 2
PLAY PATH -> We can see an excellent tool path

Finish up sequence by Done Sequence
Create 4x Trajectory milling sequence to finish walls
Copy the roughing sequence for the walls with CTRL C and CTRL
V(sequence 2)
Parameters to change
AXIS_SHIFT 0
NUM_OF_CUTS 1
PLAY PATH
DONE SEQUENCE
Create 4x trajectory milling sequence to finish walls

Use subroutines to machine all channels
(use search command located in the up right corner)
Create->Select all to include all sequences
Select settings as shown in picture on

the right
Do not forget to select Copy CL so you can simulate it in Vericut
Save cl_data from OP010 and simulate it in Vericut

Exercise 12 : 4 Axis Trajectory Milling 3d helix cut
This exercise will demonstrate 4 axis trajectory milling with

axis definition resulting in a 3d helix cut
Model used is spiral_nc.mfg

The part to be machined is used to
transport goods, see avi attached to part
3 Trajectory sequences to be made:
1 roughing 4x with central pivot axis
1 roughing 4x with axis definition using outer helix curve
1 finishing 4x with axis definition using inner helix curve
And how it should be machined

Create 4x trajectory milling with pivot axis
Be sure to set config.pro pivot_traj yes to be able to select a pivot axis

for 4-Axis trajectory milling
TOOL: BEM_1
Parameters
Accept parameters coming
from site param file
Select 4x axis Plane

Insert Tool Motions and use Curve for definition
Select options shown in next menu
Only Axis Control needs to be added
Use Curve Chain and select complete

inner helix
Create 4x trajectory milling with pivot axis (cont)

Select Pivot about an Point/Axis in the
AXIS CONTROL menuand select center axis
Select arrow as shown for tool orientation

Thats it
Use Done Cut and PLAY PATH to simulate
Create 4x trajectory milling with Axis Definition for roughing

TOOL: FEM_ROUGH
Parameters:
Select again 4x plane
Tab Tool Motions and use Curve for definition
Select options shown in next menu
Only Axis Control needs to be added
Use Curve Chain and select complete outer helix

Select Axis Control Location click a point Datum Axis sel. AA_1 and
Flip/Okay, proceed the same for the other end and select AA_2
Create one axis def at start and end of helix curve (see points
available)
You can define more axis definitions to get more accurate
PLAY PATH
Left picture shows that we need to a some AXIS_SHIFT value (use 60)
PLAY PATH
Left picture shows (in front view), that we are exactly on the curve.
We would like to remove more material -> use Material Side and
PROF_STOCK_ALLOW of 5 (see right picture for result)
This exercise will demonstrate how turning and 5 axis milling

functionality can be combined to machine an impeller
Model used is
impeller_param.mfg
Create drilling, facing and
area turning to prepare
the stock for milling
Rough one impeller blade
with 5 axis surface milling
Finish blade with 5 axis
surface milling
Pattern to machine the
complete impeller
Run VERICUT
Open impeller_param.mfg model

Check setup like retract sphere
Create turn / holemaking toolpath

Use DRILL12 solid tool
Setup NC parameters
Select center hole
Play path
Create automatic
material removal
Create area turning toolpath to face the part

Select TURN_0600 tool
Set NC parameters
Customize / Insert automatic cut motion /
Create profile / Skech
Sketch front part /
select material side
Extension +X and +Z
Done Cut / OK Customize
Play path
Create automatic
material removal
Create area turning toolpath to rough the part

Select TURN_0600 tool
Set NC parameters
Customize / Insert automatic cut motion /
Create profile / Ref envelope /
Define From -To
Extension +X and +Z
Done Cut / OK Customize
Play path
Create
automatic
material
removal
Create surface geometry to rough between two blades
Construct surface between two blade

Edit / Project / Sketch / create curve
in OBEN plane linking top of blades
Project on all impeller surface in
direction of OBEN
Select impeller inside blade surface
CTRL C / CTRL V to copy
Option Copy inside boundary
Trim using curves from blade and

the projected curve
Be careful not to miss any edge !
Create 5 axis surface milling

Setup NC parameters
Select previously create
trim surface
Define cutlines
Go back NC parameter to
set SCAN_TYPE to ONE_DIR
Play Path
Go back to NC parameter to set
NUMBER_CUTS to 3 and
OFFSET_INCREMENT to 3
Play path
Create surface geometry to finish the blade

Select complete inside blade surface
CRTL C / CTRL V to copy paste
Select side blade surface
CTRL C / CTRL V to copy paste
Select front age Edit / Extend of 4 mm
Repeat other edge
Hide ref model
Create round of 2mm between
surfaces complete inside blade
and blade
Select extended side blade surface
CTRL C / CTRL V to copy paste and trim with edges
(copy inside boundary) using the round
Create 5 axis surface milling to finish the blade

Un-hide ref model
Select BALL4 solid tool
Setup NC parameters
TILT_ANGLE = 85 or 85
depending your
direction of cut
Select previously create
trim surface
Define cutlines
Go back NC parameter
to set SCAN_TYPE to
ONE_DIR
Play Path
Pattern the milling

NC sequences
Uses subroutines
Output
complete CL
Run
VERICUT
This exercise will demonstrate a basic swarf milling using a single cutline
Use model 5axis_sample.mfg
Create swarf milling for side surfaces
Use solid tool FEM16
Set NC parameters
Select side surfaces from model

Define cut using cutline
Create close cutlines using
two times the
bottom edge curve
Play path
Run Gouge Check

Use default settings
The toolpath gauges
because the reference
model is not set
as check surface
by default
Add the reference model as check surface

Play path the tool retract
to avoid gouges
Edit the NC parameters and set
option VARIABLE_TILT to yes
Pro/NC will tilt the tool
to avoid gouges
Play path
Save NC model
Exercise 16 : 4 axis trajectory CURVE, SURFACE & 2 CONTOURS
This exercise will demonstrate the three basic techniques

used to create a trajectory
We will use axle_4axis.mfg model
Create a 4 axis trajectory using
drive and part surface
2 Contours and part surface
Curve and tool axis control
Open axle_4axis.mfg model

Create a 4 axis trajectory toolpath
Use FEM02500 solid tool

Set NC parameters
Select front of part as 4 axis plane
Define an automatic cut using surfaces :
Define drive surface (side of groove)
Define height ( bottom of groove)
Preview Axis
Define Overtravel_Distance = 0.5
Play path

Use FEM02500 solid tool
Set NC parameters
Select front of part as 4 axis plane
Define an automatic cut using curve :
Select tangeant chain bottom of side
edge of the groove
Preview Axis : note the tool axis is vertical
We are going to need to define tool axis

Control for each patch of the
drive surface (side of the groove)
Create datum axis, using edge for

each patch of the side surface (wall)
of the groove
In Define Cut select Axis CNTRL / Axis Def

Add Axis along trajectory at
each control point using the
axis you have defined previously
Go Play path to see the result

Add extension at Start and End
It is clear that for trajectory defined using surfaces are

the easiest to define and use at least in this case
Exercise 17 : 5 Axis surface machining, trajectory,
connection and entry/exit control
This exercise will go through a typical 5 axis router job.

We will use the panel_mfg.mfg model
Create 3 axis roughing
Create 3 axis surface milling (semi finishing)
Create a 5 axis surface
milling (finishing)
Create a 5 axis
trajectory (edge
cleaning)
Create a 5 axis
holemaking
Open panel_mfg.mfg model
Create a 3 axis roughing NC sequence

Use BEM1000 tool
Set NC parameters
Create silhouette window of the workpiece
Set depth of window 5 inches from top
of part
Play Path note the clamp
avoidance(allowance based
on stock allowance
of roughing)
Run VERICUT for material
removal simulation
Create a 3 axis surface milling to semi-finish the panel
Create a surface copy of the model
Select all faces of the model
including side surfaces
.. Be careful some small surfaces
CRTL C / CTRL V to copy
Remove inside loops
Extend surface by 1 inch
Select surfaced edge
Edit / Extend
Extend by 1 inch for the
complete surface
When creating surfaces to simplify selection do not hesitate to hide what you do not need
Create 3 axis surface milling

Select tool BEM1000
Set NC parameters
Select previously created

surface from model
Define cut using straight cut
Play path
Create a 5 axis surface milling

Use BEM0500 tool
Set NC parameters
Select center
surface of panel
Define cut using
straight cut
Set Approach / Exit macro
Custom entry and exit
0.25 inch radius arc
of 45 degres
Play path
Create 5 axis trajectory
Select FEM0750_LONG solid tool
Set NC parameters
Customize, insert Automatic Cut
Define cut using surfaces
Select side surface of
part as drive surface
Select bottom surface of
part as part surface (height)
In customize delete
automatic plunge
Insert Plunge and Exit
along tool axis
Play path
Create 5 axis holemaking

Select DRILL0250_LONG
Set NC parameters
Select all holes
diameter 0.25
For depth calculation
select reference model
Play path
Write complete
CL
Play VERICUT
Exercise 18 : 5 axis curve trajectory with
AXIS_LINEAR_INTERPOLATION
This exercise will demonstrate how curve trajectory with
AXIS_LINEAR_APPROXIMATION can be used
for edge trimming
Use model bedliner_truck_
edge_trimming.mfg
toolpath
Using edges
Defining axis orientation
Play path
Exercise AXIS_DEF_
CONTROL options
for curve
Open model bedliner_truck_edge_trimming.mfg
Create 5 axis trajectory toolpath

Use SF30_R1_ISO50 solid tool
Set NC parameters
Customize / Insert Automatic Cut / using curve
Select one by one the bottom curve
of the chamfer on the side of the truckliner bed.
Create Axis definition, on location
Create point and datum axis
at each vertex of the curve.
Use 2 points (top and bottom
surface) at each vertex to
create the datum axis
Play path
Note the tool orientation in
the front of the part
Axis_def_control is set to
AXIS_LEAD_ANGLE_APPROXIMATION
Change Axis_def_control parameter to AXIS_LINEAR_INTERPOLATION
Play path see the result
Additionally add AXIS_SHIFT of .5
to offset the tool bellow the edge
Using build cut Improve
Approach/Exit
and start in middle
of edge
Ex18-19
Exercise 19 : 4 Axis trajectory, multi-passes and customize
This exercise will demonstrate the multi-passes capability of trajectory

and how customize can be used to
optimize a toolpath.
Start new manufacturing using
SQM_MULTI_1.prt as a reference
model
Use a 5 axis workcell and a
cylindrical retract plane
Create 4 axis trajectory using
drive surface and part surface (height)
with flat end mill
Make multiple passes to machine completely
part surface
Create workpiece and simulate in VERICUT
Create a new manufacturing model TRAJ_5AX
Use SQM_MULTI_1.prt as reference model

Create cylindrical workpiece using protusion
Create new Operation
Create a 5 axis milling
workcell
Set Machine CSYS
on NC_ASM_DEF_CSYS
Create a 3 cylindrical
retract surface along
X axis of
Machine CSYS
Create Flat End Mill tool : FEM0500 tool
Set NC parameters
Select 4 axis plane (front of part)
In Tool Motions, select Drive Surface
Cut:
- Drive surface
- Height
Play path
Set NC parameters NUM_PROF_PASSES
to 4, PROF_INCREMENT to 8 and
OVERTRAVEL_DISTANCE to 10
Play path to see
the multiple passes
Now lets trim the toolpath using customize
- From Customize, select Tool Motions tab
- We are going to split the toolpath in multiple

sections and remove some of these.
Select 1.Drive surface CTR C / V 2 times

From the first toolpath select Follow Cut and Edit
End 1 select Pt1 End 2 select Pt2
From the second toolpath select Follow Cut
and Edit End 1 select Pt3 End 2 select Pt4 and
same for Third toolpath using points 5 and 6.
- Play Path
This exercises will demonstrate the effect of the
AXIS_DEF_CONTROL parameter on a drive/part surfaces trajectory
We will use wall_traj_test.mfg
model
Create 5 axis trajectory to exercise
RELATIVE_TO_DRIVE_SURFACE and
FROM_AXIS_AND_DRIVE_SURFACE
PROJECT_FROM_AXIS and
PROJECT_ON_DRIVE_SURFACES
RELATIVE_TO_DRIVE_SURFACE
and PROJECT_FROM_AXIS
Use FEM0500 tool
Set NC parameters
Using customize create an automatic
cut based on part and drive surface
Setup model tree column to display
AXIS_DEF_CONTROL
Use Preview to check tool axis
Add Axis Definition

Unhide layer TRAJ_TILT
Define AXIS on Trajectory at .25 and .5 and .75

using datum axis at these locations
Preview tool axis
Change value of AXIS_DEF_CONTROL to

FROM_AXIS_AND_DRIVE_SURFACES
Preview to see the difference
Use FEM0500 tool
Set NC parameters
AXIS_DEF_CONTROL
Add Axis Definition
Hide layer TRAJ_TILT unhide layer TRAJ_LEAD

Define AXIS on Trajectory at .25 and .75
Preview tool axis
Change AXIS_DEF_CONTROL
to PROJECT_FROM_AXIS
Change AXIS_DEF_CONTROL to PROJECT_OND_DRIVE_SURFACES

Use FEM0500 tool
Set NC parameters
AXIS_DEF_CONTROL
Add Axis Definition
Hide layer TRAJ_LEAD unhide layer
TRAJ_TILT_LEAD
Define AXIS on Trajectory at .25 and .75
Preview tool axis
Change AXIS_DEF_CONTROL
to PROJECT_FROM_AXIS
Exercise 21 : Blade machining - Trajectory leading edge
This exercise will demonstrate the benefit of the leading edge machining
option for blade machining
We will use
trajectory_leading_edge.mfg
model
Create 5 axis trajectory with
LEAD_ANGLE of 12 degrees
Play path check behavior at
leading edge of blade
Set LEADING_EDGE_MACHINING
option to Yes
Compare behavior
Exercise 21 : Blade machining - Trajectory leading edge
Open trajectory_leading_edge.mfg model

Use FLAT10 solid tool
Set NC parameters ..
LEAD_ANGLE = 12
cut based on drive and part surfaces
Play path check behavior at
leading edge of blade
Set LEADING_EDGE_MACHINING
parameter to YES
Play path compare behavior at
leading edge
Exercise 22 : 5 axis holemaking and custom cycles
This exercise will demonstrate the functionality
to setup a 5 axis holemaking toolpath.
We will also use a custom cycle definition
for this operation
Create a 5 axis holemaking
Simulate toolpath
Note : this is just an exercise to manipulate 5 axis definition and does not represent something that can
be done on an NC machine machining all the faces !
Exercise 22 : 5 axis holemaking and custom cycles
Select holes

Use Diameter Filter / Add /
select diameter 3

Use Preview to see
hole orientation

Use FLIP to re-orient
tool axis
Select individual axis
to re-orient
Play path

Note the GOTO
outputs in 5 axis
Thank You!

Workshop 4-5 Axe Frezare - Odp

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This exercise will demonstrate the impact in the choice of a

Change the tolerance in Operation Setup for the retract

Open 5ax_cap_nc.mfg model

Change retract surface to

Open 5axis_sample.mfg model

Open 5axis_sample.mfg model

Create mill surface for floor of the pocket

Use BALL12 solid tool

No real difference with

This exercise will cover a typical

Set hidden config.pro 5_axis_side_mill to yes

Create 5 axis surface milling using cutlines

Create 5 axis surface milling using cutlines

Create 5 axis surface milling using cutlines

Finally a solution for this machining without

This exercise will demonstrate the benefit of too axis

Open cutline_pivot_point.mfg model

Define pivot point

Create a 5 axis surface machining toolpath

This exercise will demonstrate 4 axis surface milling with cutlines

Open spiral_nozzle.mfg model

Create 4 axis Cut Line milling toolpath

Volume milling is only a 2 acis type NC sequence

This exercise will demonstrate the method

Open 4 axis_rouhging.mfg model

This exercise demonstrate the impact of tool

Create 4 axis surface milling NC sequence

Create 4 axis surface milling NC sequence

This exercise will demonstrate how surface machining can

Model used is 4x_leg.mfg

Create 4 axis surface cutline milling NC sequence

Select top surface as 4x surf

Create 4 axis surface cutline milling NC sequence using a

Create a cylindrical mill surface

Select the top and bottom edge from the

Check Cutdirection see red arrow

This exercise will demonstrate the roughing and finishing of the

Create Pivot Curve

Create cylindrical surface diam = 18

Copy helix middle surface

Hide the two construction surfaces

Create milling surface (for a more continous tool path)

Trim this surface at each side with

Close mill-surface at its ends with two boundary blends

Create milling surface (for a more continous tool path)

Create rounds on vertical edges r = 0.75

Create round on bottom of

Create 4x Cut Line milling sequence to rough the center

CUT_ENTRY_EXT / CUT_EXIT_EXT ARC_TANGENT

Select mill surface

Select only bottom surf to be milled

Create 4x surface milling sequence to rough the center

Select cut type cutline and select the two

The tool path shows some strange connections

Add complete mill-surface as check-surface .. to get correct tool path

Create 4x surface milling sequence to rough the center (cont.)

Check result with PLAY PATH

Create 4x surface milling sequence to rough the center (cont.)

Copy 1.Cutline milling and inset 2 additional Cutline milling

Go back to parameters and set a different AXIS_SHIFT for each cut

Create 4x surface milling sequence to rough the center (cont.)

Create 4x Trajectory milling sequence to rough walls