Lecture 3

To Specify Comments for an Operation

The comments for an operation can be listed in the Manufacturing info; they can also be output in the CL data files using PPRINT. 1. 2. On the Output tab of the Operation Setup dialog box, type the operation comments in the Comments text box. Use the following buttons located to the right of the Comments text box, as necessary: o o OpenRead in an existing text file containing operation comments. The contents of this file will replace the current operation comments, if any. InsertInsert the contents of an exiting text file containing operation comments at the cursor location, while preserving the current operation comments, if any. Save AsSave current operation comments in a text file. ClearRemove current operation comments.

o o

To Activate an Operation
Once an operation is created, it stays current until another operation is created or activated. All newly created NC sequences will be included in this operation. Follow the procedure below if you want to activate one of the previously created operations (to add another NC sequence to it, or to customize its tool path). 1. 2. 3. 4. Click Operation. The Operation Setup dialog box opens, with the name of the currently active operation displayed in the Operation Name text box. Select the name of the operation you want to activate from the drop-down list. Click OK to activate the operation and close the dialog box.

About Workcells
A workcell is a workpiece (or assembly) feature that specifies a machine tool using: Name Type

Number of axes A set of parameters Associated tools Associated site(s)

To Create a Machine Tool (Workcell)

1. On the MFG SETUP menu, click Workcell. Another way to access this functionality is to click in the Operation Setup dialog box.

The Machine Tool Setup dialog box opens. 2. If you already have defined some machine tools for the current manufacturing at the top of the dialog box to start creating a new machine tool.

process, click

The Machine Tool Setup dialog box displays the default settings for the machine name, type, and parameters. You can click OK or Apply at this point to create a machine tool with default name and parameters, and no cutting tools associated with it. 3. box. 3. To change the machine name, type the new name in the Machine Name text To change the machine type, use the Machine Type drop-down list. Follow the link under See Also to see a summary of the existing workcell types and the NC sequence types subsequently available for each of them. The number of axes specified for the workcell will also affect the NC sequence options; for example, if you set up a 4-Axis Mill workcell, you will have the 3 Axis and 4 Axis options available when creating NC sequences, but the 5 Axis option will not appear. Auxiliary NC sequences are available for any type of workcell. 5. To change the number of axes, use the Number of Axes drop-down list.

5. To change the parameters, use the tabs located in the lower portion of the dialog box. 5. To set up the cutting tools for the machine, click the Cutting Tool Setup button located on the Cutting Tools tab. You can also set up the tools later by clicking NC Setup > Cutting Tool Manager. 5. 5. Click OK to finalize the machine tool creation and close the dialog box. If you want to immediately create another machine tool, click Apply, and or at the top of the Machine Tool Setup dialog box.

then click

You can save the current machine tool, along with its parameters, by clicking at the top of the Machine Tool Setup dialog box. You can then create a new machine tool with the same parameters, whether in this or in another NC process, by using the icon at the top of the Machine Tool Setup dialog box.

Machine Tool Settings

A machine tool is identified by the following elements: Machine NameThe machine name identifies the machine tool within the manufacturing process. The default machine names have the format MACH01, MACH02, where the number gets automatically incremented by the system. You can type any name. When you save the machine tool data on disk, the system uses the Machine Name as a filename (with the .gph extension). o o o o Machine TypeThe machine type can be Mill, Lathe, Mill/Turn, or Wedm. Number of AxesDepending on the machine type, can be: For Mill3 Axis (default), 4 Axis, or 5 Axis. For Lathe1 Turret (default) or 2 Turrets. For Mill/Turn2 Axis, 3 Axis, 4 Axis, or 5 Axis (default). For Wedm2 Axis (default) or 4 Axis. CNC ControlThe controller name (optional). LocationThe location of the machine tool (optional). Orientation(Available only for Lathe or Mill/Turn machine tools.) Specifies the lathe orientation: Horizontal (default) or Vertical. This option defines the default Sketcher orientation when you later create Turning NC sequences in this workcell: o o For Horizontal, the z-axis of the NC Sequence coordinate system will point horizontally to the right, and the x-axisvertically upward. For Vertical, the z axis of the NC Sequence coordinate system will point vertically upward, and the x-axishorizontally to the right.

The tabs on the Machine Tool Setup dialog box enable you to specify the following parameters of a machine tool. The Output tab Post Processor Options

PP NameThe name of the default post-processor associated with the machine. Type the name in the text box. IDThe post-processor ID. The Reset button lets you change the post-processor name and ID back to the system defaults. DefaultsLets you associate a site with the workcell. PPRINTOpens the PPRINT menu to let you set up your PPRINT options. CL Command Output Options

FROMSpecifies how the FROM statement will be output to an operation CL data file: o o Do Not Output (default)No FROM statements are output. If a From point is specified, its location is output as a GOTO statement at positioning feed. Only At StartA FROM statement is output at the beginning of the file. It corresponds to the location of the From point, if specified, or to the first location on the tool path for the first machining feature. All other tool paths are added to the operation without a FROM statement. At Every Tool PathFROM statements are output at the beginning of each tool path for a machining feature. For the first tool path, this FROM statement corresponds to the location of the operation From point, if specified, or to the first location on the tool path for this machining feature.

LOADTLControls the output of the LOADTL command in the operation CL data file: o o Modal (default)The LOADTL command is output at the beginning of CL data for a feature tool path only if a tool change is needed. Not ModalOutputs the LOADTL statement at the beginning of each feature tool path, regardless of whether the tool is the same or changed. COOLNT/OFFControls the output of the COOLNT/OFF statement. o o Output (default)The COOLNT/OFF statement is output at the end of each feature tool path. Do Not OutputCOOLNT/OFF is output only once, at the end of the file. SPINDLE/OFFControls the output of the SPINDL /OFF statement. o o Output (default)The SPINDL /OFF statement is output at the end of each feature tool path. Do Not OutputSPINDL /OFF is output only once, at the end of the file.

Multiple Axis Output Options These options become accessible only for a Mill type machine tool when you set Number of Axes to 4 Axis.

Use Rotate OutputIf this option is not selected (default), all CL data is transformed and output in the coordinates of the Program Zero coordinate system. When you select this option, the system outputs the applicable TRANS and ROTABL commands to specify linear and rotational transformations. Only select this option when indexing to a new table position is desired. Rotation Output ModeAvailable only when Use Rotate Output is selected. Controls output of ROTABL statements. The values are: Incremental (default) and Absolute. In Absolute mode, zero position is defined by the Program Zero. Rotation DirectionAvailable only when Use Rotate Output is selected. Allows you to specify that rotation is performed in a particular direction (this may occur when there is an obstruction in one rotation direction but not another). The values are: o o o Shortest (default)Make the shortest possible move to the new position. CLWAlways rotate in the clockwise direction. CCLWAlways rotate in the counterclockwise direction. Rotation AxisSpecify the rotation axis: A-Axis or B-Axis (default). Milling Capability These options become accessible only for a Mill/Turn type machine tool.

Head 1Specify whether milling is available on Head 1. Head 2Specify whether milling is available on Head 2. If both Head1 and Head2 are selected, the HEAD1 and HEAD2 options will appear in the MACH AUX menu when creating Milling NC sequences. Creating a Milling or Holemaking NC sequence using HEAD2 will result in HEAD2 statement being output in the CL file. If neither Head1 nor Head2 is selected when defining the workcell, then the SEL MENU with the MILL and TURN options will not appear when creating NC sequences. That is, once you click NC Sequence on the MACHINING menu, you will be brought directly into the MACH AUX menu for Turning. Note: 5-Axis Holemaking will be allowed on a Mill/Turn workcell, even if it is defined as 2- or 3-Axis. Select the Head1 option, and then select MILL from the SEL MENU when creating the NC sequence. Cutter Compensation When you expand this field, the Output cutter position options become available:

Tool CenterCutter location (CL) data is output with respect to the tool center. Tool EdgeCutter location (CL) data is output with respect to the cutting edge of the tool. If you select this option, type the desired value in the Safe

Radius text box. This value determines the smallest concave corner radius that can be safely machined, which must be slightly bigger than the tool radius. When the system calculates the tool path for an NC sequence, it checks that the radius of every concave corner being machined is no less than (Cutter Diameter/2 + Safe Radius). If a corner does not meet this condition, the system issues an error message. You can either reduce the Safe Radius value, if possible, or use a smaller tool. If your actual cutting tool diameter is greater than the programmed cutting tool diameter, use the Comp. Oversize parameter on the Settings tab of the Tool Setup dialog box. In this case, the smallest safe concave radius is calculated as ((Cutter Diameter + Comp.Oversize)/2 + Safe Radius). The Adjust Corner drop-down list gives you a choice of corner condition options for convex corners: o o o StraightWhen passing a convex corner, the tool path consists of two straight segments extended until they intersect. FilletWhen passing a convex corner, the tool path consists of two straight segments connected with an arc. AutomaticThe system adds a fillet corner condition at all the convex corners on the outside contour of the part, and a loop corner condition at all the convex corners on the inside contour of the part.

The Spindle tab Maximum SpeedMaximum allowable spindle speed for the machine tool (optional). Type the maximum speed value in RPM (revolutions per minute). HorsepowerSpindle horsepower (optional). The Feed tab Feed UnitsSelect the rapid feed rate units from the Rapid Traverse dropdown list. The values are: o o IPM (default)inches per minute MMPMmillimeters per minute

Feed LimitsType the value of the feed rate used for rapid traverse in the Rapid Feed Rate text box (optional). The Cutting Tools tab

Tool Change TimeTime needed for changing a tool, in seconds (optional). Type the value in the text box, or use the UP and DOWN arrows next to the text box to increase or decrease the value, respectively. The Cutting Tool Setup button opens the Tool Setup dialog box to let you set up the cutting tools associated with the machine tool. For 2-turret Lathe and 4- or 5-axis Mill/Turn machines, you get separate cutting tool setup buttons for Head 1 and Head 2.

The Travel tab Lets you specify the travel limits for the machine tool: X-Axis Travel, Y-Axis Travel, and Z-Axis Travel. Specifying these values is optional. Values for the travel limits along the axes should be the actual dimensions that indicate the extent of the machine tool workspace relative to the Program Zero coordinate system. For example, if a machine tool is 60 inches wide, and the origin of the Program Zero coordinate system is located halfway between the ends, specify the travel limits for X-Axis Travel as follows: type -30 in the left text box and 30 in the text box on the right. If you display or otherwise output the CL data for a machining feature that exceeds the limitations of the machine tool where it is defined, the Information Window will appear, listing the values of the limits that have been exceeded and their corresponding actual values. The Comments tab Type the comments associated with the machine tool in the text box (optional). The Custom Cycles tab Lets you set up custom cycles for Holemaking.

Workcell Types
The workcell type determines the types of NC sequences that can be created using it (for example, 4 Axis Lathe allows you to perform 2- and 4-axis Turning and Holemaking).

Workcell Type

Description

NC Sequence Types Available Turning: Area Profile Groove Thread Holemaking: Drill Face Bore

Lathe

2- or 4-Axis Turning and Holemaking.

Countersink Tap Ream

Mill

3- to 5-Axis Milling and Holemaking.

Milling: Volume Local Mill Surface Mill Face Profile Pocketing Trajectory Thread Engraving Plunge Holemaking: Drill Face Bore Countersink Tap Ream

Mill/Turn

Mill/Turn center (2 Axis Turning to 5 Axis Milling and Holemaking).

Milling: Volume Local Mill Surface Mill Face Profile Pocketing Trajectory Thread Engraving Plunge Turning: Area Profile Groove Thread Holemaking: Drill Face Bore Countersink Tap Ream

WEDM

Wire Electric Discharge Machine (2- or 4 Axis), as well as any other type of 2D Contouring (for example, flame cut or laser.).

WEDM

You can create a workcell at setup time and then use it in an operation, or create a workcell directly when defining an operation.

About Fixtures
Fixtures are parts or assemblies that help orient and hold the workpiece during a manufacturing operation. Fixtures can be created and saved in Part or Assembly mode, and retrieved into the Manufacturing mode during fixture setup. Creating the fixture in Assembly mode is advantageous because fixtures can be created as needed during the intermediate process steps by referencing the workpiece. It is a simple process, because you can build the fixture referencing the workpiece with Use Edge. You do not have to quit out of Manufacturing mode to enter Part or Assembly mode. You can open another object (part or assembly) between NC sequences. Note: If you have an appropriate license, you can use the library of manufacturing fixtures (clamps, holding plates, chucks and jaws) of generic sizes. To use fixtures in the manufacturing process, you must first define the fixture setups for the manufacturing model. Each fixture setup has a name and contains information about the fixtures that are to be present in the model when the setup is active. Only one setup can be active at a time. Setup names can be used to manipulate fixtures within the manufacturing model. Because fixture setups contain fixture assembly information, each manufacturing model has to have its fixture setup(s) explicitly defined; unlike sites or tools, you cannot retrieve a fixture setup from one model into another manufacturing model. Fixture setups can be defined at the time of setting up an operation or at any time between NC sequences.

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