Setting Up a New Machine for Machine Simulation

Setting Up a New Machine - Files

General Information
myMachin There is a set of files that are necessary to run a machine in Machine Simulation. Usually the folder for these files is under the CAMWorks data folder. For example, to set up a machine named myMachine, the path might be D:\CAMWorksData\CAMWorks20xx\MachSim\XML\myMachine). The following configuration files are needed to set up the machines: e.xml (The name must be the same as the machine folder name) This file defines the machine kinematics model: The axis directions Axis limits Machine model The geometry which is on each axis Geometry colour Tool axis direction Part model shift coordinate system Sets of parts that are collision controlled geometry.stl STL files define the geometric components of the machine. The names of the STL files are used in myMachine.xml to assign them to the appropriate axis. Usually you have several STL files since your machine consists of different moveable axis. MyMachine.pst The names must be the same as the machine folder name. MyMachine.psb These are the post processor driver files for the machines. MyMachine.par Post processor driver definition. This file is very important, since concerning the axis directions it needs to match with the definitions in myMachine.xml. But there is more information inside. Since the machine may be also switched to work in post processor mode, for instance a flag is necessary, in which direction the axis tilts. In 5 axis machining there are always 2 possible angle combinations to achieve a desired angle of the tool in respect to the work piece. Some machines permit both. Thus a decision has to be made, which direction is selected. Some machines permit only one angle combination. In this case the machine motion has to be restricted to one selected angle. There are several other parameters which are set here and important for the functionality of Machine Simulation. The .par file will be detailed subsequently.

Creating a New Machine

1. A new machine is created in the Machine window. If the Machine window is not displayed, select View -> Windows -> Machine. You usually have a machine selected and this is listed in the tree. 2. Click the New Machine button on the toolbar. The current machine information will be removed and an unnamed machine appears instead. 3. Right click Unnamed machine and select Properties from the drop down menu. The Element properties window displays. 4. Change the ID name of the machine. This name is the name of your new machine. The name new_machine is used for this explanation. 5.

Click the Save machine button. The file dialog from windows appears. Save the 'new_machine.xml' to 'new_machine' folder (machsim/new_machine/). Remember, the machine ID name and the folder name of the machine data must be the same. 6. To check if your new empty machine was created successfully, open the new_machine.xml file with any editor. It should look like this. <?xml version="1.0" encoding="iso-8859-1" ?> - <machine_definition> <machine_data_name="new_machine" version="1.3" units="metric" /> </machine_definition> Next, you have to create the linear axes and rotation axes. Therefore, you need the geometry data of your machine. For the new_machine, we use different parts and axes. You have moveable (rotating, sliding) parts and fixed parts. For the machine simulation, the parts have to exist in a STL file format. Most important here is that: the middle point on the top face of your table is the absolute center point of your geometry. From here all other parts will be measured. the spindle center of the lower face has to be exactly on the center point of the table. the Z axis shows out vertical of the center point of the table. 7. Move the machine and the spindle to the right position, then save the single parts to STL files. Then they already have the right position. The A axis (rotation axis), 'A_AXIS.STL'. The C axis (table rotation axis), 'C_AXIS.STL'. The X axis (linear axis), 'X_AXIS.STL'. The Y axis (linear axis), 'Y_AXIS.STL'. The Z axis (linear axis), 'Z_AXIS.STL'. The housing (not movable), 'HOUSING.STL'. The fixed A axis (not moveable), 'FIXED_A_AXIS.STL'. The tool, 'TOOL.STL'. The workpiece, 'WORKPIECE.STL'. When you want to add geometry or an axis, you do this in the kinematics tree. The structure and dependence of the machine parts is hierarchical. It is exactly as you insert them in the kinematics tree. So always start from the base, the fixed parts. From here all other parts will be added.

Adding Fixed Parts

After you have defined the geometry for a new machine, you add the fixed parts. The main fixed part is the housing. From here all other geometries depend. 1. Right click new_machine in the tree and select Add geometry from the drop down menu. The Element properties window displays. 2. Type the ID name of the housing (for example, mh_housing). If you begin the name with a mh_ prefix, you are able to hide the machine housing during machine simulation. 3. Click the Browse button and select HOUSING.STL in the new_machine folder. 4. Click the Appearance tab and set the color. 5. Click OK. The housing displays in the simulation window. You can click the Maching Housing button to show or hide the display. 6. Save your machine. Continue with linear axes.

Adding Linear Axes

The next step in creating a new machine is to add the linear axes. First you add the Y axis. As said before, the hierarchy is defined about the kinematics tree. So right click the 'new_machine' machine and select 'add transl. axis'. Give the ID name 'Y' Important here is the ID name. When you send your program through the post processor, the translation needs special ID names. They are defined as following. Axes: A axis (rotation axis) ID is 'A' C axis (rotation axis) ID is 'C' X axis (linear axis) ID is 'X' Y axis (linear axis) ID here is 'Y' Z axis (linear axis)ID is 'Z'. and so on... Tool: The tool ID name has to be 'tool' Work piece: The work piece ID has to be 'workpiece_transform'. Switch to the 'Transformation' tab The Y axis of course is moving in Y direction. So set X and Z to '0' and Y to '1'. The declaration for all other axes is the same: X axis (linear axis) goes through X Y axis (linear axis) goes through Y Z axis (linear axis) goes through Z. For the rotation axes you have to get the direction from the geometry. If eg. the C axis is turning around Z you have to set Z to '1'. Rotation axes can also turn around two axes. If eg. the table is 45 tilted then you have to set two values to '1'. Now switch to the 'Limits' tab. Here you can set the motion range for the axes. This value is 'mm' for translation axes and degree for rotation axes. You have to measure the limit at the machine. Then apply them here. In our case it's -80 mm and +100 mm. After this hit 'ok'. Now we need the geometry for this axis. In our case we have two parts: a flat plate and the holder of the A axis.

Right click on our new Y axis in the kinematics tree and choose 'Add geometry'. Give any ID name (eg. Y axis) and select 'Y_AXIS.STL' as geometry. The same for the holder name it eg. 'Holder for A axis' and select the part 'FIXED_A_AXIS.STL'. The plate and the holder appears now in the simulation window. Do the same procedure for the X axis. Right click on the 'new_machine' Add transl. axis' ID name is 'X' Transformation is X 1, Y and Z 0 Limits are -120 and 120 Right click on 'X axis'. Select 'Add geometry' 'X_AXIS:STL ID name is X axis The Z axis is depended on the X axis and has to be arranged under your X axis in the kinematics tree. Right click on the 'X Axis' 'Add transl. axis' ID name is 'Z' Transformation is X0, Y 0 and Z 1 Limits are -100 and 200 Right click on the 'Z axis' Select 'Add geometry' 'Z_AXIS.STL' ID name is Z axis The axes appear in the simulation window. Now set up the rotation axes.