Housing Plate Geometry Creation Tutorial 2011 r1 v2.1

Housing Plate Geometry Creation Tutorial
Housing Plate Geometry Creation tutorial
Copyright
Copyright 2010 Planit Software Ltd. All rights reserved. Any copyright or other intellectual property right of whatever nature which subsists or may subsist in the presentation and/or content of the programs (including without limitation its look, feel, visual or other non-literal elements) remains the property of Planit Software Ltd or its licensor(s) absolutely. No part of this publication may be reproduced, transmitted, transcribed, stored in a retrieval system or translated into any language, in any form or by any means, electronic, mechanical, optical, chemical, manual or otherwise, without the express written permission of Planit Software Ltd. Unauthorised reproduction or distribution of these programs or any part thereof is unlawful and may result in civil or criminal penalties. Alphacam and the Alphacam Logo are trademarks of Planit Software Ltd. Windows is a trademark of Microsoft Corporation. All product names mentioned in this publication, and not listed above, are acknowledged as the trademarks of the respective manufacturers and producers of such products. Planit Software Ltd makes no representations or warranties with respect to the contents hereof and specifically disclaim any implied warranties of satisfactory quality or fitness for any particular purpose. Further, Planit Software Ltd reserves the right to revise this publication and to make changes in the contents hereof without obligation to notify any person of such changes or revisions. The information contained within this document is subject to change without notice and does not represent a commitment on the part of the vendor. The software described in this document is furnished under a licence agreement and may be used or copied only in accordance with the terms of the agreement.
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Contents
Conventions used in this guide ......................................................................... 5 Recommended Operating Systems and Hardware for Alphacam ..................... 6
Supported Operating Systems
Alphacam Minimum Specifications
6
6
THE PART GEOMETRY .................................................................................. 7

THE PROCESS PLAN Draw profiles 1 & 2 Draw profiles 3 & 4 Draw profile 5
Draw the 38 and 75 circles Break the circles Add Fillet Radius Join the profile
8 9 9 10
10 10 11 11
CREATING THE GEOMETRY ......................................................................... 9
Draw profile 6
Draw the 48 and 85 circles Add Tangent Lines Trim the Circles to the Lines Join the profile
12
12 12 13 13
Create profile 7
Offset profile 6. Create Hole & Lug Copy Hole and Lug Rotate Hole and Lug to 35 Deg. Mirror Holes & Lugs
14
14 14 15 15 16
Trim and Join

Method 1 Unite Method 2 Hide Geometries Trim Lugs & Outer Profile Join outer profile 1 Join outer profile 2 Turn on hidden geometries
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17 17 17 17 17 18 18 18
Fillet 4mm Draw Rapids Order Geometries. Create the material geometry Set the Material Set the ISO view Save the Job
19 19 20 21 21 22 22
Position the Geometry for Machining .............................................................. 21
Set Geometry Z Levels ................................................................................... 23
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Conventions used in this guide

To enable you to use the information in this guide effectively, you need to understand the used in the guide to represent different types of information.
Buttons on the screen are represented as the button text in square brackets. For example: Click on [Ok]. Keys on the keyboard are represented as bold lettering in between <> characters. For example: Press <Enter.> Menu options are represented as a path with the main menu in UPPER case with sub menus Capitalised and separated with a vertical bar For example: Select FILE | Open Field names are represented as bold text. And the value to be entered will be represented by Narrow Bold Text. For example: Enter the value 50 in the Offset field. Or When prompted for the X & Y values type 100,50 <Enter> This is a note. It contains useful or additional information. This is a reference. It directs you to another part of the user guide.
This is a thought box. It is generally used in exercises and contains a question for you to consider.
This is a warning, it contains information that you must not ignore. This is a tip. It is generally used in exercises and offers further advice.
1 2 3
This is the first line a number list item this is the second line of the numbered item This is the second item of the numbered instructions, which you must Follow in sequence. This is a list of items, in which The order is not important.
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Recommended Operating Systems and Hardware for Alphacam

Supported Operating Systems

Operating System Windows XP (XP Pro Service pack 2), Windows Vista, Windows 7 (Business, Ultimate or Enterprise versions) Alphacam will install and run on the 'Home' editions of the above operating systems (including Windows XP Home Edition, Vista Home Basic, and Vista Home Premium); however, this is not recommended and we cannot guarantee to fix any Alphacam issues specifically related to these operating systems. Alphacam will install and run on 64-bit versions of these operating systems, where applicable (note however that Alphacam is a 32-bit application).
We recommend you keep up to date with the with the latest service packs for the supported operating systems and drivers for your hardware base.
Windows NT, 95,98 and ME are not supported operating systems
Alphacam Minimum Specifications

Processor Intel XEON or ADM Memory 4GB RAM ATI or NVIDIA Video Card, OpenGL compatible, High Colour Setting with 512MB on-board memory 17 Monitor 1280x1024 resolution Hard Disk Space 10 Gb free hard disk space Disk Drive DVD drive for software installation Pointing Device 2 button with wheel Windows compatible mouse Ports USB 1.1 or 2.0 port for single user security key support Network TCP/IP required for network security support Optional: Space Ball and Space Mouse. Windows is a registered trademark of Microsoft Corporation in the United States and other countries. The Alphacam installer will install any additional software/drivers required if it is not already installed on your PC.
If using Autodesk Inventor please check the current Inventor requirements at www.autodesk.com
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THE PART GEOMETRY

This drawing is the part you are going to create. It was drawn, dimensioned and printed with AlphaCAM. AlphaCAM provides various ways of creating part geometry, however for the purposes of these notes we will be using only CAD style geometry creation, whereby individual geometric features are created and then trimmed in order to create geometric contours. Toolpaths are then applied to the geometric contours from which the NC program is oolpaths produced. CAD style geometry creation mainly utilises Line, Arc, Circle and rectangle commands, however, AlphaCAM also includes Special Geometries which automatically produc produces standard geometric shapes.
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THE PROCESS PLAN

As per the job process you should create a machining process plan prior to creating the geometric profiles. It is the process plan that determines what geometry is required to control the machining. In this example we can assume that all the geometry is required for machining. Prior to creating the geometry it is good practice to produce outline notes about the geometry to be defined. In this case for clarity we will number the profiles to be drawn.
Profile Outline
1 2 3 4 5 6 7 Circle 20 diameter centre at 0,0 Circle 30 diameter centre at 100,0 Circle 6mm offset from profile 2 Circle 6mm offset from profile 1 Circle 38 Radius same centre as 1 + Circle 75 radius same centre as 2. Circles need to be broken at inner quadrants to allow 13mm fillets to be created. Join to create profile Circle 48 Radius same centre as 1 + Circle 85 radius same centre as 2. 2 lines tangent to circles. Circles to be trimmed to the lines. Join to create profile Profile offset 6mm from profile 6. Circle 8mm diameter at left most quadrant, Circle 10mm radius at left most quadrant. The 2 circles are copied by their centre to two positions -18.47, 50.74 & 68.86, 85.55 plus one additional at the right most quadrant. Rotate right most set to 35 degrees. Mirror top three holes and lugs about horizontal axis through 0, 0. Use either Fabricate- Unite to create the outer boundary or Turn off profile 6 and 8mm holes. Trim profile 7 and lugs. Join to produce contour. Fillet all corners to 4mm radius. Make 8mm holes and profile 6 visible and reorder 8mm holes.
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CREATING THE GEOMETRY

Draw profiles 1 & 2
Select GEOMETRY | Circle | Centre + Diameter 0 0 for for The command line will prompt you to enter the circle diameter. Type 20 . Type 0 the co-ordinates of the circle centre. The 20mm diameter circle will be drawn. ordinates The command line will again ask you for the circle diameter. Type 30 . Type 100 the co-ordinates of the circle centre. The 30mm diameter circle will be drawn. ordinates
Draw profiles 3 & 4

Create the flanges around the two holes using the offset command. Select EDIT | Break Join etc. | Offset
Set the options as shown then [OK] Select the 20 diameter circle then a point on the outside, the new profile will be drawn. he Select the 30 diameter circle then a point on the outside, the new profile will be drawn.
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Draw profile 5
Draw the 38 and 75 circles Prior to activating the next command ensure that Auto Snap is active (is the word Auto at the bottom right of the screen). To activate Auto Snap press <F2>. Select GEOMETRY | Circle | Centre + Radius The command line will prompt you to enter the circle radius. Type 38 , position the cursor over the centre of profile 1 (the snap selector will be displayed) <L click> to select this position. The 38mm radius circle will be drawn drawn. The command line will again ask you for the circle radius. Type 75 , p position the cursor over the centre of profile 2 (the snap selector will be displayed) <L click> to select this ofile position. The 75mm radius circle will be drawn drawn. Break the circles Select EDIT | Break Join etc. | Break
Set the options as shown then [OK]
Position the cursor on the positions shown and <L click> the geometry will be broken.
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Add Fillet Radius Select EDIT | Break Join etc. | Fillet
Set the options as shown then [OK]
Select a point on the geometry either side of the position, as shown, where the fillet radius is to be created. When the fillet is created the extending lines are automatically trimmed back ted. to the fillet. Join the profile Select <Ctrl>+<G> or to display the ghost tools Select EDIT | Break Join Etc. | Join <L click> on each part of profile 5 so that it is all (selected) blue, <R click> or press <Esc> all this will action the join command and if drawn properly profile 5 will only be displayed with one ghost tool.
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Draw profile 6
Draw the 48 and 85 circles Prior to activating the next command ensure that Auto Snap is active (is the word Auto at the bottom right of the screen). To activate Auto Snap press <F2>. Select GEOMETRY | Circle | Centre + Radius The command line will prompt you to enter the circle radius. Type 48 , position the cursor over the centre of profile 1 (the snap selector will be displayed) <L click> to select this position. The 48mm radius circle will be drawn drawn. The command line will again ask you for the circle radius. Type 85 , p position the cursor over the centre of profile 2 (the snap selector will be displayed) <L click> to select this selector position. The 85mm radius circle will be drawn drawn. Add Tangent Lines Prior to creating the tangent lines ensure that Auto Snap is deactivated, (is the word Auto at the bottom right of the screen). To deactivated Auto Snap press <F2>. Although it is not deactivated mandatory to turn off auto snap we do so because the Auto Snap only snaps to End, Mid, Centre & quadrant points and it can be confusing when the position to be selected is a tangent point. Select GEOMETRY | Line For the Line From point press <F10> the prompt will change to select circle or arc. Select a position towards the top left of the 38 diameter circle. The elastic cursor line will be displayed and this will remain tangent to the 38 circle as it is moved. For the Line to point press <F10> the prompt will change to select circle or arc. Select a position towards the top right of the 75 diameter circle. The tangent line will be created <R click>or press [Esc] to finish the line command Press <Space> to reactivate the line command. o For the Line From point press <F10> the prompt will change to select circle or arc. Select a position towards the bottom left of the 38 diameter circle. The elastic cursor line will be displayed and this will remain tangent to the 38 circle as it is tangent moved. For the Line to point press <F10> the prompt will change to select circle or arc. Select a position towards the bottom right of the 75 diameter circle. The tangent line will be created <R click>or press [Esc] to finish the line command
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Trim the Circles to the Lines Select EDIT | Break Join etc.| Trim The system will prompt select the cutting geometries, <L click> on each of the lines (they should turn blue). Press [Esc] or <R Click> The system will prompt select the Geometries or Tool paths to trim, position the cursor on the portion of the circles to be removed and <L click>. Join the profile Select <Ctrl>+<G> or to display the ghost tools Select EDIT | Break Join Etc. | Join <L click> on each part of profile 6 so that it is all (selected) blue, <R click> or press <Esc> le this will action the join command and if drawn properly profile 6 will only be displayed with one ghost tool.
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Create profile 7
Offset profile 6. Select EDIT | Break Join etc. | Offset
Set the options as shown then [OK] Select profile 6 then a point on the outside, the new profile will be drawn. Create Hole & Lug Prior to activating the next command ensure that Auto Snap is active (is the word Auto at the bottom right of the screen). To activate Auto Snap press <F2>. Select GEOMETRY | Circle | Centre + Diameter The command line will prompt you to enter the circle diameter. Type 8 . position the cursor over the left most end of profile 7 as shown, (the snap selector will be displaye <L click> to displayed) select this position. The 8mm diameter circle will be drawn.
Select GEOMETRY | Circle
| Centre + Radius
The command line will prompt you to enter the circle radius. Type 10 , position the cursor as previous, (the snap selector will be displayed) <L click> to select this position. T 10mm The radius circle will be drawn.
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Copy Hole and Lug Select EDIT | Move Copy etc.| Copy <L Click> on the two circles (they should turn blue), then <R click> or press <Esc> The system will prompt you to select the base point, using the auto snap select the centre point of the two circles. The system will prompt you to Drag to Position or entre co ordinates, type -18.47 co-ordinates, both circles will be copied to the new position. The system will prompt you to Drag to Position or entre co ordinates, type 68.86 co-ordinates, again both circles will be copied to the new position. 50.74 85.55
For the third set using the auto snap select the right most quadrant position on the outer profile, as shown below.
Rotate Hole and Lug to 35 Deg. nd Select EDIT | Move Copy Etc. | Rotate <L click> on the hole and lug circles on the right side to select them, then <R click> or Press <Esc> The system will prompt you to select the base point, using the auto snap select the centre point of the 30 diameter circle. The system will prompt you to select or enter the rotation angle, type 35 The system will prompt you How many Copies Including the Original, type 1 The hole and lug will be rotated to its new position.
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Mirror Holes & Lugs Select EDIT | Move Copy Etc. | Mirror You can use a window selection to select the top three sets of holes and lugs. Position the cursor at P1 shown then <L click> move the cursor, (the window rectangle will be displayed), to the position P2 shown then <L click>. The three sets of holes and lugs will be selected hown (turned blue), <R click> or Press <esc>
The system will prompt you to select the First point on Mirror line, using auto snap select P3 The system will prompt you to select the Second point on Mirror line, using auto snap select Second P4. The Mirror options dialog is displayed as shown:
Select the [Yes] option and the holes and lugs will be duplicated and mirrored.
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Trim and Join

Method 1 Unite Select EDIT | Fabricate | Unite then select the outer profile and the lug circle, R ect R-Click to finish and the lugs and outer profile will be trimmed and joined to form the closed boundary. Method 2 In order to make the trimming of the outer profile and lugs easier you will firstly turn off the holes and profile 6. Hide Geometries Select CAD | Hide Parts Select the 8mm diameter holes and profile 6 when they are all blue <R Click> or press<Esc> and they will be turned off. This will enable easier trimming as they can no longer get in the way. Trim Lugs & Outer Profile Select EDIT | Break Join etc. | Trim For the cutting geometries select all the 10 radius circles and the outer profile. <R click> or Press <Esc> For the geometries to be cut select all the inner parts of the 10 radius circles, then select the s portions of the outer profile inside the lugs. Remember that Refresh <Ctrl>+<R> can be used at any time
When the trimming is complete <R click> or Press<Esc>. All The trimmed outer profile should be displayed as blue if not use option 2 mmed for the join option. It is only necessary to use one option.
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Join outer profile 1 Select EDIT | Break Join Etc. | Join Select the [Previous] button on the prompt line, this will select what was blue in the previous what command, <R click> or Press <esc. to completed the command. Select <Ctrl>+<G> or profile. Join outer profile 2 Select EDIT | Break Join Etc. | Join Select the [All] button on the prompt line, this will select all the visible geometries, <R click> t or Press <esc. to completed the command. Select <Ctrl>+<G> or profile. to display the ghost tools, ensure that there is only one on the outer to display the ghost tools, ensure that there is only one on the outer
Selecting other geometries that are not connected with the geometries being ometries joined has no effect. Turn on hidden geometries Select CAD | Show All This will cause all hidden items to be made visible.
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Fillet 4mm
All the sharp corners in the outer profile can be filleted in one go. Select EDIT | Break Join etc. | Fillet
Set the options as shown then [OK] Select the outer profile then <Rclick> or Press <Esc> and the fillit radii will be created around the outer profile. This concludes the geometry creation for the housing plate. However due to the nature of reproducing the 8 mm holes the geometry pattern is not as short as it could be.
Draw Rapids
Select VIEW | Display Options | Draw Rapids Because no tool has been selected and not tool paths have been created the Draw Rapids command shows the connections between the geometries in the order they were created.
You can see that the order of the holes comes back across the part to the bottom set of holes; this is because the top holes were mirrored to the bottom. This is the order in with the holes will be drilled. Whilst it is possible to reorder a series of is tool paths, it is easier to set the order of the geometries especially if the holes are to be machined more than once. i.e. Centre Drill, Drill, Tap and Chamfer Chamfer.
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Order Geometries.
Select EDIT | Start Order. | Order This command allows you to reorder geometries or tool paths.
Set the options as shown then select [OK] The system prompts you to select the geometries <L click> on each of the 8mm circles when they are all blue <R click> or Press <Esc> The way in which the geometries are selected does not affect the order. The system requires you to select the geometry that will be the first in the pattern <L click> on the left most 8 mm diameter circle. The geometries will be reordered. ies
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Position the Geometry for Machining

Create the material geometry
Select GEOMETRY | Special Geometries | Enclosing Rectangle Select the outer profile then <R click> and the enclosing rectangle is drawn Select EDIT | Break Join etc. | Offset
Set the options as shown then [OK] Select the enclosing rectangle then a point on the outside, the new rectangle will be drawn. Delete the original rectangle. Select EDIT | Delete Select the original inner rectangle the <R click> then select [Ok] on the dialog to confirm. Select EDIT | Move Copy etc. | Move Select the [All] option on the prompt line then <R click> For the Base point using the auto snap select the lower left corner of the rectangle. For the new position type 0 0
Set the Material

Select 3D | Set Materials Select the outer rectangle and the dialog will be displayed. Set the options as shown
Select [OK] Or Use the 3D | Auto Set Material Macro.
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Set the ISO view

This will enable you to see the geometry and mat material. Select VIEW | VIEWS | Iso
Prior to saving the job ensure that the geometry profiles only have one ghost tool Select <Ctrl>+<G> or to display the ghost tools
Save the Job

Select FILE | Save The save dialog is displayed, Select the required location folder then enter the job name.
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If it is required to machine the component using auto Z machining then you will need to set the geometry Z Levels
Set Geometry Z Levels

1. 2. Select 3D | Set Geometry Z Levels The system prompt you Select Geometries L Click on the 20 and 30 Diameter Holes then R Click. In the Dialog Set the Top Z = 0 and the Bottom Z = -18 then [OK] The system prompt you Select Geometries L Click on the figure 8 geometry and the flanges then R Click. In the Dialog Set the Top Z = 0 and the Bottom Z = -12 then [OK] The system prompt you Select Geometries L Click on the 3mm Recess geometry then R Click. In the Dialog Set the Top Z = 0 and the Bottom Z = -3 then [OK] The system prompt you Select Geometries L Click on the Part outer prof and profile the 8 Diameter Holes then R Click. In the Dialog Set the Top Z = -3 and the Bottom Z = -18 then [OK] R Click to finish the command.
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Version Amendments
REF
2.1
Amendment
Update to 2011 R1 Fabricate added and amendment control
Software Version
2011 R1
Ammended
07/12/2010
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Trainee Notes
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