Multi-Axis Surface Machining

CATIA V5 Training

Foils

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Multi-Axis Surface
Machining

Version 5 Release 19
January 2009
EDU_CAT_EN_MMG_FI_V5R19

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Multi-Axis Surface Machining

About this course

Objectives of the course
Upon completion of this course you will be able to
- Identify and use the Multi-Axis Surface Machining workbench tools
- Define 5-Axis machining operations such as Multi-Axis Sweeping, Multi-Axis
Contour Driven, Multi-Axis Curve Machining, Multi-Axis Isoparametric
Machining, Multi-Axis Drilling and Multi-Axis Tube Machining.

Targeted audience
Advanced NC Programmers

Prerequisites

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Students attending this course must have knowledge of CATIA V5 SMG

Fundamentals
8 hours

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Multi-Axis Surface Machining

Table of Contents (1/4)

Introduction to Multi-Axis Surface Machining
About Multi-Axis Surface Machining
Accessing the Workbench
The User Interface

Master Exercise: Fender (Wing)

Master Exercise: Step 1
Multi-Axis Sweeping Operation
About Multi-Axis Sweeping Operation
How to Create a Multi-Axis Sweeping Operation
Multi-Axis Sweeping Operation: General Process
Strategy Definition
Geometry Definition
Tool Definition
Speeds and Feedrates Definition
Macros Definition

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Master Exercise: Step 2

Multi-Axis Contour Driven Operation
About Multi-Axis Contour Driven Operation

7
8
9
11

12
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14
15
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18
34
36
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46
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Multi-Axis Surface Machining

Table of Contents (2/4)

How to Create a Multi-Axis Contour Driven Operation
Strategy Definition

Master Exercise: Step 3

Multi-Axis Curve Machining Operation
About Multi-Axis Curve Machining Operation
How to Create a Multi-Axis Curve Machining Operation
Strategy Definition
Geometry Definition
Macros Definition

Master Exercise: Step 4

Multi-Axis Isoparametric Machining Operation
About Multi-Axis Isoparametric Machining Operation
How to Create a Multi-Axis Isoparametric Operation
Strategy Definition
Geometry Definition
Macros Definition
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Multi-Axis Drilling Operation

About Multi-Axis Drilling Operation

49
50

54
55
56
57
58
66
77

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87

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89

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Multi-Axis Surface Machining

Table of Contents (3/4)

How to Create a Multi-Axis Drilling Operation
Strategy Definition
Geometry Definition
Macros Definition

Multi-Axis Tube Machining Operation

About Multi-Axis Tube Machining Operation
How to Create a Multi-Axis Tube Machining Operation
Strategy Definition
Tools Definition
Macros Definition

Multi-Axis Spiral Milling Operation

About Multi-Axis Spiral Milling Operation
How to Create a Multi-Axis Spiral Milling Operation
Strategy Definition
Geometry Definition

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Exercises
Exercise 1: Hood
Exercise 2: Pocket

90
91
92
93

94
95
96
97
105
106

108
109
110
111
114

115
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117

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Multi-Axis Surface Machining

Table of Contents (4/4)

118
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Exercise 3: Isoparametric and Drill

Exercise 4: Multi-Axis Curve Machining
Exercise 5: Tube Machining
Exercise 6: Multi-Axis Spiral Machining

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Multi-Axis Surface Machining

Introduction to Multi-Axis Surface Machining

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You will become familiar with CATIA V5 Multi-Axis Surface Machining User Interface.

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Multi-Axis Surface Machining

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About Multi-Axis Surface Machining

Multi-Axis Surface Machining enables you to produce NC
programs dedicated to machining parts designed in 3D
Wireframe or solids geometry using Multi-Axis machining
techniques.
Based on industry recognized and leading edge technologies,
Multi-Axis Surface Machining provides tight integration between
tool path definition, verification and modification.
Multi-Axis Surface Machining is an add-on on product to 3-Axis
Surface Machining.
Thus, the user benefits from superior 3-axis multiple surface
machining and leading edge 5-axis simultaneous machining
tightly integrated in a flexible NC Programming workbench.
Multi-Axis Surface Machining is particularly adapted for mockup and die machining in automotive domains where the use of
5-axis simultaneous machining brings unequalled surface
quality. Moreover, it is targeted at prototype machining, 5-axis
trimming and special machining where full 5-axis machining is
the requirement for quick and accurate manufacturing.
As an add-on product, it takes advantage of functions such as
material removal simulation and NC data generation. It adds
dedicated multi-axis surface machining techniques to the 3-Axis
surface machining capabilities offered by 3-Axis Surface
Machining.
You can define a 3D contact compensation Mode available for
every Multi-Axis operations.

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Multi-Axis Surface Machining

Accessing the Workbench (1/2)

Start > Machining > Surface Machining

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Functionalities available for

Multi-Axis Surface Machining

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Multi-Axis Surface Machining

Accessing the Workbench (2/2)

Once you have MMG license, the associated toolbar is displayed.

Multi-Axis Tube
Machining

Multi-Axis
Contour Driven

Isoparametric
Machining

Multi-Axis Spiral
Machining

Multi-Axis Curve
Machining

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Multi-Axis
Sweeping

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Multi-Axis Surface Machining

The User Interface

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3 Axis and Multi-Axis

Surface Machining
Items

Other Surface
Machining Items

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Multi-Axis Surface Machining

Master Exercise: Fender (Wing)

Exercise Presentation
70 min

In this exercise, you will learn 5-Axis Surface

Machining fundamental concepts by machining a part
from the 3D.

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You will define parameters within the Part Operation

and use provided tools within a tool catalog. You will
see also how to define a geometry and a strategy.

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Master Exercise: Fender

Step 1: Create a new Part Operation
5 min

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In this step you will learn how to define a

new Part Operation.

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Multi-Axis Surface Machining

Multi-Axis Sweeping Operation

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You will become familiar with creation of a Multi-Axis Sweeping Operation.

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Multi-Axis Surface Machining

About Multi-Axis Sweeping Operation

Multi-Axis Sweeping Operation:
It is a milling operation in which the tool path is executed in parallel planes respecting
user-defined geometric limitations and machining strategy parameters.
In Multi-Axis Sweeping, the View Direction and Starting Direction define the guiding plane.
Machining is done in planes parallel to the guiding plane.
CAUTION:
View Direction Definition: The view direction is very important because, it will decide which area is
reachable regarding this view.
Regarding the selected area and the view direction, CATIA will take care of the computed contour
outline.
Example: On a Sphere

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With a sphere: using Z axis as view direction (See Compass),

the only reachable area is the green area concretized by tool
trajectories here.
The tool axis will be computed regarding the tool axis mode
setting (interpolation, lead & tilt, etc), but never you will be
able to reach the bottom side of the sphere.
We will use the starting direction as well to compute the
guiding plane.

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How to Create a Multi-Axis Sweeping Operation

Click Multi-Axis Sweeping
Operation icon

The new Operation is created after the

current one. The Operation dialog box
displays to define its parameters

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This capability
can be removed by customizing the NC Manufacturing options.

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Multi-Axis Sweeping Operation: General Process

1

Type the Name of the Operation.

(optional because a default name is given
by the system Type_Of_Operation.X)

Type a line of comment (optional)

Define operation parameters using the 5 tab pages

Strategy tab page

Geometry tab page
Tool tab page
Feeds & Speeds tab page

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Macros tab page

4

Before replaying or creating the operation, Preview

checks that all parameters are coherent

Replay and/or Simulate the operation tool path

Click OK to create the operation

5
6

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Multi-Axis Surface Machining

Strategy Definition (1/16)

With these arrows, you can define the View

Direction, the Start Direction, and optionally
the Tool Axis

Machining Tab page

Radial Tab page

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Tool Axis Tab page

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Strategy Definition (2/16)

Machining Tab:
Machining tolerance:
Value of the maximum allowable
distance between theoretical tool path
and the tool path computed
Max discretization step:
Maximum length between two
consecutive computed points

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Max discretization angle:

Tolerate value of the tool Axis Angle
variation between two consecutive
computed points
Min Path Length:
All computed paths below this value
will be removed

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Strategy Definition (3/16)

Radial Tab:
A. Scallop Height value

B. Distance on part

C. Distance on plane

B OR C
D

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D. Number of paths

Define the Stepover

side: Left or right

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Strategy Definition (4/16)

Tool Axis tab
Lead and Tilt

Fixed axis

Thru a point

Normal to line

4-Axis lead/lag

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Optimized lead

Thru a guide

Normal to drive surface

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Strategy Definition (5/16)

Lead and tilt:
The tool axis is guided in Lead and Tilt mode.
Lead and tilt means you can set two different angles.
Lead => User-defined incline of the tool axis in a plane defined by the direction of motion and the
normal to the part surface. The tool axis incline is with respect to the part surface normal.
Tilt => User-defined incline of the tool axis in a plane normal to the direction of motion.
The tool axis incline is with respect to the part surface normal.
These angles are computed for each considered point regarding the normal vector of the surface.

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There are 3 Guidance modes for Lead and Tilt strategy:

Regarding the mode you choose, you leave some freedom
to the tool axis during the machining operation.

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Strategy Definition (6/16)

Fixed lead and tilt:

Set the fixed Lead Angle

Set the fixed Tilt Angle

Variable Lead and Fixed Tilt:

The purpose of variable Lead Mode is to avoid collisions between the machining part and tool
rear side (in case of toroidal tool) or with the full tool body (for all other tool types).

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In Variable lead and fixed tilt mode, you may set a Max lead angle value and a Min lead angle
value regarding the normal to the surface at the computed point. So you limit all big angle
variation of the tool axis between two consecutive points
A.

Set the Reference Lead Angle

B.

Set the fixed Tilt Angle

C.

Set the Min Lead Angle

A
B
C
D

D.

Set the Max Lead Angle

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Multi-Axis Surface Machining

Strategy Definition (7/16)

Fixed lead and variable tilt:
In Fixed lead and variable tilt mode, you canset a reference tilt angle value regarding the
normal to the surface at the computed point and an allowed tilt variation.
You set a fixed Lead Angle.

A.

Set the fixed Lead Angle

B.

Set the reference Tilt Angle

A
B

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C.

Set the allowed tilt variation

around its basic reference
angle value

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Strategy Definition (8/16)

In general, you must choose:

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A filleted-end tool for Variable lead and fixed tilt tool axis guidance.
A ball-end tool for Fixed lead and variable tilt tool axis guidance

Filleted-end tool

Ball-end tool

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Strategy Definition (9/16)

Fixed axis:
You can define the tool axis orientation by clicking the tool axis arrow (A) in the strategy tab
page. The tool axis will keep constant orientation during the machining operation.

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Set the value by selecting

the tool axis

Axis Selection: This type of selection is available for all other operations
Click one of the red tool axes in the sensitive icon, then specify the tool axis
orientation at the start of machining.
You can do this by selecting a surface. In this case the surface normal is used.

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Multi-Axis Surface Machining

Strategy Definition (10/16)

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Fixed axis:

Different available choices for

tool axis orientation:
By Components (coordinates)
or by Angles

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Strategy Definition (11/16)

Thru a point:
The tool axis keeps a constant direction toward the selected point during the whole
Machining operation.

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Set the Point by selecting the

point symbol

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Strategy Definition (12/16)

Normal to line:
The tool axis remains perpendicular anytime during machining to the selected axis defined by
the red Line symbol.

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Set the Line by selecting the

red line symbol

The tool axis is normal to the selected Line, and intersect it.
Its a Normal and Through a Line.
(Example: to be used for 4 Axis machine, selecting the C axis as table center axis)

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Strategy Definition (13/16)

4-Axis lead/lag:
You need to define a plane.
The tool axis is constrained regarding the normal of this
selected plane.
A. Set the Plane by selecting the plane symbol

B. Set a lead angle value

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A
B

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Strategy Definition (14/16)

Optimized lead:
The tool Axis is guided in Optimized Lead mode. In this mode the maximum material removal
is obtained when the tool curvature along the trajectory matches the part curvature.

Min heel
distance

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Set the Min and

Max lead angle

CAUTION:
The Optimized Lead Mode is currently used with Torus Tool,
so it is mandatory to set the min lead angle to a positive value
in order to avoid machining with the flat area of the tool

Set the Min heel

distance

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Strategy Definition (15/16)

Thru a guide:
You can control the tool orientation using a continuous geometrical curve (guide).
An open guide can be extrapolated at its extremities.
Mode: It defines the position of the tool on the guide.

Click to select guide curve

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Normal to the path: At a given contact point, the

intersection of the plane normal to the path with the
guide gives the tilt angle of tool.
If several intersections are found, then the nearest
intersection is taken into account.
Nearest position: The tool is orientated by the point that
gives the shortest distance between the guide and the
contact point.
Nearest position along view direction: The guide is
projected on a plane normal to the view direction. The
tool is oriented by the point that gives the shortest
distance between the projected guide and the current
contact point.
Offset on guide: Offset is computed on a plane
defined by the tangent of the guide and the
view direction or reference axis.
Lead angle: Specifies an angle in the forward direction
between default tool axis and actual tool axis.

Extrapolates extremities of an open guide

Depending on the Lead angle, the tool
axis will not remain on the tilting guide.

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Strategy Definition (16/16)

Normal to drive surface:
The tool axis remains normal to the auxiliary drive surface that you select.
Recommend you to use a smooth surface.

Drive surface

Normal to drive
surface

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Part surface

Following points are considered for tool axis computation:

Find the nearest point of the contact point on the auxiliary drive surface
Compute the normal of this point on the drive surface
Apply this normal direction on the tool axis, and rotate the tool axis in the plane (Tool
axis, Tangent to the path) if a lead angle is given.

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Geometry Definition (1/2)

Offset on part
Offset on check
Limiting curve
Part body element
to machine
Area to avoid

Check element

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Side to machine:
Inside or Outside
the limiting curve
Collision Checking
(if active or not,
Accuracy, Allowed
gouging)

Offset on limiting
contour

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Multi-Axis Surface Machining

Geometry Definition (2/2)

Covering Mode Optional within Collision Checking:
Collision Checking
Active on check elements

Without Covering mode

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Covering Mode active:

Air cuts due to collision with check can
be optimized using the covering mode.

This new option is available with MULTI-AXIS CONTOUR

DRIVEN and ISOPARAMETRIC MACHINING as well.

With Covering mode

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Multi-Axis Surface Machining

Tool Definition (1/2)

Selection of Tool or Tool Assembly plays a vital role in performing the operation. You can
select the tools from the catalog or you can define the tools as per your requirement.
1

Select the tool type available for the current operation

Type the name of the Tool.

Type a line of comment (optional)

Specify a tool number that does not already exist

Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values

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Click More to expand the dialog box to

access tool s parameters such as
Geometry, Technology and compensation

2
4
Select the icons to access the
Search Tool dialog box to query a
tool in a Catalog

For the following capabilities:

Create a new tool
Select an already existing tool from the current document
Select another tool in a catalog by means of a query

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Multi-Axis Surface Machining

Tool Definition (2/2)

You can use following tools for Multi-Axis Sweeping operation:
Face Mill, End Mill, Conical Mill, T-Slotter, Barrel Mill

Body diameter

Overall length

Vertical distance

Cutting length

Barrel radius

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Corner radius

Radial distance

Entry diameter

Barrel Mill supports Lead and tilt, Fixed axis, Thru a point and Normal to line tool axis modes

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Multi-Axis Surface Machining

Speeds and Feedrates Definition

Speed is number of revolutions of the cutting tool or workpiece per unit time.
Feedrate is the distance traveled by the cutting tool or workpiece in unit time and
A

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Define the Feedrate values for

Approach Feedrate: This feedrate is used by default
during approaches motion
Machining Feedrate: This feedrate is used during
Machining motion
Retract Feedrate: This feedrate is used by default
during retract motion
Transition Feedrate: This feedrate is used during
Transition motion
Define the Spindle Speed value according to the unit
Linear (m/mn) or Angular (turn/mn)
This Spindle Output is optional, you can remove this
information from the output by deactivating the check
box Spindle Output

Rough or Finish quality of the operation and the tool

data are taken into account for computing the feeds
and speeds from the current tool catalog.

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Multi-Axis Surface Machining

Macros Definition (1/7)

A

Specify which NC Macros you want to use among:

Approach Macro
Retract Macro
Return in a Level
Linking
Clearance

Specify a radius value to cornerize the

clearance motion.
Check the Smooth tool axis moves to
smoothen the transition path.

Corner radius

Clearance

Corner radius

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Approach motion

Retract motion

Specify for each selected NC Macro the

type of motion and the parameters like
Feedrates, Angles, etc

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Macros Definition (2/7)

You will learn how to create a NC Macro for a Multi-Axis Sweeping
Operation and for axial operations.

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For all operations, macro parameters are

accessible using the highlighted tab page

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Multi-Axis Surface Machining

Macros Definition (3/7)

Pre-defined macros
Depending on the type of macro you have selected,
different types of pre-defined macros are available:

For Approach

For Retract

Tangent, normal
Axial
Circular
Vertical
Helix for
approach

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Normal motion

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Macros Definition (4/7)

Macros Tool Box:

Tangent

Axial

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Horizontal

You can create an infinite number of

different macros by selecting each of this
basic trajectory in various order or use
contextual menu on a selected move to
add a new one, remove or edit it to tune
some parameters.

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Macros Definition (5/7)

Create your own macro:
Insert a PP word on a point of the macro.
Crosses localize the possible points to insert
the PP word.
To insert a PP word, you can also press right
mouse button on the cross and select PP
word list

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PP Table access
capability:
Possibility to select
Major/Minor words and
pre-defined syntaxes

Apply this Approach or Retract motion to all Return and

Linking macros in the operation (only available on
Approach macro and Retract macro)

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Macros Definition (6/7)

Modify parameters on your macro:
To locally modify a feedrate in the macro, right-click the element and select
feedrate to choose which feedrate to associate between Machining, Approach,
Retract, Rapid, Local or Finishing

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Depending on the feedrate

selected, the element takes a
different color:
Yellow : Approach
White : Local
Green : Machining
Blue : Retract
Red
: Rapid

To modify geometrical parameters

of a macro, double-click it.

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Macros Definition (7/7)

Return in a level, Linking and Clearance Macro:
Return in a level and Linking macros are divided in two
motions: Approach and Retract
The Clearance Macro:
Between those two motions, the system computes a
transition tool path to avoid Collisions, Islands or
Fixtures.
If you want this transition tool path to be a simple return
to a safety plan, activate Clearance Macro.
You can cornerize clearance via as shown below.
When Smooth tool axis moves is checked, if the approach
and the retract axes are different, additional points are
added on the rapid motion to smoothen the transition path.
Clearance

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Corner radius

Approach motion

Corner radius

Retract motion

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Multi-Axis Surface Machining

Master Exercise: Fender

Step 2: Create Multi-Axis Sweeping Operations
35 min

In this step you will learn how to perform a 5-Axis Sweeping Operation.
You will see a Multi-Axis Sweeping Operation with:

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Fixed lead and tilt Tool Axis Guidance,

Fixed lead and variable tilt Tool Axis Guidance,
Fixed Tool axis mode,
Thru a Point Tool axis mode,
Normal to line Tool axis mode,
4-axis lead/lag Tool axis mode,
Optimized Lead Tool axis mode.

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Multi-Axis Contour Driven Operation

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You will become familiar with creation of a Multi-Axis Contour Driven Operation.

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Multi-Axis Surface Machining

About Multi-Axis Contour Driven Operation

Concept:

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It is a milling operation in which the tool is driven along a contour while respecting
user-defined geometric limitations and machining strategy parameters.
Three machining modes are Parallel Contour, Between Contours and Spine Contour.
A number of tool axis guidance modes are available.
Same as Multi-Axis sweeping

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Multi-Axis Surface Machining

How to Create a Multi-Axis Contour Driven Operation

Click Multi-Axis Contour
Driven Operation icon

1
2

The new Operation is created after the

current one. The Operation dialog box
displays to define its parameters

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This capability
can be removed by customizing the NC Manufacturing options.

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Multi-Axis Surface Machining

Strategy Definition (1/4)

A milling operation in which the tool is driven along a contour while respecting userdefined geometric limitations and machining strategy parameters.
Three machining modes are Between Contours, Parallel contour and Spine Contour.
Tool axis guidance modes are available same as Multi-Axis Sweeping i.e Lead and
Tilt, Thru a point, Normal to line, etc
Tool Axis mode

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Choice between three

guiding Strategies

One additional Strategy tab

activated when using a reference
Parallel contour

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Strategy Definition (2/4)

Between Contours:

Guide 1

Guide 2

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The Strategy sub-Tab is

deactivated in Between
Contours mode

In Between contour mode

we have the ability to specify
different offset values and
Tool Position on the two
guides to avoid creation of
additional geometry
You can apply the same offset on
stops which is set on guides

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Strategy Definition (3/4)

Parallel Contour:
The strategy allows you to machine paths TO/FROM (new in R12) the reference contour
from the far limit defined by the Maximum width to machine parameter.

Guide 1

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The Strategy sub-Tab is

activated for Parallel
contour mode
Width to machine starting
from right side of guide
contour(or going to the
contour guide) depending on
direction choice

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Strategy Definition (4/4)

Spine Contour:

Guide 1

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The Strategy sub-Tab

is deactivated for Spine
contour mode

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Multi-Axis Surface Machining

Master Exercise: Fender

Step 3: Create a Multi-Axis Contour Driven Operation
15 min

In this step you will learn how to perform a 5-Axis Contour Driven
Operation. You will see a Multi-Axis Contour Driven Operation with:

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Case1 Between Contours guiding strategy,

Case2 With Parallel Contour guiding strategy,
Case3 With Spine Contour guiding strategy.

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Multi-Axis Surface Machining

Multi-Axis Curve Machining Operation

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You will learn how to create a Multi-Axis Curve Machining Operation.

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Multi-Axis Surface Machining

About Multi-Axis Curve Machining Operation

Concept:

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This is a milling operation in which the tool'

s side, tip or contact point is driven along a curve
while respecting user-defined geometric limitations and machining strategy parameters.
A number of tool axis guidance modes are available. Same as Multi-Axis Sweeping.

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Multi-Axis Surface Machining

How to Create a Multi-Axis Curve Machining Operation

Click Multi-Axis Curve
Machining Operation icon

The new Operation is created after the

current one. The Operation dialog box
appears to edit it

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

3

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options.

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Multi-Axis Surface Machining

Strategy Definition (1/8)

A milling operation in which the tool is driven along a contour while respecting userdefined geometric limitations and machining strategy parameters.
Three machining modes are Contact, Between 2 curves and between curve and part.
Multi-Axis Curve Machining:
The curve can be machined by the tool'
s contact point,
tip or side.
The tool axis guidance modes are available in the
strategy Tab.

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Guidance Modes

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Multi-Axis Surface Machining

Strategy Definition (2/8)

Guidance modes available in Multi Axis Curve Machining are:
Interpolation:

A
B

A. Choice of Tool Axis

at Starting Point
C

B. Choice of Tool Axis

at Ending Point

C. Tool axis orientation

B

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orient the tool axis

perpendicular to the
screen view.
Additional
Interpolation axes

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Multi-Axis Surface Machining

Strategy Definition (3/8)

Interpolation:
You can add any number of interpolation axes to control the interpolation.
Adding / modifying (editing) interpolation axes:
Create: It allows to create a new interpolation
axis. Select the position of the interpolation
axis in 3D viewer, and then the axis definition
dialog box will be displayed.
After adding all the axes, the axes displayed in
3D viewer and the list of axes appears in the
Interpolation Axes dialog box.

Clicking red arrow allows

you to add, edit or remove
the axes through dialog box.

Remove: It allows you to remove the

interpolation vector selected in the dialog box.

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Edit: It allows you to modify the interpolation

axis selected in the dialog box.

Axis definition
The Check Interferences option is available when you select the Display tool check box
and the operation parameters are coherent.

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Multi-Axis Surface Machining

Strategy Definition (4/8)

Tangent Axis for Between 2 curves and Between curve and part ONLY
In Tangent Axis mode, the tool axis is chosen to follow the ruling directions of
the Drive Surface which are supposed to be developable or planer (if one
Drive Surface does not respect these conditions, a message is displayed at
the end of the computation).
This is the only tool axis providing an linear contact between the cutter and
the Drive Surface.
Maximum material removal is obtained when ruling direction on drive surface
matches the ruling direction on tool.

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Select Drive Surface

Mode options:

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Multi-Axis Surface Machining

Strategy Definition (5/8)

Tangent Axis MODE:
We have two possible sub-strategies of the tangent axis
A) The drive surfaces are ruled (even if not developable), ruling direction are the isoparametric line
or the surfaces, so the tool axis is mapped to the iso-line (the one which is the less parallel to the
drive curve). This is done even if the surface is planar, or it is not developable.
B) The isoparametric lines of the drive surfaces are not compatible with the NC Machine travel
limits or may lead to collision with the machine head or may lead to loops in the tool path. In
these cases, the user wants the tool axis to be tangent to the drive surface, and normal to the
drive curve.
In both cases, because the tool axis is not always the ruling direction of the developable surface,
some under or over cuts may occur, and the user expect to have an immediate feedback of these
deviations.

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Three sub-strategies are added to the tangent axis:

1) Along ruling direction
Message displays when facing non- ruled surfaces
2) Along isoparametric lines
3) Normal to drive curve
For the cases 2 and 3, at the end of computation the maximum and minimum deviation to the drive
surfaces is displayed.

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Multi-Axis Surface Machining

Strategy Definition (6/8)

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Fanning Distance: The tangent axis mode is used when you machine ruled and planer
surfaces. On a planar surface before or after a ruled one the tool may change its
inclination more or less smoothly. The fanning distance is the allowed transition distance
during which the tool is changing its axis position.

Fanning Distance

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Multi-Axis Surface Machining

Strategy Definition (7/8)

Tangent Axis MODE

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Along isoparametric lines: On all computed tool position (driven by a point on the drive
curve), the tool axis is computed by selecting the closest Iso line direction from the drive
surface regarding the reference tool axis.

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Multi-Axis Surface Machining

Strategy Definition (8/8)

Tangent Axis MODE
Normal to drive Curve: On all computed tool position (driven by a point on the drive
curve), the point on the drive curve is projected on the drive surfaces, on the projected
point we evaluate the Normal vector to the surface, N

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Then we define the un-oriented direction of the tool axis Ta=T^N where T is the tangent
vector of the drive surface.

Example of maximum and minimum deviations displayed

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Multi-Axis Surface Machining

Geometry Definition (1/11)

Curve Machining Mode
Contact:

Guide Curve

Guide Curve

Support surface

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Resulting Tool
Paths

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Multi-Axis Surface Machining

Geometry Definition (2/11)

Contact:

Limit Point
Guide Curve

Limit Point

Offset on
Limit

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Option on Limits:
In , Out or On

Offset on Limit
Value

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Multi-Axis Surface Machining

Geometry Definition (3/11)

Curve Machining Mode
Between 2 curves:

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Guides

Choice between computation

points mode: Side or Tip

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Multi-Axis Surface Machining

Geometry Definition (4/11)

Between 2 curves
Choice of one curve:

A. Axial Offset Value

B. Offset Value on Contour

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Instructor Notes:

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Multi-Axis Surface Machining

Geometry Definition (5/11)

Between 2 curves
Choice of two curves:

A. Guide
B. Auxiliary Guide Curve
C. Side Mode: Tangent to Guide

B
B

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Multi-Axis Surface Machining

Geometry Definition (6/11)

Between 2 curves
Choice of two curves:

A. Guide
B. Auxiliary Guide Curve
C. Tip Mode
A

B
B

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Tip Mode: Tip on Guide

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Multi-Axis Surface Machining

Geometry Definition (7/11)

Between curve and part:
You need to select one curve and one Surface.
A. Guide Curve
B. Interpolation vectors
defined in Strategy Tab
C. Option Side = tangent to
guide Curve
D. Surface to machine

A
B

C
A

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Multi-Axis Surface Machining

Geometry Definition (8/11)

Between curve and part:
You can select a plane as part to machine in Between curve and part and Contact modes.

A. Guide Curve
B. Plane as part
A
A

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The machining is done as a planar surface. This equivalent planar surface is delimited by a bounding
box, which is twice the bounding box of the projection of the guiding curve normal to the plane.

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Multi-Axis Surface Machining

Geometry Definition (9/11)

Between Curve and Part:

A. Guide Curve
B. Limit Point
C. Option Tip = ON
guide Curve
B
A

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Instructor Notes:

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Multi-Axis Surface Machining

Geometry Definition (10/11)

Between Curve and Part:
Use of Tangent Axis Guidance Mode in Strategy Tab
A. Guide Curve
B. Part to Machine
C. Drive Surface

B
C

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Instructor Notes:

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Multi-Axis Surface Machining

Geometry Definition (11/11)

Between Curve and Part:
Use of Fanning distance Variation

Small Fanning Distance

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Infinite Fanning Distance

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Multi-Axis Surface Machining

Macros Definition

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There are 7 different main types of macros

available:
Approach
Retract
Return in a level
Return between levels
Linking
Clearance
Return to finish passes

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Multi-Axis Surface Machining

Master Exercise: Fender

Step 4: Create a Multi-Axis Curve Machining Operation
15 min

In this step you will learn how to perform a Multi-Axis Curve

Machining Operation. You will see how to create this operation using:

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Between 2 Curves mode,

Contact mode,
Between curve and part mode

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Multi-Axis Surface Machining

Multi-Axis Isoparametric Machining Operation

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You will learn how to create of a Multi-Axis Isoparametric Machining Operation.

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Multi-Axis Surface Machining

About Multi-Axis Isoparametric Machining Operation

Concept

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Isoparametric machining is an operation which allows you to select strips of faces and
machine along their isoparametrics.
A number of tool axis guidance modes are available same as Multi-Axis Sweeping. The most
advisable guidance mode is INTERPOLATION. You may control in some critical point the Tool
Axis orientation

Instructor Notes:

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Multi-Axis Surface Machining

How to Create a Multi-Axis Isoparametric Operation

Click Isoparametric
Machining Operation icon

The new Operation is created after the

current one. The Operation dialog box
appears to edit it

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

3

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This capability
can be removed by customizing the NC Manufacturing options.

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition (1/4)

This is a milling operation in which the tool paths are executed on strip surfaces
respecting user-defined geometric limitations and machining strategy parameters.
Multi-Axis Isoparametric Machining:
A number of tool axis guidance modes are available in the
strategy Tab.
In order to control the axis position anytime, it is advisable
to use the Interpolation Option

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Guidance Modes

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Multi-Axis Surface Machining

Strategy Definition (2/4)

Interpolation Guidance mode available in Multi-Axis Isoparametric Machining.
Interpolation:

Choice of Tool Axis at

Beginning Point

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Choice of Tool Axis at

Intermediate Point

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Multi-Axis Surface Machining

Strategy Definition (3/4)

Interpolation:
You can add anywhere on the machining area some Intermediate points with predefined
tool vector axis. They will be taken into account during tool path computation.

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Possibility to remove in
contextual menu all
additional Points

When the Angles option is selected,

the drop down list proposes by default
an item specific to interpolation axes:
Lead (Angle1) & Tilt (Angle 2).

Create, Remove or Edit the interpolation axes

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition (4/4)

Interpolation:
Radial Tab
Skip Path:
It is possible to skip the first, last or first-and-last paths
Extension: Start and End
It is possible to start the computation using an
extrapolation value for the Start or the End of the
operation.

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Tool path extension in Isoparametric Machining:

You can now extend or reduce the width of the tool path
before the first path and after the last path. You can extend
the width when you want machining to continue beyond the
boundary of the selected part surface. You can reduce it to
keep a given distance between check surfaces and the first
& last paths.
This avoids creating virtual part surface geometry and
gives better surface finish at ends of the part surface and
reduced risk of interference with check surfaces.
Set value for
extrapolation

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Multi-Axis Surface Machining

Geometry Definition
You may select adjacent or non- adjacent faces.
The faces will be machined in a single Isoparametric
Machining operation. In this case corners must be selected
for each face and belt of face. Also an orientation (side to
mill) must be defined for each face and belt of faces.
Advices: Create an healing or join ( with federate option)
before selecting machining surfaces. This will improve the
continuity detection between consecutive boundaries
Couple points

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Main Isoparameter directions

Couple Points (1,2)

Choice of points to drive the

first tool path direction

Covering Mode availability

Parts to machine

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Multi-Axis Surface Machining

Macros Definition
There are different types of macros available:
Approach
Retract
Clearance
Linking
Return in a level

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Approach macro

Retract macro

Use of linking option between

two groups of machined faces

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Multi-Axis Surface Machining

Multi-Axis Drilling Operation

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You will become familiar with creation of a Multi-Axis Drilling Machining Operation.

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Multi-Axis Surface Machining

About Multi-Axis Drilling Operation

Concept:

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The drilling (or axial machining) operations described in this section are intended to cover
the hole making activities in your NC manufacturing program. In particular, the commands
and capabilities included in the Geometry tab page of the Axial Machining Operation dialog
box allow support of multi-axis as well as fixed axis drilling.

Instructor Notes:

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Multi-Axis Surface Machining

How to Create a Multi-Axis Drilling Operation

Click Multi-Axis Drilling
Operation icon

The new Operation is created after the

current one. The Operation dialog box
appears to edit it

Define the Operation geometry and

parameters in the dialog box
3
4

Replay the Tool Path

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Confirm Operation creation

The Operation is created in the PPR tree with a default tool. This capability
can be removed by customizing the NC Manufacturing options.

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition
You can choose Depth, plunge modes.
You can edit the cycle to customize the syntax

Setting parameters for

drilling cycle

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Breakthrough (B) available

if option Extension is
Trough in Geometry tab

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Multi-Axis Surface Machining

Geometry Definition
Drill parameters setting:

Choice of Machining
Pattern

Multi-Axis Drill =>

Normal to Part
Surface direction

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Points to drill

More Options:
Machine different depths
Machine Blind/Through
Inverse Pattern ordering,etc

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Multi-Axis Surface Machining

Macros Definition
There are 5 different types of macros available:
Approach
Retract
Clearance
Linking Retract
Linking Approach

Macro

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Adding distance
along a line Motion
in Approach

Instructor Notes:

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Multi-Axis Surface Machining

Multi-Axis Tube Machining Operation

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You will become familiar with creation of a Multi-Axis Tube Machining Operation.

Instructor Notes:

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Multi-Axis Surface Machining

About Multi-Axis Tube Machining Operation

Concept:

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This type of Multi-Axis Machining is suitable for parts presenting an obvious central axis
While respecting user-defined geometric limitations and machining strategy parameters.
A number of tool axis guidance modes are available.
Same as Multi-Axis sweeping

Instructor Notes:

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Multi-Axis Surface Machining

How to Create a Multi-Axis Tube Machining Operation

Click Multi-Axis Tube
Machining Operation icon

1
2

The new Operation is created after the

current one. The Operation dialog box
appears to edit it

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This capability
can be removed by customizing the NC Manufacturing options.

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition (1/8)

This is a milling operation in which the tool is driven by a contour respecting userdefined geometric limitations.
Three machining modes available are Around guide, Along
guide or Helical.
Driving tool points:
Tool tip: You can use this option only with ball end tool for
good quality tool path.
Contact on part: The time required to create the tool path
will be more using this option.
The tool axis guidance modes
available are:

Choice between 3 guiding

Strategies
Driving tool points:
Tool tip, Contact on part

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Tool Axis modes

Tool path styles

Collision checking is must while using Contact on part as driving tool points.

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Multi-Axis Surface Machining

Strategy Definition (2/8)

Around guide:
Around Guide allows you to select between two different
tool path styles - Zig zag or One Way.

Guide

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Limit1
and
Limit 2

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Multi-Axis Surface Machining

Strategy Definition (3/8)

Along guide:

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Along Guide allows you to select tool path styles among Zig zag, One Way or Back and forth

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Multi-Axis Surface Machining

Strategy Definition (4/8)

Helical:

Tube

Cavity

Tube and cavity

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Zone: Available when you select Tool tip as Driving tool points.
Tube: To machine the tube.
Cavity: To machine the bottom of the tube.
Tube and cavity: To machine the tube and its
bottom in a single action.
Elevation angle:
It is the end angle of the cavity. You can specify the
value when Zone is set to Cavity.

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition (5/8)

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Axial Stepover:
There are 4 different ways to define the step over

Scallop Height

Distance on Part

Distance on Guide

Number of paths

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Multi-Axis Surface Machining

Strategy Definition (6/8)

Tool Axis Mode:
Fixed axis:
The tool axis remains constant
for the operation. There are no
associated parameters.

Thru a Point:
The tool axis passes
through a specified point.

Along guide:
The tool axis makes a constant
Tilt angle with the guide.

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You must define the Guide angle

By default, the Allows variable tilt check box is not selected.
If you select it, the axis is automatically adjusted around its
initial position to avoid collision with part or checks.
By default, the In opposite to machining direction check box
is selected. This check box enables you to decide whether
the tool is in machining direction or in the opposite direction.

Instructor Notes:

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Strategy Definition (7/8)

Tool Axis Mode:
Lead and tilt:
In this mode the tool axis is normal to the part surface with respect to a
given lead angle in the forward tool motion and with respect to a given tilt
angle in the perpendicular direction to this forward motion.
The associated parameters depend on the Guidance selected.
This Lead and tilt mode is same as for Multi-Axis Sweeping operation.

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4- Axis Tilt:
The tool axis is normal to the part surface with respect to a given tilt
angle and is constrained to a specified plane.
This 4- Axis Tilt mode is same as for Multi-Axis Curve machining.

You must type the Tilt angle and Lead angle

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Multi-Axis Surface Machining

Strategy Definition (8/8)

Guide mode selection:
The guide may be defined directly as an Axis.
For this you need to Right-click the guide and another scrolled menu will appear.

Guiding Strategy
Selection

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The machining direction is then displayed at one end of the guide.

Need to select a direction and

a point for start condition

Click the arrow to invert the machining direction if necessary.

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Tools Definition
Recommended tool families for Multi-Axis Tube Machining are:
Face mill
End mill (ball- ended or not)
Conical mill (ball- ended or not)
T- slotter

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CAUTION:

Areas that cannot be reached by the beams issued from the guide are not machined.

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Multi-Axis Surface Machining

Macros Definition (1/2)

Add normal motion :
It adds a linear motion normal to the part
surface. You can use it in the linking
macros to avoid the collision.

Add circular motion :

It adds a circular motion in a plane.

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Normal to last tool axis:

Normal to part surface:

It is useful with Along guide strategy
in return in a level macros.

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Multi-Axis Surface Machining

Macros Definition (2/2)

Enable 5-Axis Simultaneous Motion:
Using this macro you can generate a
five-axis simultaneous motion on the
next combined motion.
The macro rotates the tool in macro
paths and thus helps in minimizing
machine jolts by generating a 5-axis
simultaneous motion on the next
combined motion.

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Direction defined in new

macro motion

Tangent motion

Start tool axis of

machining path

You have to define a direction.

Instructor Notes:

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Multi-Axis Surface Machining

Multi-Axis Spiral Milling Operation

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In this lesson, you will learn how to create a Multi-Axis Spiral Milling Operation by
defining different strategies.

Instructor Notes:

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Multi-Axis Surface Machining

About Multi-Axis Spiral Milling Operation

Concept:
It is a milling operation used to machine pockets or to engrave complex surfaces in
order to get better surface quality, too life and optimization of tool path.
The tool is driven along a guide while respecting user-defined geometric limitations
and machining strategy parameters.
Three tool path styles: Helical, Back and forth and Contour only.
The tool axis guidance modes available are Fixed or Normal to part.

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Guide face

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Multi-Axis Surface Machining

How to Create a Multi-Axis Spiral Milling Operation

Click Multi-Axis Spiral Milling
Operation icon

The new Operation is created after the

current one. The Operation dialog box
appears to edit it

Define the Operation geometry and

parameters in the dialog box
4

Replay the Tool Path

3

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Confirm Operation creation

4
5
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options.

Instructor Notes:

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Strategy Definition (1/3)

Machining tab:
Machining tolerance:
It is the value of the maximum allowable distance
between theoretical tool path and the computed
tool path

Direction of cut
The cutting mode which can be
Climb or Conventional

Climb

Conventional

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Helical movement
Inward: The tool path will begin at the outer limit
of the area to machine and work inwards.
Outward: The tool path will begin at the middle of
the area to machine and work outwards.

Max discretization angle:

It is the maximum angular change of tool
axis between tool positions.

Always stay on bottom:

It forces the tool to remain in contact with the pocket
bottom when moving from one domain to another.

Instructor Notes:

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Multi-Axis Surface Machining

Strategy Definition (2/3)

Radial tab:
Distance between paths:
It allows you to define the maximum distance between
successive passes in the tool path.
Contouring pass:
It adds a contouring pass at the end of the back and forth
path.
Contouring ratio: It adjusts the position of the contouring
pass to optimize scallop removal (% of tool diameter).

Axial Parameters:
Number of levels

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Maximum cut depth

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Multi-Axis Surface Machining

Strategy Definition (3/3)

Tool Axis tab:
Fixed axis:
The axis is fixed.

Normal to part:
The tool is normal to the bottom of the
part with an angular tolerance.

HSM tab:

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Corner sub-tab
Corner radius: You can define the corner radius to
round the ends of passes.
Limit angle: It is the minimum angle the tool path
must form to allow the rounding of the corners.
Extra segment overlap: It is an overlap for the extra
segments that are generated for cornering
Transition sub-tab
Transition radius: The radius at the extremities of a
transition path.
Transition angle: It is the angle of the transition path that
ensures a smooth movement from one path to another
Transition length: It is the minimum length of the straight
segment of the transition path.

Instructor Notes:

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Multi-Axis Surface Machining

Geometry Definition
You need to select Part and Guide faces. You can define
islands using the guide faces.

Possible offsets on Part, check or Guide faces

Selection of check elements

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Selection of the Soft guide contour that closes

the guide faces if the pocket is open.
Collision Checking:
Collision checking can be performed on the cutting part of tool or on
the cutting part of the tool and its tool assembly (if check box is
selected).
To save computation time, you must select tool assembly only if the
geometry to be checked can interfere with the upper part of the cutter.

Instructor Notes:

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Exercises
You will perform following exercises to reinforce the knowledge learnt in the course.

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Exercise 1: Hood
Exercise 2: Pocket
Exercise 3: Isoparametric and Drill
Exercise 4: Multi-Axis Curve Machining
Exercise 5: Tube Machining
Exercise 6: Multi-Axis Spiral Machining

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 1: Hood
Exercise Presentation
40 min

In this exercise, you will practice 5-Axis

Machining on a Hood.
You will have the chance to try out various tools
and various modes to create 5-axis tool paths.

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You will again learn how to prepare a geometry,

define macros and start a machining process.

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 2: Pocket
Exercise Presentation
15 min

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In this exercise, you will see how to create a

Multi-Axis Operation with:
Between curve and part Curve Machining Mode
Tangent Axis Mode Strategy

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 3: Isoparametric and Drill

Exercise Presentation
15 min

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In this exercise, you will see how to create a Multi-Axis

Isoparametric Operations and Drilling Operations:
Isoparametric using Interpolation Mode Axis
Multi-Axis Drilling Operations

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 4: Multi-Axis Curve Machining

Exercise Presentation
15 min

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In this exercise, you will see the difference between the Submod
available in Multi Axis Curve Machining With Tangent Axis Mode:
Along isoparametric Line
Normal to drive curve

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 5: Tube Machining

Exercise Presentation
40 min

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In this exercise, you will see how to create fundamental Multi-Axis

Tube Machining Operations:
Use Along Guide Strategy
Use of different Tool Axis Mode
Along Guide with tilt Angle 32deg for Ouside
process
Thru Point strategy for Inside wall process

Instructor Notes:

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Multi-Axis Surface Machining

Exercise 6: Multi-Axis Spiral Machining

Exercise Presentation
10 min

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In this exercise, you will learn how to create a

Multi-Axis Spiral Machining Operation.

Instructor Notes:

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