CATIA Training

Foils & Exercises

Version 5 Release 5
November 2000
FOR-CAT-E-SMG-F-V5R5
Copyright DASSAULT SYSTEMES 2000 1
 Objectives of the Course
In this course you will see how to define and manage NC programs
dedicated to machining parts designed with Surface or Solid
geometry using 3 Axis machining techniques.
Targeted audience
Manufacturing users knowing how to work with CATIA V5 Parts

2 days
Prerequisites:
Fundamentals about CatiaV5:

Copyright DASSAULT SYSTEMES 2000 2

 Table of Contents 1/2

1. Introduction to the Workbench

2. Fundamentals of 3-Axis Surface Machining

2.1 Creating a Part Operation and a Manufacturing Program

2.1.1 Creating a Part Operation
2.1.2 Creating a Manufacturing Program
2.2 Creating a Milling Feature (Machining Area & Rework Area)
2.2.1 Machining Area Creation
2.2.2 Rework Area Creation
2.3 Creating a 3-Axis Surface Machining Operation
2.3.1 Sweep Roughing Operation
2.3.2 Roughing Operation
2.3.3 Sweeping Operation
2.3.4 Pencil Operation
2.3.5 Zlevel Operation
2.3.6 Contour-driven Operation
2.3.7 Profile Contouring Operation

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 Table of Contents 2/2

2.4 Creating an Axial Operation

2.5 Checking & Simulating Tool path
2.6 Managing Tools
2.7 Creating an Auxiliary Operation
2.8 Generating Output Files (APT, ISO)
2.9 Generating HTML Documentation
2.10 Managing Design Changes

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 Introduction to SMG :
Workbench Presentation

In this lesson, you will learn about the Surface Machining Workbench
by:

• Accessing the workbench

• Exploring the User Interface
• Understanding the Process / Product / Resources Model
• Seeing Terminology of the User Interface
• Looking at the General Process

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 Anywhere from 1- Start menu
Accessing the Workbench
or 2- File menu + New
or 3- Workbench Icon

1-
3-

Blank Manufacturing
CATProcess to start

2-

See Tools + Customize + Start menu

for the content of this Welcome Box

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 Workbench User Interface
CATProcess file extension

Manufacturing tree
Manufacturing Items

3-Axis Surface
Machining Items ...

Standard Tools

Prompt Zone
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 Workbench User Interface 1/2
3-Axis Surface Machining
Workbench

Part Operation Creation

Manufacturing Program Creation

Machining Area Creation

Rework Area Creation Manufacturing features

Manufacturing views

Sweep Roughing Operations Creation

Roughing Operation Creation
Sweeping Operation Creation

Pencil Operation Creation

3-Axis Surface Machining Product
Z-level Operation Creation

Contour-driven Operation Creation

Profile Contouring Operation Creation

Drilling Operations Creation
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 Workbench User Interface 2/2

Tool Change Creation

Machine Rotation Creation Auxiliary Operations
Machining Axis or Origin Creation
Post-Processor Instructions Creation

Tool Path Replay & Simulation

Generate NC Code Batch mode or Interactively

Generate Documentation

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 Process / Product / Resources Model

➘ The Process / Product / Resources model is shared by all the Manufacturing applications (such as
NC, Robotic, Welding, Painting, Inspection, etc…) and can be accessed by a Process Planning
Management tool

Process :
Part Operations
Process is the place where all the NC
entities will be created by the user

Product :
Parts or Products
used for
Manufacturing :
Design Parts,
Fixtures, Stock, Resources used in the Process are
automatically listed in the Resources
Manufacturing list and are available for the others
elements, etc … Manufacturing applications and for
Resources : a Process Planning Management tool
Machines & Tools

➘ With Product and Resources Assignment, links are made and managed between the Design World
(Product), the Manufacturing World (Process) and the Resources World

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 Manufacturing Terminology

➘ Part Operation :
A Part Operation (or PO) links all the operations necessary for machining a part based on a
unique part registration on a machine. The Part Operation links these operations with the
associated fixture and set-up entities.

➘ Manufacturing Program :
A Manufacturing Program describes the processing order of the NC entities that are taken
into account for tool path computation : Machining Operations, Auxiliary Operations

➘ Machining Operation :
A Machining Operation (or MO) contains all the necessary information for machining a part
of a work piece using a single tool. (Such as Roughing, Sweeping, Drilling, …)

➘ Auxiliary Operation :
A control function such as Tool Change or Machine Table/Head Rotation. These commands
may be interpreted by a specific Post-processor.

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 Part designed using Create Wireframe
3D Wireframe or Solid geometry elements necessary
for manufacturing
(Safety Planes, Axis,
Points, etc …)
General Process Define Part Operations
necessary to machine
Associative links all the part

If needed, Create Machining

Sequence the Operations and
operations simulate them

Generate Auxiliary
Operations

Generate
APT Source or
ISO Code

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 To Sum Up ...

In this introduction to the 3-Axis Surface Machining Workbench, you

have seen :

How to access the SMG Workbench

The general layout of the user interface and the basic principles.

Now we will detail each aspect of the workbench while applying

the general methodological process of how to machine the
Renfort.CATPart part.

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 Master Exercise Presentation :
“Renfort.CATPart”
140min

In this exercise you will learn 3-Axis Surface Machining

fundamentals concepts by machining a part from the 3D. This
process includes the creation of the Part Operation and all
necessary machining operations and auxiliary operations. You
will also generate the NC code and manage associativity when
the design part is modified.

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 Scenario of the exercise

• Start from the 3D solid part

• Create the dedicated geometry for manufacturing

• Define the Part Operation

• Create the Milling operations

• Generate the Tool Changes

• Apply design changes on the Part

• Update the Manufacturing Program

• Generate the NC Code

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 Creating a Part Operation and a
Manufacturing Program

You will learn how to define :

-the Part Operation
-the Manufacturing Program

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 Creating a Part Operation

The PPR tree already contains a default

Part Operation as first process

You will learn how to create a Part Operation

- Defining Geometrical Elements :

Design Part, Stock, Safety Plane

- Selecting a Machine-Tool :
3 Axis w/wo Table rotation or 5 Axis

- Defining the Machining Axis System

- Defining Part operation options :

Tool Change Point, Machine Set-up, Comments

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 Why Do You Need Part Operation ?
The Part Operation is the NC entity that groups all the technological information necessary for
part machining such as Machine-Tool, Set-up, Machining Axis System, etc ...

What about Part Operation ?

Identification in tree - A Part Operation has an unique machine-tool
- A Part Operation has an unique set-up
- On a Part Operation, we can associate a Part or a
Product to select geometrical elements
- The Machining Axis System is used to generate the
Output points in APT or ISO mode

A Process tree can contain several Part

Operations if it is necessary to change
the machine-tool or the set-up between
some machining operations

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 Creating a Part Operation…

1 Click on Part Operation Icon

2 The new Part Operation is created after the

current one
Double-Click on the Part Operation to edit it

The dialog box contents all the

parameters necessary to define
the new Part Operation

3
Enter the Part Operation
specifications in the dialog
box and confirm

Let ’s see now the different options of a Part Operation...

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 Identifier of a Part Operation

1 Enter the Name of the Part Operation.

(Optional because a default name is
given by the system ‘Part Operation.X’)

2 Enter Comments.
These comments will be generated at
the beginning of the APT (Optional)

These comments will be generated in the APT

Source with the PPRINT prefix as all the comments
available in the NC Entities like Machining
Operations, PP Instructions, Machine-tool, etc ...

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 The machine is optional, if the machine is not defined
Defining a Machine-Tool the PPWords Table ‘PPTableSample’ is used by
default.

Machine type : 3 Axis, 3 Axis with Rotable, 5 Axis

1
Spindle Data :
- Coordinates of the Home point
2 - Initial Axis orientation

Numerical Control Data :

- Name of the PPWords Table
- NC Data type (APT, Clfile, ISO)
- NC Data format (Point, Axis)

Tool Change Data : Rotary Table Data :

- Default Tools Catalog - Coordinates of the
- Radius Compensation availability Center point
- Initial angular position
- Rotary Axis (A, B, C)
Advanced Options on - Rotary Direction
2D & 3D Interpolation - Rotary Type

All the coordinates are given according to 3 Confirm Machine

the Reference Machining Axis System creation
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 Creating the Reference Machining Axis System

In the dialog box, you can

select the sensitive icons
Select the Z Axis orientation

2
Axis Orientation :
Select the Reference Point -Selecting an element
(Line, Fsur, Edge, ..)
- By means of X,Y,Z
coordinates
- From a pre-defined
list (X-,X+,Y-,Y+,Z-,Z+)
Select the X Axis orientation

Select an already existing Machining Axis

Origin checkbox.
Activate the Origin and specify the 3 Confirm axis creation
Number and Group to generate the Name of the Reference
following syntax in the Apt Source : Machining Axis System
ORIGIN/ X, Y, Z, Number, Group displayed in CATIA V5 window

All the output coordinates generated in the Apt or ISO Source

are computed according to the current Machining Axis
System.
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 Associating a Product or a Part to a Part Operation

2
3 Confirm selection

Select a Product or a Part to link this element to the Part

Operation. This Product or Part is automatically referenced in
the ProductList in the PPR tree associated to the CATProcess

The Product can contain several parts :

• The Design Part
• The Stock
• The Fixtures
• The Manufacturing Geometrical Data

You can associate different products for each Part Operation

to manage the Part Positioning and specific Set-Up

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 Associating Geometry to a Part Operation

The Design Part and Stock geometry are only used for the
material removal simulation

Click these icons to select :

- Design Part
- Stock
- Safety Plane

The Safety Plane is used for default Approach & Retract

motions on all the milling operations
You can select a Plane, a Planar Face or a Point. This item
is not mandatory for the tool path computation. The
application computes automatically a safety plane
according to your tool diameter.

All these entities can be selected on the CATIA screen or

directly in the PPR tree through the ProductList

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 Defining the Machine Position Setup

Machine Position Setup :

This translation is used to fix the
origin of the machine according to
the Reference Machining Axis
1 System

Tool Change Point :

These coordinates are only
taken into account if the
machine is not defined on the
Part Operation.
If a machine is already
selected, the Tool Change
Point will be read on it.

All the coordinates are given according to

the Reference Machining Axis System

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 Machine Option

2
1

Output type : standard : In the

generated code, the toolpath is
defined by the tool tip trajectory
Output type : cutter profile : In the
generated code, the toolpath is
defined by the contact point trajectory

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 Creating a Manufacturing Program

Why Do You Need a Manufacturing Program?

The Manufacturing Program describes the processing order of the NC entities that are taken
into account for tool path computation : Machining Operations, Auxiliary Operations and PP
Instructions

What about Manufacturing Program ?

- The screen display is done by tools
- Operations Management (Create, Edit, Copy, Move,…)
is available inside a Manufacturing Program or
between Manufacturing Programs
- Tool path simulation is done operation by operation
- Automatic generation of Tool Change and Table
Rotation orders is done at the level of the
Manufacturing Program
- Output generation (APT, ISO) is done at the level
of the Manufacturing Program

Copyright DASSAULT SYSTEMES 2000 27

 Creating a Manufacturing Program…

1 Click on Manufacturing Program Icon

2 The new Manufacturing Program is created

after the current entity (Part Operation or
Manufacturing Program)

A Part Operation contains one or several Manufacturing Programs.

These Manufacturing Programs can be managed by user choices :

• Type of Activities (Roughing, Semi Finishing, Rework, ...)
• Tools (a program by tool)
• Geometry (a program for all the pockets, for the holes, …)
• etc ...

Let ’s see now the different capabilities of a Manufacturing Program ...

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 Options of the Manufacturing Program

1 Click on the Contextual menu associated to the Manufacturing Program

Activate or Inactivate the Manufacturing Program

Hide/Show the entities of the Manufacturing Program
Tool Path Replay “operation by operation”

Simulation Commands :
• Photo or Video
• Update

Generate interactively NC Code

Generate or Remove Tool Changes between

operations
Generate or Remove Machine Rotations between
operations
Import directly NC Code for simulation
Display directly NC Code already computed

All these actions are described in the following chapters

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 Status of the Machining Operations

All the Machining Operations displayed in the Manufacturing program may have the
following status :
Operation Activate (Complete and Up to date)

Operation Deactivate (done manually by the user)

Operation Not Complete (Geometry is missing)

Operation Not Updated (Tool path must be replayed to update the operation)

During the APT Source Code or ISO NC Code computation, if the system detects a
Machining Operation with a Deactivate or Not Complete Status, this operation is not taken
into account in the computation.
In the resulting Report of the APT or ISO computation, a warning is generated to advice the
user.

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 Step1 : Create a new Part Operation

10min

In this exercise you will learn how to define a new Part Operation

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 Creating a Milling Feature

You will learn how to create a Milling Feature among :

- Machining area

- Rework area

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 Creating a Milling Feature… 1

1 Click on Milling Feature icon to be created

2 The new Milling Feature is created in the Manufacturing View

The Milling Feature dialog box appears to define it

Define the involved geometry and

3 parameters in the dialog-box 2

4 Confirm Milling Feature creation

Let ’s now see the User interface...

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 Machining Area Creation

You will learn how to create a Machining Area

3 Axis Surface Machining is a versatile application, fully adapted to

your needs and your working methods whether they are machining
area-oriented or operation-oriented. You can either define the
machining areas on your part and then assign an operation to each
of them or you can define your machining process as a series of
operations with an area to machine for each operation.

To define your Machining Areas you can use different capabilities :

- The whole part as a machining area for example for

rough machining.
- A sub-set of the faces of the part
- A sub-set of faces of the part plus a limiting limit line as
a limiting contour.
Copyright DASSAULT SYSTEMES 2000 34
 Machining Area : Presentation

1 Enter the Name of the Machining Area.

(Optional because a default name is given 1
by the system ‘M3xFeature.X’)

2 Select the machining area by using Part

sensitive item of the dialog-box
4

3 Select the Check entities by using Check sensitive item of

the dialog-box. (Optional) 2
3
4 Select the Limit line by using Limit line sensitive item
of the dialog-box. (Optional)

5 Validate the creation of the machining area

Check the created machining area by using the Manufacturing feature view icon

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 Machining Area : Domain definition

To define the machining area you have two capabilities :

Definition by selecting the whole part Definition by selecting faces

2 3

1 Select Body option in the associated 2 Select Part sensitive item in the dialog-
pop-up menu of the Part sensitive box.
item of the dialog-box. In this case,
you select one or more bodies in the
working area. 3 Select faces on the part.

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 Machining Area : Check entities definition

The definition of the Check entities is made by selecting

faces on the part

1 Select Check sensitive item in the dialog-box. 1

2 Select faces on the part.

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 Machining Area : Limit line definition

The definition of the Limit line is made by selecting edges

on the part
1

1 Select Limit line sensitive item in the dialog-box.

2 Select edges on the part or an existing contour.

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 Rework Area Creation

You will learn how to create a Rework Area

Once you have machined a part and visually checked it, you may
decide to rework certain areas where residual material remains.
Defining a rework area allows you to focus only on the areas where
there is residual material.

Copyright DASSAULT SYSTEMES 2000 39

 Rework Area : Presentation

1
1 Enter the Name of the Rework Area.
(Optional because a default name is given
by the system ‘M3xRAFeature.X’)
2
2 Define the machining area or recall an existing
machining area 3

3 Define tool’s characteristics

4 Compute the unmachinable area

2
5 Validate the creation of the Rework Area

4
5

Check the created rework area by using the Manufacturing feature view icon

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 Rework Area : Domain definition

To define the rework area you have three capabilities :

Definition by selecting the Definition by Definition by recalling

whole part selecting faces an existing machining
area

3
2 4
1

1 Select Body option in the 2 Select Part 4 Recall an existing

associated pop-up menu of sensitive item in machining area
the Part sensitive item of the dialog-box.
the dialog-box. In this case,
you select one or more Select faces on
3 the part.
bodies in the working area.

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 Rework Area : Parameters definition

Tool definition :
You can define tool’s characteristics
according to the diameter, the radius and
overlap between path according to the tool
diameter ratio (% of diameter)

Filters definition :
•With the limit line you can restrict the area
to be reworked.
•If you find that there are too many areas to
be reworked or if you decide to concentrate
on only a part of the rework area, define a
selection contour
•Use the depth, Length and Width
parameters to filter out areas that you wish
to ignore because they are not deep, long
or wide enough.

Load from button :

By using this button you can recall all the
parameters of a cycle previously computed

Copyright DASSAULT SYSTEMES 2000 42

 Step2 : Create a Milling Feature

10min

In this exercise you will learn how to create Milling Features

Copyright DASSAULT SYSTEMES 2000 43

 Creating a 3-Axis Machining Operation

You will learn how to create a Machining Operation among :

- Sweep roughing Operation

- Roughing Operation

- Sweeping Operation

- Pencil Operation

- Zlevel Operation

- Contour-driven Operation

Copyright DASSAULT SYSTEMES 2000 44

 Creating a 3-Axis Machining Operation… 2
1

1 Click on 3-Axis Machining Operation Icon to be created

2 The new Operation is created after the current one

The Operation dialog box appears to edit it

Define the Operation geometry

3 and parameters in the dialog box

4 Replay the Tool Path

3
5 Confirm Operation creation

5 4
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options.
(See the dedicated Job Aid ‘NC Manufacturing Settings’)

Let ’s now see the User interface...

Copyright DASSAULT SYSTEMES 2000 45
 Sweep Roughing Operation

You will learn how to create a Sweep Roughing Operation

A Sweep Roughing is an operation which allows you to rough

machine parts by vertical planes
- The area is machined with ZOffset, ZPlane
or ZProgressive roughing type
- The material will be removed in one or several cuts
along the radial and axial directions
- The area is machined with Zig-Zag, One way Next
or One Way Same tool path style

Copyright DASSAULT SYSTEMES 2000 46

 Sweep Roughing Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 47

 Sweep Roughing Operation : Strategy Tab Page 1/3

The 3 Roughing type for a Sweep Roughing Operation are :

ZOffset ZPlane ZProgressive

ZOffset : ZPlane : ZProgressive :

The tool path is offset from the The part is machined plane by plane The part is machined by
part interpolating the tool path
between the part and the top
of a theoretical rough stock.

Copyright DASSAULT SYSTEMES 2000 48

 Sweep Roughing Operation : Strategy Tab Page 2/3

Machining folder parameters

Tool path style

The tool path style can be:

•Zig-zag; the tool path alternates directions during

successive passes,

•One-way next; the tool path always follows the same

direction during successive passes and goes diagonally
from the end of one tool path to the beginning of the
next.

•One-way same; the tool path always has the same

direction during successive passes and returns to the
first point in each pass before moving on to the first
point in the next pass.

Machining Tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed

Copyright DASSAULT SYSTEMES 2000 49

 Sweep Roughing Operation : Strategy Tab Page 3/3

Strategy folder parameters

Axial Strategy
Definition of the maximum depth of cut

Radial Strategy
Definition of the distance which is the width of the
overlap between two successive passes

Tool axis and machining direction definition

Machining direction definition

Change the machining direction by selecting in the contextual menu (Select stepover item +
MB3)

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.
Copyright DASSAULT SYSTEMES 2000 50
 Sweep Roughing Operation : Geometry Tab Page 1/2

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining area.
4
If you are working with an operation strategy, you can use the 3
sensitive items of the dialog-box that allows the selection of :

1 •Part

2 •Check Elements (Optional)

1 5
3 •Limiting Contour which defines the outer machining limit on the 2
part (Optional). According to the definition of the Limiting Contour,
you can choose in the Limit definition where the tool stops.

4 •Safety plane (Optional). By default the application computes a

safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.
5 •Top plane and bottom plane (Optional). In this case the tool path is
limited by using these two planes. The application keeps the part of
the tool path between these two planes.

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 51

 Sweep Roughing Operation : Geometry Tab Page 2/2

Geometry parameters

Part autoLimit
If you activate Part autolimit, the tool will not go
beyond the edge of the part

Limit Definition
• Stop position defines where the tool stops:
-outside stops the tool outside the limit line,
-inside stops inside the limit line, Limit line
-on stops the tool on the limit line. Outside

•Stop mode defines which part of the tool is considered

at the Stop Position, i.e. whether it is the contact point On
Offset
or the tool tip. Inside

•Offset is the distance that the tool will be either inside

or outside the limit line depending on the Stop Mode
that you chose.
If you combine part autolimit with a Limiting
contour, in this case you will machine the area
between the limiting contour and the free
edges of the part.

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 Sweep Roughing Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 53

 Sweep Roughing Operation : Feeds & Speeds
Tab Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 54

 Sweep Roughing Operation : Macros Tab
Page

1 According to the folder, choose if you want to modify the

approach or retract macro. 1

2 2
Under Mode item, you can choice among:
- Approach/Retract along tool axis
3
- Approach/Retract along a vector
- Approach/Retract Normal
- Approach/Retract tangent to movement
- None

3 According to your Approach/Retract mode, you can

modify the default parameters

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 Step3 : Create a Sweep Roughing Operation

15 min

In this exercise you will learn how to create a Sweep Roughing

Operation

Copyright DASSAULT SYSTEMES 2000 56

 Roughing Operation

You will learn how to create a Roughing Operation

A Roughing is an operation which allows you to rough machine

parts by horizontal planes.
- The area is machined with Outer part and pocket, By
plane, Pockets only or Outer part machining mode
- The material will be removed in one or several cuts
along the radial and axial directions
- The area is machined with Zig-Zag, One way Next,
One Way Same, Helical, Contour only or HSM Helical
tool path style

Copyright DASSAULT SYSTEMES 2000 57

 Roughing Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 58

 Roughing Operation : Strategy Tab Page 1/4

Machining folder parameters

Tool path style

The tool path style can be:

•One-way next; the tool path always has the same

direction during successive passes and goes
diagonallyy from the end of one tool path to the
beginning of the next.

• One-way same; the tool path always has the same

direction during successive passes and returns to the
first point in each pass before moving on to the first
point in the next pass.

•Zig-zag; the tool path alternates directions during One-way next One-way same
successive passes.

•Spiral; the tool moves in successive concentric passes

from the boundary of the area to machine towards the
interior. The tool moves from one pass to the next by
stepping over.

•Contour only; only machines around the external

contour of the part
Zig-zag Helical
• Spiral HSM; that is spiral mode with high speed
Copyrightmilling.
DASSAULT SYSTEMES 2000 59
 Roughing Operation : Strategy Tab Page 2/4

Machining folder parameters

Machining mode
The machining mode can be:

•By plane; the whole part is machined plane by

plane,
Cutting mode
•Outer part; only the outside of the part is
The cutting mode witch can be Climb or
machined,
Conventional
•Pockets only; only pockets on the part are
machined,

•Outer part and pockets; the whole part is

machined external area by external area and Climb Conventional
pocket by pocket.

Machining tolerance
Value of the maximum allowable distance
between the theoretical tool path and the tool
path computed

Copyright DASSAULT SYSTEMES 2000 60

 Roughing Operation : Strategy Tab Page 3/4

Strategy folder parameters

Axial Strategy
Definition of the maximum depth of cut

Radial Strategy
Definition of the distance which is the width of the
overlap between two successive passes

Tool axis and machining direction definition

Machining direction definition

Change the machining direction by selecting in the contextual menu (Select stepover item +
MB3)

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.
Copyright DASSAULT SYSTEMES 2000 61
 Roughing Operation : Strategy Tab Page 4/4

Other folder parameters

Smallest area to machine

Smallest are to machine lets you filter out
areas that you consider to be too small (in
millimeters) to be machined.

Tool core diameter

Tool core diameter is the diameter of the tool
top that does not actually cut the material.

Copyright DASSAULT SYSTEMES 2000 62

 Roughing Operation : Geometry Tab Page 1/2

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining area.
4
If you are working with an operation strategy, you can use the
sensitive items of the dialog-box that allows the selection of : 6 2
1 •Part

2 •Stock (Optional if you define the stock in the Part operation)

1 5
•Check Elements (Optional)
3 3
•Safety plane (Optional). By default the application computes a
4 safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.

5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)

•A start point where the tool will start cutting. Use this option when
6 accessing the part from the outside (Optional)

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 63
 Roughing Operation : Geometry Tab Page 2/2

Geometry parameters

Tool/Rough Stock
This option is used to define where the tool center
stops :

•outside : stops the tool outside the rough stock,

• inside : stops the tool inside the rough stock,
•on : stops the tool on the rough stock.
This button helps you during rework in roughing to
Offset define the remaining material of the previous operation.
Offset defines the distance that the tool can overshoot
the Position. It is expressed as a percentage of the tool
diameter. This parameter is useful in cases where there
is an island near the edge of the part and the tool
diameter is too wide to allow the area behind the island
to be machined.

Copyright DASSAULT SYSTEMES 2000 64

 Roughing Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 65

 Roughing Operation : Feeds & Speeds Tab
Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 66

 Roughing Operation : Macros Tab Page

1 Under Mode item, you can choice among:

•Plunge; the tool plunges vertically,
•Drilling; the tool plunges into previously drilled
holes. You can change the drilling tool diameter, 1
angle and length
•Ramping; the tool moves progressively down at
the ramping angle,
•Helix; the tool moves progressively down at the
ramping angle with its center along a (vertical) 2
circular helix of Helix diameter.

According to your Approach mode, you can modify the

2 default parameters

Using Optimize retract button, you optimize tool retract

movements. This means that when the tool moves over a
surface where there are no obstructions, it may not rise
as high as the safety plane because there is no danger of
tool-part collisions. The result is a gain in time.

Copyright DASSAULT SYSTEMES 2000 67

 Step4 : Create a Roughing Operation

30 min

In this exercise you will learn how to create a Roughing Operation

Copyright DASSAULT SYSTEMES 2000 68

 Sweeping Operation

You will learn how to create a Sweeping Operation

Sweeping operations machine the part and are used for finishing
and semi-finishing work. The tool paths are executed in
vertical parallel planes.
- For the stepover definition, you have the choice
between Constant and scallop height option,
- For the definition of the Machined zone, you have the
choice between different capabilities like All,
Frontal wall, Lateral walls, Horizontal zones.
- The area is machined with Zig-Zag, One way Next,
One Way Same tool path style

Copyright DASSAULT SYSTEMES 2000 69

 Sweeping Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 70

 Sweeping Operation : Strategy Tab Page 1/5

Machining folder parameters

Tool path style

The tool path style can be:

•One-way next; the tool path always has the same

direction during successive passes and goes diagonally
from the end of one tool path to the beginning of the
next.

• One-way same; the tool path always has the same

direction during successive passes and returns to the
first point in each pass before moving on to the first
point in the next pass.

•Zig-zag; the tool path alternates directions during One-way next One-way same
successive passes.

Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed

A button allows you to reverse the tool path direction.

Zig-zag

Copyright DASSAULT SYSTEMES 2000 71

 Sweeping Operation : Strategy Tab Page 2/5

Stepover folder parameters

Stepover definition
For the stepover you have the choice between:

•Constant has a constant stepover distance

defined in a plane and projected onto the part.
You can modify the stepover distance.

•Scallop height has a stepover which depends

on the scallop height that you choose. You can
also define the maximum and
minimum distances that can exist between
passes with the scallop height that you
defined.

•Maximum distance is the stepover distance if

you have selected Constant as the value or the
maximum stepover distance if you chose Via
Scallop Height as Mode.

•Minimum distance is the minimum stepover

distance if you chose Via Scallop Height as
Mode. Scallop height Constant

•Scallop height is a value that you define.

Copyright DASSAULT SYSTEMES 2000 72

 Sweeping Operation : Strategy Tab Page 3/5

Stepover folder parameters

View direction
View direction has two options : - Along tool
axis, -Other axis.

The plane used with Along tool axis to compute

the tool stepover is perpendicular to the tool
axis.

The plane used with Other axis to compute the

tool stepover is perpendicular to the direction
given by the user. The result is more regular
machine paths that are more evenly spaced.

This option works only with Ball-end tool.

Along tool axis Other axis

Copyright DASSAULT SYSTEMES 2000 73

 Sweeping Operation : Strategy Tab Page 4/5

Tool axis and machining direction definition

Machining direction definition

Change the machining direction by selecting in the contextual menu
(Select stepover item + MB3)

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.

Copyright DASSAULT SYSTEMES 2000 74

 Sweeping Operation : Strategy Tab Page 5/5

Machined Zone folder parameters

Machined Zone parameters

The zone tab lets you decide which parts of

the part or machining area you wish to
machine:
•All; all of the surfaces are machined,
•Frontal walls; frontal surfaces of the
part are machined,
•Lateral walls; lateral surfaces of the
part are machined,
•Horizontal zones; horizontal surfaces
of the part are machined.

Min. Lateral Slope gives the minimum angle

between the tool axis and the part surface
normal for the surface to be considered to be
a lateral wall.

Min. Frontal Slope gives the minimum angle

between the tool axis and the part surface
normal for the surface to be considered to be
a frontal wall.

Copyright DASSAULT SYSTEMES 2000 75

 Sweeping Operation : Geometry Tab Page 1/2

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining area.
3 4
If you are working with an operation strategy, you can use the
sensitive items of the dialog-box that allows the selection of :

1 •Part 2
1
2 •Check Elements (Optional)
5
• Limiting contour (Optional)
3
•Safety plane (Optional). By default the application computes a 6
4 safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.

5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)

•Start plane, End plane. In this case the tool path is limited by using
6 these two planes. (Optional)

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 76
 Sweeping Operation : Geometry Tab Page 2/2

Geometry parameters

Limit definition
This option is activated is you define a Limiting
Contour.

Stop position defines where the tool stops:

•Outside: stops the tool outside the limit line,

•Inside: stops inside the limit line,
Limit line
•On: stops the tool on the limit line.
Outside

Stop mode defines which part of the tool is considered

at the Stop position, whether it is the contact point or
Offset On
the tool tip.
Inside
Offset is the distance that the tool will be either inside
or outside the limit line depending on the Stop mode
that you chose.

Part autolimit option

I f you activate Part autolimit, the tool will not go
beyond the edge of the part,

Copyright DASSAULT SYSTEMES 2000 77

 Sweeping Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 78

 Sweeping Operation : Feeds & Speeds Tab
Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 79

 Sweeping Operation : Macros Tab Page 1/2

1 According to the folder, choose if you want to modify the

approach or retract macro.

2 Under Mode item, you can choice among:

- Approach/Retract along tool axis
- Approach/Retract along a vector
- Approach/Retract Normal 1
- Approach/Retract tangent to movement 2
- None
3
3 According to your Approach/Retract mode, you can
modify the default parameters

Plunges folder can only be defined if you selected a one-

way sweeping mode in the machining strategy tab.

Copyright DASSAULT SYSTEMES 2000 80

 Sweeping Operation : Macros Tab Page 2/2

Using Optimize retract button, you optimize tool retract

movements. This means that when the tool moves over a
surface where there are no obstructions, it may not rise as
high as the safety plane because there is no danger of tool-
part collisions. The result is a gain in time.

High speed milling parameters are:

•Transition radius is the radius of the arc that joins
successive passes,
•Discretization angle is a value which, when reduced,
gives a smoother tool path.
•Safety distance is the clearance distance that the tool
over over at the feedrate in order to disengage the tool
from cutting between passes.

Island skip is the distance for intermediate approaches and

retracts, i.e. those that link two different areas to machine
and that are not at the beginning nor the end of the tool path.

Without Island skip option With Island skip option

Copyright DASSAULT SYSTEMES 2000 81

 Pencil Operation

You will learn how to create a Pencil Operation

A pencil operation is one where the tool remains tangent in two

places to the surface to be machined during the cycle. It is often
used to remove crests along the intersection of two surfaces that
were left behind by a previous operation.
- For the axial strategy, you have the choice between Up,
Down and Either option,
- For the Radial strategy, you have the choice between
Climb, Conventional and Either

Copyright DASSAULT SYSTEMES 2000 82

 Pencil Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 83

 Pencil Operation : Strategy Tab Page 1/3

Machining folder parameters

Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed

A button allows you to reverse the tool path direction.

Copyright DASSAULT SYSTEMES 2000 84

 Pencil Operation : Strategy Tab Page 2/3

Strategy folder parameters

The strategy tab concerns the tool movement,

you can select the cutting mode, the axial
direction, the minimum change length and the
minimum size for areas to machine.

The cutting mode can be:

•Conventional where the back of the
advancing tool cuts into the material
first,
•Climb where the front of the advancing
tool cuts into the material first,
•Either where either of the two
possibilities may be used.

The axial direction defines whether cutting is

effected in an upward or a downward direction
or whether either of the two may be used.

Minimum change length is the minimum

distance for a change of axial direction or
cutting mode, i.e. if a portion of the pass is
shorter than this value, the tool will ignore it
and continue in the same direction or mode.

Copyright DASSAULT SYSTEMES 2000 85

 Pencil Operation : Strategy Tab Page 3/3

Tool axis and machining direction definition

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.

Copyright DASSAULT SYSTEMES 2000 86

 Pencil Operation : Geometry Tab Page 1/2

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining area.
3 4
If you are working with an operation strategy, you can use the
sensitive items of the dialog-box that allows the selection of :

1 •Part
1 2
2 •Check Elements (Optional)

• Limiting contour (Optional)

3
•Safety plane (Optional). By default the application computes a
4 safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 87

 Pencil Operation : Geometry Tab Page 2/2

Geometry parameters

Limit definition
This option is activated is you define a Limiting
Contour.

Stop position defines where the tool stops:

•Outside: stops the tool outside the limit line,

•Inside: stops inside the limit line,
Limit line
•On: stops the tool on the limit line.
Outside

Stop mode defines which part of the tool is considered

at the Stop position, whether it is the contact point or
Offset On
the tool tip.
Inside
Offset is the distance that the tool will be either inside
or outside the limit line depending on the Stop mode
that you chose.

Part autolimit option

I f you activate Part autolimit, the tool will not go
beyond the edge of the part,

Copyright DASSAULT SYSTEMES 2000 88

 Pencil Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 89

 Pencil Operation : Feeds & Speeds Tab Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 90

 Pencil Operation : Macros Tab Page 1/2

1 According to the folder, choose if you want to modify the

approach or retract macro.
1
2 Under Mode item, you can choice among: 2
- Approach/Retract along tool axis
- Approach/Retract along a vector
3
- Approach/Retract Normal
- Approach/Retract tangent to movement
- None

3 According to your Approach/Retract mode, you can

modify the default parameters

There is a button where you can optimize retract

distances. this means that if no obstacle is detected
between two passes, the tool will not rise to the safety
plane (because it is not necessary) and the operation will
take less time.

Copyright DASSAULT SYSTEMES 2000 91

 ZLevel Operation

You will learn how to create a ZLevel Operation

ZLevel operations finishing or semi-finishing operations that

machine the part by parallel horizontal planes that are
perpendicular to the tool axis.
- For the stepover definition, you have the choice
between Constant and scallop height option,
- The area is machined with Outer part and pocket, By
plane, Pockets only or Outer part machining mode

Copyright DASSAULT SYSTEMES 2000 92

 ZLevel Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 93

 ZLevel Operation : Strategy Tab Page 1/3

Machining folder parameters

Machining mode
The machining mode can be:

•By plane; the whole part is machined plane by plane,

•Outer part; only the outside of the part is machined,

Cutting mode
The cutting mode witch can be Climb or
•Pockets only; only pockets on the part are machined,
Conventional
•Outer part and pockets; the whole part is machined
external area by external area and pocket by pocket.

Machining tolerance Climb Conventional

Value of the maximum allowable distance between the
theoretical tool path and the tool path computed

A button allows you to reverse the tool path direction.

Copyright DASSAULT SYSTEMES 2000 94

 ZLevel Operation : Strategy Tab Page 2/3

Stepover folder parameters

Stepover definition

For the stepover you have the choice between:

•Constant has a constant stepover distance

defined in a plane and projected onto the part.
You can modify the stepover distance.

•Scallop height has a stepover which depends

on the scallop height that you choose. You can
also define the maximum and
minimum distances that can exist between
passes with the scallop height that you
defined.

•Maximum distance is the stepover distance if

you have selected Constant as the value or the
maximum stepover distance if you chose Via
Scallop Height as Mode.

•Minimum distance is the minimum stepover

distance if you chose Via Scallop Height as Scallop height Constant
Mode.

•Scallop height is a value that you define.

Copyright DASSAULT SYSTEMES 2000 95
 ZLevel Operation : Strategy Tab Page 3/3

Machined Zone folder parameters

Machined Zone definition
The Zone tab lets you define:

•the maximum slope that can be considered to

be horizontal (any area that is considered to be
horizontal will not be machined),
•the width of the overlap of the end of a pass
over its beginning

Tool axis and machining direction definition

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.

Copyright DASSAULT SYSTEMES 2000 96

 ZLevel Operation : Geometry Tab Page 1/2

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining area.
3 4
If you are working with an operation strategy, you can use the
sensitive items of the dialog-box that allows the selection of :

1 •Part
5
1 2
2 •Check Elements (Optional)

• Limiting contour (Optional)

3
•Safety plane (Optional). By default the application computes a
4 safety plane according to the tool diameter. In the associated pop-up
menu you can Remove, Analyse, Offset an existing safety plane.

5 •Top plane, bottom plane. In this case the tool path is limited by
using these two planes. The application keeps the part of the tool
path between these two planes. An imposed plane that the tool must
obligatorily pass through. Use this option if the part that you are
going to machine has a particular shape (a groove or a step) that you
want to be sure will be cut. (Optional)

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 97
 ZLevel Operation : Geometry Tab Page 2/2

Geometry parameters

Limit definition
This option is activated is you define a Limiting
Contour.

Stop position defines where the tool stops:

•Outside: stops the tool outside the limit line,

•Inside: stops inside the limit line,
Limit line
•On: stops the tool on the limit line.
Outside

Stop mode defines which part of the tool is considered

at the Stop position, whether it is the contact point or
Offset On
the tool tip.
Inside
Offset is the distance that the tool will be either inside
or outside the limit line depending on the Stop mode
that you chose.

Part autolimit option

I f you activate Part autolimit, the tool will not go
beyond the edge of the part,

Copyright DASSAULT SYSTEMES 2000 98

 ZLevel Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 99

 ZLevel Operation : Feeds & Speeds Tab Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 100

 ZLevel Operation : Macros Tab Page 1/2

1 Under Linking pass item, you can choice among:

- Approach/Retract along tool axis
- Approach/Retract Circular or Ramping
- Approach/Retract Circular
- Approach/Retract Ramping
1

2 According to your Approach/Retract linking pass mode,

you can modify the default parameters 2

Copyright DASSAULT SYSTEMES 2000 101

 ZLevel Operation : Macros Tab Page 2/2

The Macro tab defines the tool approach, retract and plunge data.
There is a button where you can optimize retract distances. this means that if no
obstacle is detected between two passes, the tool will not rise to the safety
plane (because it is not necessary) and the operation will take less time.

High speed milling parameters are:

•Transition radius is the radius of the arc that joins successive passes,
•Discretization angle is a value which, when reduced, gives a smoother
tool path.
•Safety distance is the clearance distance that the tool over over at the
feedrate in order to disengage the tool from cutting between passes.

The linking pass (i.e. the means of moving from the end of one pass to the
beginning of the next one) can be:
•Along tool axis; the tool moves along the tool axis,
•Ramping; the tool follows a slope defined by the ramping angle,
•Circular; the tool describes a circle defined by the value of Radius,
•Circular or ramping; the tool uses either circular or ramping mode
depending on whichever is best adapted to the part being machined.

In certain cases, notably where there is a risk of collision with a circular linking
pass, you should choose Circular or ramping rather than simply Circular in
order to ensure that your tool path will be produced.
Approach distance is the engagement distance for plunge mode.
Safety distance is the distance that the tool moves horizontally before it begins
its approach.
Copyright DASSAULT SYSTEMES 2000 102
 Step5 : Create a Sweeping, a Zlevel
and a Pencil Operation
60 min

In this exercise you will learn how to create :

•A Sweeping operation
•A Zlevel operation
•A Pencil operation

Copyright DASSAULT SYSTEMES 2000 103

 Contour-driven Operation

You will learn how to create a Contour-driven Operation

Contour-driven operations are operations that machine the part by

using a contour as a guide.

There are three types of machining included in this task:

-Parallel contours where the tool sweeps out an area
by following progressively distant (or closer) parallel
offsets of a given guide contour.
-Between contours where the tool sweeps between
two guide contours along a tool path that is obtained
by interpolating between the guide contours. The
ends of each pass lie on two stop contours.
-Spine contour where the tool sweeps across a
contour in perpendicular planes.

Copyright DASSAULT SYSTEMES 2000 104

 Contour-driven Operation : Presentation
1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 105

 Contour-driven Operation : Strategy Tab Page 1/11

The 3 Cycle types for a Contour-driven Operation are :

Between Contour : Parallel Contour : Spine Contour :

The tool sweeps between two The tool sweeps out an area by The tool sweeps across a
guide contours along a tool path following progressively distant (or contour in perpendicular
that is obtained by interpolating closer) parallel offsets of a given guide planes.
between the guide contours. The contour.
ends of each pass lie on two stop
contours.

Copyright DASSAULT SYSTEMES 2000 106

 Contour-driven Operation : Strategy Tab Page 2/11

Machining folder parameters

Tool path style

The tool path style can be:

•One-way next; the tool path always has the same

direction during successive passes and goes diagonally
from the end of one tool path to the beginning of the
next.

• One-way same; the tool path always has the same

direction during successive passes and returns to the
first point in each pass before moving on to the first
point in the next pass.

•Zig-zag; the tool path alternates directions during

successive passes.

Machining tolerance
Value of the maximum allowable distance between the
theoretical tool path and the tool path computed

A button allows you to reverse the tool path direction.

Copyright DASSAULT SYSTEMES 2000 107

 Contour-driven Operation : Strategy Tab Page 3/11

Strategy folder parameters

These folder parameters are only available for Between

Contour & Parallel Contour.

The first panel displayed is the one used by Parallel

Contour, the second one corresponds to Between
Contour.

Parallel Contour panel

The tool sweeps out an area by following progressively
distant (or closer) parallel offsets of a given guide
contour.

The parameters for parallel contours are:

•Offset on contour,
•The maximum width to machine, Guide contour
• The offset side, i.e. the side of the guide Past
contour to be used for machining.
•The direction, i.e. whether the parallel contours
will be directed towards or away from the guide
contour. On
•The initial position of the tool; whether it will To
start on the guide contour, before the guide
contour (to) or beyond the guide contour (past)

Copyright DASSAULT SYSTEMES 2000 108

 Contour-driven Operation : Strategy Tab Page 4/11

Strategy folder parameters

These folder parameters are only available for Between

Contour & Parallel Contour.

The first panel displayed is the one used by Parallel

Contour, the second one corresponds to Between
Contour.

Between Contour Panel

The tool sweeps between two guide contours along a
tool path that is obtained by interpolating between the
guide contours. The ends of each pass lie on two stop
contours. You can choose to synchronize the starting
points on both contours so that when you are
machining between concentric contours, the starting
points on both of them are facing each other so that the
tool does not sweep across the contour.

Synchronized Not synchronized

Copyright DASSAULT SYSTEMES 2000 109

 Contour-driven Operation : Strategy Tab Page 5/11

Stepover folder parameters

For the stepover you have the choice between:

•Constant has a constant stepover distance

defined in a plane and projected onto the part.
You can modify the stepover distance.

•Scallop height has a stepover which depends

on the scallop height that you choose. You can
also define the maximum and minimum
distances that can exist between passes with
the scallop height that you defined.

•Constant on part is a stepover that has a

constant distance on the part itself (this option
is only available with between contour
strategy).

Copyright DASSAULT SYSTEMES 2000 110

 Contour-driven Operation : Strategy Tab Page 6/11

Stepover folder parameters

Constant parameters

Maximum distance is the stepover distance if

you have selected Constant as the value .

Constant

Copyright DASSAULT SYSTEMES 2000 111

 Contour-driven Operation : Strategy Tab Page 7/11

Stepover folder parameters

Scallop height parameters

Maximum distance is the maximum stepover

distance witch is used during the computation
of the tool path.

Minimum distance is the minimum stepover

distance witch is used during the computation
of the tool path.

Scallop height is a value that you define for the

definition of the scallop height.

According to these parameters SMG computes

a stepover between Minimum & Maximum
distance witch respects the Scallop Height
parameter.

Scallop height

Copyright DASSAULT SYSTEMES 2000 112

 Contour-driven Operation : Strategy Tab Page 8/11

Stepover folder parameters

Constant on part parameters

The parameters that you can define are:

•the maximum distance; the constant
distance between two successive
passes,
•the tool initial position with respect to
the guide contour (inside, outside, on),
•the tool reference; whether the tool
end or the tool contact point is used for
the computation,
•the tool offset with respect to the guide
contour. With a negative value the tool
path will start outside the guide
contour, with a positive value it will
start inside the guide contour.

Copyright DASSAULT SYSTEMES 2000 113

 Contour-driven Operation : Strategy Tab Page 9/11

Stepover folder parameters

View direction
View direction has two options : - Along tool
axis, -Other axis.

The plane used with Along tool axis to compute

the tool stepover is perpendicular to the tool
axis.

The plane used with Other axis to compute the

tool stepover is perpendicular to the direction
given by the user. The result is more regular
machine paths that are more evenly spaced.

This option works only with Ball-end tool.

Along tool axis Other axis

Copyright DASSAULT SYSTEMES 2000 114

 Contour-driven Operation : Strategy Tab Page 10/11

Tool axis and machining direction definition

Tool axis definition

Change the tool axis by selecting in the contextual menu which will display a dialog box
where you can choose one of the following options:
•Feature-defined; you select a 3D element such as a plane that will serve to define the
tool axis or machining direction.
•Selection; you select a 2D element such as a line or a straight edge that will serve to
define the tool axis or machining direction,
•Manual; you enter the XYZ coordinates,
•Main axis; choose X+, Y+, Z+, X-, Y- or Z-.

Copyright DASSAULT SYSTEMES 2000 115

 Contour-driven Operation : Strategy Tab Page 11/11

Machined Zone folder parameters

Machined Zone parameters

The zone tab lets you decide which parts of

the part or machining area you wish to
machine:
•All; all of the surfaces are machined,
•Frontal walls; frontal surfaces of the
part are machined,
•Lateral walls; lateral surfaces of the
part are machined,
•Horizontal zones; horizontal surfaces
of the part are machined.

Min. Lateral Slope gives the minimum angle

between the tool axis and the part surface
normal for the surface to be considered to be
a lateral wall.

Min. Frontal Slope gives the minimum angle

between the tool axis and the part surface
normal for the surface to be considered to be
a frontal wall.

Copyright DASSAULT SYSTEMES 2000 116

 Contour-driven Operation : Geometry Tab Page 1/

There are two ways of defining your machining program, you

can either base it on operation definition or on area definition.

If you are working with an area definition strategy, you only

need to recall an existing machining or rework area.
2 6
If you are working with an operation strategy, the dialog-box is
updated according to Cycle type chosen in strategy tabs. You 5 1 4
can use the sensitive items of the dialog-box that allows the
selection of :
1 •Part 3 7
2 •Guide contours

3 •Check Elements (Optional)

4 • Limiting contour (Optional)

5 •Stop contours (Optional)

•Safety plane (Optional).

6
•Top plane, bottom plane. (Optional)
7

Offsets can be applied on Part and Check Elements

Copyright DASSAULT SYSTEMES 2000 117

 Contour-driven Operation : Geometry Tab Page 2/

Geometry parameters
Limit definition
This option is activated is you define a Limiting
Contour.

Stop position defines where the tool stops:

•Outside: stops the tool outside the limit line,

Limit line
•Inside: stops inside the limit line,
Outside
•On: stops the tool on the limit line.

Stop mode defines which part of the tool is considered

Offset On
at the Stop position, whether it is the contact point or
Inside
the tool tip.

Offset is the distance that the tool will be either inside

or outside the limit line depending on the Stop mode
that you chose.
Choose Select 4 open contours if you want to use the guide
Part autolimit option and stop contours to define the area to machine. These
I f you activate Part autolimit, the tool will not go contours may be selected in any order you choose.
beyond the edge of the part.
When you use Select 4 points on a closed contour, the
sensitive icon is slightly different. Choose four points on a
closed contour to define the area you want to machine. You
must select four points and you must also select them in the
order stipulated in the sensitive icon.
Copyright DASSAULT SYSTEMES 2000 118
 Contour-driven Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 119

 Contour-driven Operation : Feeds & Speeds
Tab Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion 1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining
Feedrate for the Bottom Finish Pass according to the 2
unit Linear (mm/mn) or Angular (mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 120

 Contour-driven Operation : Macros Tab Page
1/2

1 According to the folder, choose if you want to modify the

approach or retract macro.

2 Under Mode item, you can choice among:

- Approach/Retract Along tool axis
1
- Approach/Retract Along a vector
- Approach/Retract Normal 2
- Approach/Retract Tangent o movement
- Approach/Retract None
3

3 According to your Approach/Retract linking pass mode,

you can modify the default parameters

Copyright DASSAULT SYSTEMES 2000 121

 Contour-driven Operation : Macros Tab Page
2/2

There is a button where you can optimize retract distances. this means that if no
obstacle is detected between two passes, the tool will not rise to the safety
plane (because it is not necessary) and the operation will take less time.

High speed milling parameters are:

•Transition radius is the radius of the arc that joins successive passes,
•Discretization angle is a value which, when reduced, gives a smoother
tool path.
•Safety distance is the clearance distance that the tool over over at the
feedrate in order to disengage the tool from cutting between passes.

Copyright DASSAULT SYSTEMES 2000 122

 Step6 : Create a Rework Area and a
Contour-driven Operation
15 min

In this exercise you will learn how to create :

•A Rework Area
•A Contour-driven Operation (between contour)

Copyright DASSAULT SYSTEMES 2000 123

 Profile Contouring Operation

You will learn how to create a Contouring Operation

A profile contouring Operation consists in cutting material along a

hard boundary.
-The hard boundary may be either open or closed.
-Along axial direction, the material will be removed from the top to
the bottom in one or several cuts.
-Along radial direction, the material will be removed by
approaching the hard boundary in one or several parallel paths
-The area is machined in One-way or in Zig-zag style.

Copyright DASSAULT SYSTEMES 2000 124

 Profile Contouring Operation : Presentation

1
2
1 Enter the Name of the Operation. 3
(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

3 Define operation parameters using the 5 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
4

Copyright DASSAULT SYSTEMES 2000 125

 Profile Contouring Operation : Strategy Tab Page 1/5

The 2 Tool path styles for a Facing Operation are :

Zig-zag One Way

Zig - zag : One Way :

The tool alternatively machines in one The tool machines always in the
direction then in opposite direction same direction

Copyright DASSAULT SYSTEMES 2000 126

 Profile Contouring Operation : Strategy Tab Page 2/5

Radial Strategy Axial Strategy

Distance between Max depth of cut

paths : You specify the distance
You enter directly the
between two levels
distance between two
radial pass

Number of levels
Number of paths :
You specify the number of
You enter directly the
levels from the bottom to
number of radial paths
the top

Number of levels
without top
you specify the bottom,
the number of levels and
the depth of cut.

Copyright DASSAULT SYSTEMES 2000 127

 Profile contouring Operation : Strategy Tab Page 3/5
Machining Strategy parameters

Sequencing To change the tool axis

orientation select the Axis
Representation
Radial first Axial first

Close contour
Option to machine the complete
contour of a closed area.

Percentage overlap
when « close contour option » is active, « percentage overlap » represents the
recovery of the tool path in tool diameter ratio

Automatic draft angle

Machine a draft in the contour event thought
the draft is not designed

Copyright DASSAULT SYSTEMES 2000 128

 Profile Contouring Operation : Strategy Tab Page 4/5
Machining Strategy parameters

Machining Tolerance
Value of the maximum allowable distance between the theoretical tool path
and the tool path computed

Fixture Accuracy
Local machining tolerance for fixtures

Type of Contour
• Circular : The tool pivots around the corner point, following a contour whose radius
is equal to the tool radius
• Angular : The tool does not remain in contact with the corner point, following a
contour comprised of 2 line segments
• Optimized : The tool follows a contour derived from the corner that is continuous in
tangent
• Forced Circular : The tool follows a near-circular contour comprised of line segment

Direction of Cut Circular

• Climb : The front of the advancing tool cuts into the material first
• Conventional : The back of the advancing tool cuts into material first
Angular

Optimized
Climb Milling
Conventional Milling

Copyright DASSAULT SYSTEMES 2000 129

 Profile contouring Operation : Strategy Tab Page 5/5

Side Finish Pass mode Bottom Finish Pass mode

At last level : activate a

Specify the thickness used
radial finish pass only at
for the bottom finishing
last level

At each level : Activate a

radial finish pass at each
level

Output type : standard : In the

Spring Pass : Activate a last finish
generated code, the toolpath is
pass to compensate the spring of the
defined by the tool tip trajectory
tool (same parameters as Side Finish
Output type : cutter profile : In the
Pass for offset, feedrates, …)
generated code, the toolpath is
Compensation : Number of the tool defined by the contact point trajectory
compensation used if this one is already
defined on the tool

The Finishing Feedrate will be used to cut the

material on the finish pass (Side & Bottom)

Copyright DASSAULT SYSTEMES 2000 130

 Profile Contouring Operation : Geometry Tab Page 1/2

This Tab Page includes a Sensitive Icon dialog box that

allows the selection of :
1 • Bottom Plane
2 • Top Plane (only in Multi-Levels strategy case) 4
3 2
• Drive Elements
3
4 • Check Elements (Optional)
1 5
5 • Start Point (Optional)

Offsets can be applied on the Top Plane, Bottom Plane,

Contour and Check Elements

To remove the bottom, click on

To start (or end) out of the part, click on Start (or Stop)
with right mouse button

Copyright DASSAULT SYSTEMES 2000 131

 Profile Contouring Operation : Geometry Tab Page 2/2

In the geometry panel click on

to reach 3 axis contouring operation :

- contouring between two curves :

- contouring between curve and surfaces

Copyright DASSAULT SYSTEMES 2000 132

 Profile contouring Operation : Tool Tab Page

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

3 Enter a line of comment (Optional)

Select this icon to access the Search Tool
dialog box to query a tool in a Catalog
4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 133

 Profile Contouring Operation : Feeds & Speeds Tab Page

1 Define the Feedrate values for

• Approach Feedrate : This feedrate is used by default
during approaches motion
1
• Machining Feedrate : This feedrate is used during
Machining motion
• Retract Feedrate : This feedrate is used by default
during retract motion
• Finishing Feedrate : This feedrate is used as Machining 2
Feedrate for the Bottom Finish Pass
According to the unit Linear (mm/mn) or Angular
(mm/turn)

2 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 134

 Profile Contouring Operation : Macros Tab Page

1 Specify which NC Macros you want to used among :

- Approach Macro 1
- Retract Macro
- Return in a Level 2
- Return between Levels
- Linking
- Clearance
- Return to Finish Pass
3
2 Specify a radius value to cornerize the clearance motion
Clearance
Corner radius Corner radius

Approach motion Retract motion

3 Specify for each selected NC Macro the type of motion

and the parameters like Feedrates, Angles, etc ...

To define the NC Macros, see the dedicated Job

Aid ‘NC Macros Definition’

Copyright DASSAULT SYSTEMES 2000 135

 NC Macros Definition

You will learn how to create a NC Macro

for a Profile contouring and for axials
operation

For all operations, macro

parameters are accessible via this
tab page

Copyright DASSAULT SYSTEMES 2000 136

 7 different types of macro…

7 different types of macros are available : Approach, Retract, Return between level, Return in a
level, Linking, Return to finish passes, Clearance

• Return between level

• Return in a level

• Linking
• Approach • Return to finish pass

• Retract

•Clearance (next slide)

Copyright DASSAULT SYSTEMES 2000 137

 Clearance Macro

The Clearance Macro

Each of the following macro :
- Return between level
- Return in a level
- Return to finish pass
- Linking
is divided in two motions : Approach and Retract

Between those two motions, the system computes a transition tool path to avoid :
- Colisions
- Islands
- 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

Clearance
Corner radius Corner radius

Approach motion Retract motion

Copyright DASSAULT SYSTEMES 2000 138

 Pre-defined macros

Depending on the type of macro you have selected,

different type of pre-defined macros are available :

For Approach For Retract

Tangent, normal, vertical

Circular

Vertical

Ramping Not available

Copyright DASSAULT SYSTEMES 2000 139

 Macros Tool Box

Tool box to create your own macro

Tangent, normal, bi-normal trajectory

Circular

Ramping

Vertical up to safety plane

You can create an infinite number of
different macro by selecting each of this
Erase basic trajectory in various order.

Copyright DASSAULT SYSTEMES 2000 140

 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 »

Apply this Approach or Retract motion to all Return and

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

Copyright DASSAULT SYSTEMES 2000 141

 Modify parameters on your macro

-To modify a local feedrate or spindle speed in the macro,

press right mouse button on a element and select
« feedrate »
Depending on the feedrate
selected, the element takes
a different color :
Yellow : Approach
White : Local
Green: Machining
Bleu : Retract
Red : Rapid

-To modify geometrical parameters of an element of the

macro double-click on it.

Copyright DASSAULT SYSTEMES 2000 142

 Step 7 : Create contouring operations

30min

In this exercise you will learn how to create a Contouring

operation

Copyright DASSAULT SYSTEMES 2000 143

 Creating an Axial Operation

You will learn how to create an Axial Operation among :

- Drilling Operation
- Spot Drilling Operation
- Drilling With Dwell Delay Operation
- Drilling Deep Hole Operation
- Drilling Break Chips Operation
- Tapping Operation
- Reverse Threading Operation
- Thread Without Tap Head Operation
- Boring Operation
- Boring & Chamfering Operation
- Boring Spindle Stop Operation
- Reaming Operation
- Counter boring Operation
3-Axis Surface Machining V5R5
- Countersinking Operation includes 18 axial machining operations
- Chamfering 2 Sides Operation that can be created on a single point or
- Back Boring Operation on a pattern of points
- T-Slotting Operation
- Circular Milling

Copyright DASSAULT SYSTEMES 2000 144

 Creating an Axial Operation…
1
2
1 Click on Axial Operation Icon 3

2 Select the Operation to be created

The new Operation is created after the current one

3 The Operation dialog box appears to edit it

4 Define the Operation geometry

and parameters in the dialog box 4

5 Replay the Tool Path

6 Confirm Operation creation

5
The Operation is created in the PPR tree with a default tool. This
capability can be removed by customizing the NC Manufacturing options. 6
(See the dedicated Job Aid ‘NC Manufacturing Settings’)

Let ’s see now the User interface...

Copyright DASSAULT SYSTEMES 2000 145
 Axial Operations User Interface Presentation

1 Enter the Name of the Operation.

(Optional because a default name is given
by the system ‘Type_Of_Operation.X’)

2 Enter a line of comment (Optional)

This comment will be generated in the APT Source
with the PPRINT prefix at the beginning of the
operation

3 Define operation parameters using the 4 tab pages

• Strategy tab page

• Geometry tab page
• Tool tab page
• Feeds & Speeds tab page
• Macros tab page

4 Replay and / or Simulate the operation tool path

(See dedicated Job Aid ‘Replay a Tool Path’)
Copyright DASSAULT SYSTEMES 2000 146
 The Strategy Tab page

The picture describes the tool path and the parameters

impacting the cycle.
This picture is updated as soon as you change a parameter
modifying the tool path
Depth defined by Shoulder or by Tip

1 Define parameters for the operation

• Approach Clearance offset (A)
• Depth Computation mode
• Plunge Options (See dedicated Job Aid ‘Plunge Options’)
• Breakthrough value for Through Hole (B)
• Tool Compensation number
• etc ...
Copyright DASSAULT SYSTEMES 2000 147
 The Geometry Tab page

Select the Axis Icon to define the Hole

Axis using the axis selection dialog box

Activate the Extension type : Blind or Through.

The Hole icon is updated

Select several points or Patterns of points then manage

their right order by selecting the algorythm between
Closest or Manual.
Specify the Jump Distance between points or directly
drag along hole axis to modify the distance
(See dedicated Job Aid ‘Pattern of Points Management’)

Define the geometry to machine (Depth & Diameter)

If a Design Feature is selected as geometry, these
parameters are automaticaly fill up with the right values

Information available on the selected Design Feature

Use the sensitive area to select directly the geometry in

the CATIA V5 window (Top Plane, Hole Cylinder, …)
• Green color : Geometry already selected
• Orange color : Optional geometry or Default Tool
• Red color : Geometry to be defined

Copyright DASSAULT SYSTEMES 2000 148

 Select this icon to access the Search Tool
The Tool Tab page dialog box to query a tool in a Catalog

1 Select the tool type available for the current operation

2 Enter the Name of the Tool.

(Optional because a default tool name is given
by the system ‘X_Drill_Default_Tool’)

3 Enter a line of comment (Optional)

4 Specify a tool number that does not already exist

5 Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values
Click More to expand the dialog box to access all tool ’s
parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Tools Management ’)

Copyright DASSAULT SYSTEMES 2000 149

 The Feeds & Speeds Tab page

1 Define the Feedrate values for

• Plunge Feedrate
• Machining Feedrate 1
• Retract Feedrate
According the unit Linear (mm/mn) or Angular (mm/turn)

Activate the checkbox Rapid to initialize the Plunge or Retract 2

Feedrate value with the rapid value of the machine-tool

2 Define the Spindle Speed value according 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
checkbox Spindle Output

Copyright DASSAULT SYSTEMES 2000 150

 Axial Operation : Macros Tab Page

1 Specify which NC Macros you want to used among :

- Approach Macro 1
- Retract Macro
- Linking
2

2 Specify for each selected NC Macro the type of motion

and the parameters like Feedrates, Angles, etc ...

To define the NC Macros, see the dedicated Job

Aid ‘NC Macros Definition’

Copyright DASSAULT SYSTEMES 2000 151

 Creating a Drilling Operation

The Total Depth to drill is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to drill
• The Breakthrough offset on bottom in case of Through Hole

Drilling : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Drilling Operation :

• Drill
• Multi-Diameter Drill
• End Mill
• Boring & Chamfering
• Boring Bar
• Reamer

Copyright DASSAULT SYSTEMES 2000 152

 Creating a Spot Drilling Operation

The Spot Drilling Operation can be defined according a specific

Diameter to reach or a Depth to drill.

Depth defined by Diameter Depth defined by Tip

Spot Drilling : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Optional Dwell time at 2
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Spot Drilling Operation :

• Spot Drill
• Center Drill
• Drill
• Multi-Diameter Drill

Copyright DASSAULT SYSTEMES 2000 153

 Step 8 : Create spot-drilling and drilling
operations
30 min

In this exercise you will create spot-drilling and drilling operations

Copyright DASSAULT SYSTEMES 2000 154

 Creating a Drilling with Dwell Delay Operation

The Total Depth to drill is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to drill
• The Breakthrough offset on bottom in case of Through Hole

The Dwell Mode can be set with the 2 following values :

• By time units : The time is given in Seconds
• By revolutions : the revolution is given in Turns

Drilling with Dwell Delay : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified duration at 2
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Drilling Dwell Delay Operation :

• Drill
• Multi-Diameter Drill
• End Mill
• Boring & Chamfering
• Boring Bar
• Reamer

Copyright DASSAULT SYSTEMES 2000 155

 Creating a Drilling Deep Hole Operation

The Drilling Deep Hole Tool motion :

1 - Motion at Machining Feedrate from 1 to 2

2 - Dwell at 2 for specified duration
3 - Retract at Retract Feedrate from 2 to 3
4 - Motion at Rapid Feedrate from 3 to 4
5 - Motion at Machining Feedrate from 4 to 5
6 - Dwell at 5 for specified duration
7 - Retract at Retract Feedrate from 5 to 6
8 - Motion at Rapid Feedrate from 6 to 7
9 - Motion at Machining Feedrate from 7 to 8

Distance (1,2) = A + Dc (Maximum Depth of Cut)

Distance (3,4) = A + Dc - Or (Retract Offset)
Distance (4,5) = Or + Dc*(1 - Decrement Rate)
Distance (7,8) = Or + Dc*(1 - 2*Decrement Rate)

This decrementation is limited by the parameter Decrement Limit Rate

Tools allowed for a Drilling Deep Hole Operation :

• Drill
• Multi-Diameter Drill
• End Mill

Copyright DASSAULT SYSTEMES 2000 156

 Creating a Drilling Break Chips Operation

The Drilling Break Chips Tool motion :

1 - Motion at Machining Feedrate from 1 to 2

2 - Dwell at 2 for specified duration
3 - Retract at Retract Feedrate from 2 to 3
4 - Motion at Machining Feedrate from 3 to 4
5 - Dwell at 4 for specified duration
6 - Retract at Retract Feedrate from 4 to 5
7 - Motion at Machining Feedrate from 5 to 6
8 - Dwell at 6 for specified duration
9 - Retract at Retract Feedrate from 6 to 7

Distance (1,2) = A + Dc (Maximum Depth of Cut)

Distance (2,3) = Distance (4,5) = Or (Retract Offset)
Distance (3,4) = Distence (5,6) = Or + Dc

Tools allowed for a Drilling Break Chips Operation :

• Drill
• Multi-Diameter Drill
• End Mill

Copyright DASSAULT SYSTEMES 2000 157

 Creating a Tapping Operation

The Total Depth to tap is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to tap
• The Breakthrough offset on bottom in case of Through Hole

Tapping : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Reverse Spindle Rotation
3 - Retract at Machining Feedrate from 2 to 3
4 - Reverse Spindle Rotation

Tool allowed for a Tapping Operation :

• Tap

Copyright DASSAULT SYSTEMES 2000 158

 Creating a Reverse Threading Operation

The Total Depth to thread is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to thread
• The Breakthrough offset on bottom in case of Through Hole

Reverse Threading : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Spindle Off then Reverse Spindle Rotation
3 - Retract at Machining Feedrate from 2 to 3

Tool allowed for a Reverse Threading Operation :

• Tap

Copyright DASSAULT SYSTEMES 2000 159

 Creating a Thread Without Tap Head Operation

The Total Depth to thread is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to thread
• The Breakthrough offset on bottom in case of Through Hole

Thread Without Tap Head : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Spindle Stop
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tool allowed for a Thread Without Tap Head Operation :

• Boring Bar

Copyright DASSAULT SYSTEMES 2000 160

 Creating a Boring Operation

The Total Depth to bore is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to bore
• The Breakthrough offset on bottom in case of Through Hole

Boring : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified duration
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Boring Operation :

• Boring Bar
• Boring & Chamfering
• End Mill

Copyright DASSAULT SYSTEMES 2000 161

 Creating a Boring & Chamfering Operation

Boring & Chamfering : Tool motion

Boring Step
1 - Motion at Machining Feedrate from 1 to 1 ’ (Hole bottom)
2 - Possibly, activation of second tool compensation number
3 - Motion at Plunge Feedrate from 1 ’ to reach A2 clearance

Chamfering Step
4 - Motion at Machining feedrate to 2 (Chamfer Diameter)
5 - Dwell for specified duration
6 - Possibly, activation of first tool compensation number
7 - Retract at Retract feedrate (or Rapid) from 2 to 3

Tools allowed for a Boring & Chamfering Operation : The First Compensation is associated to the Boring
• Boring & Chamfering The Second Compensation is associated to the
• Multi-Diameter Drill Chamfering

Copyright DASSAULT SYSTEMES 2000 162

 Creating a Boring Spindle Stop Operation

The Boring Spindle Stop Operation is a Boring Operation with

the capability to take away the tool from the hole cylinder to
avoid to mark it during the retract motion. This lift motion can
be defined according Linear or Polar coordinates

Boring Spindle Stop : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified time at 2
3 - Spindle Stop
4 - Motion at Retract Feedrate (or Rapid) from 2 to 3
5 - Retract at Retract Feedrate (or Rapid) from 3 to 4
6 - Motion at Retract Feedrate (or Rapid) from 4 to 1
Tools allowed for a Boring Spindle Stop Operation :
• Boring Bar
• Boring & Chamfering
• End Mill

Copyright DASSAULT SYSTEMES 2000 163

 Creating a Reaming Operation

The Total Depth to ream is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to ream
• The Breakthrough offset on bottom in case of Through Hole

Reaming : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified time at 2
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Reaming Operation :

• Reamer
• Boring Bar
• Boring & Chamfering
• End Mill

Copyright DASSAULT SYSTEMES 2000 164

 Creating a Counterboring Operation

The Total Depth to mill is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth to mill

Counterboring : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified time at 2
3 - Retract at Retract Feedrate (or Rapid) from 2 to 3

Tools allowed for a Counterboring Operation :

• Drill
• End Mill

Copyright DASSAULT SYSTEMES 2000 165

 Creating a Countersinking Operation

The Total Depth to drill is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of material to drill given by Diameter or Depth

Countersinking : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified time at 2
3 - Retract at Retract Feedrate (or Rapid) from 3 to 4

Tools allowed for a Countersinking Operation :

• Countersink
• Center Drill
• Spot Drill

Copyright DASSAULT SYSTEMES 2000 166

 Creating a Chamfering 2 Sides Operation

The Total Depth to drill is defined by

• The Approach Clearances (safety offsets on top & bottom)
• The Depth of the hole

Chamfering 2 Sides : Tool motion

1 - Motion at Machining Feedrate from 1 to 2
2 - Dwell for specified duration
3 - Activation of the second tool compensation number
4 - Motion at Plunge Feedrate (or Rapid) from 2 to 3
5 - Motion at Machining Feedrate from 3 to 4
6 - Dwell for specified duration
7 - Activation of the first tool compensation number
8 - Retract at Retract Feedrate (or Rapid) from 4 to 5
The First Compensation is used for top chamfering
Tools allowed for a Drilling Operation :
The Second Compensation is used for bottom
• Two Sides Chamfering
Chamfering

Copyright DASSAULT SYSTEMES 2000 167

 Creating a Back Boring Operation

The Total Depth to bore is defined by

• The Approach Clearance (safety offset on top & bottom)
• The back bore depth

Back Boring : Tool motion

1 - Shift motion at Rapid Feedrate from 1 to 2
2 - Motion at Rapid Feedrate from 2 to 3
3 - Shift motion at Rapid Feedrate from 3 to 4
4 - Motion at Machining Feedrate from 4 to 5
5 - Dwell for specified duration
6 - Motion at Retract Feedrate from 5 to 6
7 - Shift motion at Retract Feedrate from 6 to 7
8 - Motion at Retract Feedrate from 7 to 8
9 - Shift motion at Retract Feedrate from 8 to 9
Tools allowed for a Back Boring Operation :
• Boring Bar

Copyright DASSAULT SYSTEMES 2000 168

 Creating a T-Slotting Operation

The Total Depth to plunge is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth between the top plane and the bottom of the slot

T-Slotting : Tool motion

1 - Motion at Rapid Feedrate from 1 to 2
2 - Motion at Machining Feedrate from 2 to 4
3 - Retract at Retract Feedrate (or Rapid) from 4 to 6
Tools allowed for a T-Slotting Operation :
• T-Slotter

Copyright DASSAULT SYSTEMES 2000 169

 Creating a Circular Milling Operation 1/2

The Total Depth to mill is defined by

• The Approach Clearance (safety offset on top of hole)
• The Depth of the hole
• The Offset on bottom in case of Through Hole

Machining Strategy :
Radial : Number of paths and Distance
Axial : Depth of Cut or Number of Levels

Sequencing Mode :
Side First or Depth First

Direction of Cut :
Climb or Conventional

Tools allowed for a Drilling Operation :

• End Mill

Copyright DASSAULT SYSTEMES 2000 170

 Creating a Circular Milling Operation 2/2

In the Macros Tab Page you can specify

• Approach motion (Axial & Circular) with dedicated Feedrates
• Retract motion (Circular & Axial) with dedicated Feedrates
• Return motion in a level (Circular Approach & Retract)
• Return motion between levels (Circular Approach & Retract)

Rapid

Retract Feedrate

Approach Feedrate

Machining Feedrate

Copyright DASSAULT SYSTEMES 2000 171

 Axial Operation Options

You will learn how to manage some specific Axial Operations

capabilities:
- Manage a Pattern of Points

- Plunge Option

Copyright DASSAULT SYSTEMES 2000 172

 Pattern of Points Management 1/3

Create a Machining Pattern from an Axial Operation

1 Select the red hole depth representation in the

sensitive icon

2 Select a Design Pattern or an already created

Machining Pattern in the Manufacturing View panel
1
or
Select directly the geometry in the CATIA screen
to add it to the Machining Pattern

3 Double-Click in the CATIA screen

or Use Esc key to quit the
Machining Pattern selection mode
A Machining Pattern can include a Design Pattern
and/or single holes and/or another Machining Patterns

Copyright DASSAULT SYSTEMES 2000 173

 Pattern of Points Management 2/3

Machining Pattern options

1 The Jump Distance is used to specify an offset on the top of the holes that will be applied for
the transition paths between two holes.
This transition path is perform in RAPID mode

2 The 2 ways for ordering pattern points are Manual and Closest
Manual : Successively select the points in the order you want them sequenced
Closest : The pattern point closest the first point is given the next sequence number, the
next closest to that is given the next sequence number and so on

Copyright DASSAULT SYSTEMES 2000 174

 Pattern of Points Management 3/3

Local modification of a Pattern of Points

On each point of a Machining Pattern a contextual menu is available thanks

the MB3. The following action are available for this selected point :
• Deactivate / Activate the point : The selected point is removed or added to
the Machining Pattern and the sequencing is updated according the action
• Set As Start Point : The selected point is set as the first point of the
Machining Pattern and the algorythm is updated with this new constraint
• Modify entry distance… : A specific offset is applied for the approach
motion on the selected point and for the retract motion of the previous one
• Modify exit distance… : A specific offset is applied for the retract motion
on the selected point and for the approach motion of the next one

Modify exit distance

Jump
Distance
Deactivate point
X1 X2 X0 X3 X4
Copyright DASSAULT SYSTEMES 2000 175
 Plunge Options

The Plunge option can be defined through the mode

By Tip or By Diameter

1 4

Plunge Mode : Tool motion

1 - Motion at Plunge Feedrate (or Rapid) from 1 to 2
2 - Motion at Machining Feedrate from 2 to 3
3 - Retract at Retract Feedrate (or Rapid) from 3 to 4

The Plunge depth is computed according the following formula :

Approach Clearance (A)+ Plunge Tip (Pt) - Plunge Offset (Po)

Copyright DASSAULT SYSTEMES 2000 176

 Tool Path Verification & Simulation

You will learn how to verify and simulate the Manufacturing

Program :

- Replay a Tool Path

- Material Removal Simulation by Photo Mode

- Material Removal Simulation by Video Mode

Copyright DASSAULT SYSTEMES 2000 177

 Replay a Tool Path 1/2

The Replay of the tool path is available at two levels :

1 - Manufacturing Program level
2 - Operation level

1 Select Manufacturing Program or Operation in the tree

Click on icon in the menu bar

2 or
Right-Click and select Replay Tool Path in the
contextual menu
or
Edit the Operation and use Replay button
The tool tip coordinates (X,Y,Z) and current feedrate
value are displayed during the tool path simulation

Animation Stop
Backward Forward

Go to Start Display Complete Tool Path

Animation Speed control for

Number of Points to be visualized for
Continuous Replay Mode
Point by Point Replay Mode
Copyright DASSAULT SYSTEMES 2000 178
 Replay a Tool Path 2/2

The following Replay Options are available :

Replay mode : Tool Visualization Mode : Color Mode :

Continuous Point to Point Tool at the last position Same Color

Plane by Plane Feedrate by Feedrate Tool Axis displayed at each position Different Colors by feedrate type:
Tool displayed at each position Yellow : Approach
Green : Machining
Blue : Retract
Simulation mode : Photo & Video Red : Rapid
(See the dedicated Job Aid ‘Simulate a Tool Path’)

Copyright DASSAULT SYSTEMES 2000 179

 Simulate a Tool Path : Photo mode 1/4

The Photo mode displays the result of the material removal at

the end of the Machining Operation.
This very fast simulation is based on a Pixel algorithm.

1 Select Manufacturing Program or Operation in the tree

Click on icon in the menu bar

2 or
Right-Click and select Replay Tool Path in the
contextual menu
or
Edit the Operation and use Replay button

3 Click on icon to Start the

Simulation

The Photo simulation is performed in a new CATIA window

called Zip Mill

The result of this simulation can be analyzed to detect the

Gouging, Undercut and Tool Clash

Copyright DASSAULT SYSTEMES 2000 180

 Simulate a Tool Path : Photo mode 2/4

Analyze Photo to compare the machined part

with the design part

The following errors can be detected thanks the Analyze Photo

capability :
Gouge : Areas where the tool has removed excess material
from the workpiece
Undercut : Areas where the tool has left behind material on the
workpiece
Tool Clash : Areas where the tool collided with the workpiece
during a rapid move
These detection are computed according a user Tolerance
Results of the comparison are reflected on the workpiece, based on the extent of severity of the fault
and the customized color settings

Copyright DASSAULT SYSTEMES 2000 181

 Simulate a Tool Path : Photo mode 3/4

The list of detected faults are listed in the Faults combo box (Gouge, Undercut and Tool Clash) and
detailed information related to these faults are displayed (Type, Operation, Normal Deviation and Area)

At any time you can pick on the surface of the workpiece and a dialog box appears giving information
about the picked point

The operation used for removing material

The normal deviation between the workpiece and the design part
The X, Y, and Z coordinates of the pick point
The tool used for machining

Copyright DASSAULT SYSTEMES 2000 182

 Simulate a Tool Path : Photo mode 4/4

Customize the settings for the material

removal simulation

1 - In the Faults Tab Page you can specify the colors used to
highlight the Remaining Material, Tool Clash and Gouge
according the tolerance. This tolerance is initialized in the
Analyze Tab Page.

2 - In the General Tab Page, different colors can be assigned to

each tool used in the Manufacturing Program. These colors will
be reflected on the simulated workpiece wherever the tools have
been used to cut material.

The machining resolution can be tuned from Coarse to Fine to

improve the quality of the level of detailing but memory and
computation time will increase.

In the Close-up section, you can customize the size of the

workpiece scooped out whenever you use the Material Removal
Simulation Close-up and Point Selection options

Copyright DASSAULT SYSTEMES 2000 183

 Simulate a Tool Path : Video mode
Stop
Backward

The Video Simulation is a removal material simulation with

Floating Tool. This simulation is an animation of the tool
path and take into account the Machine Rotations
generated in the program.The goal is to verify that a good
tool path program is being sent to the post processor

1 Select the operation to simulate

Click on icon in the menu bar

2 or
Edit the Operation and use Replay button
or
MB3 and select Replay Tool Path in the
contextual menu
3 Click on icon to Start the
Simulation Stop
Forward
The Video simulation is performed in a new CATIA window
called AnimZip Go to End

By selecting the icon, you are able to save the result of the simulation as a new model
and to use it as the stock of the next Part Operation.
This new model will be saved as a CGR model (CATIA Geometric Representation)

Copyright DASSAULT SYSTEMES 2000 184

 Managing Tools

You will learn how to choose or create a tool

For all operations, you choose or

create a tool via this tab page

Copyright DASSAULT SYSTEMES 2000 185

 The Tool Tab Page

The different types of tool you can use

for the operation

Name of the tool (attribute)

Comment (attribute)

Number in the tool in the catalog.

(attribute)

Ball end tool. If you activate this

option, the system automatically fits
the corner of the tool do the diameter
to get a ball end.

Select a tool already used in Select a tool from a catalog

the document

Copyright DASSAULT SYSTEMES 2000 186

 Select a Tool from a Tools Catalog 1/2

The different types of tool you can Select the catalog (the Windows
use for the operation path is specified in Tool/options)

Different type of query

Copyright DASSAULT SYSTEMES 2000 187

 Select a Tool from a Tools Catalog 2/2

Simple query : specify

- the name of the tool (or a part of it)
And/or
- the tool diameter

Advanced query : create criteria for

search via Attribute-condition-value
panel
To appear in the list, a tool of the
catalog must fill in all conditions

Via contextual menu you can

- Reorder the list of attribute
- Look for a tool by a string of
character

Copyright DASSAULT SYSTEMES 2000 188

 Create a new Tool

1 - Select the type of tool you are

creating

2 - Enter a new name for your tool

3 - Enter a comment if needed

4 - Click on « More » to access to tool

parameters :- Geometry
- Technology
- Compensation

Copyright DASSAULT SYSTEMES 2000 189

 Tool Compensation 1/3
1 3

1 Edit the Tool Change Operation

4
2 Select the More button

3 Click on Compensation Tab Page

4 MB3 on Compensation site to edit

5 Modify the Compensation parameters 2

Corrector Number
Length Register Number
Radius Register Number
5
Tool Diameter to specify the compensation site location
The site P2 of the drill for example

The Radius register number is only available if the option Radius Compensation has been
activated on the Machine-Tool

Copyright DASSAULT SYSTEMES 2000 190

 Tool Compensation 2/3

The following tool types have only one compensation site (P1) and this site is located at
the extremity of the tool :
• End Mill
• Face Mill
• Boring Bar
• Tap
• Reamer

Copyright DASSAULT SYSTEMES 2000 191

 Tool Compensation 3/3

The following tool types have more than compensation site :

2 Sites •T-Slotter
• Drill

3 Sites • Spot Drill

• Countersink
• Conical Mill
4 Sites • Boring & Chamfering Tool
6 Sites • Center Drill
7 Sites • Two Sides chamfering tool
9 Sites • Multi-Diameter Drill

Copyright DASSAULT SYSTEMES 2000 192

 Creating an Auxiliary Operation

You will learn how to create an Auxiliary Operation

among :

- Tool Change

- Machine Rotation (Table Rotation or Head Rotation)

- Machining Axis / Origin Change

- PP Instruction

Copyright DASSAULT SYSTEMES 2000 193

 Why Do You Need Auxiliary Operations ?
An Auxiliary Operation is a control function such as Tool Change, Machine Table/Head Rotation
or a single PP Instruction. These operations may be interpreted by a specific Post-processor.

What about Auxiliary Operations ?

- Auxiliary Operations are predefined syntaxes stored
in the Post-processor Table (PP Table)
- The PP Table is linked to the Machine-Tool as a
parameter
- All the syntaxes in the PP Table are customizable by
the user

- Machining Axis Change

- Tool Change
- Machine Rotation
- PP Instruction

To customize the predefined syntaxes associated to these

Auxiliary Operations, see the dedicated Job Aid ‘PPWords
Table Customization’

Copyright DASSAULT SYSTEMES 2000 194

 Creating manually an Auxiliary Operation…
1

1 Click on Auxiliary Operation Icon

The new Operation is created after the current one

2 The Operation dialog box appears to edit it
2
3 Confirm Operation creation

Let ’s see now the automatic creation...

Copyright DASSAULT SYSTEMES 2000 195
 Creating automatically an Auxiliary Operation…
1
1 MB3 on the Manufacturing Program

2 Select the type of Auxiliary

Operation to be automatically
generated among :
• Tool Changes 2
• Machine Rotations

CATIA will check that all the operations tool axis are reachable by the
Part Operation’s machine-tool and an Information Message or Warning
Message will be displayed

It is also possible to remove all the Tool Changes and / or Machine

Rotations by this automatic step. These items are available in the same
panel

Let ’s see now the User interface...

Copyright DASSAULT SYSTEMES 2000 196
 Insert a Tool Change Operation 1/2

1 Select in the displayed list the Tool type to be created

2 Enter the Name of the Tool Change Operation and a line

of comment (Optional)

3 Select the Tool Tab Page to define your tool

Specify a name, a comment or a tool number that does
not already exist to create a new tool
Use the 2D Viewer to modify the parameters of the tool.
The 2D Viewer is updated with the new values

Click More>> to expand the dialog box to access all tool ’s

parameters such as Geometry, Technology and
Compensation

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
(See the dedicated Job Aid ‘Manage the tool of an Operation’)

Copyright DASSAULT SYSTEMES 2000 197

 Insert a Tool Change Operation 2/2

1
4 Select the Syntax Tab Page to display the syntaxes
associated to the Tool Change operation
• Init From PPTable : the predefined syntax is read on the
PPWords Table linked to the machine and the syntax
parameters are updated with the Tool Change parameters
• Otherwise : Key your own user-syntax that will have no
link with the PPTable

The Sequence Number allows the user to choose between the several syntaxes associated to this
command in this PPWords Table
To learn how to associate several syntaxes to a Tool Change Operation, see the dedicated Job Aid
‘PPwords Table Customization’

Copyright DASSAULT SYSTEMES 2000 198

 Step 9 :Generate Tool Changes

5min

In this exercise you will generate tool changes in the manufacturing

program

Copyright DASSAULT SYSTEMES 2000 199

 Insert a Machine Rotation Operation

1 Enter the Name of the Machine Rotation Operation and

a line of comment (Optional)

2 Define Rotation Parameters in the Properties Tab Page

• Rotation Angle in Degrees
• Rotation Direction between CLW, CCLW or Both (Shortest)
• Rotation Type between Absolute or Incremental (Not V5R4)
3 Define the associated PPWords Syntax in the Syntax
Tab Page
• Init From PPTable : the predefined syntax is read on the
PPWords Table linked to the machine and the syntax
parameters are updated with the Rotation parameters
• Otherwise : Key your own user-syntax that will have no link
with the PPTable
4 Simulate the Rotation by selecting the Replay button

The Machine Rotation operation can be generated only if a machine-tool

with table rotation has been selected on the Part Operation. The rotation
axis (A,B or C) is read on the machine-tool.

Copyright DASSAULT SYSTEMES 2000 200

 Step 10 :Generate Machine Rotation

5min

In this exercise you will generate a machine rotation in the manufacturing

program

Copyright DASSAULT SYSTEMES 2000 201

 Insert a Machining Axis / Origin Change Operation 1/2

1 Enter the Name of the Machining Axis Operation and a

line of comment (Optional)

2 Define the new Machining Axis in the Properties

Tab Page
• Click the symbol representing the origin in the sensitive icon
and select a point or a vertex to fix the machining axis origin
• Select the axes in the sensitive icon to specify their orientation
• Key an Axis Name which is displayed in CATIA screen

Activation of the Origin Checkbox, with a number and a group, will generate
in the output the following syntax :
$$ ORIGIN/ X, Y, Z, Number, Group

3 Define the associated PPWords Syntax in the Syntax

Tab Page
• Init From PPTable : the predefined syntax is read on the
PPWords Table
• Otherwise : Key your own user-syntax that will have no link
with the PPTable

Copyright DASSAULT SYSTEMES 2000 202

 Insert a Machining Axis / Origin Change Operation 2/2

Outputs are computed in the current Machining

Axis :
TLAXIS/ 0.000000, 0.000000, 1.000000
$$*CATIA0
$$ Manufacturing Program.1
$$ 1.00000 0.00000 0.00000 54.13857
$$ 0.00000 1.00000 0.00000 -33.03097
$$ 0.00000 0.00000 1.00000 73.00000
SPINDL/ 70.0000,RPM,CLW
GOTO/ -46.32305, 38.67889, -25.00000 First Machining Axis : Second Machining Axis :
GOTO/ -33.82813, 38.67889, -25.00000 Define on the Part Define through a
… Operation Machining Axis operation
TLAXIS/ 1.000000, 0.000000, 0.000000 (Change-Axis in the tree)
$$ Start generation of : Change-Axis
$$*CATIA0
$$ Change-Axis
$$ 0.00000 0.00000 1.00000 74.13857
$$ 1.00000 0.00000 0.00000 -33.03097
$$ 0.00000 1.00000 0.00000 0.00000
SPINDL/ 70.0000,RPM,CLW
GOTO/ 41.86405, 28.93750, -25.00000
GOTO/ 48.44451, 28.93750, -25.00000

Copyright DASSAULT SYSTEMES 2000 203

 Step 11 : Generate a new Machining Axis

5min

In this exercise you will generate a machine axis in the manufacturing

program

Copyright DASSAULT SYSTEMES 2000 204

 Insert a Post-Processor Instruction

1 Enter the Name of the Machining Axis Operation and a line of

comment (Optional)

2 Enter the Post-Processor Instructions to be generated

The Post-Processor Instructions will be generated in the APT

following exactly the format that you have used to define them

3 Confirm operation creation

The result is the following in the APT Source :

GOTO/ 41.86405, 43.00000, -25.00000
PPRINT End of generation of : Pocketing.2
PPRINT OPERATION NAME : Post-Processor Instruction.1
PPRINT Start generation of : Post-Processor Instruction.1
PPRINT RESET ALL CURRENT ACTIONS
COOLNT/ OFF
CUTCOM/ OFF
PPRINT End of generation of : Post-Processor Instruction.1

Copyright DASSAULT SYSTEMES 2000 205

 Step 12 : Insert Post Processor Words

5min

In this exercise you will insert a Post Processor word in the PPR tree

Copyright DASSAULT SYSTEMES 2000 206

 Auxiliary Operations Status

In the PPR Tree, for each Auxiliary Operation is associated a graphical icon which give
information to the user

Tool Change Operation :

Operation created Automatically
Operation created Manually
Machine Rotation :
Operation created Automatically
Operation created Manually

All the Auxiliary Operations may have also the following status :
Operation Deactivate (done manually by the user)

Operation Not Complete (Some information are missing : geometry,...)

Operation Not Updated (Toolpath must be replayed to update the operation)

Copyright DASSAULT SYSTEMES 2000 207

 Generating Output Files

You will learn how to generate Manufacturing

Program Outputs :

- APT Source Code in Interactive Mode

- APT Source Code in Batch Mode

- ISO NC Code in Batch Mode

- HTML Documentation

Copyright DASSAULT SYSTEMES 2000 208

 Generate APT Source Code in interactive Mode

1 Select the Manufacturing Program to compute in

the PPR Tree

2 Click on to generate NC Code Interactively

3 Select the folder where the APT Source Code will

be generated

4 Specify the name of the new file

5 Click on Save to start the computation

Interactive Mode : You don’t need to write the

CATProcess to generate the APT Source Code, but
during the computation, your CATIA V5 session is no
more available

The APT Source Code can be also generated using the The resulting file is generated with the .aptsource extension.
MB3 on the Manufacturing Program entity In the same folder, a file with .LOG extension is generated and
it is including all the computation information

Copyright DASSAULT SYSTEMES 2000 209

 Generate APT Source Code in Batch Mode 1/2

1 Save the CATProcess before generating the APT

Source Code

2 Click on to generate NC Code in Batch Mode

3

3 Select the In/Out Tab Page to specify the

Input and Output of the computation :
• The CATProcess and Manufacturing Program names
• The Output Type (APT or ISO)
• The Output File name 4

If needed, you can choose to write the document after

processing.
4 Just select the Save document checkbox and specify
where you want to save it using the Document button

Batch Mode : You need to write the CATProcess before to generate the APT Source
Code, but during the computation, your CATIA V5 session is available

Copyright DASSAULT SYSTEMES 2000 210

 Generate APT Source Code in Batch Mode 2/2

5 Select the Options Tab Page to specify some output

parameters 5
• Circular Interpolation : Auto, None, Z-Axis, Any Axis
• Tool Motion Statement : Automatic, Point, Axis
• Information Statement : None, PPRINT, $$
• Rapid Feedrate : Automatic, Value
• Syntax Used for Axial Operation : Yes, No
If the syntaxes are used, the output will be the
predefined syntaxes associated to each Axial
operation and stored in the PPWords Table, otherwise
6
the output will be only GOTO points.

6 Click on Execute to request computation of the APT

Source file

Automatic : the information are automatically The resulting file is generated with the .aptsource extension.
retrieved on the Machine-Tool associated to the In the same folder, a file with .LOG extension is generated and
current Part Operation it is including all the computation information

Copyright DASSAULT SYSTEMES 2000 211

 Generate ISO NC Code in Batch Mode

1
1 Use the same procedure as to generate APT
Source Code but specify ISO type for the Output
format in the In / Out Tab Page

2 Select the ISO Tab Page to specify the name of the

Post-Processor to use for ISO NC Code generation

2
3 Click on Execute to request computation of the
ISO NC Code

By clicking the ? near the name of the Post-Processor, you

access to the documentation of the selected Post-Processor.
This online documentation includes the Post-Processor
definition and samples of APT Source and ISO NC Code

The resulting file is generated with the .CATNCCode extension.

In the same folder, a file with .LOG extension is generated and
includes all the computation information
The system generates also a file including the APT Source 3
named by default APTFile.aptsource in the same folder

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 Step 13 : Generate NC Code

15 min

In this exercise you will generate APT and ISO code

APT CODE

ISO CODE
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 Generate HTML Documentation

1 Click on to generate the HTML

Documentation

2 Specify in the Process Documentation dialog

box the following information :
3
• Documentation script (CATScript document)
• Process type (only Process in this version)
• Folder where the documentation will be
generated

3 Click Document now to

generate your documentation

Some samples and helps are delivered under intel_a/startup/Manufacturing/Documentation of your CATIA V5 installation

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 Step 14 : Generate HTML Documentation

15 min

In this exercise you will generate HTML documentation

HTML document

Copyright DASSAULT SYSTEMES 2000 215

 Managing Design Changes

You will learn how to manage the Design Changes on

an already created Part Operation

Copyright DASSAULT SYSTEMES 2000 216

 Detection of a Modification on a Machining Operation

After to have perform a modification of

design the machining operations are
displayed in the PPR tree with the
following symbols :

Update symbol : The geometry

has changed since the last replay of the
tool path

Incomplete symbol : The

geometry is now missing
After Design Changes

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 Analyze the Modification on the Geometry 1/2

1
1 Edit a None-Updated Operation

2 A Orange traffic light is displayed on the

geometry Tab Page
Select Analyze contextual command in the
sensitive icon zone 2
The Geometry Analyzer Dialog box is
displayed

The Geometry Analyzer dialog box displays the

status of each geometrical element associated to the
Machining Operation
- Drive elements
- Check elements
- Relimiting planes (Top / Bottom)
- Relimiting elements (Start / End)

The different status of the geometry can be

- Up to date --> OK
- Not up to date --> Operation have to be replayed
- Not found --> The geometry has been deleted

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 Analyze the Modification on the Geometry 2/2

2 types of analysis can be performed through the

Geometry Analyzer dialog box :

Smart icon is used to visualize the original

geometry used by the operation before the
modification. This geometry is visualized in Red on the
Part

Highlight icon is used to visualize the new

geometry used by the operation since the last
modification. This geometry is displayed in Blue on the
part

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 Validate the Modification on the Geometry

To validate the operation on the new geometry and to

change the status of the geometrical elements from
Not up to date to Up to date, you need to Replay the
tool path of the operation.

The replay of the tool path is automatically done on the

new geometry without any user interaction. After this
simulation, the operation is now consistent with the
design changes and the machining operation status is
also updated in the PPR graph

In case of Geometry Not Found, you need to reselect

a new geometry or to delete the operation if it is no
more useful

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 Step 15 : Design associativity

5 min

In this exercise you will make a change in the design and check that your
change is automatically taken into account in the toolpath replay

Replay

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