Within the tenth video of this 25-video series on programming a Multus U3000 with TopSolid, we will verify the toolpaths we created within the previous videos.
When you are working to verify in TopSolid, there are a couple of ways to work. However in this demonstration, I simply window select all of the operations I want to verify. You will notice that TopSolid’s machine simulation is more robust than many solutions out there because it includes full machine simulation.
Within this verification simulation, you will notice that the stock comes in at the exact moment that it would based on our previously programmed operations. Once we hit start, you can see all of the operations happening in real time and we ultimately verify that there are no collisions within our programming so far and that we are good to move forward.
You have a great product idea – you can see it in your mind’s eye. In the end, your new product will be proudly displayed and will likely even go down in history as industrial design genius. Given that you are an experienced and talented practical machinist, we could hardly expect anything less. But wait, your ideas require multiple materials and a complex design.
Check out this cool video demonstrating how our team in France designed and ultimately fabricated this awesome, multi-material custom foosball table (the French call a foosball table a babyfoot…what can we say?).
As this team of Missler Software team members discovered, the complexity required is no match for TopSolid. Above all else, TopSolid’s mission is always to make manufacturing simple for both practical machinists and the entire design team.
Within the ninth video of this 25-video series on programming a Multus U3000 with TopSolid, I will program five operations on a five-axis mill-turn machine in a matter of seconds using TopSolid’s drag and drop functionality. Sound too good to be true? Stick with me and I will prove that it is not only possible, but easy.
To mill additional faces, I drag and drop the open pocket cutting toolpath I created in the previous video. I now demonstrate how easy it is to apply that toolpath to five additional faces in a matter of clicks and in just a few seconds.
Using the kinemetric definitions of the machine TopSolid already knows, when we drag and drop our toolpath, TopSolid automatically finds the correct angular solutions for the new faces and creates the new toolpaths accordingly.
Five operations completed in 50 seconds – impressive!
Now that we have most of our turning done, in the eighth video of this 25-video series on programming a Multus U3000 with TopSolid, we want to start doing some milling. We will start by milling an open pocket. As you will see, when I select the face I want to mill, TopSolid suspects that it is an open pocket and proposes it as such.
The area we are working on is, in fact, an open pocket, so I move forward by selecting an appropriate tool. In this demonstration, I want to remind you just how easy it is to work with tooling in TopSolid. I can either choose the style tool I want and build from there, or select a tooling template. Either selection makes it easy to program the needed tooling information.
Because TopSolid is a highly intelligent solution, as soon as we make our tooling characteristic settings, TopSolid proposes a toolpath. After some quick feeds, speeds and cutting settings, we are all set.
As always, after these settings made, TopSolid automatically updates the stock model. Simulation allows us to check this operation for collisions and we notice in this case that the spinning axis is the tool and we can check for collisions even when the tool is spinning.
Milling and Open Pocket – Reviewing what You’ve Learned
This open pocket milling video further highlights TopSolid’s ability to help intelligently make decisions, but also offers the easy ability to adjust those decisions. Finally, TopSolid’s goal is always to give you 100% confidence when you ultimately hit start to begin post processing. Our machine simulation function for every process gives you this confidence.
In the seventh video of this 25-video series on programming a Multus U3000 with TopSolid, we test synchronizations of the operations we have programmed. We have programmed a few operations, but the key question is – do these operations perform effectively together?
To answer this question, I switch to the final machining phase and bring up my scenario that contains all of our operations. TopSolid’s extremely powerful automatic layout command sets all the needed synchronizations dynamically.
Finally, I hit play on our simulation and we can watch all of the operations in the order they are going to happen and see that they are synchronized appropriately.
In the fifth video of this 25-video series on programming a Multus U3000 with TopSolid, I finish our groove using a lower turret.
I changed the type of finished I want to profiling, but just to be a little different, I decided to use the machine’s lower turret. After selecting the tool I believe will be best for the job, I must adjust the toolpath because the machine contains a slant bed lower. The machine’s kinemetric information I have already taught TopSolid allows me to visualize exactly what is going on and make the proper decisions.
Finally, I want to program from two directions at once and to program my two points for a highly accurate toolpath.
After a quick setting of our feeds and speeds and a final check using TopSolid’s simulation, we are all set.
In the fourth video of this 25-video series on programming a Multus U3000 with TopSolid, we continue roughing our part. Specifically, within this video you will learn how to manage groove roughing.
The Efficiency of Reusability. The Ease of Adjustments.
As is the case with nearly every function performed with TopSolid, you will notice the combination of utilizing information we have already taught the system, and being able to easily make customized tweaks for this step in the programming process. For instance, in the video you will notice that TopSolid “assumes” that we want to use the same tool and cutting angle that we were previously using.
However, we in fact need a different tool and cutting method to rough our groove, but that is easy enough to change. I simply access a groove roughing method I have already taught the system and select the appropriate tool. Again, showing off the efficiency built into the very fabric of TopSolid, we drag and drop our feeds and speeds settings and avoid having to re-input data and settings the system already knows.
TopSolid, as always, updates the stock model based on our programming changes.
The Power of “Close Call” Collision Detection
Finally, and extremely importantly, TopSolid simulations checks for collisions, including potential fixture collisions. In this case, we are extremely close to colliding with the chuck, but do not in fact collide. TopSolid allows you to have 100% confidence in your end result, even in close calls.
Groove Roughing – Reviewing What You’ve Learned
This groove roughing video particularly highlights the efficiencies TopSolid creates by reusing the information you have already taught the system, while still being able to easily make needed adjustments. Additionally, this video highlights the power of TopSolid’s simulation capabilities to detect collisions, including fixture collisions, even when it’s a very close call.
In the third video of this 25-video series on programming a Multus U3000 with TopSolid, you will learn how to use the B-Axis of the Multus U3000 to continue roughing the part. As always, you will begin by selecting the geometry to machine. From there you will select a neutral style turning tool that is mounted on the B-Axis of the machine. Once you have the geometry and the tool selected you will learn how to set the B-Axis angle of the turret. Finally, you will learn how to re-use the cutting conditions from the first operation by simple drag-n-drop.
Smarter Software with fantastic visualizations
One of the first things that should be pointed out is that machine simulation and tool simulation are much more than just pretty pictures on the screen. During this step, play close attention to the preview of the tool path based on the orientation of the neutral tool selected. You will see that TopSolid always is checking both the forward and the back angle of the insert based on the orientation of the tool and the angular solution of the B-Axis. This is done automatically and in real time so that you are always sure to have the most accurate tool path possible.
Setting the B-Axis angle
When working with a machine like the Multus U3000 from Okuma, it is critical to understand what the machine can and more importantly cannot do. It is crucial that you know that the machine is going to do exactly what you tell it to do. In this example, you will learn how to set the B-Axis of the machine to be at 45 degrees. What’s cool is that as you tell TopSolid to set the axis to that condition, TopSolid listens to you in real time and updates the graphic on the screen to reflect the change. This way you are sure that you have entered the information correctly!
The simplicity of re-usability
One of the key development points behind TopSolid was re-usability. And TopSolid takes this to an entire new level. In this video, you will learn how to reuse the cutting conditions from the first operation by simply dragging and dropping the first operation onto the cutting conditions button of the new operation. The simplicity of this action is fantastic as the complexity of what’s actually happening is enormous! When you drag-n-drop an operation onto one of the specific operation buttons, the software automatically copies all common parameters over to the new operation. In the case of cutting conditions this can be 10-15 parameters that get copied. However, try doing this on other operations. For example, take an existing operation and drag-n-drop it onto the settings button of the new operation. And presto! All the common variables are now copied over!
Setting the correct driven point for a U3000
When working on a mill/turn machine like the U3000, it is important that you understand how to define the correct driven point for your turning tool when you are working on the B-Axis turret. In the case where the B-Axis is either vertical or horizontal, you can use the standard driven points of the tool. However, if the turret is at an angle outside of vertical or horizontal, you will need to do some additional work to set the point correctly.
In this step, you will learn how to do exactly that. It will start by duplicating the TopSolid driven point. From there you will activate the duplicate and the choose to rotate the point. This is the key element here…the rotation of the driven point. Because of TopSolid’s ability to offer this, you can affectively drive almost any tool from any angular solution with relative ease.
Reviewing what you’ve learned
In this video, you want to pay close attention to a couple of key elements. First, the dynamic simulation of the B-Axis. Any change you make to the orientation of the B-Axis or even the orientation of the cutting tool is dynamically displayed to you in real time. This eliminates guess work on your side and also costly mistakes.
You should also pay attention to the simplicity of how you can reuse cutting conditions from a previous operation. It’s just simple drag-n-drop!
Finally, spend some time practicing how you set the driven point of the tool. When you use custom B-Axis angles, this is a critical step to understand.
In the second video of this 25-video series on programming a Multus U3000 with TopSolid, you will learn how to use the lower turret of the Multus U3000 to turn down the front face of the part. To do this, you will start by selecting the face to machine with the left mouse button. Then you will right mouse click and choose Roughing from the Turning section of the contextual menu. Once you get into the operation for rough turning, you will need to select your tool and set your cutting conditions.
Selecting a tool from the U3000 lower turret
To select the tool that you want to use, you need to click on the Tool icon from the operation icon bar. Next, it is important that you select the turret where you want to select the tool from. In this samples case, it will be the lower turret. Once you are viewing the lower turret, you can choose the appropriate tool by selecting the check box to the left of the tool number you wish to use. In this sample, all the tooling is pre-loaded on the Multus U3000 Machining template. This way, the common tools that are usually found on your machine are easy to use because they are already there!
Setup the rest of the operation for the U3000
Now that you have your tool selected, it is time to setup the rest of the operation. In this first operation, you will use the Quick Settings Balloon to modify the depth of cut and the stock to leave. As TopSolid is a fully certified Windows application, this can be done by just double left clicking on the field to modify. If you pay close attention to the preview of the tool path, you will see that everything you change dynamically updates on the screen.
From there you will click on the Feeds & Speeds button in the operation navigation bar. Once the dialog box is open, you will modify the settings to use constant surface feet. Once this is activated you will set the appropriate surface feet, chip load and finally the max RPM for the spindle.
Reviewing what you’ve learned
In this video, you want to pay close attention to the simplicity of how you create the tool path. There are three main points to remember when creating any tool path in TopSolid. You must:
Select an operation type
Select a cutting tool
Set Feeds & Speeds
Select geometry to machine
Tweak operation settings
That’s all that is required! What’s even more impressive is that every single tool path command has the same requirements and the same way of being applied. So really, once you practice a bit, you should be able to apply any tool path operation that your machine can handle!