Tag Archives: Turning

Step 12 – Programming a Multus U3000 – ID Drillings

Within the twelfth video of this 25-video series on programming a Multus U3000 with TopSolid, we will program ID drillings.

Before I begin programming our ID drillings, I wanteStep 12 - Programming a Multus U3000 – ID Drillingsd to show you yet another really cool feature within TopSolid. A function called part display allows us to enable a turning preview that allows us to see the inside of the part as well as the outside. This viewing option is, of course, really handy when programming a drilling operation.

To remind you just how easy it is to program a tool in TopSolid, I will create a flat drill. Then, of course, program specific tool settings.

ID Drillings – Should the Part Spin or Should the Tool Spin?

TopSolid provides you the control to easily specify whether you want the part to spin or the tool to spin during the cutting process. Or, maybe I want to double my feed rate and program both the tool and the part to spin.

Simulation Discovery – A Bit Too Close for Comfort

Our simulation is successful, but we notice that the way the drill approaches is not very safe. Our programmed approach path is a bit too close to the turret for comfort. So, within the next video I will show you how to edit a link movement to rectify this concern.

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Step 11 – Programming a Multus U3000 – Milling a 4-Axis Radial Slot

Within the eleventh video of this 25-video series on programming a Multus U3000 with TopSolid, we will explore milling a 4-axis radial slot. So many CAM software packages make an operation like this much harder than it needs to be.

Milling a 4-axis radial slot is really just milling an open pocket, so we select end milling Programming a Multus U3000 – Milling a 4-Axis Radialwithin the list of 2D operations. After selecting end milling, I will turn on multi-axis. Because I have already taught TopSolid all of the definitions of this machine, the system knows that the machine I am programming is capable of multi-axis milling. Therefore, TopSolid made the multi-axis function available.

As you will see, as soon as I select 4-axis radial mill, a toolpath generates. However, I need to change my tool selection because the tool the system selected for me was too large.  I simply select the tool I want to work with and the toolpath recalculates.

Programming Final Details

As smart as TopSolid is, the system does not automatically know where to start cutting. So, you still must be a little bit of a NC programmer and select an appropriate starting point for the operation. Finally, we need to set our precise cutting attributes.

In a matter of minutes, we have created a 4-axis tool path and as always when working in TopSolid, our machine simulation is there to verify that everything is working flawlessly.

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Step 10 – Programming a Multus U3000 – Verify the Milling Toolpath

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 Programming a Multus U3000 - Verify the Milling Toolpaththis 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.

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Step 9 – Programming a Multus U3000 – Use Drag and Drop to Copy Toolpath

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 Programming a Multus U3000 - Use Drag and Drop to Copy Toolpathprevious 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!

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Step 8 – Programming a Multus U3000 – Milling an Open Pocket

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.Programming a Multus U3000 - Milling an Open Pocket

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.

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Step 7 – Programming a Multus U3000 – Test Synchronizations

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?Step 7 - Programming a Multus U3000 - Test Synchronizations

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.

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Step 6 – Programming a Multus U3000 – Finish Turn with B axis at 45 Degrees

In the sixth video of this 25-video series on programming a Multus U3000 with TopSolid,  Step 6 - Programming a Multus U3000 - Finish turn with B axis at 45 degreeswe will finish turn select faces.

I return to my B axis of 45 degrees, reuse previously created feeds and speeds setting and do a final check using the simulation tool and I learn that we are good to go.

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Step 5 – Programming a Multus U3000 – Finish Groove with Lower Turret

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.Step 5 - Programming a Multus U3000 – Finish Groove with Lower Turret

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.

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Step 4 – Programming a Multus U3000 – Groove Roughing with TopSolid

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.Step 4 - Programming a Multus U3000 – Groove Roughing with TopSolid

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 DetectionTopSolid 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.

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Looking forward…and backward

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Blower Wheel Machining with TopSolid 7

Introduction

In this 7 step video series, you will learn how to machine a blower wheel within TopSolid 7.  This will include preparing your cad data, defining your stock model, selection of a machine, adding a fixture, and adding your MPS file to cut.  From there, you learn how to use Turning to machine as much as possible prior to moving on to 4 axis continuous roughing and semi finishing.  Lastly we will cover a few different types of 5 axis finishing.  Oh and don’t forget that you will also learn a lot of tips and tricks along the way too!

Prepare Data for Blower Wheel

Create an MPS document for the blower wheel in TopSolidIn this sample, we are assuming that the first operation has been completed by someone else.  So you will need to create a stock model that is representative of that. In Step 1, we will focus on building a custom assembly so that you can define your stock correctly.

In all reality, you have two choices here. You can create the custom stock directly within a MPS file (Machine Part Setup), or you can do it within an assembly file.

If you choose to use a MPS file, the creation of this custom stock will be tied to that MPS file.  This means that in the parametric world that is TopSolid, the birth of this custom stock block will be tied to the existence of the MPS file.  Now if this is a simple, one off part then this method works well. However if there is a chance that you might use this stock model another way, it is better to use an assembly first. Besides, if you start with an assembly, you will have more freedom as to how you design the stock model.  The video below will show you how to build the assembly first and then how to use it within a Machine Part Setup Document.

Setup the machine

Like in every real job, you have choices to make.  You need to select a machine to run a job on…choose fixturing and tooling and of course you need to setup the machine.  In TopSolid, it’s no different.  In TopSolid, we always start with machine selection.  It is a critical part of the manufacturing process that will affect how you hold the part and how many setups are required to machine the part. In this sample, we will choose a DMG CTX Beta 1250 TC to machine our blower wheel.

Select a machine for the Blower Wheel project in TopSolidIn Step 2, you will start by creating a new, empty machining document.  From there you will use the “select a machine” command to browse to and select the CTX Beta.  After TopSolid loads the machine definition, your next step will be to select and add the correct chuck and jaw combination.  In this case, you will browse to a sample chuck library and choose the 3 jaw Rohm chuck.  You will use standard windows drag-n-drop to include the chuck into the machining file.  Next you will use standard TopSolid constraint positioning methodologies to position the chuck.  Play close attention to the fact that the jaws on the chuck move in and out according to the stroke of that specific chuck as well! Continue reading Blower Wheel Machining with TopSolid 7