Transcript
00:08
Now that we have programmed all of the features necessary to machine our part, let's start by running a machine simulation.
00:16
Just as a reminder, machine simulations allow us to visually check if we have any gouges or collisions, while we see a great visual representation of what the actual machining of our part will look like.
00:30
So, with machine simulation selected in my Simulation section of the Home ribbon, I'll select "Play", and let's watch this part get machined.
00:43
First, we do our Z level rough with step cutting.
00:46
And then we start our X parallel finishing operation.
00:49
But it looks like our holder has gouged into our stock.
00:54
Let's take a front view to get a closer look.
01:01
If we look closely, it looks like our tool is not long enough, and the sight of our holder has collided into our part.
01:09
Now, there's a couple different ways we could fix this.
01:11
If we were just on a 3-axis machine, really our only option would be to select a longer tool.
01:18
However, as we select longer tools to do a machining operation, we increase the likelihood of unwanted vibrations, ultimately giving us a poor surface finish.
01:29
However, since we're using a 5-axis machine, we can simply tilt the tool axis, machine the same part while still maintaining a good surface finish.
01:42
So let's eject the simulation, open up our finishing operation in the surface mill 2 feature, and navigate to the 5-axis tab inside of the parallel operation.
01:55
This fifth axis tab is enabled in our parallel finishing operation when we indicate during import that we will be using fifth axis positioning.
02:08
Because we indicated to FeatureCAM that we would be machining a 5-axis part, the 5-axis tab is now available inside of the parallel finishing operation.
02:19
Here you'll see by default, we've selected vertical in the Z.
02:23
So this is just what we saw.
02:25
Our tool axis stayed vertical along the Z of our setup 1 direction that we defined while importing.
02:31
And ultimately, we ended up colliding our holder into our part.
02:36
Let's take a look at this first option, fixed.
02:40
The fixed option on the 5-axis tab allows us to simply define a vector that will define our tool axis.
02:47
While machining this part, our tool axis will always be aligned to this defined vector.
02:53
So for this part, let's enter a vector of negative 0.5 in the X, 0 in the Y, and 1 in the Z.
03:05
Just to help you visualize, if we wanted our tool to be perfectly aligned with the Z going vertical, we could enter in a vector of 0,0,1.
03:16
If we wanted our tool completely horizontal aligned with our X direction, we could enter in 1,0,0.
03:24
And likewise, if we wanted our tool oriented horizontal in the Y direction, we would enter in 0,1,0.
03:33
So this fixed vector has both an X and a Z component.
03:38
So we can expect to see some tilting in both the X and the Z directions, but not in the Y.
03:44
With that vector indicated, let's select "Apply", "OK", and run another machine simulation.
04:06
Now we can see that while we were finishing the part, the tool axis changed to reflect our fixed tool axis vector.
04:14
This change has completely eliminated the collisions we were experiencing earlier, and this program is now safe to run on the machine.
04:22
However, let's dig a little bit deeper and take a look at some of the other options we have to utilize our 5-axis machine’s capabilities
04:30
when programming surface milling features.
04:32
So, I'll eject the simulation, reopen surface milling tool, go back to the parallel finishing operation, and navigate to the 5-axis tab.
04:45
Next, let's take a look at our first multi-axis option titled use Lead and Lean.
04:51
Select use Lead and Lean, in the from drop-down, select Contact normal and enter in a lead angle of zero and a lean angle of zero.
05:03
Right now, we're telling FeatureCAM that by entering in a zero and a zero value for both angles, at all times we would like to be perpendicular to the contact normal surface.
05:15
Lead and lean angles are the angles that we would like to rotate both in the direction of travel and perpendicular to the direction of travel.
05:24
So a lead angle allows us to lean either forward or backward in the direction of travel.
05:32
Lean angle allows us to lean left or right perpendicular to the axis of travel.
05:39
Think about a sprinter running around a track.
05:43
When a sprinter takes off, the sprinter’s body is tilted forward along the direction of travel.
05:50
Think of this as a lead angle of maybe 15 degrees.
05:54
Now as the sprinter approaches the turn, the sprinter must lean to the left.
06:00
This would be a lean angle of, let's say, negative 15 degrees.
06:05
So lead angles are the amount that you would like to tilt in the direction of travel.
06:11
Lean angles are the amount that you would like to tilt left or right perfectly perpendicular to the direction of travel.
06:19
Hopefully that analogy helps you visualize.
06:22
But let's hit "Apply", "OK", and run a machine simulation to get a better idea of what a lead and lean angle of zero looks like.
06:35
As we begin to machine our finishing operation, after this first roughing operation, we’ll be able to see that the lead and lean tools allow us to specify a tool axis angle in reference to the direction of travel at all times.
06:49
When we're machining a horizontal wall, the tool is completely vertical.
06:53
When we're machining a vertical wall, the tool should be completely horizontal.
06:58
These options can help us generate safe and efficient toolpath in a lot of situations.
07:03
But it looks like in this situation, it seems that the lead and lean angles have created a machining collision where the table has collided with the machine.
07:13
So, in this case, lead and lean angles of zero may not be our best option.
07:20
At this time, feel free to experiment with some various lead and lean angles until you generate safe toolpath.
07:27
As you change the angles, notice how that affects our tool axis while machining the finishing operation.
07:37
Once you feel comfortable with the lead and lean options, open up surface mill 2 and navigate to the parallel operation 5-axis tab.
07:47
The last option I'd like to take a look at is the Tilt Axis for Gouge Avoidance option.
07:54
Here we can tell FeatureCAM among other options to lead or lean only if we are going to collide.
08:02
So, if I select to lead and move my axis back to a vertical, going perfectly aligned with our positive Z direction, "Apply" and "OK", we'll see that my finishing operation now starts and stays vertical at all times, unless it's going to collide.
08:21
In that case, it automatically leads as much as it needs to not collide.
08:28
As we move out of danger of collision, our tool axis will align itself vertically again.
08:33
Let's play through our roughing operation, then slowly watch our finishing operation.
08:48
Notice how the tool axis stays perfectly vertical until we are in danger of colliding.
08:54
Then it changes the lead angle until we're out of danger and moves the tool axis back to vertical.
09:14
In this revised portion, we took a look at three different 5-axis simultaneous options.
09:20
First, we tried fixing our tool axis along a defined vector to avoid collisions, and that seemed to work.
09:27
Next, we tried changing the lead and lean angles to zero, so that we would always stay perfectly perpendicular to the contact normal.
09:37
As you may recall, this actually ended up resulting in a collision.
09:42
Hopefully, you took the time to explore various lead and lean angles that prevented that collision.
09:48
Finally, we looked at the Tilt Axis for Gouge Avoidance option.
09:53
Here, we told FeatureCAM that whenever possible we would like to keep our tool axis vertical along the Z.
10:01
But if we are in danger of colliding, we would like to either lead or lean to safety while still simultaneously machining.
10:12
So as we can see, there's always multiple solutions for us to machine the exact same part.
10:18
Pick the one that makes most sense to you and run your final machine simulation before moving on to the next section, NC Code.
00:08
Now that we have programmed all of the features necessary to machine our part, let's start by running a machine simulation.
00:16
Just as a reminder, machine simulations allow us to visually check if we have any gouges or collisions, while we see a great visual representation of what the actual machining of our part will look like.
00:30
So, with machine simulation selected in my Simulation section of the Home ribbon, I'll select "Play", and let's watch this part get machined.
00:43
First, we do our Z level rough with step cutting.
00:46
And then we start our X parallel finishing operation.
00:49
But it looks like our holder has gouged into our stock.
00:54
Let's take a front view to get a closer look.
01:01
If we look closely, it looks like our tool is not long enough, and the sight of our holder has collided into our part.
01:09
Now, there's a couple different ways we could fix this.
01:11
If we were just on a 3-axis machine, really our only option would be to select a longer tool.
01:18
However, as we select longer tools to do a machining operation, we increase the likelihood of unwanted vibrations, ultimately giving us a poor surface finish.
01:29
However, since we're using a 5-axis machine, we can simply tilt the tool axis, machine the same part while still maintaining a good surface finish.
01:42
So let's eject the simulation, open up our finishing operation in the surface mill 2 feature, and navigate to the 5-axis tab inside of the parallel operation.
01:55
This fifth axis tab is enabled in our parallel finishing operation when we indicate during import that we will be using fifth axis positioning.
02:08
Because we indicated to FeatureCAM that we would be machining a 5-axis part, the 5-axis tab is now available inside of the parallel finishing operation.
02:19
Here you'll see by default, we've selected vertical in the Z.
02:23
So this is just what we saw.
02:25
Our tool axis stayed vertical along the Z of our setup 1 direction that we defined while importing.
02:31
And ultimately, we ended up colliding our holder into our part.
02:36
Let's take a look at this first option, fixed.
02:40
The fixed option on the 5-axis tab allows us to simply define a vector that will define our tool axis.
02:47
While machining this part, our tool axis will always be aligned to this defined vector.
02:53
So for this part, let's enter a vector of negative 0.5 in the X, 0 in the Y, and 1 in the Z.
03:05
Just to help you visualize, if we wanted our tool to be perfectly aligned with the Z going vertical, we could enter in a vector of 0,0,1.
03:16
If we wanted our tool completely horizontal aligned with our X direction, we could enter in 1,0,0.
03:24
And likewise, if we wanted our tool oriented horizontal in the Y direction, we would enter in 0,1,0.
03:33
So this fixed vector has both an X and a Z component.
03:38
So we can expect to see some tilting in both the X and the Z directions, but not in the Y.
03:44
With that vector indicated, let's select "Apply", "OK", and run another machine simulation.
04:06
Now we can see that while we were finishing the part, the tool axis changed to reflect our fixed tool axis vector.
04:14
This change has completely eliminated the collisions we were experiencing earlier, and this program is now safe to run on the machine.
04:22
However, let's dig a little bit deeper and take a look at some of the other options we have to utilize our 5-axis machine’s capabilities
04:30
when programming surface milling features.
04:32
So, I'll eject the simulation, reopen surface milling tool, go back to the parallel finishing operation, and navigate to the 5-axis tab.
04:45
Next, let's take a look at our first multi-axis option titled use Lead and Lean.
04:51
Select use Lead and Lean, in the from drop-down, select Contact normal and enter in a lead angle of zero and a lean angle of zero.
05:03
Right now, we're telling FeatureCAM that by entering in a zero and a zero value for both angles, at all times we would like to be perpendicular to the contact normal surface.
05:15
Lead and lean angles are the angles that we would like to rotate both in the direction of travel and perpendicular to the direction of travel.
05:24
So a lead angle allows us to lean either forward or backward in the direction of travel.
05:32
Lean angle allows us to lean left or right perpendicular to the axis of travel.
05:39
Think about a sprinter running around a track.
05:43
When a sprinter takes off, the sprinter’s body is tilted forward along the direction of travel.
05:50
Think of this as a lead angle of maybe 15 degrees.
05:54
Now as the sprinter approaches the turn, the sprinter must lean to the left.
06:00
This would be a lean angle of, let's say, negative 15 degrees.
06:05
So lead angles are the amount that you would like to tilt in the direction of travel.
06:11
Lean angles are the amount that you would like to tilt left or right perfectly perpendicular to the direction of travel.
06:19
Hopefully that analogy helps you visualize.
06:22
But let's hit "Apply", "OK", and run a machine simulation to get a better idea of what a lead and lean angle of zero looks like.
06:35
As we begin to machine our finishing operation, after this first roughing operation, we’ll be able to see that the lead and lean tools allow us to specify a tool axis angle in reference to the direction of travel at all times.
06:49
When we're machining a horizontal wall, the tool is completely vertical.
06:53
When we're machining a vertical wall, the tool should be completely horizontal.
06:58
These options can help us generate safe and efficient toolpath in a lot of situations.
07:03
But it looks like in this situation, it seems that the lead and lean angles have created a machining collision where the table has collided with the machine.
07:13
So, in this case, lead and lean angles of zero may not be our best option.
07:20
At this time, feel free to experiment with some various lead and lean angles until you generate safe toolpath.
07:27
As you change the angles, notice how that affects our tool axis while machining the finishing operation.
07:37
Once you feel comfortable with the lead and lean options, open up surface mill 2 and navigate to the parallel operation 5-axis tab.
07:47
The last option I'd like to take a look at is the Tilt Axis for Gouge Avoidance option.
07:54
Here we can tell FeatureCAM among other options to lead or lean only if we are going to collide.
08:02
So, if I select to lead and move my axis back to a vertical, going perfectly aligned with our positive Z direction, "Apply" and "OK", we'll see that my finishing operation now starts and stays vertical at all times, unless it's going to collide.
08:21
In that case, it automatically leads as much as it needs to not collide.
08:28
As we move out of danger of collision, our tool axis will align itself vertically again.
08:33
Let's play through our roughing operation, then slowly watch our finishing operation.
08:48
Notice how the tool axis stays perfectly vertical until we are in danger of colliding.
08:54
Then it changes the lead angle until we're out of danger and moves the tool axis back to vertical.
09:14
In this revised portion, we took a look at three different 5-axis simultaneous options.
09:20
First, we tried fixing our tool axis along a defined vector to avoid collisions, and that seemed to work.
09:27
Next, we tried changing the lead and lean angles to zero, so that we would always stay perfectly perpendicular to the contact normal.
09:37
As you may recall, this actually ended up resulting in a collision.
09:42
Hopefully, you took the time to explore various lead and lean angles that prevented that collision.
09:48
Finally, we looked at the Tilt Axis for Gouge Avoidance option.
09:53
Here, we told FeatureCAM that whenever possible we would like to keep our tool axis vertical along the Z.
10:01
But if we are in danger of colliding, we would like to either lead or lean to safety while still simultaneously machining.
10:12
So as we can see, there's always multiple solutions for us to machine the exact same part.
10:18
Pick the one that makes most sense to you and run your final machine simulation before moving on to the next section, NC Code.
