Ruled Surface Swarf Milling Mastercam 9 For Cad Model & CL File Generation Postprocessor Mathematca 5-Axis - Machine Mimt

RULED SURFACE SWARF MILLING
MASTERCAM 9 for CAD Model & CL file Generation

PostProcessor MATHEMATCA
5-axis - MACHINE MIMT
NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation
RULED SURFACE
P1 (-24,-24,0)
P2 (24,0,0)
P3(-24,-24,-20)
P4 24,-24,-20
Generate Multi-Axis Swarf Toolpath
Black Plot Tool path To Observe

Overcut/Undercut
Observe Large Ovecut
Observe CL vectors (Blue lines)
Define Blank
48x48x20
Define Tool
10
11
Verify CL file in Solid Simulation
12
Generate NCI file (NC Intermediate file)

Non ISO standard Cutter Location File
13
What is Inside the NCI file
We only need to pick up Line with Code 11

x1 y1 z1 x2 y2 y3 I j k
14
Strip un-neccessary information with excel

S
t
r
15
16
17
18
Record below code 11 is required CL data

19
20
After Stripping we have

Code 11
Record x y z I j k
21
5 AXIS PROGRAMMING
22
OVERVIEW
Haas Control
5-Axis Theory
5-Axis Control
CAD-CAM Programming
Tool Paths and Geometry
Tool Axis Control
Feed Rates
Posting
Troubleshooting G-Code
Machine Set-up
23
HAAS CONTROL
24
Configurations
Head-Head
25
Head-Head
26
Head-Head
27
Head-Head
28
Head-Table
29
Head-Table
30
Head-Table
31
Table-Table
32
Table-Table
33
Table-Table
34
Table-Table
35
Table-Table
36
Simultaneous Dual Axis

Rotary and Linear Motion
Rotary Axis Brakes
Unclamp - M11-4th, M13-5th
Clamp - M10-4th, M12-5th
Calculating Rotary and Linear Speeds

Pi*D/360 = Inches per degree
o D= Diameter (Distance from rotation centerline to
tool tip, multiplied by 2)

Pi*D = Circumference
o 3.14*4./360=0.035/deg.
IPM/Inches per degree = degree per min.

o 75/0.035.=2143 degrees per min.
o Maximum feed on the VF6TR is 2000deg/min
o MaxSURFACE
NIMT - RULED
- Vericut
Simulation
feed onMILLING
the VR- September
series is2013
600
deg/min
37
Simultaneous Dual Axis Rotary

Linear Motion
Inverse Time - G93
F = Strokes per minute
o F = Inches per minute / stroke length
If F=120., each stroke takes 60/120=.5
seconds to complete
An F value is required for each
interpolated motion
38
Parameters and Settings

Parameter 104/165 - In Position Limit
Parameter 302 - Feed Acceleration
Parameter 303 - Feed Time Constant
39
Parameters and Settings

(cont)
Parameter 314 - Feed Delta V
Setting 85 - Max Corner Rounding
G187 - Accuracy Control
40
5-Axis Programming
Tool Paths and CAD Geometry

Tool Axis Control
Feed Rates - Inverse Time
Posting the G-Code
Troubleshooting bad code
Non-uniform rotary and/or linear output
41
Machine Set-up
Setting up the Trunnion
Finding the Centerline of Rotation
Setting Machine Offsets
Trunnion
VR series
Setting Tool Offsets

Trunnion
VR series
Dry Run
42
Tool Length Offsets

VR Series
43
Tool Length Offsets

VR Series
44
Offsets
Trunnions
Indicate Parallel to the Y Axis

Rotate to A+90. and indicate
parallel to the X Axis
Use indicator and sweep

Platter
align Trunnion
NIMT - RULED SURFACE
MILLINGto
- September
2013 - Vericut Simulation
45
Tool Length Offsets

Trunnions
46
Y-Distance
47
Offsets (cont)
Trunnions
Use indicator to find

center of Bore for X
and Y Offsets
NIMT - RULED SURFACE MILLING
Touch Tools to Fixture

- September 2013 - Vericut Simulation
48
Prepared by Haas Automation

Training Department
Oxnard, CA 93030
49
50
TOOL
CL-VECTOR
INVERSE
= - September 2013 - Vericut Simulation
NIMT -KINEMATICS
RULED SURFACE MILLING
Move X,Y,Z,A,B untill TOOL=CL-VECTOR
51
RULED SURFACE SWARF MILLING

52
53
54
CL File for Ruled Surface

11
0.0
0.0
0.0
0.0
0.0
1.0
11
-17.89099-27.557858
34.640646
0.111073
11
-21.777038
-28.47523-0.1172270.111073 0.026221
11
-24
-29
-20
0.111073 0.026221 0.993466
11
-22.222222
-28.995069
-19.777997
11
-20.444444
-28.980363
-19.557301
11
-18.666667
-28.95614-19.339181
0.109347
11
-16.888889
-28.922813
-19.124833
11
-15.111111
-28.880935
-18.915348
11
-13.333333
-28.831175
-18.711687
11
-11.555556
-28.774284
-18.514667
0.026221 0.993466
0.993466
0.110878 0.070238 0.991349

0.110299 0.113814 0.98736
0.156713 0.981572
0.108041 0.198717 0.974084
0.106407 0.23963 0.965016
0.104475 0.279286 0.954507
0.102281 0.317547 0.94271
55
11
-9.777778-28.711073
11
-8
-28.642383
11
-6.222222-28.569058
11
-4.444444-28.491922
11
-2.666667-28.411765
11
-0.888889-28.329325
11
0.888889 -28.245283
11
2.666667 -28.160251
11
4.444444 -28.074777
11
6.222222 -27.989337
11
8
-27.904344
-18.324952
0.099862 0.354305 0.929783
-18.143047
0.097254 0.389482 0.915885
-17.969308
0.094496 0.423028 0.901176
-17.803949
0.091624 0.454916 0.885808
-17.647059
0.088672 0.485144 0.869927
-17.498612
0.085672 0.513727 0.853665
-17.358491
0.082651 0.540698 0.837146
-17.226499
0.079636 0.566101 0.82048
-17.102381
0.076647 0.589991 0.803763
-16.985835
0.073701 0.61243 0.787082
-16.876525
0.070815 0.633483 0.770509
56
11
9.777778 -27.82015-16.774096
0.068
0.653222
11
11.555556
-27.737047
-16.678181
11
13.333333
-27.655276
-16.588409
11
15.111111 -27.575033
-16.504412
0.060063
11
16.888889
-27.496471
-16.425830.057603
11
18.666667
-27.419706
-16.352314
11
20.444444
-27.344824
-16.283529
11
22.222222
-27.271884
-16.219157
11
24
-27.200922
-16.158894
0.048732
11
25.522423
-3.0779313.63416 0.048732 0.772158
11
26.680234
15.267743
18.686893
0.754106
0.065265 0.671718 0.737926
0.062618 0.689041 0.722012
0.705263 0.706397
0.720452 0.691108
0.05524 0.734674 0.676168
0.052974 0.747992 0.66159
0.050805 0.760468 0.647385
0.772158 0.63356
0.63356
0.048732 0.772158 0.63356
57
Solution B4 A3
58
(* Geometry Transform for NIMT 5-axis machine - *)

cldata = ReadList["C:\\Documents and Settings\\Tin\\My Documents\\My Webs\\AT
{RecordLists -> True}];
ncprog = OpenWrite["C:\\Documents and Settings\\Tin\\My Documents\\My Webs\\
(* Workpiece Offsets *)
rowcol = Dimensions[cldata];
Print["row col = ",rowcol[[1]]];
(* o1 origin workpiece coordinate system on surface of B table so 3.307 lower then
(* o2 on B table centerline at intersection of B and A axis level *)
(* o4 on the same location as o2 *)
(* o3 on A table centerline but 0.003 mm further in the machine *)
(* x axis positive move table to right *)
(* y axis positive move table move toward operator in front of machine *)
(* z axis positive tool spindle move up *)
(* B rotation is around z positive following right hand rule *)
(* A rotation is around x positive following right hand rule *)
59
X+
Y+
Blank Workpiece Set UP on MIMT HAAS 5-axis Machine
60
Blank Workpiece Set UP on MIMT HAAS 5-axis Machine
61
xo1o2 =- 4.689;
yo1o2 = 28.577;
zo1o2 = 123.4;(* workpiece offset for rulesuface *)
xo2o3 = 0;
yo2o3 = -0.003; (* actualy -0.003 micron *)
zo2o3 = -3.307;
xo3o4 = 0;
yo3o4 = 0;
zo3o4 = 3.307; (* should be 3.307 *)
z4T = 137.74; (* tooltip coordinate in o4 Tool length L = 133.734 mm *)
62
i = 1;
Write[ncprog,"%"];
Write[ncprog,"O33004 ( ruled surface solution B4 A3 )"];
Write[ncprog,"N100 T2 M06 F300"];
Write[ncprog,"N101 G90 G54 X0.0 Y0.0 Z0.0 A0.0 B0.0 (Trunnion Table startup) "];
Write[ncprog,"N102 S1500 M03"];
Write[ncprog,"N103 G43 H02 Z0.1"];
While[ i <= rowcol[[1]]/2,
x1 = cldata[[2i,1]];
y1 = cldata[[2i,2]];
z1 = cldata[[2i,3]];
i1 = cldata[[2i,4]];
j1 = cldata[[2i,5]];
k1 = cldata[[2i,6]];
(* when workpiece coordinate system is not oriented as machine *)
(* computation of the C angles and B *)
63
If[ Abs[j1] <= 0.0001 , j1 = 0.00001];

B1 = -ArcTan[j1/i1]; B2 = 2 Pi + B1;
B4 = Pi + B1; B4 = -Pi + B1;
(* A angles for solutions B1 & B2 *)
A1 = -ArcCos[k1];A2 = -2Pi + A1; (* two solution but must check range limit *)
(* A angles for solutions B3 & B4 *)
A3 = +ArcCos[k1]; A4 = 2Pi + A3; (* two solution but must check range limit*)
(* workpiece motion o2 coincides with o4 as machine coordinate system
in reference*)
(* tool x-axis,y-axis, B-axis - workpiece z-axis,C axis *)
(* x+ tool move right - y+ tool move away - z+ workpiece up - B+ righthand
around y+ - C+ righthand around z+*)
(* workpiece *)
BB = B4;
(* o1 and o2 in plane of rotary table x-axis of rotation is higher *)
x2w = x1 + xo1o2;
y2w = y1 + yo1o2;
z2w = z1 + zo1o2;(* coordinate transform o1 -> o2 *)
(* Rotation B around z in o2 *)
x2wb = x2w Cos[BB] - y2w Sin[BB];
y2wb = y2w Cos[BB] + x2w Sin[BB];
z2wb = z2w; (* rotation BB in o2 *)
64
(* Coordinate transform from o2 to o2 *)

x3w = x2wb + xo2o3;
y3w = y2wb + yo2o3;
z3w = z2wb + zo2o3;
AA = A3;
(* rotation AA in o3 *)
x3wa = x3w;
y3wa = y3w Cos[AA] - z3w Sin[AA];
z3wa = z3w Cos[AA] + y3w Sin[AA];
(* coordinate transform o3 to o4*)
x4w = x3wa + xo3o4 + delX;
y4w = y3wa + yo3o4 + delY;
z4w = z3wa + zo3o4-z4t;
(* coodinates of tooltip in o4 and translation delZ
*)
x4t = 0;
y4t = 0;
z4t = z4T+delZ;
65
(* machine slide motions from handshake *)

delX = -x3wa - xo3o4;
delY = -y3wa - yo3o4;
delZ = z3wa + zo3o4 - z4T;
If[Abs[N[delX]] <= 0.0001,delX = 0.000];
If[Abs[N[delY]] <= 0.0001,delY = 0.000];
If[Abs[N[delZ]] <= 0.0001,delZ = 0.000];
Write[ncprog,"N",100+10i," G01 X",PaddedForm[delX,{6,3}],
" Y",PaddedForm[delY,{6,3}]," Z",PaddedForm[delZ,{6,3}]," B",
PaddedForm[BB 180/Pi,{6,3}], " A", PaddedForm[AA 180/Pi,{6,3}], " F300"];
i++];
Write[ncprog,"N800 G00 Z50.0"];
Write[ncprog,"N900 M30"];
Write[ncprog,"%"];
Close[ncprog];
66
%
O33004 ( ruled surface solution B4 A3 )
N100 T2 M06 F300
N101 G90 G54 X0.0 Y0.0 Z0.0 A0.0 B0.0 (Trunnion Table startup)
N102 S1500 M03
N103 G43 H02 Z0.1
N110 G01 X -4.689 Y 28.580 Z -14.340 B-180.000 A 0.000 F300
N120 G01 X -6.180 Y -39.256 Z 16.809 B-256.717 A 6.553 F300
N130 G01 X -6.180 Y -39.256 Z -18.178 B-256.717 A 6.553 F300
N140 G01 X -6.180 Y -39.256 Z -38.191 B-256.717 A 6.553 F300
N150 G01 X -14.048 Y -35.922 Z -37.999 B-237.647 A 7.542 F300
N160 G01 X -17.768 Y -33.487 Z -37.986 B-224.101 A 9.119 F300
N170 G01 X -18.937 Y -32.674 Z -38.149 B-214.906 A 11.017 F300
N180 G01 X -18.792 Y -33.170 Z -38.481 B-208.533 A 13.073 F300
N190 G01 X -17.973 Y -34.548 Z -38.974 B-203.943 A 15.200 F300
N200 G01 X -16.791 Y -36.482 Z -39.617 B-200.510 A 17.349 F300
N210 G01 X -15.402 Y -38.757 Z -40.397 B-197.854 A 19.488 F300
N220 G01 X -13.888 Y -41.228 Z -41.302 B-195.741 A 21.599 F300
N230 G01 X -12.295 Y -43.798 Z -42.317 B-194.020 A 23.668 F300
N240 G01 X -10.651 Y -46.400 Z -43.428 B-192.592 A 25.687 F300
N250 G01 X -8.970 Y -48.988 Z -44.621 B-191.388 A 27.649 F300
67
N260 G01 X -7.266 Y -51.531 Z -45.883 B-190.358 A 29.550 F300

N270 G01 X -5.543 Y -54.006 Z -47.201 B-189.468 A 31.387 F300
N280 G01 X -3.807 Y -56.397 Z -48.562 B-188.691 A 33.160 F300
N290 G01 X -2.061 Y -58.696 Z -49.957 B-188.008 A 34.867 F300
N300 G01 X -0.307 Y -60.897 Z -51.374 B-187.402 A 36.509 F300
N310 G01 X 1.452 Y -62.996 Z -52.804 B-186.862 A 38.086 F300
N320 G01 X 3.216 Y -64.992 Z -54.241 B-186.378 A 39.600 F300
N330 G01 X 4.983 Y -66.888 Z -55.677 B-185.943 A 41.053 F300
N340 G01 X 6.753 Y -68.684 Z -57.106 B-185.550 A 42.445 F300
N350 G01 X 8.525 Y -70.383 Z -58.523 B-185.193 A 43.779 F300
N360 G01 X 10.299 Y -71.990 Z -59.924 B-184.868 A 45.057 F300
N370 G01 X 12.075 Y -73.507 Z -61.304 B-184.571 A 46.282 F300
N380 G01 X 13.852 Y -74.940 Z -62.662 B-184.300 A 47.455 F300
N390 G01 X 15.629 Y -76.292 Z -63.995 B-184.051 A 48.579 F300
N400 G01 X 17.407 Y -77.567 Z -65.301 B-183.822 A 49.655 F300
N410 G01 X 19.186 Y -78.771 Z -66.579 B-183.611 A 50.687 F300
N420 G01 X 19.186 Y -78.771 Z -35.338 B-183.611 A 50.687 F300
N430 G01 X 19.186 Y -78.771 Z -11.579 B-183.611 A 50.687 F300
N800 G00 Z50.0
N900 M30
%
68
Solution B3 A3
69
Solution B2 A1
70
Solution B1 A2
71

Ruled Surface Swarf Milling Mastercam 9 For Cad Model & CL File Generation Postprocessor Mathematca 5-Axis - Machine Mimt

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Ruled Surface Swarf Milling Mastercam 9 For Cad Model & CL File Generation Postprocessor Mathematca 5-Axis - Machine Mimt

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RULED SURFACE SWARF MILLING

MASTERCAM 9 for CAD Model & CL file Generation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Generate Multi-Axis Swarf Toolpath

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Black Plot Tool path To Observe

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Observe Large Ovecut

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Observe CL vectors (Blue lines)

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Verify CL file in Solid Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Generate NCI file (NC Intermediate file)

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

What is Inside the NCI file

We only need to pick up Line with Code 11

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Strip un-neccessary information with excel

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Record below code 11 is required CL data

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

After Stripping we have

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Simultaneous Dual Axis

Calculating Rotary and Linear Speeds

tool tip, multiplied by 2)

IPM/Inches per degree = degree per min.

Simultaneous Dual Axis Rotary

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Parameters and Settings

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Parameters and Settings

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Tool Paths and CAD Geometry

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Setting Tool Offsets

Tool Length Offsets

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Tool Length Offsets

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Indicate Parallel to the Y Axis

Use indicator and sweep

Tool Length Offsets

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

Use indicator to find

Touch Tools to Fixture

Prepared by Haas Automation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation

NIMT - RULED SURFACE MILLING - September 2013 - Vericut Simulation