TopSolid’Cam 2011 Main improvements
Main improvements
2D operations multi-geometry 2D contouring improvements New 3D finishing cycles 4 Axis improvements 5 Axis Turning improvements Machine replacement
2D contouring
Multi-geometry contouring (1/2)
The user is able to machine several profiles at different altitudes. The links between each tool path, the order of the tool paths, the depths and the starting Z can be managed in the dialog box directly. This creates one operation and only one. The strategy ÂŤ by Z levels Âť allows the machining of parts which present very thin walls which are frequently used on aeronautical parts.
2D contouring
Multi-geometry contouring (2/2)
This technique could be used to make some engraving and avoid jumps between tool paths. State surface quality is preserved.
2D contouring
Profile to contour calculation
In some particular cases, the calculation of the profile to contour fails because the bottom face of the part to machine is not planar. This new setting allows the definition of the altitude to cut the face to define the profile to machine. More, this technique makes easier the compare and replace of parts replacement.
2D contouring
Contouring / engraving self-intersected profiles
ZMI_SELF_INTERSECTED_CURVE_PARALLEL 1 TopSolid’Cam 2011 supports self-intersected profiles. This option is accessible trough a configuration word. See the differences between the left and right pictures.
2D contouring
Helical and alternate contouring on open profiles
TopSolid’Cam 2011 supports helical contouring on open profiles. Bi-directional cutting is supported too. For aeronautical parts, this allows efficiently tool paths which remove lot of material. Cutter compensation changes are managed automatically.
Multi-Pocketing
Running processes on multi-pocketing function
Processes can be run trough faces analysis. The user rights click on the selected face to choose the process to use. Machine this part can be done fully automatically.
3D Finishing new cycle
Helical Z Level (1/2) Helical Z Level allows constant contact between the tool and the material. When the part has some bosses (like the pictures on the left), the application manages retracts to prevent tool overloads in the areas which aren’t still machined.
3D Finishing new cycle
Helical Z Level (2/2) Helical Z Level should become a common strategy for parts which are like this tripod car. The application creates a tool path which goes down of one Z step by revolution.
3D Finishing new cycle
Z Level contact mode
Z Level finishing operation supports “contact� mode. The user can select the faces where he wants to be in contact. The tool path is trimmed by the contact faces. Very useful for aeronautical parts. Note: it was developed last year for Parallel plane technology. (PPT)
3D Finishing new cycle
Morphing (1/3) Morphing is a new strategy. The tool path is created from 2 open or 2 closed curves. The first selected curve is deformed progressively to obtain the second one. Intermediate curves can be set to modify the “look� of the tool path. This one is helical to perform better cutting conditions. The scallop height cannot be constant but the tool never jumps to guaranty a good surface quality.
3D Finishing new cycle
Morphing (2/3) Morphing supports several modes to define the tool position regarding the curves. Contact, on, before and after are available. However, undercut aren’t handled by the application.
3D Finishing new cycle
Morphing (3/3)
In some cases, morphing can be seen as a tool path strategy which should replace the sweeping strategy. In the sample above, the faces aren’t machinable by using ISO-Parametric machining because the ISOs are too different. Morphing between 2 open curves solves that question!
3D Finishing new cycle
3D tool radius compensation Some modern numerical controllers support 3D tool radius compensation. In that case, the application must provide a direction to apply the compensation (difference between the programmed tool radius and the real tool radius). These vectors can be displayed on user demand. To be efficient, the tool radius must be smaller than the local radius of the part. On other hands, the tool path must be continuous.
4D Roughing
Areas and limitation curves
4 Axis roughing can be trimmed by curves for specific cases. The application does the same thing with the finishing option (picture on the right).
5D Machining
3D to 5D conversion: new collision check settings
In case of collisions between the tool and the part which aren’t avoidable by changing the tilt angles, the application allows other different settings. For example, by jumping to the clearance point like the example above.
5D Machining
Miscellaneous Database Database structures and database models have been completely reviewed to perform better tool path, faster computation and realistic simulation. User interfaces have been modified too, to be homogeneous. 5 Axis vectors modification 5 axis vectors modification has been completely reviewed and merged with the tool path solution edition. When executing an operation plan again, if the 5 axis tool path is not modified, vectors modifications are kept (so, it is no necessary to do it again) Simulation Simulation takes account of the real angular position of the tool according the previous operations
5D Machining
Swarf machining drive & check surfaces
Swarf machining provides a new option where the user can define Drives & Checks surfaces to perform the tool path calculation.
5D Machining
Swarf machining faces selection (mode ISO)
In the case of the part which is above, selecting the faces (called ISO mode selection) makes a “nightmare� on the tool path because the ISO-Parametric structure is not continuous and the application cannot chain the faces correctly. Look at the faces as the software sees them.
5D Machining
Swarf machining faces selection (Drive & check surfaces)
By using drive and check faces, the application creates a guide curve which is the base of the tool path calculation. In that specific case, the tool path can be created even if the topology of the part is bad. You can compare with the result of the previous slide.
5D Machining
Swarf machining air cutting management
A new setting allows the trim of all the tool paths which aren’t in contact with the part. This avoids air cuttings.
5D Machining
Homogeneous user interface Swarf machining, 5 axis contouring, 5 axis sweeping, 3D to 5D function purpose the same user interface, especially on “Axis and angular limitations” and on “Retracts movements”. Some new options are available to set parameters which were set automatically before: • What the application have to do in case of undefined solution or in case of undetermined solution? • What the application have to do when bounds are reached? • Locally clearance block or cylinder definition. • Etc.
Turning
Plunge roughing
Inside the plunge roughing cycle itself, an optimization can be apply to avoid air cuttings on large grooves. The retract movements are made until the places where the material has been removed to save time and productivity.
Turning
Management of small displacements in contouring In case of very small movements (length movement is smaller than the feed rate per revolution value), it is necessary to reduce the feed rate to obtain the right shape. By default, the feed rate was divided by 2. However, now, the customer can choose the wanted ratio.
Machine
Machine replacement A wizard allows the replacement of a machine by another one, even if the kinematics of the original and destination machines are completely different. Operations which aren’t possible to be performed on the destination machine are automatically inactivated. The wizard is based on 5 steps.
Machine
Machine replacement Wizard
1 Start replacement 2 Choice of the replacement machinetool
5 Part positioning
3 Axis analysis and replacement
4 Tools replacement
Miscellaneous
Tool paths • Different colors on approaches and retracts to make the difference with the tool path itself. Operations manager: The cutting conditions tab has 2 new columns: • Tools numbers • Tools compensation numbers Part creation • In the part creation command, the lasso allows to select several parts as finish parts to share the same stock • Stock dimensions setting have been reviewed
Differed computing • Revolved parallel plane and swarf machining can use the differed computing. Minimal tool length for a tool • The minimal tool length of a tool can be set according the stock WCS • The function « WCS list » can display the list of all the WCSs of all the parts
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