Edu Cat en Mmg Fi v5r19 Toprint

7/23/2019 Edu Cat en Mmg Fi v5r19 Toprint

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Multi-Axis Surface Machining

Copyright DASSAULT SYSTEMES 1

CopyrightDASSAULTSYSTEMES

Multi-Axis SurfaceMachining

CATIA V5 TrainingFoils

Version 5 Release 19January 2009

EDU_CAT_EN_MMG_FI_V5R19


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About this course

Objectives of the courseUpon completion of this course you will be able to

- Identify and use the Multi-Axis Surface Machining workbench tools

- Define 5-Axis machining operations such as Multi-Axis Sweeping, Multi-AxisContour Driven, Multi-Axis Curve Machining, Multi-Axis IsoparametricMachining, Multi-Axis Drilling and Multi-Axis Tube Machining.

Targeted audienceAdvanced NC Programmers

Prerequisites

Students attending this course must have knowledge of CATIA V5 SMGFundamentals

8 hours


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Table of Contents (1/4)

Introduction to Multi-Axis Surface Machining 7

About Multi-Axis Surface Machining 8

Accessing the Workbench 9

The User Interface 11

Master Exercise: Fender (Wing) 12

Master Exercise: Step 1 13

Multi-Axis Sweeping Operation 14

About Multi-Axis Sweeping Operation 15

How to Create a Multi-Axis Sweeping Operation 16

Multi-Axis Sweeping Operation: General Process 17

Strategy Definition 18

Geometry Definition 34

Tool Definition 36

Speeds and Feedrates Definition 38

Macros Definition 39Master Exercise: Step 2 46

Multi-Axis Contour Driven Operation 47

About Multi-Axis Contour Driven Operation 48


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How to Create a Multi-Axis Contour Driven Operation 49



Multi-Axis Curve Machining Operation 55

About Multi-Axis Curve Machining Operation 56

How to Create a Multi-Axis Curve Machining Operation 57



Macros Definition 77


Multi-Axis Isoparametric Machining Operation 79

About Multi-Axis Isoparametric Machining Operation 80

How to Create a Multi-Axis Isoparametric Operation 81


Geometry Definition 86Macros Definition 87

Multi-Axis Drilling Operation 88

About Multi-Axis Drilling Operation 89


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How to Create a Multi-Axis Drilling Operation 90




Multi-Axis Tube Machining Operation 94

About Multi-Axis Tube Machining Operation 95

How to Create a Multi-Axis Tube Machining Operation 96


Tools Definition 105


Multi-Axis Spiral Milling Operation 108

About Multi-Axis Spiral Milling Operation 109

How to Create a Multi-Axis Spiral Milling Operation 110



Exercises 115

Exercise 1: Hood 116

Exercise 2: Pocket 117


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Exercise 3: Isoparametric and Drill 118

Exercise 4: Multi-Axis Curve Machining 119

Exercise 5: Tube Machining 120

Exercise 6: Multi-Axis Spiral Machining 121


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Introduction to Multi-Axis Surface Machining

You will become familiar with CATIA V5 Multi-Axis Surface Machining User Interface.


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About Multi-Axis Surface Machining

Multi-Axis Surface Machining enables you to produce NC

programs dedicated to machining parts designed in 3DWireframe or solids geometry using Multi-Axis machiningtechniques.

Based on industry recognized and leading edge technologies,Multi-Axis Surface Machining provides tight integration betweentool path definition, verification and modification.

Multi-Axis Surface Machining is an add-on on product to 3-AxisSurface Machining.

Thus, the user benefits from superior 3-axis multiple surfacemachining and leading edge 5-axis simultaneous machiningtightly integrated in a flexible NC Programming workbench.

Multi-Axis Surface Machining is particularly adapted for mock-up and die machining in automotive domains where the use of5-axis simultaneous machining brings unequalled surfacequality. Moreover, it is targeted at prototype machining, 5-axistrimming and special machining where full 5-axis machining is

the requirement for quick and accurate manufacturing.As an add-on product, it takes advantage of functions such asmaterial removal simulation and NC data generation. It addsdedicated multi-axis surface machining techniques to the 3-Axissurface machining capabilities offered by 3-Axis SurfaceMachining.

You can define a 3D contact compensation Mode available forevery Multi-Axis operations.


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Accessing the Workbench (1/2)

Start > Machining > Surface Machining

Functionalities available for



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Accessing the Workbench (2/2)

Once you have MMG license, the associated toolbar is displayed.

Multi-AxisContour Driven

Multi-Axis SpiralMachining

Multi-Axis CurveMachining

Multi-AxisSweeping

Multi-Axis TubeMachining

IsoparametricMachining


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The User Interface

3 Axis and Multi-Axis

Surface MachiningItems

Other SurfaceMachining Items


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Master Exercise: Fender (Wing)

Exercise Presentation

70 min

In this exercise, you will learn 5-Axis SurfaceMachining fundamental concepts by machining a partfrom the 3D.

You will define parameters within the Part Operationand use provided tools within a tool catalog. You will

see also how to define a geometry and a strategy.


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Master Exercise: Fender

Step 1: Create a new Part Operation

5 min

In this step you will learn how to define anew Part Operation.


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Multi-Axis Sweeping Operation

You will become familiar with creation of a Multi-Axis Sweeping Operation.


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About Multi-Axis Sweeping Operation

It is a milling operation in which the tool path is executed in parallel planes respectinguser-defined geometric limitations and machining strategy parameters.

In Multi-Axis Sweeping, the View Direction and Starting Direction define the guiding plane.Machining is done in planes parallel to the guiding plane.

CAUTION:

View Direction Definition: The view direction is very important because, it will decide which area isreachable regarding this view.

Regarding the selected area and the view direction, CATIA will take care of the computed contouroutline.

Multi-Axis Sweeping Operation:

With a sphere: using Z axis as view direction (See Compass),the only reachable area is the green area concretized by tool

trajectories here.

The tool axis will be computed regarding the tool axis modesetting (interpolation, lead & tilt, etc), but never you will beable to reach the bottom side of the sphere.

We will use the starting direction as well to compute theguiding plane.

Example: On a Sphere


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How to Create a Multi-Axis Sweeping Operation

2

3

4

5

The Operation is created in the PPR tree with a default tool. This capabilitycan be removed by customizing the NC Manufacturing options.

1

The new Operation is created after thecurrent one. The Operation dialog boxdisplays to define its parameters

2

Define the Operation geometry andparameters in the dialog box

3

Replay the Tool Path4

Click Multi-Axis SweepingOperation icon

1

Confirm Operation creation5


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Multi-Axis Sweeping Operation: General Process

Define operation parameters using the 5 tab pages

Strategy tab page

Geometry tab page

Tool tab page

Feeds & Speeds tab page

Macros tab page

Type the Name of the Operation.(optional because a default name is givenby the system Type_Of_Operation.X)

1

2 Type a line of comment (optional)

3

Replay and/or Simulate the operation tool path

4

2

4

Before replaying or creating the operation, Previewchecks that all parameters are coherent

55

3

1

Click OK to create the operation6

6


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Strategy Definition (1/16)

With these arrows, you can define the ViewDirection, the Start Direction, and optionallythe Tool Axis

Machining Tab page

Radial Tab page

Tool Axis Tab page


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Machining tolerance:Value of the maximum allowable

distance between theoretical tool pathand the tool path computed

Max discretization step:Maximum length between twoconsecutive computed points

Max discretization angle:Tolerate value of the tool Axis Anglevariation between two consecutivecomputed points

Min Path Length:All computed paths below this valuewill be removed

Machining Tab:


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A. Scallop Height value

B. Distance on part

C. Distance on plane

D. Number of paths


Define the Stepoverside: Left or right

Radial Tab:

A

D

B OR C


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Lead and Tilt

Fixed axis

Thru a point

Normal to line

4-Axis lead/lag

Optimized lead

Thru a guide

Normal to drive surface

Tool Axis tab


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Lead and tilt:

The tool axis is guided in Lead and Tilt mode.

Lead and tilt means you can set two different angles.

Lead => User-defined incline of the tool axis in a plane defined by the direction of motion and thenormal to the part surface. The tool axis incline is with respect to the part surface normal.

Tilt => User-defined incline of the tool axis in a plane normal to the direction of motion.

The tool axis incline is with respect to the part surface normal.

These angles are computed for each considered point regarding the normal vector of the surface.

There are 3 Guidance modes for Lead and Tilt strategy:Regarding the mode you choose, you leave some freedomto the tool axis during the machining operation.


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Fixed lead and tilt:


Set the fixed Lead Angle

Set the fixed Tilt Angle

Variable Lead and Fixed Tilt:The purpose of variable Lead Mode is to avoid collisions between the machining part and toolrear side (in case of toroidal tool) or with the full tool body (for all other tool types).

In Variable lead and fixed tilt mode, you may set a Max lead angle value and a Min lead angle

value regarding the normal to the surface at the computed point. So you limit all big anglevariation of the tool axis between two consecutive points

A. Set the Reference Lead Angle

B. Set the fixed Tilt Angle

C. Set the Min Lead Angle

D. Set the Max Lead Angle

A

B

C

D


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A. Set the fixed Lead Angle

B. Set the reference Tilt Angle

C. Set the allowed tilt variationaround its basic referenceangle value

Fixed lead and variable tilt:

In Fixed lead and variable tilt mode, you canset a reference tilt angle value regarding the

normal to the surface at the computed point and an allowed tilt variation.

You set a fixed Lead Angle.

A

C

B


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In general, you must choose:

A filleted-end tool for Variable lead and fixed tilt tool axis guidance.

A ball-end tool for Fixed lead and variable tilt tool axis guidance

Filleted-end tool Ball-end tool


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Fixed axis:

You can define the tool axis orientation by clicking the tool axis arrow (A) in the strategy tabpage. The tool axis will keep constant orientation during the machining operation.

Set the value by selectingthe tool axis

Axis Selection: This type of selection is available for all other operationsClick one of the red tool axes in the sensitive icon, then specify the tool axisorientation at the start of machining.

You can do this by selecting a surface. In this case the surface normal is used.


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Fixed axis:

Different available choices fortool axis orientation:

By Components (coordinates)or by Angles


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Thru a point:

The tool axis keeps a constant direction toward the selected point during the wholeMachining operation.

Set the Point by selecting thepoint symbol


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Normal to line:

The tool axis remains perpendicular anytime during machining to the selected axis defined bythe red Line symbol.

Set the Line by selecting thered line symbol

The tool axis is normal to the selected Line, and intersect it.Its a Normal and Through a Line.(Example: to be used for 4 Axis machine, selecting the C axis as table center axis)


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4-Axis lead/lag:

You need to define a plane.The tool axis is constrained regarding the normal of this

selected plane.

A. Set the Plane by selecting the plane symbol

B. Set a lead angle value

A

B

A


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Optimized lead:

The tool Axis is guided in Optimized Lead mode. In this mode the maximum material removalis obtained when the tool curvature along the trajectory matches the part curvature.

Set the Min and

Max lead angle

Set the Min heeldistance

CAUTION:The Optimized Lead Mode is currently used with Torus Tool,so it is mandatory to set the min lead angle to a positive valuein order to avoid machining with the flat area of the tool

Min heeldistance


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Thru a guide:

You can control the tool orientation using a continuous geometrical curve (guide).An open guide can be extrapolated at its extremities.

Depending on the Lead angle, the toolaxis will not remain on the tilting guide.

Mode: It defines the position of the tool on the guide.

Normal to the path: At a given contact point, theintersection of the plane normal to the path with theguide gives the tilt angle of tool.If several intersections are found, then the nearestintersection is taken into account.

Nearest position: The tool is orientated by the point thatgives the shortest distance between the guide and thecontact point.Nearest position along view direction: The guide isprojected on a plane normal to the view direction. Thetool is oriented by the point that gives the shortest

distance between the projected guide and the currentcontact point.

Offset on guide: Offset is computed on a planedefined by the tangent of the guide and theview direction or reference axis.

Lead angle: Specifies an angle in the forward directionbetween default tool axis and actual tool axis.

Extrapolates extremities of an open guide

Click to select guide curve


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Normal to drive surface:

The tool axis remains normal to the auxiliary drive surface that you select.Recommend you to use a smooth surface.

Normal to drivesurface

Drive surface

Part surface

Following points are considered for tool axis computation:Find the nearest point of the contact point on the auxiliary drive surfaceCompute the normal of this point on the drive surfaceApply this normal direction on the tool axis, and rotate the tool axis in the plane (Tool

axis, Tangent to the path) if a lead angle is given.


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Geometry Definition (1/2)

Check element

Limiting curve

Part body elementto machine

Area to avoid

Collision Checking(if active or not,Accuracy, Allowedgouging)

Offset on partOffset on check

Side to machine:Inside or Outsidethe limiting curve

Offset on limitingcontour


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Collision CheckingActive on check elements

Covering Mode active:Air cuts due to collision with check canbe optimized using the covering mode.

Without Covering mode

With Covering modeThis new option is available with MULTI-AXIS CONTOUR

DRIVEN and ISOPARAMETRIC MACHINING as well.

Covering Mode Optional within Collision Checking:


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Tool Definition (1/2)

Type the name of the Tool.

Type a line of comment (optional)

For the following capabilities:Create a new toolSelect an already existing tool from the current documentSelect another tool in a catalog by means of a query

Use the 2D Viewer to modify the parameters of the

tool. The 2D Viewer is updated with the new values

Select the tool type available for the current operation

Specify a tool number that does not already exist

Click More to expand the dialog box toaccess tool s parameters such as

Geometry, Technology and compensation

2

3

5

1

4

1

2

4

5

Selection of Tool or Tool Assembly plays a vital role in performing the operation. You canselect the tools from the catalog or you can define the tools as per your requirement.

Select the icons to access theSearch Tool dialog box to query a

tool in a Catalog

3


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Tool Definition (2/2)

You can use following tools for Multi-Axis Sweeping operation:

Face Mill, End Mill, Conical Mill, T-Slotter, Barrel Mill

Body diameter

Vertical distance

Cutting length

Overall length

Barrel radius

Corner radius

Entry diameterRadial distance

Barrel Mill supports Lead and tilt, Fixed axis, Thru a point and Normal to line tool axis modes


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Speeds and Feedrates Definition

Define the Spindle Speed value according to the unitLinear (m/mn) or Angular (turn/mn)

This Spindle Output is optional, you can remove this

information from the output by deactivating the checkbox Spindle Output

A

Rough or Finish quality of the operation and the tooldata are taken into account for computing the feeds

and speeds from the current tool catalog.

C

B

Define the Feedrate values for

Approach Feedrate: This feedrate is used by defaultduring approaches motion

Machining Feedrate: This feedrate is used during

Machining motion

Retract Feedrate: This feedrate is used by default

during retract motion

Transition Feedrate: This feedrate is used during

Transition motion

A

B

C

Speed is number of revolutions of the cutting tool or workpiece per unit time.

Feedrate is the distance traveled by the cutting tool or workpiece in unit time and


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Macros Definition (1/7)

A

C

B

Specify which NC Macros you want to use among:

Approach Macro

Retract Macro

Return in a LevelLinking

Clearance

Specify a radius value to cornerize theclearance motion.

Check the Smooth tool axis moves tosmoothen the transition path.

Specify for each selected NC Macro thetype of motion and the parameters likeFeedrates, Angles, etc

A

B

CClearanceCorner radius

Retract motionApproach motion

Corner radius


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For all operations, macro parameters areaccessible using the highlighted tab page

You will learn how to create a NC Macro for a Multi-Axis SweepingOperation and for axial operations.


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Depending on the type of macro you have selected,different types of pre-defined macros are available:

Tangent, normalAxial

Circular

Vertical

Helix forapproach

For Approach For Retract

Pre-defined macros

Normal motion


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Tangent

You can create an infinite number ofdifferent macros by selecting each of this

basic trajectory in various order or usecontextual menu on a selected move toadd a new one, remove or edit it to tunesome parameters.

Macros Tool Box:

Horizontal

Axial


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Insert a PP word on a point of the macro.

Crosses localize the possible points to insertthe PP word.To insert a PP word, you can also press rightmouse button on the cross and select PPword list

Apply this Approach or Retract motion to all Return andLinking macros in the operation (only available onApproach macro and Retract macro)

Create your own macro:

PP Table accesscapability:Possibility to selectMajor/Minor words and

pre-defined syntaxes


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Modify parameters on your macro:

To locally modify a feedrate in the macro, right-click the element and select feedrate to choose which feedrate to associate between Machining, Approach,Retract, Rapid, Local or Finishing

To modify geometrical parametersof a macro, double-click it.

Depending on the feedrateselected, the element takes adifferent color:Yellow : Approach

White : LocalGreen : MachiningBlue : RetractRed : Rapid


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Return in a level, Linking and Clearance Macro:

Return in a level and Linking macros are divided in twomotions: Approach and Retract

The Clearance Macro:Between those two motions, the system computes atransition tool path to avoid Collisions, Islands orFixtures.

If you want this transition tool path to be a simple returnto a safety plan, activate Clearance Macro.

You can cornerize clearance via as shown below.When Smooth tool axis moves is checked, if the approachand the retract axes are different, additional points areadded on the rapid motion to smoothen the transition path.

Clearance

Corner radius

Retract motionApproach motion

Corner radius


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Step 2: Create Multi-Axis Sweeping Operations

35 min

In this step you will learn how to perform a 5-Axis Sweeping Operation.You will see a Multi-Axis Sweeping Operation with:

Fixed lead and tilt Tool Axis Guidance,Fixed lead and variable tilt Tool Axis Guidance,Fixed Tool axis mode,Thru a Point Tool axis mode,Normal to line Tool axis mode,4-axis lead/lag Tool axis mode,Optimized Lead Tool axis mode.


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Multi-Axis Contour Driven Operation

You will become familiar with creation of a Multi-Axis Contour Driven Operation.


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About Multi-Axis Contour Driven Operation

It is a milling operation in which the tool is driven along a contour while respectinguser-defined geometric limitations and machining strategy parameters.

Three machining modes are Parallel Contour, Between Contours and Spine Contour.A number of tool axis guidance modes are available.

Same as Multi-Axis sweeping

Concept:


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How to Create a Multi-Axis Contour Driven Operation

2

3

4

5


1

The new Operation is created after thecurrent one. The Operation dialog boxdisplays to define its parameters

2


3


Click Multi-Axis ContourDriven Operation icon

1



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Tool axis guidance modes are available same as Multi-Axis Sweeping i.e Lead andTilt, Thru a point, Normal to line, etc

Choice between threeguiding Strategies

Tool Axis mode

One additional Strategy tabactivated when using a reference

Parallel contour

A milling operation in which the tool is driven along a contour while respecting user-defined geometric limitations and machining strategy parameters.

Three machining modes are Between Contours, Parallel contour and Spine Contour.


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Between Contours:

The Strategy sub-Tab isdeactivated in Between

Contours mode

Guide 2

Guide 1

In Between contour mode

we have the ability to specifydifferent offset values andTool Position on the twoguides to avoid creation ofadditional geometry

You can apply the same offset onstops which is set on guides


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Parallel Contour:

The strategy allows you to machine paths TO/FROM (new in R12) the reference contour

from the far limit defined by the Maximum width to machine parameter.

The Strategy sub-Tab is

activated for Parallelcontour mode

Guide 1

Width to machine startingfrom right side of guidecontour(or going to thecontour guide) depending on

direction choice


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Spine Contour:

The Strategy sub-Tabis deactivated for Spine

contour mode

Guide 1


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Step 3: Create a Multi-Axis Contour Driven Operation

15 min

In this step you will learn how to perform a 5-Axis Contour DrivenOperation. You will see a Multi-Axis Contour Driven Operation with:

Case1 Between Contours guiding strategy,Case2 With Parallel Contour guiding strategy,Case3 With Spine Contour guiding strategy.


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Multi-Axis Curve Machining Operation

You will learn how to create a Multi-Axis Curve Machining Operation.


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About Multi-Axis Curve Machining Operation

This is a milling operation in which the tool's side, tip or contact point is driven along a curvewhile respecting user-defined geometric limitations and machining strategy parameters.

A number of tool axis guidance modes are available. Same as Multi-Axis Sweeping.

Concept:


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How to Create a Multi-Axis Curve Machining Operation

2

3

4

5

The Operation is created in the PPR tree with a default tool. Thiscapability can be removed by customizing the NC Manufacturing options.

1The new Operation is created after thecurrent one. The Operation dialog boxappears to edit it

2


3


Click Multi-Axis CurveMachining Operation icon

1



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Multi-Axis Curve Machining:

The curve can be machined by the tool's contact point,tip or side.

The tool axis guidance modes are available in the

strategy Tab.

Guidance Modes

A milling operation in which the tool is driven along a contour while respecting user-defined geometric limitations and machining strategy parameters.

Three machining modes are Contact, Between 2 curves and between curve and part.


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Interpolation:

A. Choice of Tool Axisat Starting Point

B. Choice of Tool Axis

at Ending Point

C. Tool axis orientation

Guidance modes available in Multi Axis Curve Machining are:

A

A

B

B

C

C

orient the tool axisperpendicular to thescreen view.

AdditionalInterpolation axes


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Interpolation:You can add any number of interpolation axes to control the interpolation.

Clicking red arrow allowsyou to add, edit or removethe axes through dialog box.

Adding / modifying (editing) interpolation axes:

Create: It allows to create a new interpolationaxis. Select the position of the interpolationaxis in 3D viewer, and then the axis definitiondialog box will be displayed.

After adding all the axes, the axes displayed in3D viewer and the list of axes appears in theInterpolation Axes dialog box.

Remove: It allows you to remove theinterpolation vector selected in the dialog box.

Edit: It allows you to modify the interpolation

axis selected in the dialog box.

Axis definition

The Check Interferences option is available when you select the Display tool check box

and the operation parameters are coherent.


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Tangent Axis for Between 2 curves and Between curve and part ONLY

In Tangent Axis mode, the tool axis is chosen to follow the ruling directions ofthe Drive Surface which are supposed to be developable or planer (if oneDrive Surface does not respect these conditions, a message is displayed at

the end of the computation).

This is the only tool axis providing an linear contact between the cutter andthe Drive Surface.

Maximum material removal is obtained when ruling direction on drive surfacematches the ruling direction on tool.

Select Drive Surface

Mode options:


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A) The drive surfaces are ruled (even if not developable), ruling direction are the isoparametric line

or the surfaces, so the tool axis is mapped to the iso-line (the one which is the less parallel to thedrive curve). This is done even if the surface is planar, or it is not developable.

B) The isoparametric lines of the drive surfaces are not compatible with the NC Machine travellimits or may lead to collision with the machine head or may lead to loops in the tool path. Inthese cases, the user wants the tool axis to be tangent to the drive surface, and normal to thedrive curve.

In both cases, because the tool axis is not always the ruling direction of the developable surface,some under or over cuts may occur, and the user expect to have an immediate feedback of thesedeviations.

Tangent Axis MODE:

We have two possible sub-strategies of the tangent axis

Three sub-strategies are added to the tangent axis:

1) Along ruling direction

Message displays when facing non- ruled surfaces2) Along isoparametric lines

3) Normal to drive curve

For the cases 2 and 3, at the end of computation the maximum and minimum deviation to the drive

surfaces is displayed.


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Fanning Distance

Fanning Distance: The tangent axis mode is used when you machine ruled and planersurfaces. On a planar surface before or after a ruled one the tool may change itsinclination more or less smoothly. The fanning distance is the allowed transition distanceduring which the tool is changing its axis position.


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Along isoparametric lines: On all computed tool position (driven by a point on the drive

curve), the tool axis is computed by selecting the closest Iso line direction from the drivesurface regarding the reference tool axis.

Tangent Axis MODE


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Normal to drive Curve: On all computed tool position (driven by a point on the drive

curve), the point on the drive curve is projected on the drive surfaces, on the projectedpoint we evaluate the Normal vector to the surface, N

Then we define the un-oriented direction of the tool axis Ta=T^N where T is the tangentvector of the drive surface.

Example of maximum and minimum deviations displayed

Tangent Axis MODE


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Curve Machining Mode

Contact:

Support surfaceGuide Curve

Resulting ToolPaths

Guide Curve


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Limit Point

Guide Curve

Offset on LimitValue

Contact:

Limit Point

Offset onLimit

Option on Limits:In , Out or On


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Choice between computationpoints mode: Side or Tip

Curve Machining Mode

Between 2 curves:

Guides


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Between 2 curves

Choice of one curve:A. Axial Offset Value

B. Offset Value on Contour

A

B

B

A


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A. Guide

B. Auxiliary Guide Curve

C. Side Mode: Tangent to Guide

Between 2 curves

Choice of two curves:

B

C

B

A

A

C


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Tip Mode: Tip on Guide

Between 2 curves

Choice of two curves:A. Guide

B. Auxiliary Guide Curve

C. Tip Mode

C

B

B

A

A

C


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Between curve and part:

You need to select one curve and one Surface.

A. Guide Curve

B. Interpolation vectorsdefined in Strategy Tab

C. Option Side = tangent toguide Curve

D. Surface to machine

B

A

D

C

A

C

D


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Between curve and part:

You can select a plane as part to machine in Between curve and part and Contact modes.

A

B

A

B

A. Guide Curve

B. Plane as part

The machining is done as a planar surface. This equivalent planar surface is delimited by a boundingbox, which is twice the bounding box of the projection of the guiding curve normal to the plane.


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A. Guide Curve

B. Limit Point

C. Option Tip = ONguide Curve

A

B

C

B

C

A

Between Curve and Part:


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A. Guide Curve

B. Part to Machine

C. Drive Surface


Use of Tangent Axis Guidance Mode in Strategy Tab

A

A

B

BC

C


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Infinite Fanning Distance Small Fanning Distance


Use of Fanning distance Variation


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Macros Definition

Approach

RetractReturn in a level

Return between levels

Linking

Clearance

Return to finish passes

There are 7 different main types of macrosavailable:


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Step 4: Create a Multi-Axis Curve Machining Operation

15 min

In this step you will learn how to perform a Multi-Axis CurveMachining Operation. You will see how to create this operation using:

Between 2 Curves mode,Contact mode,Between curve and part mode


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Multi-Axis Isoparametric Machining Operation

You will learn how to create of a Multi-Axis Isoparametric Machining Operation.


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About Multi-Axis Isoparametric Machining Operation

Isoparametric machining is an operation which allows you to select strips of faces and

machine along their isoparametrics.

A number of tool axis guidance modes are available same as Multi-Axis Sweeping. The mostadvisable guidance mode is INTERPOLATION. You may control in some critical point the ToolAxis orientation

Concept


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How to Create a Multi-Axis Isoparametric Operation

2

3

4

5


1

The new Operation is created after thecurrent one. The Operation dialog boxappears to edit it

2


3


Click IsoparametricMachining Operation icon

1



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Multi-Axis Isoparametric Machining:A number of tool axis guidance modes are available in thestrategy Tab.

In order to control the axis position anytime, it is advisableto use the Interpolation Option

Guidance Modes

This is a milling operation in which the tool paths are executed on strip surfacesrespecting user-defined geometric limitations and machining strategy parameters.


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Interpolation Guidance mode available in Multi-Axis Isoparametric Machining.

Interpolation:

Choice of Tool Axis atBeginning Point

Choice of Tool Axis atIntermediate Point


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Interpolation:

You can add anywhere on the machining area some Intermediate points with predefinedtool vector axis. They will be taken into account during tool path computation.

Possibility to remove incontextual menu alladditional Points

Create, Remove or Edit the interpolation axes

When the Angles option is selected,the drop down list proposes by defaultan item specific to interpolation axes:Lead (Angle1) & Tilt (Angle 2).


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Set value for

extrapolation

Interpolation:

Skip Path:

It is possible to skip the first, last or first-and-last paths

Extension: Start and End

It is possible to start the computation using anextrapolation value for the Start or the End of theoperation.

Radial Tab

Tool path extension in Isoparametric Machining:You can now extend or reduce the width of the tool pathbefore the first path and after the last path. You can extendthe width when you want machining to continue beyond theboundary of the selected part surface. You can reduce it tokeep a given distance between check surfaces and the first

& last paths.

This avoids creating virtual part surface geometry andgives better surface finish at ends of the part surface andreduced risk of interference with check surfaces.


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Geometry Definition

Choice of points to drive thefirst tool path direction

Parts to machine

Main Isoparameter directionsCouple Points (1,2)

Covering Mode availability

You may select adjacent or non- adjacent faces.

The faces will be machined in a single IsoparametricMachining operation. In this case corners must be selectedfor each face and belt of face. Also an orientation (side tomill) must be defined for each face and belt of faces.

Advices: Create an healing or join ( with federate option)before selecting machining surfaces. This will improve the

continuity detection between consecutive boundaries

Couple points


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Macros Definition

Use of linking option between

two groups of machined faces

Approach

Retract

ClearanceLinking

Return in a level

There are different types of macros available:

Retract macro

Approach macro


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Multi-Axis Drilling Operation

You will become familiar with creation of a Multi-Axis Drilling Machining Operation.


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About Multi-Axis Drilling Operation

The drilling (or axial machining) operations described in this section are intended to coverthe hole making activities in your NC manufacturing program. In particular, the commandsand capabilities included in the Geometry tab page of the Axial Machining Operation dialogbox allow support of multi-axis as well as fixed axis drilling.

Concept:


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How to Create a Multi-Axis Drilling Operation

2

3

4

5The Operation is created in the PPR tree with a default tool. This capability

can be removed by customizing the NC Manufacturing options.

1


2


3


Click Multi-Axis DrillingOperation icon

1



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Strategy Definition

You can choose Depth, plunge modes.

You can edit the cycle to customize the syntax

Setting parameters fordrilling cycle

Breakthrough (B) availableif option Extension is

Trough in Geometry tab


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Geometry Definition

Drill parameters setting:

Choice of MachiningPattern

Points to drill

More Options:Machine different depthsMachine Blind/Through

Inverse Pattern ordering,etc

Multi-Axis Drill =>Normal to PartSurface direction


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Macros Definition

Adding distancealong a line Motionin Approach

Approach

Retract

Clearance

Linking Retract

Linking Approach

There are 5 different types of macros available:

Macro


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Multi-Axis Tube Machining Operation

You will become familiar with creation of a Multi-Axis Tube Machining Operation.


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About Multi-Axis Tube Machining Operation

This type of Multi-Axis Machining is suitable for parts presenting an obvious central axis

While respecting user-defined geometric limitations and machining strategy parameters.

A number of tool axis guidance modes are available.Same as Multi-Axis sweeping

Concept:


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How to Create a Multi-Axis Tube Machining Operation

2

3

4

5


1


2


3


Click Multi-Axis TubeMachining Operation icon

1



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Choice between 3 guidingStrategies

Tool Axis modes

Driving tool points:Tool tip, Contact on part

This is a milling operation in which the tool is driven by a contour respecting user-defined geometric limitations.

Three machining modes available are Around guide, Along

guide or Helical.

The tool axis guidance modesavailable are:

Tool path styles

Driving tool points:Tool tip: You can use this option only with ball end tool forgood quality tool path.Contact on part: The time required to create the tool pathwill be more using this option.

Collision checking is must while using Contact on part as driving tool points.


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Around guide:

Guide

Limit1and

Limit 2

Around Guide allows you to select between two differenttool path styles - Zig zag or One Way.


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Along guide:

Along Guide allows you to select tool path styles among -Zig zag, One Way or Back and forth


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Helical:

Tube

Tube and cavity

Cavity

Tube: To machine the tube.Cavity: To machine the bottom of the tube.Tube and cavity: To machine the tube and itsbottom in a single action.

Zone: Available when you select Tool tip as Driving tool points.

Elevation angle:It is the end angle of the cavity. You can specify thevalue when Zone is set to Cavity.


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Axial Stepover:

Scallop Height

There are 4 different ways to define the step over

Distance on Part Distance on Guide Number of paths


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Tool Axis Mode:

Fixed axis:

The tool axis remains constantfor the operation. There are noassociated parameters.

Thru a Point:

The tool axis passesthrough a specified point.

Along guide:

The tool axis makes a constantTilt angle with the guide.

You must define the Guide angle

By default, the Allows variable tilt check box is not selected.If you select it, the axis is automatically adjusted around itsinitial position to avoid collision with part or checks.By default, the In opposite to machining direction check boxis selected. This check box enables you to decide whether

the tool is in machining direction or in the opposite direction.


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Tool Axis Mode:

Lead and tilt:In this mode the tool axis is normal to the part surface with respect to a

given lead angle in the forward tool motion and with respect to a given tiltangle in the perpendicular direction to this forward motion.The associated parameters depend on the Guidance selected.This Lead and tilt mode is same as for Multi-Axis Sweeping operation.

4- Axis Tilt:The tool axis is normal to the part surface with respect to a given tiltangle and is constrained to a specified plane.This 4- Axis Tilt mode is same as for Multi-Axis Curve machining.

You must type the Tilt angle and Lead angle


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The guide may be defined directly as an Axis.

For this you need to Right-click the guide and another scrolled menu will appear.

Guide mode selection:

Guiding StrategySelection

Need to select a direction anda point for start conditionThe machining direction is then displayed at one end of the guide.

Click the arrow to invert the machining direction if necessary.


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Tools Definition

Recommended tool families for Multi-Axis Tube Machining are:

Areas that cannot be reached by the beams issued from the guide are not machined.

Face mill

End mill (ball- ended or not)

Conical mill (ball- ended or not)T- slotter

CAUTION:


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Add normal motion :

It adds a linear motion normal to the partsurface. You can use it in the linking

macros to avoid the collision.

Add circular motion :

It adds a circular motion in a plane.

Normal to last tool axis:

Normal to part surface:

It is useful with Along guide strategyin return in a level macros.


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Enable 5-Axis Simultaneous Motion:

Using this macro you can generate afive-axis simultaneous motion on the

next combined motion.

The macro rotates the tool in macropaths and thus helps in minimizingmachine jolts by generating a 5-axissimultaneous motion on the nextcombined motion.

You have to define a direction.

Tangent motion

Start tool axis ofmachining path

Direction defined in newmacro motion


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Multi-Axis Spiral Milling Operation

In this lesson, you will learn how to create a Multi-Axis Spiral Milling Operation by

defining different strategies.


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About Multi-Axis Spiral Milling Operation

It is a milling operation used to machine pockets or to engrave complex surfaces inorder to get better surface quality, too life and optimization of tool path.

The tool is driven along a guide while respecting user-defined geometric limitationsand machining strategy parameters.

Three tool path styles: Helical, Back and forth and Contour only.

The tool axis guidance modes available are Fixed or Normal to part.

Concept:

Guide face


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How to Create a Multi-Axis Spiral Milling Operation

2

3

4

5

The Operation is created in the PPR tree with a default tool. Thiscapability can be removed by customizing the NC Manufacturing options.


2


3


Click Multi-Axis Spiral MillingOperation icon

1


1


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Machining tab:

Climb Conventional

Direction of cut

The cutting mode which can beClimb or Conventional

Machining tolerance:

It is the value of the maximum allowable distancebetween theoretical tool path and the computed

tool path

Helical movementInward: The tool path will begin at the outer limitof the area to machine and work inwards.

Outward: The tool path will begin at the middle ofthe area to machine and work outwards.

Max discretization angle:It is the maximum angular change of toolaxis between tool positions.

Always stay on bottom:

It forces the tool to remain in contact with the pocketbottom when moving from one domain to another.


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Radial tab:

Maximum cut depth Number of levels

Distance between paths:It allows you to define the maximum distance betweensuccessive passes in the tool path.

Contouring pass:

It adds a contouring pass at the end of the back and forthpath.Contouring ratio: It adjusts the position of the contouringpass to optimize scallop removal (% of tool diameter).

Axial Parameters:


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Tool Axis tab:

Fixed axis:The axis is fixed.

HSM tab:

Corner sub-tab

Corner radius: You can define the corner radius toround the ends of passes.

Limit angle: It is the minimum angle the tool pathmust form to allow the rounding of the corners.

Extra segment overlap: It is an overlap for the extra

segments that are generated for cornering

Normal to part:The tool is normal to the bottom of thepart with an angular tolerance.

Transition sub-tab

Transition radius: The radius at the extremities of atransition path.

Transition angle: It is the angle of the transition path that

ensures a smooth movement from one path to another

Transition length: It is the minimum length of the straightsegment of the transition path.


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Geometry Definition

You need to select Part and Guide faces. You can defineislands using the guide faces.

Possible offsets on Part, check or Guide faces

Selection of the Soft guide contour that closesthe guide faces if the pocket is open.

Collision Checking:Collision checking can be performed on the cutting part of tool or onthe cutting part of the tool and its tool assembly (if check box isselected).

To save computation time, you must select tool assembly only if thegeometry to be checked can interfere with the upper part of the cutter.

Selection of check elements


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Exercises

You will perform following exercises to reinforce the knowledge learnt in the course.

Exercise 1: Hood

Exercise 2: PocketExercise 3: Isoparametric and Drill

Exercise 4: Multi-Axis Curve Machining

Exercise 5: Tube Machining

Exercise 6: Multi-Axis Spiral Machining


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Exercise 1: Hood


40 min

In this exercise, you will practice 5-AxisMachining on a Hood.

You will have the chance to try out various toolsand various modes to create 5-axis tool paths.

You will again learn how to prepare a geometry,

define macros and start a machining process.


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Exercise 2: Pocket


15 min

In this exercise, you will see how to create aMulti-Axis Operation with:

Between curve and part Curve Machining Mode

Tangent Axis Mode Strategy


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Exercise 3: Isoparametric and Drill


15 min

In this exercise, you will see how to create a Multi-AxisIsoparametric Operations and Drilling Operations:

Isoparametric using Interpolation Mode Axis

Multi-Axis Drilling Operations


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Exercise 4: Multi-Axis Curve Machining


15 min

In this exercise, you will see the difference between the Submodavailable in Multi Axis Curve Machining With Tangent Axis Mode:

Along isoparametric Line

Normal to drive curve


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Exercise 5: Tube Machining


40 min

In this exercise, you will see how to create fundamental Multi-AxisTube Machining Operations:

Use Along Guide Strategy

Use of different Tool Axis Mode

Along Guide with tilt Angle 32deg for Ousideprocess

Thru Point strategy for Inside wall process


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Exercise 6: Multi-Axis Spiral Machining


10 min

In this exercise, you will learn how to create aMulti-Axis Spiral Machining Operation.

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