Senior Design Project
Senior Design Project AME 40463
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This 0 page Class Notes was uploaded by Yesenia Hansen on Sunday November 1, 2015. The Class Notes belongs to AME 40463 at University of Notre Dame taught by Staff in Fall. Since its upload, it has received 14 views. For similar materials see /class/232724/ame-40463-university-of-notre-dame in Aerospace Engineering at University of Notre Dame.
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Date Created: 11/01/15
ProE Wild re 20 CAM Tutorial1 Figure 1 Part to Machine Creating the Part In this tutorial we will machine the part shown in Figure 1 We will assume you can create it in ProE so to save time the part has already been created To begin open ProE and then download and open the part Demoprt which is found on the Senior Design homepage Figure 2 Finished part Establishing a Manufacturing Model This segment of the tutorial will establish the manufacturing models used within this tutorial Two models are utilized design part and manufacturing The design part model is the part that is to be produced by the manufacturing code generated in this tutorial The manufacturing model is the collection of the design part1 assembly model and the manufacturing processes generated within the manufacturing object le Step 1 Select FILE gtgt NEW Step 2 Select Manufacturing Type on the New dialog box then Select NC ASSEMBLY as the Subtype Name gtgt Demomfg Figure 3a Step 3 Step 4 Menu Manlger Sub Ups 6 NE Assembly 0 Expeu Machlmsl w MM 0 Sheelmelal 0 East Eavlly O Mold new 0 Delete 0 Harness O Prunes Plan Name 4 wall common Name 2 delaull template Figure 321 New File DialogBox FigureSb Reference Model Select MFG MODEL gtgt ASSEMBLE gtgt Ref MODEL on the Menu Manager F ig 3b Open Demoprt as the part to manufacture Your block part represents the design model It Will be used as geometry to de ne tool paths Within your manufacturing model Place Move Eunnebl Eanshamls Assemble at Default Location Eamwnent Helermce x Assembly Halevermz Flacananl sums Nat M Eumlmned Figure 3c Component Placement Step 5 Using the Assemble Component at Default Location Constraint Type constrain the location of the reference model Figure 3c Choose OK to exit the Component Placement menu Step 6 Select DONERETURN to exit the Manufacturing Model MFG MDL menu Setting the Manufacturing Environment 1 All In this section of the tutorial you will establish the lug f iug mode provides the Manufacturing Setup MFG SETUP menu to establish specific settings for your model Within this menu examples of items that can be set include the machining workcell tooling the machine coordinate system and fixtures You must define a workcell and a coordinate system before you can start creating NC sequences Step 1 Select MFG SETUP on the Menu Manager Pro ENGINEER will launch the Operation Setup dialog box An operation is one specific setup of a machine tool for the manufacturing of a design It can consist of multiple NC Sequences Within any operation the minimum required setup includes a machine work cell and a machine coordinate system The Operation Setup dialog box Figure 4a contains the following elements Operation Name gtgt The operation name identifies the operation within the manufacturing process The default operation names have the format OP010 OP020 where the number gets automatically incremented by the system You can type any name NC Machine gtgt The name of the machine tool workcell used to perform the operation If you have set up some machine tools prior to creating the operation their names appear in the NC Machine dropdown list Fixture Setup gtgt This section contains the icons for creating modifying and deleting fixture setups The dropdown list contains the names of all the fixture setups defined for the operation with the name of the currently active setup displayed in the list box Machine Zero gtgt Select or create the Program Zero coordinate system to be used for NC output and for other machining references The Retract group box gtgt Specify how the tool retracts between the cuts Surface gtgt Set up the retract surface Tolerance gtgt Controls maximum deviation of the tool when it moves along a nonplanar retract surface The default is 01quot in English units or 1 mm in metric units You can type any value Stock Material gtgt Select a name of the stock material Step 2 Select the Machine Tool Icon on the Opemuon Setup dmlog box Step 3 On the Machine Tool Setup analog box entex the pmmetexs shown m Figure 4a Fntex the followlng pammetels 3 raxlsrmlll M111 w Tm Numbel39ofoes 3AM W l 3 Flgure 42 Machlne Tuul Setup Step 4 Select OK to exltthe Machine Tool Setup dialog box Opui nn Setup Hzlulegtelup totvu v E 4 E enela Flam aw gloom Nanth Zem out Eil WW gunmen liummnee v El Flgure 4b Machlne Zem Opth Step 5 Step 6 Step 7 Step 8 On the Operation Setup dialog box select the Machine Zero pick icon Figure 4b The Machine Zero option allows you to establish the operation s machine coordinate system When machining it is essential that you know where to consider the origin 000 for machining to be It is common to de ne one corner of the top surface of the material as zero The Z Axis must point upward Numeric control machine tools manufacture parts through the utilization of a Cartesian coordinate system This coordinate system is used to define precise tool movements In this tutorial you will create a new coordinate system to serve this purpose however an existing coordinate system can be selected Select CREATE on the Machine Coordinate System menu then pick the part DEMO on the menu tree on left Select Origin from the Coordinate System Dialog Box Select the three surfaces shown in Figure 5 abc Use the Ctrl key to select multiple surfaces lst Surface 391 camle svsrm El um WW magenta Hermes smalgxmuog an an 4 W J 9 Figure 5a lst Surface coonmnm 5mm 3 mud lyps Badman v it Figure 5b 2nd Surface 7 noImINArr 5mm 1 2a m 3rd Surface Figure 5c 3rd Surface Step 9 Next select Orientation on the Coordinate System menu These steps will orient the coordinate system With respect to the part Step 10 Use the lst surface Figure 6a to orient the ZAxis Be sure this axis points upward away from your part Use the Flip option to change the direction an axis is pointing Ist Smface ZAxis 2 COORDINATE wsrm E G 3972127102 seiechan lsiented ms axes e EHNFE E r m vvmect Figure 6a lst Surface A LOORD INATE wsTrM X n nan Due la mm by 9 5212mm saleman sxsmea sYs we we ladelevmme Use E T 2nd Surface Y 39s Figure 6b 2nd Surface Step 11 Use the 2nd surface Figure 6b to orient the Y Axis Use the Flip option to change the direction an axis is pointing Your nal Machining Coordinate System should appear as shown in Figure 6c Choose OK in the Coordinate System Setup Dialog Box Figure 6c Coordinate System De nition Step 12 Select Apply and OK to exit the Operation Setup dialog box Step 13 Select DONERETURN to exit the Manufacturing MFG Setup menu Step 14 Save your manufacturing model Facing Sequence Tu rd r eutung tool the tool s parameters the retraet depth and the surface to face Step 1 Step 2 Step 3 Step 4 Seleet MACHDUNG on the Menu Manager Seleet Nc SEQUENCE on the Maehrmng menu SeleetMACHmmG Se FACE Se DON39E Check the Maehrmng Parameters shown m Fxgure 6 Pro NGJNEER wru eheek the minimum parameters reqmred for a speer e machmmg operatron Nouee m Fxgure s the parameters that are eheeked and the premous segment of thrs tutonal p t 7 it Fxgu39e 7a Sequance Setup Parameters Fxgu39e 7b Tau Setup DnlagEax Step 5 Step 6 Step 7 Step 8 Select DONE on the Sequence Setup menu Figure 7a A er selecting Done Manufacturing mode Will launch the Tool Setup dialog box Figure 7b Notice in Figure 7a the parameters checked for defining Starting om the top of this list Tool in this case ProENGINEER Will in order automatically move you through the required menus and dialog box to define each parameter Enter the tool parameters shown in Figure 7b Define the following tool parameters 39 ToolilD Tool Type CutteriDiam length This parameter Will define the specific tool number ie T0001 Set Milling as the type of tool This option sets the diameter ofthe cutting tool ie 025 This setting defines the length ofthe cutting tool ie 300 Select APPLY to create the tool Select OK Select SET on the Manufacturing Parameters menu ian FaeeMillmg Manulaelmmg Favemelevs ELITJEED mu STEFLDEPTH m swater m5 annumsmmmuw LILANGLE smuva TVPEJ SPlNDLLSPEED lEEIEI u w in FF APPRDAEHiDlSTANEE EXlLDlSTANEE Distance needed in mmvletelv clear the wavkwece mm m vetvattmn Figure 7c Manufacturing Tool Parameters Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 The next seveml steps will de ne machining parameters for the tool selected within this machining sequence Ex ples of parameters include feed rate and spindle speed If desired the Retrieve option will allow you to select an existing tool 39tion Enter the tool parameters shown in Figure 7c Manufacturing mode requires the de nition of any parameter shown with a 1 value A er the values in Figure 7c are set select FILE gtgt EXIT to save and exit the Pammeter Tree dialog box Select DONE on the Manufacturing Parameters menu Observe Figure 7a Up to this point of the tutorial you have de ned the tool and the tool39s pammeters The next seveml steps will de ne the retract depth of the tool The retmct depth will be de ned 75 inches along the Z axis Note From the previous de nition of the machine coordinate system the ZAxis points away from the top surface of the part Figure 6c Once the Manufacturing Parameters menu is closed the Retract Selection Dialog box appears Select ALONG Z AXIS on the Retmct Selection dialog box e i Q Smlace r H mm rm 2 new 751 Figure 8 Retract Selection dialog box Enter 75 as the Z Depth Select OK Select Mill Surfacegtgt DONE on the Surface pick menu The surface to be milled in this tutorial will be created within the NC Sequence You can also use a surface of the design model or de ne a surface from a previously created mill volume y 5 Sketch Plane V 1 El Sela2H mmme items Raglan saleman is available Figure 9a Surface to Face Step 15 Select CREATE SRF and name the surface FacingiSurf Step 16 From the Surface Define menu select Add Then choose Flat ltlt Done Step 17 Choose the surface shown in Figure 9a as a sketch plane and choose OK on the Direction menu Orient the sketch environment as shown in Figure 9b by choosing the right side indicated in Figure 9a Choose the four outside edges of the part as References H Figure 9b Sketch boundary of pan Step 18 Using the Rectangle Tool sketch a rectangle around the boundary of the part Figure 9b and then Check out of sketch mode Step 19 Step 20 Step 21 Step 22 Step 23 Step 24 Choose OK on the surface dialog box and DONERETURN on the Surf De ne menu Now choose OK on the Select Surfaces menu Now choose Add on the Select Surface menu Select the surface you just created as shown in Figure 9c Choose OK on the Select dialog box and DoneReturn on the Add Surfaces menu To make your model easier to see hide the surface you just created from the model tree Figure 9c Select the Surface you created Select PLAY PATH on the NC SEQUENCE main menu Manufacturing mode provides several capabilities for viewing your cutting tool path Within this tutorial you will play the tool path on the work screen Select SCREEN PLAY on the Play path menu Use the Play Path dialog box to play the NC Sequence To better observe the cutting tool you can slow down the display speed with the Display Speed option Figure9d PlayPath Step 25 Close the Play Path dialog box Step 26 Select DONE SEQ on the NC Sequence menu Step 27 Save your manufacturing model Creating 21 Mill Volume This segment of the tutorial will create tool paths to manufacture the pocket shown in Figure 10 As you may recall you may have multiple NC Sequences under one operation In this tutorial the rst sequence faced the top of the work piece This new sequence will mill the pocket volume shown in Figure 10 Mill Volume Step 1 Step 2 Step 3 Step 4 Step 5 El Attachment Parameters II Coord Sys II Ratract Volume II window I Close Loops II ScallnpSrf Exrld Surfs El Top Surfaces El Appr Walls I Build Cut Start El End Done Quit Figure 10 Volume Milling Figure 11 Sequence Setup Parameters On the Machining menu select the NC SEQUENCE gtgt NEW SEQUENCE option This speci c NC sequence will consist of a volume milling operation Select MACPHNING gtgt VOLUME gtgt DONE Select the parameters shown in Figure 11 to de ne for this speci c NC Sequence select DONE In order the settings that will be de ned include the tool parameters and the mill volume We will use the same tool and retract plane as we de ned in the previous sequence Select SET on the Manufacturing parameters menu The next requirement is to define specific tool settings Examples of tool settings include cutting speed and spindle speed Enter the tool parameters shown in Figure 12 They are the same as was used before You could also have selected Use Previous Step 6 Step 7 Step 8 Step 9 Step 10 Step 11 239 Param Tree QE Flle Edll VIEW Wm lnzs VI 2 We We Memeemneeeemeee mm mm meow m mew m5 pengsmemhuw n RDUEHisIDEKiALLEIW El Burrnmsmcmettnw em Mme we Rum WWN Rum mime semesm isnn nuLANLnPHuN me Distance needed m ampletely leav the wmkpiece my m vetvattmn Figure 12 Manufacturing Tool Parameters Select FILE gtgt EXIT on the Parameter Tree dialog box Select DONE on the Manufacturing Parameters menu Select CREATE VOL on the De ne Volume menu Enter VOLUMEl as the name of the mill volume Select SKETCH gtgt EXTRUDE gtgt SOLID gtgt DONE You Will de ne this mill volume by sketching the area to mill You Will sketch this area as a rectangle and extrude the section the depth of the pocket 025 inch The actual mill volume Will be de ned by trimming empty space from this sketched volume Select ONE SIDE gtgt DONE then pick the sketching plane shown in Figure 13a Sketching Plane Step 12 Step 13 Step 14 Step 15 Step 16 Figure 13a Orient the Sketching Environment Figure 13b Section Creation Orient the sketching environment to match Figure 13a and 13b Sketch around the volume to be milled as shown in Figure 13b Modify the dimension values Select the Continue option to exit the sketching environment Extrude the section a BLIND distance of 030inch Another workable solution would be to extrude the object using the UP TO SURFACE depth option Step 17 Step 18 Step 19 Step 20 Step 21 Step 22 Step 23 Select OK on the Feature De nition dialog box Select TRIM on the Create Volume menu and select the model The TIim option Will de ne the mill volume by subtracting the model from the extiuded sketch Select DONERETURN on the Create Volume menu Select PLAY PATH gtgt SCREEN PLAY Figure 13c The speed of the tool path veIi cation can be slowed down using the Display Speed option Close the Play Path dialog box Fig 13c Screen Play Select DONE SEQ on the NC Sequence menu Save your manufactuiing model Holemaking Sequence wtthtn thts segment of the tutona1 you wtu create an Nc sequence that wtu hnaehtnednu the parts ho1es Step 1 Se1eet Nc SEQUENCE on the Maehtntng menu th thts tutona1 the hnaehtntng operations faetng volume muhng and dnllmg wtu be performed on one Workcell maehtne tool wtth one setup Due to thts the four sequences de ned wtthtn thts tutona1 wtu be de ned under one operation A new operation ean be estabhshed wnh the Operation opuon Step 2 Se1eetNEw SEQUENCE Step 3 Se1eetNLACHJNG gtgt HOLEMAKING Se DONE Step 4 Se1eetDR1LL gtgt STANDARD Se DONE dnued Step 5 PARAMETERS and HOLES We wtu use the Check the fouowtng setup operations same tool as before as well as the same retract plane Figure Ma Sequencesetup Pnnnems Step 6 Select USE PREVIOUS on the menu and VOT UMP MHT INF From the NC Sequence List menu as shown in Figure 14b size Visihihw Set Figure 14b Use Previous Tool Setup Step 7 Select DONE on 1e Manufacturing Pammeters menu Figure 15 Hole Selection Step 3 Step 9 Step 10 Step 1 1 Step 12 Step 13 Step 14 Step 15 Step 16 Step 1 7 239 Hale Set Depth real camel Palm m t 1 Select pans la he used VD dewh ealeulalun Flgure l lluleDepth On the Hole Selectlon dlalog box plck the PATTERN Option Flgure 15 Note If W n H must use the Single option on the Hole Set Dlalog Box The Patten opuon wlll allow you to plck a hole pattem as the holes to dnll In thS Select the ADD optlon on the dlalog box plck one othe axes Compnslng the hole pattem then select OK on the Selecuon box t A t t V as shown m Flgure 15 Select the DEPTH Option on the dlalog box Select AUTO gtgt OK onthe Hole Set Depth Dlalog Box Flgure 16 Select OK on the Hole Set dlalog box Select DONERETURN on the Holes menu Use the PLAY PATH optlon to play your tool path Select DON39E SEQ on the Nc Sequence menu Select DONERETURN to exlst the Machlnlng menu Save your manufacmnng model Pro ling Sequence Within this section you Will create an NC sequence to pro le around the part Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 9 Step 10 Step 11 Select NC SEQUENCE on the Machining Menu Select NEW SEQUENCE Select MACHINING gtgt PROFILE gtgt DONE Check the following setup operations Parameters and Surfaces Select DONE Choose USE PREVIOUS on the Manufacturing Parameters menu and then select one of the previous sequences you have created all of the sequences you have created use the same tool and the same setup parameters Select DONE on the Manufacturing Parameters menu On the Ncseq Surfs menu choose SELECT SURFACES ltlt MODEL ltlt DONE Choose Surface on the Surf7Loop menu Choose the four surfaces shown in Figure 17 Use Ctrl to select multiple surfaces Second Surface Step 12 Figure 17 Choose the Surfaces to Pro le Choose DONE RETURN ltlt DONE RETURN ltlt DONE RETURN Step 13 Step 14 Step 15 Choose PLAYPATH ltlt SCREENPLAY and see that the tool pro les around the edges selected Select DONE SEQ 0n the NC Sequence menu and DONE RETURN to exit the Machining Menu Save your manufacturing model Outputting the Centerline CL Data Within this segment of the tutorial you will run the operation to include all NC sequences After displaying the tool paths this tutorial will show you the procedure for postprocessing the CL data Step 1 Select CL DATA on the Menu Manager Step 2 Select OUTPUT gtgt OPERATION Step 3 Select your current operation from the Selection Menu Your current operation should be OPOlO Step 4 Select Display as the location of the output Step 5 Select Done on the Play Path menu The speed of your display can be slowed or increased with the Time increment option Step 6 Select File on the Path menu Next you will postprocess the CL data to a speci c machine tool Step 7 On the Output Type menu be sure the CL FILE INTERACTIVE and COMPUTE CL options are selected Step 8 Select Done on the Output Type menu Step 9 On the Save As dialog box enter Machiningidemo as the name for the CL le then select OK Once the CL data has been created you send it to a post processor to output the G code for a speci c machine mill lathe etc Step 10 Select Done Output on the Path menu and then select Post Process on the CL DATA Step 11 menu Select the le Machiningidemoncl from the Open Dialog box select Open to close the window In the PP Options menu make sure the Verbose and Trace options are selected Post processing is the act of converting the toolpaths from a standard language le called a cutter location le ncl to the language of our speci c CNC machine controller The resultant le in ProEngineer is known as a tape le tap which contains all the G codes to control the CNC machine The post processor is a program which performs the translation process Select Done on the PP OPTIONS menu and a list of postprocessors appears The specific machine tool we have inhouse is uncx01p20 Fanuc 16M controller Milltronics Note This controller also works for the Techno machining cells in Rm B19 Fitzpatrick Hall Choose the UNCXOlp20 Option Step 12 Close the information window and Select DONERETURN from the CL DATA menu Step 13 Save your manufacturing le The postprocessed le created 0P010tap is found in your current working directory This text file may be edited using a standard text editor If you are planning to use the Techno machining cells you must rename the file from quotfilenamequottap to quotfilenamequotnc Note For this operation we only used a single tool with the same setup parameters for every sequence If we had used multiple tools we would have had to output the CL Data for each and run each sequence separately on the milling maching
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