Practice exercise

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In this solution video for practice exercise 3, you’ll: select the appropriate machining strategy,

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define the tool orientation for multi-axis positioning,

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determine toolpath containment geometry and approach,

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define the tool orientation for simultaneous multi-axis machining,

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determine a collision avoidance strategy,

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and determine strategies to optimize individual multi-axis machining toolpaths.

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Open the file Program Toolpaths.f3d in the Manufacture workspace.

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In the Browser, select Setup1 to review the current setup of the file.

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Notice that the work coordinate system has been applied to the base of the workholder.

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With a setup in place, you can begin applying toolpaths.

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To start, create a roughing toolpath.

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From the Toolbar, expand the 3D drop-down and select Adaptive Clearing.

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In the dialog, under Tool, click the Tool selection prompt.

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In the tool library, from the list of tools within the document, select the 3/8" Flat Endmill.

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Under Cutting data, select Aluminum-Roughing.

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Click Select.

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Back in the Adaptive dialog, open the Geometry tab.

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You can allow the program to calculate everything within the stock contour that needs to be machined.

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Next, open the Heights tab.

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Under Top Height, leave From set to Stock top and, under Bottom Height, leave From set to Model bottom.

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In the Offset field, enter -.03.

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Now, open the Passes tab.

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Notice that the Maximum Roughing Stepdown value is red, indicating a warning.

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Hover the cursor over the value.

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A message appears, indicating that the maximum stepdown is greater than the flute length of the tool.

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Update the value to .875.

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Then, in the Fine Stepdown field, enter .05.

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Ensure that both Flat Area Detection and Order by Area are enabled.

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Under Stock to Leave, set both the Radial Stock to Leave and Axial Stock to Leave to .01.

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Open the Linking tab.

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Expand the Retraction Policy drop-down and select Minimum retraction.

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Then, in the Maximum Stay-Down Distance field, enter 4.

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Expand the Stay-Down Level and set it to 80%.

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Set the Lift Height to .01.

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Set the No-Engagement Feedrate to 400.

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Click OK.

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The toolpath calculates after several moments.

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From the Toolbar, Actions panel, select Simulate.

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From the Simulate dialog, ensure that under Toolpath, the Mode is set to Tail,

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and that under Stock, Colorization is set to Comparison.

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Notice that, in the timeline, there are a few collisions.

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From the Simulation player controls, click Play.

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Review the toolpath as it plays.

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You can see that the tool is not sticking out the toolholder far enough,

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which causes a collision between the toolholder and the part.

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Outside of those collisions, the toolpath performs as it should.

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Close the Simulate dialog.

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Apply a second toolpath.

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Expand the 2D drop-down and select 2D Adaptive Clearing.

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In the 2D Adaptive dialog, use the same tool as the previous toolpath.

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Open the Geometry tab.

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Enable Tool Orientation.

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Expand the Tool Orientation drop-down and click Select Z axis/plane & X axis.

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Then, in the canvas, pick a face of the part that you want the tool to be perpendicular to.

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Now, under Geometry, click the Pocket Selections prompt.

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In the canvas, pick the edge of a pocket.

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Then, back in the dialog, open the Heights tab.

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Under Top Height, expand the From drop-down and select Model top.

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Under Bottom Height, expand the From drop-down and choose Selected contours.

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Then, in the canvas, pick a bottom edge within the pocket.

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Open the Passes tab.

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Under Stock to Leave, in the Radial Stock to Leave field, enter .01.

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Set the Axial Stock to Leave to 0.

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Open the Linking tab.

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Expand the Stay-Down Level drop-down and select 80%.

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Set the Lift Height to .01.

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Finally, set the No-Engagement Feedrate to 400.

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Click OK.

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No toolpath is applied.

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In the browser, a warning indicator displays.

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Right-click the toolpath and select Edit.

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Back in the 2D Adaptive dialog, open the Linking tab.

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Under Ramp, the Helical Ramp Diameter value is too large to fit within the pocket.

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Change the value to .125.

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Click OK.

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The toolpath now displays in the canvas.

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With multi-axis, you can also machine in hard-to-reach areas, such as the chamfered edge of the pockets.

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Once the pocket has been cleared, you can apply a toolpath to chamfer it.

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From the Toolbar, expand the Multi-Axis drop-down and select Swarf.

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In the Swarf dialog, open the Geometry tab.

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Expand the Drive Mode drop-down and select Contours.

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Then, expand the Selection Mode drop-down and choose Contour pairs.

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Enable Tool Orientation, and then expand the Tool Orientation drop-down and choose Select Z axis/plane & X axis.

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Then, in the canvas, pick a face to set the WCS.

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Now, back in the dialog, under Geometry, click the Contours selection prompt and,

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in the canvas, pick the two edges of the chamfer.

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Open the Passes tab.

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In the Tool Offset field, enter .02.

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Then, open the Linking tab.

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Expand the Retraction Policy drop-down and select Minimum retraction.

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Click OK.

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The toolpath displays in the canvas.

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From the Toolbar, simulate the toolpath.

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In the Simulate dialog, ensure Toolpath is enabled, with Mode set to Tail.

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Then, ensure Stock is disabled.

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Review the simulation.

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While this simulation does not encounter collisions, it is possible the spindle may interfere with the machine at some point.