Lesson 1 - Simulate, Revise

00:08

Now that we have programmed all of the features necessary to machine our part, let's start by running a machine simulation.

00:16

Just as a reminder, machine simulations allow us to visually check if we have any gouges or collisions, while we see a great visual representation of what the actual machining of our part will look like.

00:30

So, with machine simulation selected in my Simulation section of the Home ribbon, I'll select "Play", and let's watch this part get machined.

00:43

First, we do our Z level rough with step cutting.

00:46

And then we start our X parallel finishing operation.

00:49

But it looks like our holder has gouged into our stock.

00:54

Let's take a front view to get a closer look.

01:01

If we look closely, it looks like our tool is not long enough, and the sight of our holder has collided into our part.

01:09

Now, there's a couple different ways we could fix this.

01:11

If we were just on a 3-axis machine, really our only option would be to select a longer tool.

01:18

However, as we select longer tools to do a machining operation, we increase the likelihood of unwanted vibrations, ultimately giving us a poor surface finish.

01:29

However, since we're using a 5-axis machine, we can simply tilt the tool axis, machine the same part while still maintaining a good surface finish.

01:42

So let's eject the simulation, open up our finishing operation in the surface mill 2 feature, and navigate to the 5-axis tab inside of the parallel operation.

01:55

This fifth axis tab is enabled in our parallel finishing operation when we indicate during import that we will be using fifth axis positioning.

02:08

Because we indicated to FeatureCAM that we would be machining a 5-axis part, the 5-axis tab is now available inside of the parallel finishing operation.

02:19

Here you'll see by default, we've selected vertical in the Z.

02:23

So this is just what we saw.

02:25

Our tool axis stayed vertical along the Z of our setup 1 direction that we defined while importing.

02:31

And ultimately, we ended up colliding our holder into our part.

02:36

Let's take a look at this first option, fixed.

02:40

The fixed option on the 5-axis tab allows us to simply define a vector that will define our tool axis.

02:47

While machining this part, our tool axis will always be aligned to this defined vector.

02:53

So for this part, let's enter a vector of negative 0.5 in the X, 0 in the Y, and 1 in the Z.

03:05

Just to help you visualize, if we wanted our tool to be perfectly aligned with the Z going vertical, we could enter in a vector of 0,0,1.

03:16

If we wanted our tool completely horizontal aligned with our X direction, we could enter in 1,0,0.

03:24

And likewise, if we wanted our tool oriented horizontal in the Y direction, we would enter in 0,1,0.

03:33

So this fixed vector has both an X and a Z component.

03:38

So we can expect to see some tilting in both the X and the Z directions, but not in the Y.

03:44

With that vector indicated, let's select "Apply", "OK", and run another machine simulation.

04:06

Now we can see that while we were finishing the part, the tool axis changed to reflect our fixed tool axis vector.

04:14

This change has completely eliminated the collisions we were experiencing earlier, and this program is now safe to run on the machine.

04:22

However, let's dig a little bit deeper and take a look at some of the other options we have to utilize our 5-axis machine’s capabilities

04:30

when programming surface milling features.

04:32

So, I'll eject the simulation, reopen surface milling tool, go back to the parallel finishing operation, and navigate to the 5-axis tab.

04:45

Next, let's take a look at our first multi-axis option titled use Lead and Lean.

04:51

Select use Lead and Lean, in the from drop-down, select Contact normal and enter in a lead angle of zero and a lean angle of zero.

05:03

Right now, we're telling FeatureCAM that by entering in a zero and a zero value for both angles, at all times we would like to be perpendicular to the contact normal surface.

05:15

Lead and lean angles are the angles that we would like to rotate both in the direction of travel and perpendicular to the direction of travel.

05:24

So a lead angle allows us to lean either forward or backward in the direction of travel.

05:32

Lean angle allows us to lean left or right perpendicular to the axis of travel.

05:39

Think about a sprinter running around a track.

05:43

When a sprinter takes off, the sprinter’s body is tilted forward along the direction of travel.

05:50

Think of this as a lead angle of maybe 15 degrees.

05:54

Now as the sprinter approaches the turn, the sprinter must lean to the left.

06:00

This would be a lean angle of, let's say, negative 15 degrees.

06:05

So lead angles are the amount that you would like to tilt in the direction of travel.

06:11

Lean angles are the amount that you would like to tilt left or right perfectly perpendicular to the direction of travel.

06:19

Hopefully that analogy helps you visualize.

06:22

But let's hit "Apply", "OK", and run a machine simulation to get a better idea of what a lead and lean angle of zero looks like.

06:35

As we begin to machine our finishing operation, after this first roughing operation, we’ll be able to see that the lead and lean tools allow us to specify a tool axis angle in reference to the direction of travel at all times.

06:49

When we're machining a horizontal wall, the tool is completely vertical.

06:53

When we're machining a vertical wall, the tool should be completely horizontal.

06:58

These options can help us generate safe and efficient toolpath in a lot of situations.

07:03

But it looks like in this situation, it seems that the lead and lean angles have created a machining collision where the table has collided with the machine.

07:13

So, in this case, lead and lean angles of zero may not be our best option.

07:20

At this time, feel free to experiment with some various lead and lean angles until you generate safe toolpath.

07:27

As you change the angles, notice how that affects our tool axis while machining the finishing operation.

07:37

Once you feel comfortable with the lead and lean options, open up surface mill 2 and navigate to the parallel operation 5-axis tab.

07:47

The last option I'd like to take a look at is the Tilt Axis for Gouge Avoidance option.

07:54

Here we can tell FeatureCAM among other options to lead or lean only if we are going to collide.

08:02

So, if I select to lead and move my axis back to a vertical, going perfectly aligned with our positive Z direction, "Apply" and "OK", we'll see that my finishing operation now starts and stays vertical at all times, unless it's going to collide.

08:21

In that case, it automatically leads as much as it needs to not collide.

08:28

As we move out of danger of collision, our tool axis will align itself vertically again.

08:33

Let's play through our roughing operation, then slowly watch our finishing operation.

08:48

Notice how the tool axis stays perfectly vertical until we are in danger of colliding.

08:54

Then it changes the lead angle until we're out of danger and moves the tool axis back to vertical.

09:14

In this revised portion, we took a look at three different 5-axis simultaneous options.

09:20

First, we tried fixing our tool axis along a defined vector to avoid collisions, and that seemed to work.

09:27

Next, we tried changing the lead and lean angles to zero, so that we would always stay perfectly perpendicular to the contact normal.

09:37

As you may recall, this actually ended up resulting in a collision.

09:42

Hopefully, you took the time to explore various lead and lean angles that prevented that collision.

09:48

Finally, we looked at the Tilt Axis for Gouge Avoidance option.

09:53

Here, we told FeatureCAM that whenever possible we would like to keep our tool axis vertical along the Z.

10:01

But if we are in danger of colliding, we would like to either lead or lean to safety while still simultaneously machining.

10:12

So as we can see, there's always multiple solutions for us to machine the exact same part.

10:18

Pick the one that makes most sense to you and run your final machine simulation before moving on to the next section, NC Code.