Tool Path Problem in 5-Axis Machining

[sohail abbas]

Hi Guys


I am sending some Bitmap file in attachment,review them carefully, I have suggested the surface machining technique, you can see the toolpath is very smooth from begining of the toolpath, but at the bottom the toolpath is too bad, that the tool gouges inside the part.


suggest me what to do to get rid of such kind of voilatoin, to keep the tool smooth through out the part.


If required i can send you the maching fils also.


2006-06-03_033315_Blad-problem.rar

 

[appinmi]

I cannot read a "*.rar" file. If you could upload the machining file(s), maybe I could help. I am still using Wildfire 1, so I cannot read a Wildfire 2 or 3 file.

 

[sohail abbas]

Sorry Allan


I don't have wildfire, since my company only using the Latest version


Second solution is i can send you the part file in IGES formate, tell me what to do


regards

 

[appinmi]

It's worth a try, but could you send a "step" file instead of IGES. I find that step files are more stable.

 

[sohail abbas]

ok i am sending you in IGES and Step format


thnx and regards





2006-06-06_050724_sohail.rar

 

[sohail abbas]

Hi allan





i waiting for your reply,let me know about the progress?


regards

 

[appinmi]

I cannot unpack the ".rar" file. Our system administrator will not allow it. Could you create a ".zip" file.

 

[sohail abbas]

Here i am sending you the zip file,


2006-06-08_022326_blade_step_file.zip

 

[appinmi]

I am not sure how you want to machine this, but I have created rough and finish cutter paths for it. I believe your problem came from not having a fillet between the fin and the base stock. My 2MM ballnose endmill was jumping all over the place until I added a 1MM fillet. I do not usually work with metric parts, so forgive me if my parameters are a little strange.


For the 4MM ballnose endmill that I used to rough with, I created a mill volume, trimmed the part from it, and added a 2MM fillet.


2006-06-10_083814_5_MAN.zip

 

[chf65]

Hi soheil,


You can also get the result that AllanP showed you without changing the part geometry. Select the triangle at Cut Line references to expand the options, and select 'Tool Extent". This will automatically give you the extent of the machined surfaces that are reachable but the tool, so you can define proper cutlines (use boundary chains).


View attachment 2372


This is helpful in more complex cases where the end cutline is not so easily derived.

 

[sohail abbas]

Hi allan


you have applied the 4-axis strategy for this part but actually i want to machine this part with true 5-axis strategies. Since out machine is vertial, so the datum setting is very easy for us, also we need not to convert Y into Z.


More over on the basis of this i have to machine another part, which has built in40 blades on its pereiphery, and for that part you can not apply the 4-axis strategy.


so please check the other jpeg i have already sent to you.

 

[sohail abbas]

i am sure that Pro-E could not machined parts like this uptill now, may be in latest version they include some strategies to handle such parts.

 

[chf65]

Hi Sohail,


I agree with Allan. Why do you want to use 5-axis startegy on this part? You will get a much more stable machine kenematics with the 4-axis toolpath that Allan has suggested.


The only 2 recommendation I can add to Allan's toolpath is the following: Use SCAN_TYPE=Helical. It will give you a nice continuous toolpath. Also, add a lead_angle (about 30 deg)so that the tool is not machining with the tip, so you get a much higher surface footage at the leading edge.


If you insist on using 5-axis toolpath, I recommend using the helical scan type, and using the Tool extent that I suggested earlier to determine the machinable area. Also, use lead angle and tilt angle to make sure the tool does not impede on the shroud at the bottom, so you tool extent is a nice contour at the bottom.