Surface Machining

Student Notes:

CATIA Training
Exercises

Surface Machining
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Version 5 Release 17
September 2006
EDU_CAT_EN_SMG_FX_V5R17

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 Surface Machining

Connecting Rod
Student Notes:

Master Exercise Presentation

60 min

In this exercise you will create various 3-Axis Surface

Machining Operations to machine a die for connecting
rod.
To do so, you will have to:

Create the Roughing operations to rough machine the part.

Create the Semi-finishing operations after roughing.
Finally, create Finishing operations to finish the part to
match with design specifications.
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 Surface Machining

Student Notes:
Connecting Rod - Design Process (1/2)
1
Create a
Roughing
Operation

2
Create a ZLevel.
3 1 & 2 Operations
Create Spiral Milling.1
Operation

4 5

Create Create a Sweeping

Contour-driven.1 Operation
Operation
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 Surface Machining

Student Notes:
Connecting Rod - Design Process (2/2)
6
Create a
Zlevel.3
Operation
8
Create Spiral Milling.2 7
Operation Create
Contour-driven.2
Operation
9
Create
Contour-driven.3
Operation

10
Finished Part
Create
Contour-driven.4
Operation
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 Surface Machining

Connecting Rod
Student Notes:

Creating the Roughing Operation

10 min

In this step you will create a Roughing operation.

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 Surface Machining

Student Notes:
Roughing Operation
Open Start_MasterExercise_SMG.CATProcess

Create a Roughing.1 Operation

Define Geometry:
Select Full Part
Select Imposed planes (except top) by
Search/View => Reachable Planes.
Offset on part & check = 0.2 mm

Define Strategy:
Tool path style = Spiral
Stepover: Overlap Ratio = 70
Maximum cut depth = 1.5 mm

Define Tool: T1 End Mill D10Rc2.5 as

shown.

Define Feeds and Speeds as shown.

Define Automatic Macro:

Mode: Ramping
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Check ‘Optimize retract’

Axial safety distance = 2 mm
Ramping angle = 4 deg

Replay the operation Tool- End Mill D10Rc2.5 Feeds and Speeds

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 Surface Machining

Connecting Rod
Student Notes:

Creating the Semi-finishing Operations

20 min

In this step you will create Semi-finishing

operations:
ZLevel.1 Operation (1)
ZLevel.2 Operation (2)
Spiral Milling.1 Operation (3)
Contour- driven.1 Operation (4)

2
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 Surface Machining

Student Notes:
ZLevel.1 Operation
Use result of Step1

Create a ZLevel.1 Operation after Roughing.1 operation

Define Geometry:
Select Full Part
Select boundary as a ‘Limiting Contour’
Select Imposed planes (except top) by
Search/View => Reachable Planes.
Offset on part & check = 0.15 mm
Clear ‘Part autoLimit’

Define Strategy:
Machining tolerance = 0.07 mm
Stepover: Constant,
Distance between pass = 1.1 mm

Define Tool: T2 End Mill D8Rc1 as shown.

Define Feeds and Speeds as shown.

Define Macros:
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Ramping 5 deg & 2 mm- for Approach,

Retract & Between passes
Clearance: Distance = 1 mm

Replay the operation Tool- End Mill D 8Rc1 Feeds and Speeds

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 Surface Machining

Student Notes:
ZLevel.2 Operation

Copy/paste ZLevel.1 Operation for defining ZLevel.2 operation

Define Geometry:
Edit Imposed planes as shown.
Offset on part & check = 0.1 mm
Select ‘Part autoLimit’

Define Strategy:
Machining tolerance = 0.05 mm
Stepover: Constant, Distance
between pass = 0.7 mm

Define Tool: T3 Ball Nose D6 as shown.

Define Feeds and Speeds as shown.

Replay the operation

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Tool- Ball Nose D6 Feeds and Speeds

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 Surface Machining

Student Notes:
Spiral Milling.1 Operation

Create a Spiral Milling.1 Operation after Zlevel.2 operation

Define Geometry:
Select Part & Limiting Contour, same as ZLevel.2
Clear ‘Part autoLimit’
Stop position ‘Inside’

Define Strategy:
Zone
Max frontal slope = 3 deg
HSM
Corner radius = 2 mm

Define Tool: T3 Ball Nose D6.

Define Feeds and Speeds, same

as of ZLevel.2
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Define Macros as shown.

Replay the operation Approach Macro Retract Macro

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 Surface Machining

Student Notes:
Contour-driven.1 Operation

Create a Contour-driven.1 Operation after Spiral Milling.1 operation

Define Geometry:
Select Full Part

Define Strategy:
Guiding Strategy: Parallel contour
Contour
Machining tolerance = 0.02 mm
Offset on contour = -1 mm

Define Tool: T3 Ball Nose D6.

Define Feeds and Speeds:

Machining Feedrate = 4000 mm_mn
Machining Spindle Approach Macro
Speed = 20000 turn_mn
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Define Macros as shown.

Replay the operation

Retract Macro

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 Surface Machining

Connecting Rod
Student Notes:

Creating the Finishing Operations

30 min

In this step you will create Finishing operations:

Sweeping.1 Operation (1)
1
ZLevel.3 Operation (2)
Contour- driven.2 Operation (3)
Spiral Milling.2 Operation (4)
2
Contour- driven.3 Operation (5)
Contour- driven.4 Operation (6)
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6 5
4

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 Surface Machining

Student Notes:
Sweeping.1 Operation
Use result of Step2
Create a Sweeping.1 Operation after Contour-driven.1 operation

Define Geometry:
Select face and Limit line as shown.
Offsets on part and check = 0 mm
Limit Definition
Stop position = On

Define Strategy:
Max. distance between pass = 0.15mm
Machining tolerance = 0.02 mm
Scallop height = 0.1

Define Tool: T3 Ball Nose D6.

Define Feeds and Speeds:

Machining Feedrate = 4000 mm_mn
Machining Spindle
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Speed = 20000 turn_mn

Replay the operation

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 Surface Machining

Student Notes:
ZLevel.3 Operation

Create a ZLevel.3 Operation after Sweeping.1 operation

Define Geometry:
Select Full Part
Select boundary as a ‘Limiting Contour’
Select Imposed plane at depth = - 6.524
Select Check surfaces as highlighted
Offset on part & check = 0 mm

Define Strategy:
Machining mode: Outer part and pockets
Max. horizontal scope = 0 deg

Define Tool: T4 Ball Nose D4 as shown.

Define Feeds and Speeds:

Machining Feedrate = 3000 mm_mn
Machining Spindle Speed = 24000 turn_mn

Define ‘Circular or ramping’ Macros for:

Tool- Ball Nose D4
Approach, Retract & Between passes
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Clearance: Distance = 1 mm

Replay the operation

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 Surface Machining

Student Notes:
Contour-driven.2 Operation

Create a Contour-driven.2 Operation after ZLevel.3 operation

Guide2
Define Geometry:
Select Full Part

Guide1
Define Strategy:
Guiding Strategy: Between contours
Select Guide1 & Guide2 as shown
Radial parameters as shown.

Define Tool: T4 Ball Nose D4.

Define Feeds and Speeds:

Machining Feedrate = 2000 mm_mn
Machining Spindle
Speed = 24000 turn_mn
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Replay the operation

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 Surface Machining

Student Notes:
Spiral Milling.2 Operation

Create a Spiral Milling.2 Operation after Contour-driven.2 operation

Define Geometry:
Select full Part & Limiting Contour as shown
Use ‘Geometrical Zone’ to select
3 limiting contours
Limit Definition
Offset = -2 mm

Define Strategy:
Clear High speed milling Limit
contours
Define Tool: T4 Ball Nose D4.

Define Feeds and Speeds:

Machining Feedrate = 3000 mm_mn
Machining Spindle
Speed = 24000 turn_mn

Define Macros:
Approach & Retract
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Along tool axis = 4mm

Clearance:
Distance = 1 mm

Replay the operation

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 Surface Machining

Student Notes:
Contour-driven.3 Operation

Create a Contour-driven.3 Operation after Spiral Milling.2 operation

Define Geometry:
Select Full Part

Define Strategy:
Guiding Strategy: Parallel contour
Select Guide1 as shown
Radial & Strategy parameters as shown.

Define Tool: T4 Ball Nose D4.

Define Feeds and Speeds:

Clear Automatic modes of Feedrate
and Spindle Speed

Define Macros:
Retract
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Along tool axis = 2mm

Replay the operation

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 Surface Machining

Student Notes:
Contour-driven.4 Operation

Create a Contour-driven.4 Operation after Contour-driven.3 operation

Define Geometry:
Select Full Part

Define Strategy:
Guiding Strategy: Between contours
Select Guide1 & 2 as shown
Radial parameters as shown.

Define Tool: T4 Ball Nose D4.

Define Feeds and Speeds:

Clear Automatic modes of Feedrate
and Spindle Speed

Define Macros:
Between passes link
High speed milling

Replay the operation

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End (Finish) part

See Result in End_MasterExercise_SMG. CATProcess

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