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Surface Machining Detailed Steps
Master Exercise: Renfort
Step 1: Create a new Part Operation (PO) and A Machining
Feature
1.1 - Create a new Part operation
Reset all options in Tool menu, select Option

Click on
Select Reset all options



Click Yes
Deactivate Automatic backup in General folder.
Select Machining





Activate option Create a CATPart to store geometry for Manufacturing
Click OK to close the dialog-box

1.2 - Open the part to machine
Menu File, Open
Open the Renfort.CATPart
Surface Machining Detailed Steps
Launch the Surface Machining workbench
In the Start menu, select Machining, then Surface Machining.



1.3 - Define Part Operation parameters
In the PPR tree, double-click on Part Operation.1 :



The following (Part Operation or PO) window appears:
Surface Machining Detailed Steps


To select the machine:
Click on the Machine icon:
In the machine editor, click on the 3-axis icon,

Click OK to accept the 3-axis_default_machine.

To select the part to machine:
Click on the No design part selected (for simulation only) icon,
Double click on the Part in the 3D View to assign it.
Click OK to accept and close the PO window (we will come back to this later).

To define and create the stock:
Click on the Creates Rough Stock icon located on the SMG workbench
Click in the area of the Destination field



Then expand the Part1 in the PPR tree and select Part1
Click on Yes in the Warning that pops up.

Select the part in the screen, the stock to be created is previewed according to the
contentment box of the part.

Surface Machining Detailed Steps


Change the Z min coordinate from 88.011mm to 100mm.
Change the Z max coordinate from 63.348mm to 70mm.
Click OK in the dialog-box to accept and create the stock.

In the PPR tree, double-click on Part Operation.1 to reopen the PO.

Click on the No stock selected icon,

Double click on the Stock in the 3D View to assign it.

Click OK to accept and close the Part Operation
Hide the stock by right clicking (Mouse Button 3 or MB3) on it in the view and selecting
Hide/Show

1.4 - Create a Machining Feature
Click Machining/Slope Area icon:
Next, you will define a Machining Area comprised of the whole part
Type in Whole part in the name field.
Surface Machining Detailed Steps


In the Machining Area window, select the Part symbol.
Then select the part in the 3D viewer by single clicking on it.



Double-click in an empty part of the screen to stop and accept the selection.
Click OK to accept the definition of the current Machining Area
Save your file as Step 1
Surface Machining Detailed Steps
Step 2A: Create a Sweep Roughing Operation



2.1 - Create a Sweep Roughing operation by using a ZPlane roughing type
Expand the tree so it looks as shown below.



Click once on Manufacturing Program.1 in the PPR tree to make it active. It will turn
orange as shown above.
Select the Sweep Roughing icon. The Sweep Roughing menu opens up.
To recall the Machining Area you previously created as Whole part:
Click the down arrow in the Feature field and select Whole part from the list.


Clear Part autoLimit.

Select the tool in the Tool tab page,
Surface Machining Detailed Steps

Clear the Ball-end tool button
Change the tool name to T1 End Mill D50 rc10. Hit the Enter key to accept the changed
name
Double click on the tool diameter dimension D and change it from 10 to 50.
Double click on the corner radius definition Rc and change it from 2 to 10.
Double click on the body diameter dimension db and change it from 15 to 35.


Select the Strategy/Options tab page.


Select the Machining tab and set the values as shown in the picture below:



Select the Radial tab and set the values as shown in the picture below:
Surface Machining Detailed Steps


Select the Axial tab and set the values as shown in the picture below:



Click on the Replay icon to compute and reply.





Click on the Photo

Surface Machining Detailed Steps


Click OK to end and close Photo window
Click on Replay again and then click on the Video icon





Click OK to accept and close the Video.
Click OK to accept the creation of the Sweep Roughing operation.
Close your file without saving

Surface Machining Detailed Steps

Step 2B: Create a Roughing Operation
Open file
Step:1


3.1 - Definition of the roughing operation
Click on Roughing icon

To select the geometry

Recall Whole part Machining Area the same way you did in the previous operation.




Tool path style is Spiral

Use tool T1 End Mill D50 rc10 which is same for previous operation

Feeds & Speeds
Select only Spindle output

Macros



Click on Replay button in the dialog-box.

Surface Machining Detailed Steps

Check the result of the computation by using Photo simulation.

You can see that material remains on one side of the part and that the pass overlaps are not
good.

Click OK to close the Photo

Click on Strategy tab,



Select the Radial tab and set the Tool diameter ratio to 65.



Select the Axial tab and set the Maximum depth of cut to 4mm.



Replay the current operation
Click on Photo icon
Surface Machining Detailed Steps


The result is now better than the previous one.
Click OK to close the Photo
Click on Strategy tab,



In Machining tab, change the Tool path style from Spiral to One-way next.


Replay the operation.
Using ICU (Instant Cycle Update) capability, the result is instantaneously updated.
Re-compute the tool path with Helical mode and replay.



Click OK to close the replay.
Click OK again to accept and close the operation
Surface Machining Detailed Steps

3.2 - Definition of a roughing rework
To duplicate Roughing.1 operation:
Right click (MB3) on the Roughing.1 operation in the PPR tree and select Copy in the pop-
up menu.
Right click (MB3) on the Roughing.1 operation again and select Paste in the pop-up menu.

Double-click on Roughing.2 operation to open it up.
Select Tools tab page and change the name to T1 End Mill D 25 rc5 . Be sure to hit the
Enter key after typing the name. Set the D & db to 25. Set the Rc to 5 as shown below.



Select Geometry folder and change Offset on part from 1mm to 0.5mm.



Set Minimum thickness to machine to 2mm

Click on Replay button to compute and replay.

Surface Machining Detailed Steps






Click OK once to end Photo and then click OK again to accept and end the Roughing
operation.
Run a Photo simulation

Surface Machining Detailed Steps

Step 3: Create a Slope Area, a Sweeping, Zlevel and a Pencil
Operation

First you will create a new tool change after the Roughing.2 operation.



Click once on Roughing.2 (Computed) in the PPR tree to make it active. It will turn orange
as shown above.



Click on the Endmill Tool Change icon.

In the Tool Change window and change the name to T1 Ball-nose D10 rc5. Be sure to hit
the Enter key after typing the name. Set the D & db to 10. Select the Ball-end tool button as
shown below.



Select OK to accept and create the tool change
Surface Machining Detailed Steps

4.1 - Select Machining/Slope area icon

In the Name field change the name to Slope Area 1




Select the Part symbol and select the part in the view by single clicking on it then double
clicking in an empty area of the screen to accept and the end selection.
Select the Slope Area checkbox and select Define tab.
In the Tool Reference field select T1 Ball-nose D10 rc5 tool as the reference tool and
change the Upper and Lower angles to 20.

Surface Machining Detailed Steps



Click on Compute button

Switch to Operations tab page
Click in the Insertion Level field and select the last Tool Change in the PPR tree.



Select Horizontal in the Area filed and change the associated operation from Spiral to
Sweeping
Click OK to accept. The Zlevel and Sweeping operations are automatically added in the
PPR tree

Expand the Tool Change by clicking the + next to it to see the operations that were
added.
Surface Machining Detailed Steps




Change the order of two operations
Right click on Manufacturing Program.1 and in the pop-up menu
select Manufacturing Program.1 .object Compute Tool path






Select OK in the pop up window to compute.
Open both operations and replay and simulate. Close when done.


Surface Machining Detailed Steps





Select the last operation in the PPR (ZLevel.1) and then select the Pencil icon

In the Pencil dialog box assign the Whole Part Machining Area the same way as you did in
the Roughing operations..
Click on Tool tab . Create a T1 Ball-nose D8 tool.
Replay the operation and do a Photo or Video.





You can see that the tool paths sometimes up mill and sometimes down mill. Next we will
recomputed this operation but with other parameters. We will change to always up mill and to
respect to a Climb cutting mode.
Click on Strategy tab


Change the Axial direction from to Up.
Surface Machining Detailed Steps

Replay the operation and do a Photo or Video, you can see that the tool path has been
modified to take into account the modification of Axial strategy parameter.
Click OK twice to end the Replay and close the current operation

Copy/Paste Pencil.1 after Pencil.1 the same way you copied and pasted the Roughing.
Double-click on Pencil.2 operation; create now a T1 Ball-nose D5 tool.
Replay the tool path and check the result.




Click OK twice to end the Replay and close the current operation.
Surface Machining Detailed Steps
Step 4: Create a Rework area, ZLevel and Contour-driven
Operations

Create a new tool change operation after the Pencil.2 operation in the PPR tree. Use the
same methods used previously to create a 2mm Diameter Ball-nose tool. Name it: T1 Ball-
nose D2.

5.1 - Select Rework area icon



Change the Name to Rework Area 1.
In the dialog box use Load from button and then select in Pencil.2 operation. All of the
parameters are automatically copied from in Pencil.2 ( tool definition, machining tolerance,
part to machine definition)
Click on the Other tab and change the Tolerance to 0.05mm
Click on Compute button.



Surface Machining Detailed Steps
The Cutting Areas are computed and displayed..
5.2 - Rework area edition
Select Edit tab in the Rework area dialog box



Right click on Vertical and select Add / Remove



Click on the three lines shown above (pointed to with green arrows) (to change them from
Horizontal (blue) to Vertical
Double-click in an empty area to stop the selection. The selected lines turn Vertical (red)
5.3 - Operations association
Switch to Operation tab in the dialog-box,

Surface Machining Detailed Steps


Select in the Insertion Level field and then select the last created Tool Change in the PPR.
Select the T1 Ball-nose D2 tool from the Tool Reference list.
Select OK to accept and create the operations. All of the rework operations are
automatically added inside the PPR tree. You just need to compute the tool path.
Click the + next to the last tool change in the PPR to expand show the operations.



Right click on Manufacturing Program.1 and in the pop-up menu
select Manufacturing Program.1 .object Compute Tool path
Select OK in the pop up window to compute.
Replay both operations. The results will appear as shown on the next page.




Surface Machining Detailed Steps