ESPRIT has machining technology that is designed specifically for 2-axis through 5-axis mills. This technology is called SolidMill.
SolidMill technology lets you define the physical properties of your milling machine, create milling tools and stock models, create specialized milling features with automatic feature recognition, create milling operations and simulate them.
The technology for SolidMill machining cycles is displayed on a tab in the Project Manager. This makes it easy to enter machining parameters and view the part model at the same time. The user can also click on any of the other tabs in the Project Manager to make it easier to select features or create new cutting tools.
The technology for a machining cycle will not open unless a valid feature is selected first.
The way that machining parameters are organized for all SolidMill machining cycles is consistent to make it easy to learn and use the technology.
The interface is organized in three main areas:
• Toolbar area
• Vertical tabs
• Parameters area
The Toolbar area contains commands to validate (OK) and close (Cancel) the current technology as well as a Help button to open the help file for the current technology. The drop-down button displays the context menu for the technology. The icon reflects the last command used by the user.
The vertical tabs are arranged to save space. Parameters are grouped on the tabs in a “top down”
approach, where you define the most general information about the cutting cycle on the General tab, then move to the Strategy tab to define a bit more detail such as the cutting strategy or depths, moving down each tab to add more detail about your machining operation.
The display of some tabs is controlled by a parameter setting. For example, if the parameter ‘Finish Pass’ on the Strategy tab is set to ‘Yes’, the Finish tab will display to let you define parameters for a final finishing pass. If ‘Finish Pass’ is set to ‘No’, the tab is hidden.
The Parameters area displays the machining parameters for the current technology. Parameters are grouped by category and each group control can be collapsed or expanded for visualization purposes.
For example, if the user sets ‘Trochoidal Move’ to ‘Yes’ for high-speed tool path, all the parameters to define the trochoidal movement are displayed.
Otherwise, they are hidden.
When an arrow button displays next to a parameter, you can click the arrow and select an element in the work area to load a value.
Features can also be loaded from the Features tab. Click inside the parameter field, click the Features tab, select a feature from the list, and then click the technology tab.
If the value for a parameter is invalid or missing, an error displays next to the parameter. If you hover your mouse over the error icon, a description of the error displays so that it can be corrected.
Saving Machining Technology
Machining technology settings can be easily saved as a separate *.prc (process) file and used over and over for the machining of similar parts. To save the technology for a machining cycle, click Save on the drop-down menu. Enter a name for the file, browse to the location where you want to save the file, and click Save.
After a technology file has been saved, it can be loaded in a technology page. Click ‘Open’ on the drop-down menu, browse to the file, and click Open.
X The type of technology in the file must match the machining cycle. For example, you can only load Pocketing technology into a Pocketing cycle. For this reason, it is important to name the saved technology file with the type of technology in the file.
Feeds and Speeds
The settings for feed rates and spindle speed are set on the General tab and displayed in two columns that are interactive. The column on the left is for actual feed and speed values, while the column on the right is used for chip load programming. If you enter a value in one column, the value in the next column is automatically calculated. This allows you to “fine tune” your feed and speed values.
Cut Speed
You can use ‘Cut Speed RPM’ (Revolutions Per Minute) or ‘Cut Speed SPM’ (Surface feet/meters Per Minute). Cut speed is defined as the distance in feet or meters that the edge of the rotating tool travels per minute. Cut speed is affected by the tool diameter. At a fixed number of RPMs, a larger tool diameter results in a greater cutting speed.
When a value is entered in ‘Cut Speed RPM’, the system takes that value and the tool diameter and calculates and displays the value for ‘Cut Speed SPM’. The relationship of RPM to SPM is based on the following formula:
SPM in Inch = RPM * PI * Tool Diameter / 12 SPM in Metric = RPM * PI * Tool Diameter / 1000
You can also go in the opposite direction. If you set Cut Speed SPM, the system takes that value and the tool diameter and calculates the Cut Speed RPM. The system uses the following formula:
RPM in Inch = (12 * SPM) / (PI * Tool Diameter) RPM in Metric = (1000 * SPM) / (PI * Tool Diameter) XY Feedrate PM, PT
These values are also interactive. Feed rate is defined as units (inch/millimeter) per minute (PM) or per tooth (PT). In general terms, the feed rate is the speed at which the cutter moves with respect to the work material. XY Feedrate allows you to specify the feed rate for movement in the XY plane.
To calculate the feed rate PT (per tooth) from the feed rate PM (per minute), the system uses the following formula:
PT = PM / (Number of Flutes * RPM)
Going the other way, the system uses the following formula:
PM = PT * Number of Flutes * RPM
X The Tool Diameter and Number of Flutes are set on the tool page.
There are three types of moves possible in the XY plane. These moves are represented by the following examples of NC code. The value you enter for XY Feedrate determines the feed rate for these three types of moves.
Type 1: N15 G01 X_ Y_
Type 2: N15 G01 X_
Type 3: N15 G01 Y_
Z Feedrate PM, PT
Z Feedrate allows you to specify the feed rate for moves along the tool axis. These moves are represented by the following examples of NC code. The value you enter for Z Feedrate determines the feed rate for these four types of moves.
Type 1: N15 G01 X_ Y_ Z_
Type 2: N15 G01 X_ Z_
Type 3: N15 G01 Y_ Z_
Type 4: N15 G01 Z_
Constant Removal Rate
This option can be set to Yes or No. When set to Yes, the feed rate is adjusted on arcs to maintain the feed rate at the edge of the tool where it contacts the material. The feed rate increases around exterior arcs and decreases around interior arcs in the NC code output. The Max Feedrate setting is used to limit the increase in feed rate.
Max Feedrate PM, PT
Max Feedrate is used to place a limit on the feed rate increase around exterior arcs when Constant Removal Rate is set to Yes.
Use Feed and Speed KB
This option can be set to Yes or No. When set to Yes, feed and speed values from the KnowledgeBase will be inserted automatically.
Before setting this option to Yes, you must:
• Have speed and feed data set up in the Speed Feeds Manager in the KnowledgeBase
• Select a Speeds Feeds Standard and Material Class in KnowledgeBase Document Setup (on the Common Machining tool bar)
• Select a tool in Tool ID
• Select a Type of Cut (the Type of Cut option displays only when Use Feed and Speed KB is set to Yes)
ESPRIT will combine the Speeds Feeds standard and material selected in KnowledgeBase Document Setup with the tool and technology settings on the operation page to provide
acceptable cutting speeds and feed rates. The inserted speeds and feeds are affected by the “Tool Material” and “Number of Flutes” specified on the tool page of the same Tool ID. The Type of Cut selected on the operation page also affects the inserted speed and feed values.
Milling Clearances
Parameters that control tool clearances during milling are located on the Links tab. Clearances define how you want to position the tool when it makes a rapid move from one location to another.
ESPRIT lets you define two separate distances for retract moves: Clearance and Full Clearance.
Once you define the two distances, you can use them to control the heights of retract moves.
• Full Clearance: This is an absolute value, measured from the origin of the coordinate system.
ESPRIT supports two types of coordinate systems: global (system default) and local (user defined).
• Clearance: This is a relative value, measured from the top of the feature or the starting depth.
negative (-) value. In that case, clearance is measured from the starting depth since it is above the feature.
Both methods of measurement have advantages. When you know the heights of specific obstacles on the work table, such as clamps and fixtures, you can use Full Clearance to make the tool retract to a safe height that will always avoid those obstacles. To save time, you can set a minimum retract height in Clearance that keeps the tool as close to the work piece as possible.
In addition to the retract distances, ESPRIT lets you control the behavior of the tool between separate machining operations and between sections of a single operation.
• Return Plane: This setting establishes the plane position of the tool as it rapids to the beginning of an operation and rapids away at the end of an operation.
• Retract Plane: This setting establishes the plane position of the tool as it rapids between two sections of a cutting operation (for example, when the tool needs to move between two pocket areas in a Pocketing operation).
Return Plane and Retract Plane share the same four options. However, you can use a different option for each.
X The Return Plane is always used. Whether the Retract Plane is used depends on the areas that are being machined. If you are not sure about when the retract plane is used, it is a good idea to set the retract plane and return plane to the same option.
Options for Return Plane and Retract Plane
Clearance: The tool retracts to the Clearance distance, measured from the Starting Depth. See
“Depths of Cut”. When the tool will encounter no obstacles during repositioning, this is a good choice.
Initial Clearance: The value for Initial Clearance is specified on the tool page for the selected tool.
The distance is an absolute value, always measured from ESPRIT origin P0. When the tool must avoid all obstacles (such as fixtures and clamps) while moving to the next position, this is a good choice.
Full Clearance: The tool retracts to the distance entered in Full Clearance. If you are outputting from World coordinates, this value is measured from P0. If you are outputting from a local coordinate system, this value is measured from the origin of the Work Coordinate used. When the tool must avoid vertical obstacles on the work piece between operations, this is a good choice.
Partial Depth: The tool retracts to the Clearance distance measured from the tool location at the time of the retract. When you know the tool will be repositioning to a lower plane, this is a good choice.
Depths of Cut
The depths of cutting passes are controlled by the Depth settings on the Strategy tab. The depth settings let you control the z-level where the tool will start cutting, the depth of each incremental pass, and the depth of the final cutting pass.
• Total Depth: This value establishes the bottom Z level for cutting passes. This value is measured from the selected feature. A positive value cuts below the selected feature, a negative value cuts above.
• Incremental Depth: This value controls the distance between each Z-level cutting pass. The values for Total Depth and Incremental Depth are used to determine the number of depth passes. The depth of the last incremental pass may be adjusted depending on the value for Total Depth and any stock allowance applied to the floors.
• Starting Depth: This value establishes the top Z level for cutting passes, measured from the selected feature. The first incremental depth pass is measured from this top Z level. A positive value cuts below the selected feature, a negative value cuts above.
• Retract for IDepth: This value controls the retract position of the tool before and after each incremental pass. Since this setting controls a tool retract distance, it shares the Full Clearance, Initial Clearance, and Partial Depth options that are used for clearances. You can also use the None option to have the tool feed between incremental passes without retracting. The Surface Clearance option is similar to the Clearance option except that the retract is either the clearance distance above the feature or the clearance distance above the starting depth, whichever is higher.
• Retract Between Cuts (Contouring only): This value controls the retract position before and after each lateral contouring pass. If the contour does not have lateral steps, this setting does not apply.
• Through Depth (Pocketing only): This value is used only when a pocket has no floor. Enter a value beyond the depth of the pocket so the tool can cut completely through. When a value is entered, the operation cuts to the total depth plus the distance for the through depth.