Summer 00.qxd
Transcription
Summer 00.qxd
GibbsNews ® A Publication for Manufacturing Professionals What’s Inside Tech Tip 2 New Training CDs 3 Join Our Mailing List 3 CAD Corner 6 New Training Schedule 7 GibbsCAM 2000 Shipping this Summer! The much anticipated GibbsCAM® 2000 release will be shipping this summer with all new enhancements and features. General Improvements A number of new enhancements have been integrated into the GibbsCAM system’s base functionality providing added value to your machining capabilities, whether simple 2 or 21⁄2D production work or complex 3D multisurface machining. NEW Stock Wizard Stock definition has been improved with the new Stock Wizard, which guides the user through defining circular and rectangular stock objects with circular or rectangular pockets or thru holes. Conventional stock definition from geometry has been extended to support nested shapes allowing complex cross sections to be entered. customized or used to create new report templates. Images, such as work-in-progress, can also be included in the report. You will also be able to post process select operations without sorting each process in a G-code editor. Simply choose the process tiles you want to post and only the ones chosen will be generated by the system. Complex jobs can be managed in a single .vnc file. A new utility that scans through your model to identify and remove duplicate geometry will also be included in the new release. This eliminates the task of having to flip through labels or play hide-and-seek with duplicate geometry, saving you both time and effort. Stored processes can be structured by placing them into separate folders in your stored process directory. When the system displays your stored processes, they will be nested in the pull-down menu according to how they are arranged in the folders. You will be able to quickly and easily identify any particular process. Production Annotation The annotation capability has been enhanced to provide XYZ annotation. This allows the location of points to be graphically displayed to facilitate positioning on the shop floor— helpful when setting up fixtures. NEW Reporter The new Reporter will provide report forms generated using Microsoft Excel with complete compatibility with Microsoft Windows 2000. A set of report templates for part, operations, and tooling is included that can be A significant number of improvements and new capabilities for the Production user will be included in the GibbsCAM 2000 release. You will find that many of these make the GibbsCAM system even easier to use and more powerful than before. NEW Hole Wizard™ With the Hole Wizard interface, compound holes are defined in a simple four-step process. The first step is to define the type of hole you want to create. The second is to define what the various values are for the hole, or select a standard hole from a table of predefined holes. In the third step, the Continued, pg 4 Summer 2000 • Volume XI • Issue II Published by Gibbs and Associates 2 ech Tip Utilizing the Material Only Cutting Function This issue’s Tech Tip focuses on the Material only cutting function with an emphasis on machining solids. Material only cutting is a function that is used to remove material left by a previous operation. It calculates toolpath for all remaining material left on walls by prior pocketing operations only. Remaining material is then stored for 2D contouring and pocketing operations. The material only cutting function can be used either as a single operation or as part of a multiple process group. Setting the proper machining preferences The Allow Mill Material Only setting must be selected in the Machining Prefs dialog box in order for the system to track and Before material only function applied store remaining material conditions. If the material only option is not going to be used in operations, it is strongly recommended that this option be deselected. When this preference is on, the system will perform the calculations needed for a material only operation, even if the calculations will not be applied. This information will also be saved with the part file. You can conserve significant amounts of processing power and disk space by turning this option off when not being used. When optimal material removal is required, it is best to use the largest cutter possible. This might leave material in corners or around islands or bosses that are too close to an internal wall for the larger cutter to pass through. A subsequent pocketing operation can be created with a cutter smaller After material only function applied than that used to generate the first rough operation. With the material only function checked in the rough process dialoge box, the pocketing operation will remove only the material left by the previous tool. This greatly enhances the efficiency of the cutting operation. The effectiveness of the material only cutting function will be affected by the value entered in the Past Stock setting. Past Stock is the distance a tool’s edge is allowed to travel into an open area to remove material. The recommended value for Past Stock is the tool diameter minus 2.5 times the maximum surface tolerance of any previous operation. A Past Stock value set too large will result in Machining Preferences Dialog Box toolpath in areas where there is no material left to cut from a previous operation, thus creating unwanted air cuts. Conversely, a Past Stock value set too small may result in toolpath that does not clean up all the material remaining. The following example helps illustrate how to calculate the Past Stock value for a material only machining operation using a 0.5" diameter endmill and a prior operation with a surface tolerance of 0.005". Example: 0.5"-(2.5*0.005) = 0.4875" Past Stock The Overhang value is another setting that must be considered to produce an effective material only cutting operation. Overhang is the distance a tool’s edge will move past an open boundary. The recommended value for this setting is the tool radius. As stated before, the material only function can be used as a single process after a pocketing operation, or it can be used as part of a multi-process machining operation. When using the material only function, it is recommended that the check box for ignore tool profile be selected. When ignore tool profile is checked, the system performs a simple 2D calculation of material left on walls. Tool corner radii and tapers are ignored and material left on floor by corner radius is not considered. A conflict could arise if a sharp Continued, pg 3 3 Tech Tip, Cont. from pg. 2 corner endmill is used to perform the material only cut. To prevent this conflict, you can direct the system to consider all remaining material by deselecting the ignore tool profile checkbox. When not to use material only Certain situations are not ideal for using the material only function. Currently depth first is not supported, meaning that if multiple Z steps are defined and the material only function is applied, the function will not finish one feature before moving on to the next. If no toolpath is generated, the final cut depth could be below the stock bottom. To avoid this, redefine the stock for this operation only, and move the stock bottom value to the desired final cut’s Z depth. Avoid full-body selections and select only the faces to be cut. Whenever possible, use 2.5D optimization. This choice will produce toolpath with circular interpolation (G2s and G3s) and will also allow for a tighter surface tolerance setting. Since the material only function does not support custom stock bodies with undercuts, these should be avoided. Likewise, tools with undercut cutting edges are not supported either and should also be avoided. If material only fails on the solid, extract the edge geometry that defines the pocket and machine as geometry. When extracting the edge geometry, specify a small tolerance so the edges will be extracted as lines, arcs and circles (analytic geometry instead of B splines). Zero tolerance will extract B splines and any tolerance greater than zero will extract analytics. If you have a speciific question and need further assistance, the Gibbs Technical Support Department is available to you via telephone (805-523-0004) or e-mail (support@gibbsCAM.com). ✦ Training CD Now Available New training CDs are now available for purchase. There are four individual CDs including one for milling, one for turning, one for SolidSurfacer™ and one for advanced mill, rotary mill and solids import. Created by a GibbsCAM Reseller, Virtual CD Trainer utilizes a graphical interface that simulates the functionality familiar to GibbsCAM customers. The tutorial is designed to take the user through the completion of a part either step-bystep or by specific functions, depending on the preference of the user. The user is lead through the same process used to set up and program a real part. The “How Do I?” feature contains a library of frequently asked questions categorized by major topics. WithVirtual CD Trainer, a suplemental training aid is readily and conveniently available to you any time you need it. Virtual CD Trainer is priced at $300 for each of the milling, turning, and SolidSurfacer CDs. The advanced mill, rotary mill and solids import CD is priced at $75. If you would like a copy of one or more of these training CDs, contact your local GibbsCAM Reseller or visit the Virtual CD Trainer website at www.virtualcdtrainer.com or e-mail at virtual@houston.rr.com. Join Our GibbsCAM® Mailing List In an effort to continue improving our customer communications, Gibbs and Associates has set up a mailbot specifically for its customers. Mailbots are mailing list managers, which can be used to manage mass distribution of information. Initially, we will be using the mailbot to distribute VGNEWS, an electronic newsletter containing information regarding maintenance releases, tech tips, new business ventures or other information of value to our customers. In order to subscribe to the VGNEWS mailing list, go to the Gibbs website (www.gibbsCAM.com) and log into the Gibbs secured support pages (Click on Gibbs Online, enter User ID and Password). Under the release software section, you will find a link to subscribe to VGNEWS. In the fields provided, type in your name and e-mail address and click on the SUBSCRIBE button. At any time, you can unsubscribe from VGNEWS at this link as well by clicking on the REMOVE button after typing in your name and e-mail address. When you subscribe, the mailbot will send a confirmation message back to the e-mail address you entered. To confirm your subscription, simply reply to the confirmation message. You will not be added to the list until a confirmation reply has been received from you. 4 GibbsCAM 2000, Cont. from pg. 1 system determines what processes and tooling is required based on user-provided information. Finally, the hole pattern pallet is used to locate the holes and then create the processes and operations. Operations are completely associative. If a change is needed, simply enter the Hole Wizard interface and make the modifications and all operations and processes will automatically update. With the Hole Wizard, creating compound holes can now be a simple task. Drilling improvements include bore, fine bore and back bore drill cycles. In addition, all drill cycles can now specify a dwell amount allowing even finer control of drill motion. Note: Your posts might require an update in order to take advantage of these additional drill cycles, consult your reseller for more information. Pocketing With the new zig zag pocketing, pockets can be cleaned out with a highly efficient zig zag toolpath. Various methods for handling islands and pocket walls can be specified allowing the best overall result, while maintaining a high-level of efficiency. Greater control of toolpath generation is provided with additional enhancements that support ramp angle for pocket entries, variable Z step and constraint loops. Roughing For lathe users, a new lathe rough retract move pulls the tools back at a 45o angle during retract allowing for additional clearance. NEW G-code Editing The new G-code editor will allow users to edit GCode from within the GibbsCAM system. To demonstrate this capability, a simple code browser is supplied that can be used to display and edit posted output in a scrollable text window. You can launch Gibbs Editor 1 or another editor of your choice. Creating radial patterns is now possible with new functionality that will enable you to translate, rotate and duplicate toolpath and maximize your productivity. High-Speed Machining Three new improvements for high-speed machining and machining hardened materials will be introduced in the GibbsCAM 2000 release. You will be able to create 2D or 3D spirals, which are extremely useful for cutting hardened materials. The resulting toolpath uses G2 and G3 codes to output interpolated helical spirals. The third, trochoidal pocketing, creates tool motions that are continually circular, which brings the tool into contact with the material on the front sweep of the motion. This allows the tool to cool and chips to be removed during the non-cutting portion of the motion, extending tool life. Since sharp corners are eliminated, feed rates are maximized. Interoperability A seat of CATIA is no longer required to directly read CATIA .DLV and .model files. Support for VDAFS trimmed surface files has also been added. Depending on your GibbsCAM system configuration, either wireframe or surface information can be accessed. Both of these capabilities are available as options that can be purchased individually. In addition, the ability to select sessions within a SolidWorks® or Solid Edge® file will be supported. Previously, users were only able to select the first session within a multi-session file. Now, users will be able to select any session within the file, ensuring that no critical design data will be missed. Support for direct read of SolidWorks 2000 and Solid Edge v.8 has also been added. Solids Import New enhancements have been added to 2 and 2.5D machining functions that make it possible to handle solid fixtures. Users no longer have to derive 2 or 2.5D geometry from solids, such as fixtures or clamps, before performing a 2 or 2.5D machining operation. Continued, pg. 5 5 GibbsCAM 2000, Cont. from pg. 3 SolidSurfacer™ The GibbsCAM 2000 release will bring new capabilities and enhancements to SolidSurfacer as well. If your business focuses on multi-surface machining and you rely on SolidSurfacer to cut your parts, you will benefit from the many improvements made to SolidSurfacer. Intersection Machining The GibbsCAM 2000 release will introduce a robust intersection machining capability that supports generating toolpath either along or across the intersection edge, allowing the user to control the toolpath based on the actual machining conditions. This will enable users to go back and remachine the intersection area between a pair of surfaces, if needed. Gen II Toolpath Engine The GibbsCAM ‘99 release incorporated the first half of the Gen II toolpath engine. The GibbsCAM 2000 release will include the completion of the transition from the Gen I engine to the new Gen II toolpath engine, which produces multi-surface toolpath faster, smoother and more accurately than before. Not only that, but the new engine provides the user levels of control that weren’t possible before. For example, you can now set different tolerances for various face classes, allowing fixtures to be handled differently from unselected faces or stock. Containment can be controlled so that the toolpath stays inside stock or clears stock. Step-over motions are gouge-free. High-Speed Machining Roughing - The plunge roughing capability in the GibbsCAM 2000 release uses an end cutting mill or drill, keeping the machining forces along the axis of the tool rather than against the axis. Users whose machining demands require a lot of roughing to clean out significant amounts of material, particularly in deep cavities or stock amounts, will benefit from the extensive amount of time saved. NURBS - The GibbsCAM system uses a different approach for NURBS toolpath creation than other PC CAM systems. Rather than fitting a NURBS curve to posted output, where the system has no access to the original surfaces nor any means to control tolerance drift, the GibbsCAM system’s approach actu- ally creates NURBS inside the Gen II toolpath engine itself. The resulting NURBS toolpath is more accurate than NURBS output created using conventional post processing. Currently the Gen II toolpath engine supports NURBS output for lace cutting with ball end mills. With the NURBS technology that’s included in the GibbsCAM 2000 release, you will be covered no matter what your situation. The NURBS technology being introduced with the GibbsCAM 2000 release is the foundation for a whole series of functionality. If your controller supports arcs on primary planes, then the NURBS output can be directly converted into polyarc format with absolutely no data degradation. This allows the accurate curve fitting capability of NURBS to be used by controllers without NURBS support capabilities. The polyarc data is a very compact format, making it quicker to download the program into your machine. The new release will output polyline data that is derived from the NURBS representation. This creates a much more accurate toolpath, minimizing surface artifacts and reducing the amount of hand finishing required. To really take advantage of more advanced machine tool controllers, you need to feed them the highest level of information that they’re capable of handling. With many controllers today, that means NURBS elements. Controllers capable of supporting NURBS can perform feed rate adjustment as part of processing the NURBS data, resulting in optimal performance. Post processors are available for Fanuc and Siemens controllers, which utilize NURBS Gcode internally. Smoothed Polyarc NURBS These significant improvements, along with many system enhancements, make the GibbsCAM system a more powerful tool to improve your efficiency and productivity. ✦ 6 The CAD Corner Corner Spotlight: CADKEY (CADKEY Corporation) The CADKEY Product Line — Hybrid Modeling at its Best CADKEY® products have been used by manufacturers and moldmakers worldwide since its introduction in 1985 as the first 3D CAD system for the personal computer. Along with CADKEY PARAMETRICS, CADKEY 99 (as well as the upcoming CADKEY v.20) offers a unique “hybrid” approach to mechanical design. CADKEY PARAMETRICS is an optional modeling technique, not a mandatory way of thinking or working. From 2D layouts to 3D models— parametric and hybrid solids, wireframe, and surfaces, the user has maximum control to address any phase of product definition. It is the classic CADKEY trademark. Industry renown for superior interoperability, CADKEY’s essential “collection” of features achieve the highest level of data handling and compatibility: 1) an open hybrid modeling environment, 2) world class data translators, 3) core technology based on pure geometry and 4) the most extensive set of design, edit, and validation tools in the PC-CAD industry. Job shops rely on this combination of tools to import CAD data and manipulate this data as if it were created natively. CADKEY’s hybrid modeling environment allows users to model, edit, refine and validate both product designs and molds. Powerful interoperability tools like solid body healing and tolerant edge help repair less precise “imported” model geometry. Industrial-strength data translators are an integral part of CADKEY and are included in the product price: STEP One-pass IGES translator to import wireframe, surfaces and solids geometry ACIS SAT Parasolid X_T DXF DWG (including AutoCAD® R14 format support) STL for rapid prototyping CADL (CADKEY Advanced Design Language) Real World CAD Features for Job Shops Most mid-range parametric modeling software forces users to completely rebuild non-native data in their own proprietary feature-based format before any editing can take place. With CADKEY’s hybrid environment, there is no need to rebuild existing or imported solids, surfaces or wireframe. Parametric features can be added to and created from non-parametric solids. Even more impressive is that nonparametric portions of a model can be edited with CADKEY’s extensive face modification functions. CADKEY 99 running the optional CADKEY PARAMETRICS product. This screen shows multiple parametric solid models within a single part file. Great Combination with GibbsCAM Innovative approaches to CAD and CAM make CADKEY and GibbsCAM® an ideal combination for moving products to production. CADKEY’s fully resourced CAD system gives job shops a cost effective design medium to work in tandem with GibbsCAM 2000. The GibbsCAM system’s newest toolpath technology for faster, smoother, and more Continued, pg 7 7 CAD Corner, Cont. from pg. 6 accurate output meets the demands of long-time 3D power users. GibbsCAM’s ability to utilize NURB geometry, surfaces or solids for efficient mold roughing, pocketing and other key operations is another added bonus for CADKEY customers performing conceptual product design with multiple hybrid tools. CADKEY Corporation — Focused on Mechanical CAD CADKEY Corporation is a Boston-area software developer of CADKEY and CADKEY-integrated 2D/3D PC-CAD product lines– CADKEY DESIGN SUITE, CADKEY 99, CADKEY PARAMETRICS, CADKEY WIREFRAME, FastSURF®, DRAFT-PAK®, CADKEY POWER-PAK and CADKEY TRUE TEXT. Dedicated entirely to the mechanical CAD marketplace, CADKEY Corporation has over 100 resellers, distributors and sub-distributors serving a global user base in more than 40 countries. The product has been translated into many international language versions including German, French, Italian, Spanish, Portuguese, Czechoslovakian, Hungarian, Hebrew, Chinese, Korean and more. For late-breaking information, visit the CADKEY website at http://www.cadkey.com and the CADKEY WebStore at www.cadkey.com/webstore. ✦ Training Schedule Our training schedule is based on a dual track system. The two tracks differ slightly in the topics covered and the order in which each topic is covered. Choose the track schedule that best suits your individual training needs. A more detailed listing of the topics covered each day can be found on our website at www.gibbsCAM.com, or contact the Gibbs Sales Department at (805) 523-0004 for more information. Dates Track Sep Oct Nov Dec 13 - 22 1 12 - 20 2 8 - 17 1 7 - 15 2 Classes are held at the Gibbs office in Moorpark, CA. Dates exclude weekend days. Limited class space is available. Contact the Gibbs Sales Department at (805) 523-0004 to reserve your seat or for more information. Cost is $250.00 per day (U.S. dollars). Track 1 Day 1 - 3 . . . . .Introductory Mill and Lathe Day 4 - 7 . . . . .3D SolidSurfacer Day 8 . . . . . . . .Rotary Mill and Mill/Turn Track 2 Day 1 - 2 . . . . .Introductory Mill Day 3 - 6 . . . . .3D SolidSurfacer Day 7 . . . . . . . .Introductory Lathe Day 8 - 9 . . . . .Advanced SolidSurfacer Gibbs News Published by: Gibbs and Associates Editor: Josie Carrillo Contributors: John Brix, John Callen and Mario Guerrero See Us at IMTS 2000 Sept. 6 - 13, 2000 McCormick Place / Chicago, IL Booth #D-3001 Address: 323 Science Drive, Moorpark, CA 93021 Telephone: (805) 523-0004 • Fax: (805) 523-0006 Internet: www.gibbsCAM.com E-mail Sales: sales@gibbsCAM.com E-mail Technical Support: support@gibbsCAM.com © 2000 Gibbs and Associates. All Rights Reserved. GibbsCAM, Gibbs SFP, Hole Wizard, SolidSurfacer and Virtual Gibbs are either trademark(s) or registered trademark(s) of Gibbs and Associates in the United States and/or other countries. All other trademarks belong to their respective owners. ® ™ Gibbs and Associates 323 Science Drive • Moorpark, CA 93021-2092 PRSRT STD US POSTAGE PAID THOUSAND OAKS CA PERMIT #1 Mailroom Attendant: If the person listed on the address is no longer with the company, please forward to the NC Programming Department.