I. Introduction
For the 5-axis milling of the ruled-surface impeller, familiar people are aware that the MAX-5, the special programming software for the impeller, has obvious advantages. The software defines a wide variety of machining trajectories, a wide selection of tools, and a very good machining result. However, because it is dedicated software, its post-processing program is written by the software company based on the actual machine tool structure, and it is not versatile and editable. In the actual work, we may encounter various machine tools with different movement relations and structures. Can we extract the tool file generated by the MAX-5 and use other software to implement flexible rear settings? If such a method can be implemented, it will bring us great convenience, and it will also enhance the adaptability of the MAX-5 software.
UG is a high-end integrated software that enables multi-axis machining with variable-axis milling in the CAM function. At the same time, the software has a great advantage. It can flexibly post-seat its own location file, and the user-defined post-processing program can generate the code file needed by the actual machine tool. As a result, we tried to use the UG software to post position files generated by the MAX-5 software and successfully implemented it on a 5-axis machine tool with a double rotary table. This article describes the specific implementation of this method as follows.
Second, UG software multi-axis processing post-processing user-defined
Post-Builder in UG software is a functional module that provides users with custom post-processing programs. This module, as shown in Figure 1, not only defines the program structure and code, but also defines the machine's kinematics. This creates the conditions for us. Here, considering the postposition of multi-axis machining, we mainly introduce the definition of the machine's movement relations, and the rest will not be described.
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Figure 1 UG Post-Builder function module
Let's first explore the machine definition functions provided by the UG software. As shown in Fig. 2, in the interface of Create New Post Processor, the definition of the machine tool includes all the 5-axis motion relations. There is a need to define the machine motion relation that corresponds to the actual one. In this article, it is defined as 5-Axis with Dual Rotary Tables. , and then clear other options to enter the subsequent set. In the definition of 5-Axis Mill, there are a total of three parts: General Parameters, Fourth Axis, and Fifth Axis. These definitions can be referred to the UG training course. Details are not included here. As shown in FIG. 3 , it is worth noting that the definition of the mutual relationship between the rotation axes and the zero point of the machine tool and the rotation angle offset of each rotation axis has a great influence on the correctness of the post-processing.
Figure 2 UG machine definition interface
Figure 3 defines the machine axis
In addition, as shown in Figure 4, we can use the Machine Tool Display to display at any time when we define the machine tool movement relationship, and compare it with the actual one. Finally after the completion of all the definitions form the initial post-procedure. This program usually needs to make necessary adjustments and modifications based on actual post-results to meet actual needs.
Figure 4 Machine Simulation in UG
Third, using UG post-processing MAX-5 tool file specific implementation process
After getting the initial post-program above, we can start using UG software to serve us. The following steps are introduced in accordance with the implementation process. For ease of introduction and intuitive presentation, we have only imported one blade machining profile here.
1. Import of MAX-5 tool file
The tool file generated by the MAX-5 is a standard APT text file. Compared with the UG multi-axis tool location file, it only adds some annotations and its tool path description is exactly the same. After the test, only the file format of the cutter file generated by the MAX-5 is changed to the UG's file format (CLS file), and the rest can be changed. Then through the UG software Manufacturing→Tools→CLSF can be directly imported. It is worth noting that the tool information in the tool path cannot be imported. If necessary, the tool can be added to the UG software and the original tool path can be copied. At the same time, it is recommended that the 3D model of the impeller be established in advance in the UG software. The processing is very intuitive and easy to operate. The track introduced in this example is shown in Figure 5.
Fig. 5 Curved track
2. Perform the necessary processing and conversion of the imported tool path
The actual machining of the impeller is based on the structure of the machine tool. The machining direction may be performed within the four quadrants of the impeller (looking at the impeller). Therefore, it is necessary to perform the necessary conversion of the tool path introduced into the UG according to the actual machine tool structure. This is easy to understand. It is easier to coordinate with post processing. This example considers that the machining direction of the impeller is the second quadrant. Therefore, the trajectory of the tool is rotated by 45° counterclockwise through CAM Transformations to meet the actual machining requirements.
3. Post-processing with a pre-defined post-processing program
Post Process After selecting the post-processing program, the tool path needs to be post-placed, and then the machining code must be set in the direction of the rotation axis, the continuity of the rotation angle (without an abrupt angle change), and the actual coordinates of the post-processing code. Values ​​are analyzed. Normally, it is necessary to modify the initially formed post-processing program. After several iterations, the correct processing code can be obtained.
4. Use VERICUT software to process the resulting G code file and perform the necessary verification
It is necessary to carry out five-axis machining on the machining center and check and simulate the machining process in advance. At the same time, it must be considered in accordance with the actual machining environment. We have chosen VERICUT software to do this work. The specific process is not described here. Figure 6 shows the real results of the processing code obtained after the post-processing in the VERICUT software.
Figure 6 Simulation Results in VERICUT
Fourth, the conclusion
This paper uses the UG software to postprocess the toolpath file generated by MAX-5 and realizes the machining on the double rotary table machine tool. A successful attempt is made to flexibly postprocess the toolpath of MAX-5. It can be seen that this method is relatively easy to implement, it is an effective 5-axis tool path post-processing method.
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