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Get Started with ESPRIT 2010
Get Started with ESPRIT 2010 Copyright © 2009 DP Technology Corp. All rights reserved. U.S. Patent No. 6,907,313. Other U.S. patents pending. Information is subject to change without notice. No part of this manual may be reproduced, transmitted, translated in any form or by any means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any information storage or retrieval system, without written permission from DP Technology Corp. The software described in this document may only be used or copied in accordance with the terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the software onto any medium except as specified in the license or non-disclosure agreement. All DP Technology Corporation software products contain integrated security programs and/or plug-in modules that are required for the software license to properly operate. It is a violation of the DP Technology Corporation copyrights and U.S. Copyright law to disable or attempt to disable or remove or otherwise operate the software without the security programs and/or modules installed. Any software not supplied by DP Technology Corporation which is intended to allow the operation of the software without the required plug-in security module and/or integrated security programs is a copyright violation. ESPRIT is a registered trademark of DP Technology Corp. All brand or product names or proprietary file types mentioned in this document are trademarks or registered trademarks of their respective holders. Contact the appropriate companies for more information regarding trademarks and registration. DP Technology Corp. 1150 Avenida Acaso Camarillo, California 93012 USA Tel: +1 805 388 6000 Fax: +1 805 388 3085 www.dptechnology.com Printed in the United States of America
Contents Welcome to ESPRIT 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installing ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ESPRIT Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ESPRIT Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 The ESPRIT Graphical User Interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Opening and Storing Files in ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Selecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Controlling the Display of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Working with Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Geometry commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Work Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Draw 2D Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Working with Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Types of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Creating and editing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Feature Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Work Planes assigned to features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Import a CAD drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Position the part for machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Draw dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Create 3D features from a 2D drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Milling on a Standard Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SolidMill Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SolidMill Traditional Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Create a milling tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Create milling features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Remove excess material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Cut the pockets and slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Mill and drill the holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Simulate milling operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Turning on a Standard Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 SolidTurn Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SolidTurn Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Create a turning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Create turning features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Create lathe stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Rough the face and the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Drill on the center line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Rough and finish the groove on the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Contour the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Rough and finish the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Groove the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Thread the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Perform the cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Simulate turning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Burning on a 2-axis Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 SolidWire Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SolidWire Gold Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Set the EDM Machine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Create EDM features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Contour the group of holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Contour the die openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Sort EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Simulate wire EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Using CAD files from other systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 AutoCAD files (*.dxf, *.dwg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 IGES files (*.igs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 ACIS files (*.sat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Parasolid files (*.x_t, *x_b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 SolidEdge files (*.par, *.psm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 SolidWorks (*.sldprt, *.sldasm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 STEP files (*.stp, *.step) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 STL files (*.stl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 CATIA files (.model, .catpart, .exp, .dlv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 UG files (*.prt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Pro/E files (.prt.*, .prt, asm.*, .asm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Inventor files (*.ipt, *.iam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 ESPRIT Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 File Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Welcome to ESPRIT 2010   | 1 Welcome to ESPRIT 2010 ESPRIT has all the power you need to machine any part... ESPRIT is a high-performance computer-aided manufacturing (CAM) system for a full range of machine tool applications. ESPRIT delivers powerful full-spectrum programming for 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turn machining, and B-axis machine tools. ESPRIT’s high-performance capabilities include machining any part geometry (solid, surface, or wireframe), universal post processing to format G-code for virtually any machine tool, and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency. ESPRIT’s multitasking component provides powerful capabilities for driving mill-turn machines, multi-axis lathes, and Swiss-style machine tools. ESPRIT provides synchronization of simultaneous cutting cycles using any combination of turrets and spindles for milling or turning, factory-certified post processors for all the leading multitasking machine tools, and dynamic solid simulations for dry run verification of the machining processes. Get Started with ESPRIT will teach you all the basics of how to machine your parts, plus show you advanced techniques to help you get the most out of ESPRIT. Installing ESPRIT................................ 2 ESPRIT 2010 System and Component Requirements........................................... 2 Hardware Key........................................... 2 Install ESPRIT from the DVD......... 3 Use ESPRIT................................................. 3 ESPRIT Support................................... 4 Phone Support........................................ 4 ESPRIT Help on the Web.................. 5 Software Maintenance Contract (SMC).............................................................. 5
2 |  Get Started with ESPRIT 2010 Installing ESPRIT ESPRIT 2010 System and Component Requirements The installation program verifies all requirements before proceeding. If the system does not meet requirements, the installation will abort until the system complies. Existing users should review their computer systems to be sure that they comply with the latest ESPRIT installation and system requirements. The following are minimum hardware requirements for ESPRIT 2010: • 1 GHz 32-bit (x86) processor or greater1 • RAM requirements of a minimum of 1 GB • 128 MB SVGA video card (1024 x 768) • 40 GB hard disk drive • 3 GB of free hard drive space • DVD-ROM drive • Parallel or USB port (required for ESPRIT security) ESPRIT requires certain operating system components to be installed to function properly. These are prerequisites of installing ESPRIT. These components must be installed prior to installing ESPRIT. Systems failing to meet these criteria will cause the ESPRIT installation to fail. • Microsoft® Windows® XP SP323 or Windows® Vista™ or Windows® 73 • Microsoft® Internet Explorer version 6.0 or greater 1 Processor must support the SSE2 instruction set. 2 ESPRIT 2010 will be the last version of ESPRIT supported on Microsoft® Windows® XP. 3 ESPRIT is compiled as an x32 bit application. When run on an x64 OS ESPRIT will be run as x32 bit. Hardware Key Plug your ESPRIT locking device, normally a hardware key (security dongle) provided by DP Technology, into the appropriate USB or parallel port on your computer. If you have a parallel port security dongle, plug it into the primary parallel port (LPT1) at the back of your computer. Do not plug it into a serial port. ESPRIT will not function if the security dongle is not inserted correctly. Take special care to protect your security dongle from loss or damage. It is an integral component of the software and your license. The only device you may attach to the back of a parallel security dongle is a parallel printer. Important: Do not plug any tape backup systems, portable CD-ROMs, DVD players or recorders, Zip drives, multi-function office systems (all-in-one printer/fax/scanner/copier devices) into a parallel security dongle. These will damage your hardware key. If your security dongle becomes damaged, your ESPRIT software will not work until a replacement security dongle and new password can be shipped to you at your expense. Security dongle replacement is not covered by Software Maintenance Contracts. Lost or stolen security dongles are your responsibility. Please check with your insurance carrier to be sure your business insurance has them covered for the full value of your ESPRIT software.
Welcome to ESPRIT 2010   | 3 Install ESPRIT from the DVD Please set your computer’s date correctly before installing ESPRIT and do not change the date thereafter. Important: An incorrect date can damage the security module and render ESPRIT inoperative. Your ESPRIT software will not work again until a replacement security module and new password can be shipped to you. 1. Download and install the latest Windows® service packs. 2. Disable any anti-virus software. 3. Open the file “ESPRIT_ReadThisFirst.pdf” on the DVD. 4. Follow the instructions to perform a new installation of ESPRIT 2010 or to upgrade from a previous version of ESPRIT. Use ESPRIT ESPRIT is a single instance application and does not support multiple instances. ESPRIT does not limit the number of instances running, but you may experience unexpected and undesirable results in choosing to run more than one instance of ESPRIT at the same time. Double-click the ESPRIT icon on your Windows desktop Or, From the Windows Start menu, select All Programs » DP Technology » ESPRIT. Other ESPRIT menu items: NC Editor: NC file editing tool Settings Manager: Saves the ESPRIT configuration to allow it to be backed up or transferred to another machine. KnowledgeBase: Database setup and management
4 |  Get Started with ESPRIT 2010 ESPRIT Support The DP Technology web site provides a wide variety of information about the company and its products. You can access the web site at: http://www.dptechnology.com For support issues, please send an e-mail to: support@dptechnology.com Phone Support Contact your reseller first. Resellers of ESPRIT give specialized information related to the custom solution they provided to you. This is the best place to start. If you do not have a reseller, contact the nearest DP Technology office. Corporate Offices 1150 Avenida Acaso Camarillo, CA 93012 USA Tel: +1 805 388 6000 Fax: +1 805 388 3085 dptechnology.com Midwest USA 10275 West Higgins Road Suite 420Rosemont, IL 60018 USA Tel: +1 847 297 8100 Fax: +1 847 297 8107 dptechnology.com Eastern USA 8535 Cliff Cameron Drive Suite 112 Charlotte, NC 28269 USA Tel: +1 704 594 9551 Fax: +1 704 594 9802 dptechnology.com DP Japan Level 28, Shinagawa InterCity Tower A 2-15-1 Konan, Minato-ku Tokyo 108-6028 Japan Tel: +81 3 6717 2896 Fax: +81 3 6717 4545 dptechnology.jp DP China 458 North Fu Te Road Building No. 2, 1F Wai Gao Qiao F. T. Z. Shanghai 200131 China Tel: +86 21 5868 3696 Fax: +86 21 5868 2803 dptechnology.cn DP Europe “Le Thèbes” 68 Allée de Mycénes 34000 Montpellier France Tel: +33 4 67 64 99 40 Fax: +33 4 67 64 99 41 dptechnology.fr DP Germany Sommerleite 1 D-96 148 Baunach Germany Tel: +49 9544 98756-0 Fax: +49 9544 98756-29 dptechnology.de DP Italy Via Iacopo Nardi 2 50132 Florence Italy Tel: +39 055 2342286 Fax: +39 055 2347858 dptechnology.it
Welcome to ESPRIT 2010   | 5 ESPRIT Help on the Web Get the most current information about ESPRIT, new product features and enhancements, latest releases, post processors, advanced tips, and creative solutions. The ESPRITWeb is a family of websites dedicated to serving the needs of the ESPRIT community. Register for the ESPRITWeb at: http://www.dptechnology.com/ew • The ESPRITWeb home page is the central point for the ESPRIT online user community. It contains up-to-date information on all ESPRIT products and includes links to all other ESPRIT online areas. • Discussion is a discussion group that provides you with an open forum for discussion on any topic related to ESPRIT. Ask questions and share your ideas, solutions, and experiences with other ESPRIT programmers. • Technical Bulletins is a web-based library of technical information and tips about ESPRIT, including a library of ESPRIT@Work technical training guides for SolidMill, SolidTurn, SolidWire, Post Processor, and ESPRIT API. • SupportWeb is a web-based three-step technical support system. Start by using the Frequently Asked Questions (FAQs) to find a solution to your problem. If your initial FAQ search does not answer your question, search the solution database for answers. Finally, if you have not found your solution in either of these places, you can submit your question to our technical support engineers directly from the web and subsequently via e-mail.File Library is a web-based library of post processors, macros, and other data files useful to ESPRIT programmers. The ESPRITWeb is only available to registered ESPRIT users who have an active Software Maintenance Contract (SMC). For more information on SMC, go to http://www.dptechnology.com and click on the link to Professional Services. We look forward to hearing your comments and suggestions on how we can improve the DP Technology website. Send your comments via e-mail to ESPRIT@dptechnology.com or even better, post your message on the Discussion group. Software Maintenance Contract (SMC) Our goal is to build successful ESPRIT users. We believe the best way to do this is through the SMC program. Participants receive... • Unlimited phone support • Continuous ESPRIT software and documentation upgrades • ESPRIT de Corps Newsletter, our informative and technical newsletter • Opportunity to participate in and gain from cutting edge field testing • 24-hour web access to the DP Help Center and FTP site • Invitation to ESPRIT World Conference For more details on the DP Technology SMC, please call 1+ 805 388 6000.
6 |  Get Started with ESPRIT 2010
ESPRIT Fundamentals   | 7 ESPRIT Fundamentals Before you begin the lessons in this guide, you should familiarize yourself with how to work with part files in ESPRIT. As a native Windows-based application, the ESPRIT interface and its menus and toolbars should look familiar to you. This chapter introduces the ESPRIT work environment and explains how to work with ESPRIT part files. You will learn: • How to use ESPRIT menus and toolbars • How to open and store ESPRIT files • How to select, or group, elements using various selection modes such as HI, SNAP, and SUB-ELEMENTS • How to control the display of elements with views, masks, and layers XX Before beginning to use ESPRIT, you should have a working knowledge of your computer, the Microsoft® Windows® operating system and its conventions. You should know how to use a mouse and standard menus and commands. To review these techniques, refer to the documentation for Microsoft® Windows®. The ESPRIT Graphical User Interface (GUI)......................................8 Menus............................................................9 Default Toolbars...................................10 The Smart Toolbar..............................10 Other Toolbars........................................ 11 Displaying the XYZ Axis and the UVW Axis...................................................... 11 Opening and Storing Files in ESPRIT.......................................................13 Creating a New File...........................13 Opening an Existing File................14 Saving a File............................................14 Selecting Elements..........................15 Selecting Elements in the Work Area................................................................15 The Group Command.........................15 Selection Modes...................................16 Deselecting Elements.......................19 Selecting Items in the Project Manager.......................................................19 Controlling the Display of Elements................................................ 20 Shaded and Wireframe Displays.20 Views........................................................... 20 Pan, Zoom, and Rotate the View.21 Masks...........................................................23 Layers..........................................................23
8 |  Get Started with ESPRIT 2010 The ESPRIT Graphical User Interface (GUI) Let’s start by taking a look at the ESPRIT screen. This window is displayed when you create a new file or open an existing one. The ESPRIT window contains: 1. Menus and default toolbars along the top of the screen. You can select commands from the menus or from toolbars. 2. A graphic work area where you can view your work. This is the largest area of the screen. 3. The Prompt area, at the bottom left of the screen, displays prompts that tell you what to do next. Always pay attention to what the prompt is telling you. 4. The Status area, at the bottom of the ESPRIT screen, provides dynamic information about the current work environment. As you select commands or move the cursor, the information is constantly updated. ESPRIT also provides two specialized windows that provide additional information about the parts you are working on and provide an excellent way to manage your work. 5. The Project Manager consists of a tabbed set of windows that list every feature, every cutting tool, and every operation in the current session. The Project Manager lets you manage, sort, and reorder these items. To view the Project Manager, press the F2 key or click Project Manager on the View menu. 1 2 3 4
ESPRIT Fundamentals   | 9 6. The Property Browser displays the specific properties of any item selected in the graphic work area or the Project Manager. The types of properties displayed depend on the type of item selected. You can view and change individual properties for the selected item. To view the Property Browser, click Properties on the View menu or hold down the Alt key as you press Enter. Menus Commands are located on eight menus. Most of the menu commands are also available on the toolbars. • File: Open an existing file or create a new one. Save files that have changed. • Edit: Copy or delete items, move the origin point or change the orientation of an imported model. • View: Set the display of the work environment. • Create: Draw new geometry and dimensions, create features, surfaces, or solids. • Machining: Set up the machine definition, create cutting tools, create and simulate machining operations. • Tools: Set the system unit, create macros, load add-in programs, and personalize ESPRIT. • Window: Create new windows and arrange the display of multiple windows. • Help: Access the online help files or learn about your current version of ESPRIT. 5 6
10 |  Get Started with ESPRIT 2010 Default Toolbars The default toolbars are located near the top of the ESPRIT screen. 1. The Standard toolbar has file management commands that let you create, open, save, and print files. This is also where you can find the Copy command when you want to copy elements in the work area. 2. The View toolbar has several commands that let you control the display in the work area, such as zooming and rotating the view plus commands that let you choose whether to display parts in shaded or wire frame modes. 3. The Edit toolbar gives you selection tools that let you filter the types of elements that can be selected or automatically select (group) multiple elements from the selection of a single element. 4. The Layers and Planes toolbar has commands for creating and selecting work planes, layers, and view planes. The Smart Toolbar Use the Smart toolbar to quickly display and hide ESPRIT toolbars based on the type of work you want to do. The first three icons on the toolbar relate to the machining modes in ESPRIT: milling, turning, and wire EDM. If you click “Switch to SolidMill”, the toolbar is updated to display commands that let you create milling tools and operations. If you click “Switch to SolidTurn”, the milling commands are hidden and new commands display that let you create turning and mill/turn operations and tools. If you want to create geometry, just click the Geometry icon to activate the Geometry group of toolbars. If you click Milling Tools, the geometry toolbars are hidden and milling tool commands are displayed. All visible toolbars activated from the Smart toolbar will always be shown in the same position so you never have to hunt for a command. 1 2 3 4
ESPRIT Fundamentals   | 11 Other Toolbars In addition to the Smart toolbar, you can display other toolbars. To display other toolbars: • On the View menu, click Toolbars... and then select a toolbar from the list. Any toolbar that has a check mark next to the name is already displayed on the screen. • Right-click on any visible toolbar and select the toolbar you want to display • To show toolbars for machining operations, select the machining type on the Machining menu, such as SolidMill Traditional, and then select the machining type again on the secondary menu. To hide a toolbar: • On the View menu, click Toolbars... and select a toolbar that has a check mark next to the name • Right-click on a toolbar and select the toolbar you want to hide • To hide a machining toolbar, right-click on the toolbar and select Hide To move a toolbar, place the cursor on the double line at the top or to the right of the toolbar and drag it to a new location. When you drag a toolbar near the edge of the screen, it will automatically snap to the edge. Instructions that describe how to create your own toolbars or customize existing toolbars are available in ESPRIT Help. Press F1 to display the help and then click “Customize” in the index. If you would like to customize the Smart toolbar, click “Smart Toolbar Add-In” in the index. Displaying the XYZ Axis and the UVW Axis You can display two types of axes in the work area: XYZ Axis: The global axis positioned at the global origin point UVW Axis: The local axis of the current work plane The display of the two axes is controlled on the View menu.
12 |  Get Started with ESPRIT 2010 The XYZ axis shows the position of the part model in relation to the global axis. The UVW axis shows the origin and orientation of the current work plane. You will learn more about work planes in the lesson “Working with Geometry”.
ESPRIT Fundamentals   | 13 Opening and Storing Files in ESPRIT When you start a new session in ESPRIT or create a new file, you are given the choice of starting with a blank file or basing your new work session on a predefined template. The <Blank Document> option opens a new file that uses the ESPRIT defaults. A template file contains user-defined elements and settings for the way you machine parts at your company. You can create templates that include regularly used tools, machine setup configurations, simulation settings, repeated geometry, and KnowledgeBase settings. As you become more familiar with ESPRIT, you can create templates that make it easier and faster to work on similar types of jobs. As a new user, select <Blank Document> and click OK. The commands on the File menu or the icons on the Standard toolbar (located near the upper left of the ESPRIT screen) are used to manage part files. The display of the template dialog is controlled by the “Display Template Dialog” option on the Input page of the Options dialog, available on the Tools menu. By default, the template dialog displays. For more information about how to create and use template files, please refer to the ESPRIT help. Creating a New File Clicking the New command closes the current file so that you can begin work on a new file. If changes have been made to the current file, ESPRIT will prompt you to save those changes before the file is closed.
14 |  Get Started with ESPRIT 2010 Opening an Existing File Clicking the Open command lets you open native ESPRIT files (.esp extension), native 2D and 3D files from other CAD systems such as SolidWorks or Pro/E, stereolithography (STL) files, and translated files such as IGES and STEP. Since ESPRIT is based on the Parasolids kernel, it is adept at opening a variety of solid model files. After you click Open, you can use the “Files of type” pulldown to list only files with a specific extension. This makes it easier to browse for the file you want. If the file you’re looking for has an unlisted extension, select “All Files”. XX The list of available file formats is based on the licensed options. For example, if your license does not allow you to open CATIA files, this option will not display in the “Files of Type” pulldown. Saving a File After working in ESPRIT, you’ll want to save your work so you can retrieve it later. The Save command stores the current file as a native ESPRIT file or as another type of CAD format. ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file format, select the “Save as type” pulldown and then select a file extension.
ESPRIT Fundamentals   | 15 Selecting Elements One of the most important tasks in any CAD/CAM system is the ability to select a variety of elements in the part file. A single part file may include one or more solid models, wireframe geometry, surfaces, and toolpath. In addition, you must have the ability to select individual components of an element, such as edges on a solid model or the endpoint of a line. Selecting Elements in the Work Area Elements in the work area can be selected individually, as a group or by type of element. • Use your mouse to select an individual element in the work area • To select more than on element, hold down the Ctrl key as you select elements or drag a selection box over a group of elements • To select a group of connected elements, hold down the Shift key as you select an element Use the Selection Filter to select elements by type. If Geometry is chosen, you will only be able to select geometry elements in the work area. When you are finished, remember to set the Selection type back to All. The Group Command If you want to select all elements that fit specific selection criteria, you can use the Group command on the Edit menu. The Group command lets you select all elements using the following criteria: • Element type • Color • Layer • Work Plane
16 |  Get Started with ESPRIT 2010 After you identify the selection criteria, click OK to automatically select all elements that meet those criteria. Selection Modes Five selection modes are provided in the status area at the lower right of the screen: • HI (highlight) mode • SNAP mode • SUB-ELEMENTS mode • INT (intersection) mode • GRID mode When a mode is grayed out, that means the mode is disabled. Click on a mode to enable or disable it. HI Mode When HI mode is enabled, ESPRIT always asks you to confirm element selections. This allows you to select from elements that are close to, or even on top of, each other. For example, you can use HI mode to select a solid model, an edge on that model, or feature created from a solid model.
ESPRIT Fundamentals   | 17 When HI mode is enabled, ESPRIT will prompt “Is this the correct choice” and highlights an element near the selection point. If this is not the correct element, answer No by pressing the right mouse button. ESPRIT will highlight the next closest element. In this example, you want to select the feature but a segment is highlighted instead. You would click the right mouse button until the feature highlights. When the correct element is highlighted, answer Yes by pressing the left mouse button.
18 |  Get Started with ESPRIT 2010 SNAP Mode When SNAP mode is enabled, the cursor recognizes the midpoints and endpoints of lines and segments and the center points of circles and arcs as valid point selections. With SNAP enabled, the cursor changes to: when you hover over the end of a segment or arc when you hover near the midpoint of a segment or arc when you hover over the center point of a circle or arc SUB-ELEMENTS mode When SUB-ELEMENTS mode is enabled, you can select the individual sub-elements of solid models or features in the work area. For example, you can select the faces, faces loops, or edges of a solid model. You can also select the sub-elements of features. The selection of sub-elements is extremely useful for selecting the individual faces on a solid model that you want to machine. The Grouping Properties command relies on the selection of sub-elements to automatically group faces for several types of features: Holes, Pockets, Draft Feature Recognition, Turning Profiles, and FreeForm features. INT Mode When INT mode is enabled, the cursor recognizes the intersections of segments, lines, arcs, and circles as valid point selections. With INT set on, the cursor changes immediately to and remains as the INT cursor until an intersection is chosen. The cursor exits INT mode immediately after an intersection is chosen.
ESPRIT Fundamentals   | 19 GRID Mode ESPRIT uses the grid configuration settings from the Options dialog box (from the Tools menu, select Options and then the Input tab). This lets you select from a defined invisible array of screen locations in response to prompts for points, angles, distances, and so on. You may want to set the grid spacing to match your part drawing values. Deselecting Elements To deselect all items simply click anywhere in a blank area of the work area. Selecting Items in the Project Manager Features and machining operations can be selected directly in the Project Manager. Most of the time, this is much easier than selecting these items in the work area. When a feature or operation is selected within the Project Manager, the same item highlights in the work area.
20 |  Get Started with ESPRIT 2010 Controlling the Display of Elements ESPRIT provides a variety of methods that let you control how your parts are displayed. Shaded and Wireframe Displays For solids and surfaces, you can set the display to shaded or wireframe mode. Shaded Wire: Creates a shaded image with wireframe. The display of the wireframe is light source dependent. Wireframes will appear in different colors and/or disappear depending on the part orientation with respect to the light. Silhouettes are not supported, only true edges. Shaded: Creates a shaded image. Has no effect on geometry elements. You can also shade the simulation of cutting operations. Hidden Wireframe: Displays visible solids, surfaces, and geometry as wireframe depending on the orientation of the part. Elements that would normally be hidden by a shaded view are not displayed. Wireframe: Displays all solids, surfaces, and geometry as wireframe. Views ESPRIT provides several standard view orientations. When you change from one view plane to another, the display in the work area rotates to the new view orientation and the display automatically zooms to fit all elements within the screen. You can control the rotation animation speed on the Workspace tab of the Options dialog (available on the Tools menu).
ESPRIT Fundamentals   | 21 You can also store your own view orientations. Pan, rotate or zoom the view to the orientation you prefer and then create a new view to store the view for later use. Pan, Zoom, and Rotate the View Commands on the View toolbar let you fit, zoom, pan and rotate the display of your part in the work area. However, it is faster to use the mouse and keyboard to modify the view. Fast Rotate Hold down the Ctrl key and the middle mouse button, or scroll wheel, and move the mouse to quickly rotate the view. If you hold the mouse button down over an axis or geometry element, the view will rotate about that element. Alternatives • Click the Rotate command on the View toolbar • Hold down the Ctrl key and press the up or down keys to rotate 15° around the horizontal axis • Hold down the Ctrl key and press the right or left arrow keys to rotate 15° around the vertical axis • Hold down the Alt key and press the right or left arrow keys to rotate 15° around the normal axis • Hold down Shift+Ctrl and press the up or down arrow keys to rotate 90° around the horizontal axis • Hold down Shift+Ctrl and press the right or left arrow keys to rotate 90° around the vertical axis Zoom Spin the scroll wheel forward to zoom in. Spin the scroll wheel backwards to zoom out. The zoom takes place from the location of the cursor on the screen. Alternatives • Use the zoom commands on the View toolbar: Zoom, Zoom Previous, Zoom Dynamic • Hold down the Shift key and press the up or down arrow keys to zoom in or zoom out
22 |  Get Started with ESPRIT 2010 Smart Zoom Hold down the Shift key and the middle mouse button, or scroll wheel, and move the mouse forward to zoom in or move backwards to zoom out. With Smart Zoom, the zoom takes place from the center of the model regardless of the position of the mouse. That way, the model is always visible when you zoom. Pan Hold down the middle mouse button, or scroll wheel, and move the mouse right, left, forward, or backward to pan the view. Alternatives • Click the Pan command on the View toolbar • Press the right, left, up, or down keys Keyboard Shortcuts Press F5 to redraw the screen. Press F6 to fit all visible graphic elements on the screen. Press F7 to switch to a top view. Press F8 to switch to an isometric view.
ESPRIT Fundamentals   | 23 Masks The Masks command on the View menu lets you hide the display of specific types of elements. Press Ctrl+M to display the dialog. Items with a check mark are displayed. Select any items you want to hide to remove the check mark. All elements of that type will be hidden in the work area. To display the elements again, select the item in the dialog. Layers Layers are very useful for controlling the display of different types of elements in a complex part file. For example, you can set up different layers for machine components, the initial part stock or casting, the finished part, roughing tool paths and finishing tool paths, or any other type of geometry. When new elements are created, they are placed on the active layer. Layers can be turned on or off to hide or show the different aspects of your part. The elements are not deleted, just temporarily hidden. You can turn a layer back on at any time. Elements can be placed on a different layer by first selecting one or more elements and then changing the “Layer” property in the Property Browser.
24 |  Get Started with ESPRIT 2010
Working with Geometry   | 25 Working with Geometry A basic requirement of any CAD/CAM system is to provide functions that allow the creation of 2-dimensional and 3-dimensional geometry. For machinists, the ability to create geometry to aid in the creation of proper tool path is critical. ESPRIT provides functions to create two types of geometry: unbounded and bounded. Unbounded geometry has no end point or start point, such as an infinite line, or the start point and end point are the same, such as a circle or ellipse. Bounded geometry is limited to a start point and end point, such as a line segment or arc. Some geometric elements are neither bounded or unbounded, such as points, rectangles, and polygons. In addition, ESPRIT lets you trim or extend geometry, or add fillets and chamfers to corners. The intent of this lesson is to teach you the basics of creating 2-dimensional geometry in ESPRIT. You will learn: • About the commands for creating geometry • About work planes and how to modify their location and orientation • How to draw lines, rectangles, points, and circles • How to trim geometry and fillet corners • How to draw a hole pattern from an array of points Geometry commands.................... 26 Unbounded Geometry...................... 26 Bounded Geometry.............................27 Entering Values....................................27 Geometry creation modes............ 28 Work Planes........................................ 28 Saving a work plane.........................29 Draw 2D Geometry......................... 30
26 |  Get Started with ESPRIT 2010 Geometry commands Geometry commands are available on two toolbars: Unbounded Geometry and Bounded Geometry. Unbounded Geometry The Unbounded Geometry toolbar displays automatically when you click Geometry on the Smart toolbar. Point: Creates a point using a reference element or entered values. The user can enter XYZ coordinate values, select grid points, or choose a reference element to create a point: on a Snap location (end point, midpoint, or center point), at the intersection of two elements, at a specified distance along an element, or at a specified distance and angle from a reference location. Line 1: Creates a line from one reference element. The line can be created through a point, tangent to a circle or arc, or parallel to another line, segment, or axis. Line 2: Creates a line from two reference elements. The line can be created between two points, tangent to circles or arcs, or perpendicular to another line through a specified location. Circle 1: Creates a circle from one reference element. The circle is centered at a specified location or created concentric to another circle. Circle 2: Creates a circle from two reference elements. The circle is created through or tangent to two elements or Snap locations. Circle 3: Creates a circle from three reference elements. The circle is created through or tangent to three elements or Snap locations. The radius is calculated from the three locations. Ellipse 1: Creates an ellipse centered about a point or Snap location. The user is prompted for the center point, angle of major axis, major radius, and minor radius. Ellipse 3: Creates an ellipse from three points or Snap locations. The user is prompted for the center point, a point that defines the angle of the major axis and the major radius, and a point anywhere on the ellipse. Fillet/Chamfer: Creates an arc (fillet) or segment (chamfer) between two reference elements. Depending on the selected geometry, the elements are either trimmed or extended to the end points of the fillet or chamfer. Keep: Keeps the portion of an element between two reference elements and trims the rest. This command can also be used to convert an arc to a circle, a segment to a line, or a bounded ellipse to an unbounded ellipse. Trim: Trims the portion of an element between two reference elements. Point Array: Creates multiple points at evenly spaced intervals. The user can specify the number of points to create in a linear array, circular array, or grid array. In addition, the user can choose to automatically create a PTOP feature from those points at the same time. Horizontal/Vertical Line: Creates a line parallel to the X-axis (horizontal) or the Y-axis (vertical) at a specified distance.
Working with Geometry   | 27 Rectangle: Creates a rectangle or cube from two points or Snap locations. When the reference points lie on the same plane, a rectangle is created from four separate segments. When the reference points lie on different planes, a cube is created from twelve separate segments. Polygon: Creates a closed shape with any number of sides centered about a point or Snap location. Bounded Geometry To display the Bounded Geometry tool bar, click ‘Bounded Geometry’ on the Create tool bar. Most of the commands are the same except that you can create segments instead of lines and arcs instead of circles. Segment 1: Creates a segment from one reference element. The segment can be created through a point, tangent to a circle or arc, or parallel to another line, segment, or axis. The user specifies the length and angle. Segment 2: Creates a segment from two reference elements that define the start and end points. The segment can be created between two points, tangent to circles or arcs, or perpendicular to another line, segment, or axis. Arc 1: Creates an arc from a center point, a radius value, and start and end angles. Arc 2: Creates an arc with a specified radius through or tangent to two reference elements. Arc 3: Creates an arc from three reference elements that define the start point, a point on the arc, and the end point. Ellipse 1: Creates an open ellipse centered about a point or Snap location. The user is prompted for the center point, angle of major axis, major radius, minor radius, start angle, and end angle. Ellipse 3: Creates an ellipse from three points or Snap locations. The user is prompted for the center point, a point that defines the angle of the major axis and the major radius, and an end point. The second point selected also defines the start point of the ellipse. Entering Values Each geometry command displays a series of messages in the prompt area (located at the lower left corner of the screen). The messages typically prompt you to select a reference element in the work area, such as a center point for a circle or an end point for a line, and then prompt you to input a value, such as a radius or distance. You can accept the displayed value by pressing the Enter key or you can type a new value. As soon as you begin typing on the keyboard, an input box displays.
28 |  Get Started with ESPRIT 2010 You can type the value or you can enter a mathematical expression to calculate the value, such as SQR(PI*3) or 10/3. Geometry creation modes When a geometry command is clicked on the toolbar, its mode of geometry creation is activated. The mode stays active until you press the Escape key or click another command. For example, if you click the Circle 1 command, you can create one circle after another. Work Planes When geometry is created, it is drawn on the current work plane. Work planes let you draw geometry on a plane other than the default XYZ plane. The location and orientation of the current work plane is shown by the UVW axis. To display the UVW axis, click ‘UVW Axis’ on the View menu. ESPRIT provides three work plane orientations, all starting at the system origin point: • XYZ: U, V, and W share the same orientation as X, Y, and Z. Geometry is drawn on the XY plane. • ZXY: U, V, and W are aligned along Z, X, and Y respectively. Geometry is drawn on the ZX plane. • YZX: U, V, and W are aligned along Y, Z, and X respectively. Geometry is drawn on the YZ plane. In ESPRIT, the tool axis is always aligned along the W, or Z, axis. Users have the ability to create their own work planes in any orientation and location using the commands on the ‘Modify Work Plane’ tool bar. This tool bar displays automatically when ‘Geometry’ is clicked on the Smart tool bar.
Working with Geometry   | 29 Work Plane from Geometry: Creates a work plane from selected elements that define a plane. Any of the following can be selected: two intersecting lines or edges of a surface or solid, a line and a point not on that line, three points not on the same line, a circle. The first element selected defines the U axis, the second element defines the V. Parallel Work Plane: Moves the UVW axis incrementally according to the U, V, and W values you enter. Follow the prompts at the lower left of the screen. If the UVW has the same orientation as the XYZ axis, Parallel Work Plane works the same as Translate Work Plane. Translate Work Plane: Moves the UVW axis incrementally according to the X, Y, and Z values you enter and according to the orientation of the XYZ axis. Follow the prompts at the lower left of the screen. Rotate Work Plane: Rotates the UVW axis any angle about a selected line or segment. Rotate UVW: Rotates the UVW axis any angle about the U, V, and W axis. Symmetry Work Plane: Moves the UVW axis symmetrically with respect to a selected plane. You can select elements to define the mirror plane (see Work Plane from Geometry) or use an existing plane as the mirror plane. To do so, type the word “name” and then enter the name of the plane you want to use. XX After a work plane is repositioned, you can use it immediately. The position of the elements you create will be based on the new location and orientation of the UVW axis. Saving a work plane To save the current position of the UVW, open the Work Planes dialog (press F10) and click New. Enter a name for the new plane and click OK. When “Include View” is checked, the same name and orientation is added to the list of View Planes so you can change to that view at any time. The view is created with the ‘W’ of the UVW axis pointing out towards you so that you can create elements on the UV (or XY) plane. An asterisk (*) displays after the new plane name in list for both Work Planes and View Planes to indicate that the work plane includes a view.
30 |  Get Started with ESPRIT 2010 Draw 2D Geometry In this lesson you will learn to draw points, lines, and circles and become familiar with how to trim elements. You will draw the geometry using the dimensions in this drawing. All dimensions are in millimeters. Create a new ESPRIT document You will start with a new document that does not have any geometry at all. Open ESPRIT or, if ESPRIT is already running, click New. Make sure System Unit, on the Tools menu, is set to Metric. Set the view to ‘Top’. Make sure SNAP mode and HI mode are active.
Working with Geometry   | 31 Draw the part boundary as a rectangle The outer boundary of the part is the perfect shape for using the Rectangle command. The Rectangle command requires the entry of two point locations that define the opposite corners of the shape. You will learn how to enter a point location when no points exist in the document. On the Smart tool bar, click Geometry. • Click Rectangle . • You are prompted to “Select First Reference Point”. Select the origin point located in the middle of the screen. • You are prompted to “Select Second Reference Point”. You do not have a second point, but you do know that the part boundary measures 120 mm wide by 90 mm high. • Type the letter N to indicate there is no point and press the Enter key. • You are prompted to “Enter X Value”. Type the number 120 and press Enter. • You are prompted to “Enter Y Value”. Type the number 90 and press Enter. XX You could also enter all the values for a point location in the input box as a single string. For example, n;120;90.
32 |  Get Started with ESPRIT 2010 Draw the boundary lines for the pocket The edges of the pocket are offset from the part boundary by 5 mm. Now that you have the boundary geometry, you can use it as a reference for additional geometry. You will use the segments in the boundary to create parallel lines. • Press F6 to fit the rectangle in the window. • Click Line 1 . • You are prompted to “Select Reference Element”. Select one of the segments. • You are prompted to “Enter Distance”. Type 5 and press Enter. • You are prompted to select an offset direction of “Up, Down, Left, or Right”. Digitize inside the boundary.
Working with Geometry   | 33 Trim the pocket boundary • Click Keep . • Select a line by digitizing it inside the pocket boundary since this is the portion of the line you want to keep. • Digitize the other three lines in the same way so that all the lines are trimmed. • You are again prompted to select a reference element. Select another segment in the boundary. • This time the distance defaults to 5, so just press Enter. • Again digitize inside the boundary. • Follow the prompts to create the next two lines for the pocket.
34 |  Get Started with ESPRIT 2010 Add more detail to the pocket The upper portion of the pocket is 35 mm across. There is also an angled line that starts 45 mm above the bottom of the part boundary. • Click Line 1 . • Select the left pocket segment and enter a distance of 35. • Digitize to the right of the selected segment. • Select the bottom segment of the part boundary and enter a distance of 45. • Digitize above the selected segment.
Working with Geometry   | 35 Draw the angled line With Line 1 still active, click INT mode to activate it. • Move the cursor over the intersection of the two lines you just created and click to select the intersection. • You are prompted to “Enter Angle”. Type -10 and press Enter. • Click ‘Select’ and then select the horizontal line. Press the Delete key since you do not need this line anymore.
36 |  Get Started with ESPRIT 2010 Fillet the pocket corners All the corners of the pocket have a 6 mm fillet except for the intersection of the angled line, which is sharp. • Click Fillet/Chamfer . • In the dialog, set the Radius to 6. • Select the segments at each corner, digitizing on the side of the segment that is inside the pocket boundary. • Change the Radius to 0. • Select the angled segment to the right of the intersection. • Select the vertical segment above the intersection.
Working with Geometry   | 37 Draw the first point for the hole pattern From the drawing, you know that one circle is positioned 8 mm away from the top right corner of the part boundary. You also know the width and height of the part, so you can calculate the location for the first circle. Click Point . In the dialog, select ‘Cartesian/Center’. For the X value, enter 120-8 (width minus the offset). For the Y value, enter 90-8 (height minus the offset). Set Z to 0 and click Apply to create the first point.
38 |  Get Started with ESPRIT 2010 Draw an array of points The holes in the hole pattern are evenly spaced 64 mm horizontally and 30 mm vertically. The easiest way to create a hole pattern is to use the Point Array command to create the center points. • Click Point Array . • In the dialog, select ‘Grid’. • Set ‘Number’ to 2 horizontally and 2 vertically. • Set ‘Distance’ to -64 horizontally and -30 vertically. Negative values are used because you want to create the array below and to the left of the point you just created. • Set ‘Angle’ to 0 horizontally and 90 vertically. • Select the first point of the hole pattern.
Working with Geometry   | 39 Draw the hole pattern The last step is to draw the 7 mm diameter holes using the points you created. • Click Circle 1 . • Select a point. • You are prompted to “Enter Radius”. Type 7/2 and press Enter. • Select another point and press Enter to accept the default radius. Create the other two circles in the same way. • Press the Escape key to exit the Circle 1 command.
40 |  Get Started with ESPRIT 2010
Working with Features   | 41 Working with Features Features are an integral component to the machining functions in ESPRIT and serve several purposes: • They describe the shape of the parts you want to machine. ESPRIT uses standard manufacturing terms for features such as pocket, hole, profile, face, and so on. In this way, a set of features can describe the shape of an entire part. • Features contain machining properties that control where material removal should occur. These properties include cutting depths, draft angles, cut direction, entry and exit points, and lead-in/lead-out points to name a few. • When a feature (or features) is selected before a machining command is clicked, ESPRIT will automatically load the machining properties from the selected feature onto the operation technology page. This saves time and prevents the errors caused by entering values manually. • Features help automate machining processes because they provide a single source of information about how to cut a part. Any number of machining operations can be associated with a single feature. Associated tool paths are easily updated whenever a feature is modified. The intent of this lesson is to introduce the user to the importance of features in machining operations and to provide an introductory lesson on how to create 2-dimensional features from the geometry in a drawing and modify those features to add 3-dimensional properties for machining. You will learn: • About the different types of features • Commands for creating and editing features • Properties assigned to features • Work planes assigned to features • How to create 3-dimensional features from a 2D drawing Types of Features............................42 Chain Feature........................................42 PTOP Feature..........................................42 Feature Set..............................................42 Custom Object.......................................42 Creating and editing features.43 Creating features................................43 Editing features...................................44 Feature Properties.........................45 Work Planes assigned to features 46 Prerequisites.......................................47 Import a CAD drawing..................47 Position the part for machining 50 Draw dimensions...............................51 Create 3D features from a 2D drawing...................................................53
42 |  Get Started with ESPRIT 2010 Types of Features When a feature is created, it is classified as one of the following: Chain Feature An individual feature is considered to be a chain feature. A chain feature could be the boundary around a part, a simple pocket, or a path constructed of wire frame geometry. A chain feature defines the start location, direction, and end location for a cutting path. Chain features are quite simple and are used when you want the cutter to follow a defined path. Typically, these are contouring or profiling operations. In most cases, the tool can be centered on the chain feature or offset to the right or left. PTOP Feature A PTOP (point-to-point) feature defines a path connecting a series of holes or points. PTOP features are typically used for drilling operations and can also be used for manual milling. The tool will follow this path to drill each hole. PTOP features contain information about the depth and diameter of holes along the path as well as information about chamfers and counter bores. Feature Set A collection of individual features that comprise an area to be machined is considered a feature set. Feature sets are represented by a folder in the Feature Manager. A feature set is typically a Pocket feature that has sub-pockets or islands or it can be a Part feature containing all features found within a part boundary. Custom Object All EDM features created with the Draft Feature Recognition command are custom objects. Custom Objects also have an associated Feature Type that designates the feature as a Draft Conic Feature (2- axis) or Ruled Feature (4-axis).
Working with Features   | 43 Creating and editing features Features are created using the commands on the Features toolbar. To display the toolbar, click Features on the Smart tool bar. Two toolbars display: Create Features and Edit Features. Creating features Features are created from commands on the Create Features toolbar. Manual Chain: Creates a chain feature from manually selected elements or point locations. This command can also be used to re-open a chain for editing. Auto Chain: Creates a chain feature automatically from elements that form a closed or open shape. The feature can be created from grouped elements or a manually selected start point, the next element in the chain, and an end point. Manual PTOP: Creates a PTOP feature from grouped or manually selected circles or point locations. Holes: Automatically recognizes holes on a solid model using criteria that defines the allowable range of diameter values. Face Profiles: Creates a profile feature from any combination of solid faces, face loops, solid edges, or wire frame geometry. Face Profiles also processes any holes within the selected face like the Holes command, using the allowable range of hole diameters defined in Feature Parameters. Pocket: Recognizes pockets, and any internal islands, found within a closed boundary and creates features on them. A Pocket feature can be created from a solid model, a face or face loop on a solid model, or a chain feature. Feature Parameters: Defines the parameters used for automatic hole recognition in the Holes and Face Profiles commands and the recognition of milled holes in the Pocket command. An additional setting controls the creation of multiple pockets when the Pocket function is used. Part Profile: Creates geometry or, optionally, a chain feature at the intersection of the UV plane of the UVW axis and a selected solid, NURB surface, or composite. For solid models, a cross-section is created at the UV plane. For NURB surfaces and composites, the geometry marks the silhouette of the part projected along the W axis onto the UV plane. Turning Profiles: Analyzes a part to find OD, ID, or face projection profiles and generates a profile for use in turning operations. A turning profile can be created from a solid model, solid faces, surfaces, surface composite, or STL model. The calculated profile can be created as a chain feature or as individual geometric elements. Draft Feature Recognition: Creates a 2-axis or 4-axis EDM feature automatically from a solid model, grouped wire frame geometry, or solid faces. This command is only available when the machining mode is set to SolidWire. Gear: Creates a chain feature of an inner or outer involute gear from specified gear data.
44 |  Get Started with ESPRIT 2010 Cam: Creates a chain feature of a cam profile based on values provided by the user. Editing features The Features tool bar also displays commands you can use to edit features. Insert Point: Inserts a point in an existing PTOP feature. New Start: Changes the start location on a chain feature to any element defined in the original chain. Remove from PTOP Feature: Removes a point from a PTOP feature. Move Back: Removes any number of elements, from last to first, on an existing chain or PTOP feature. This command is available only when the Manual Chain function is active. Modify Sharp Corner: Places arcs on corners (non-tangent junctions) of a chain feature. Arcs can be applied to the entire chain or any portion of a chain. Modify Internal/External Corners: Analyzes a chain or EDM feature to find and identify all corners, then automatically applies a user-defined corner style to those corners. A corner style can be applied to all corners, internal corners only, external corners only, clockwise corners, or counter clockwise corners. Find Shortest Path: Optimizes the travel distance between points in a PTOP or Hole feature. Reverse: Reverses the direction of a curve, chain feature, or PTOP feature. Commands to edit EDM features Several commands on the Edit Features toolbar are designed specifically for EDM features. Taper Change - Inserts a pivot or gradual taper change into a draft conic feature. Add Match Line - Adds a new synchronization line to a 4-axis ruled feature. Remove Match Line - Deletes a synchronization line from a 4-axis ruled feature. Add Slug Retention Profile - Adds small slots or grooves to an EDM die feature to prevent a slug from staying in the die during a punching operation. Remove Slug Retention Profile - Removes slug retention profiles from EDM die features. Add Extra Cut-off - Adds an extra break point to an existing EDM feature at a user-defined location and distance. Remove Extra Cut-off - Removes an extra break point that was previously added to an EDM feature.
Working with Features   | 45 Feature Properties The Property Browser displays all the properties of a selected item. These include general properties such as color, layer, and element type plus any machining properties. Features always have machining properties. To display the Property Browser, hold down the Alt key as you press the Enter key (Alt+Enter) or select Properties on the View menu. In addition to properties for the entire feature, each feature also has properties for each sub- element such as the position of each point in a PTOP feature, the length of segments in a chain feature, plus attributes that show whether an edge is open or closed. You can highlight sub- elements in a selected feature using HI mode. To edit a feature property, click on the value to the right of the property and make your change. In this way, you can create a feature from 2D geometry and quickly give it 3D properties by adding depth and draft angles.
46 |  Get Started with ESPRIT 2010 Work Planes assigned to features Each time a new feature is created, a work plane is assigned to it automatically. The assigned work plane property affects the orientation of the tool for milling and turning operations placed on that feature. It has no effect on the orientation of the wire in EDM operations. You can view the work plane property in the Property Browser. ESPRIT assigns only one work plane to each feature, regardless of the complexity of the feature. If you try to delete a work plane associated with an existing feature, ESPRIT protects you from accidentally deleting the work plane by displaying a warning that your action is not allowed.
Working with Features   | 47 Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. The files are also available for download from ESPRITWeb » File Library » ESPRIT 2010. All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set to “Metric”. If you would like to review and simulate the machining operations from this lesson, the completed ESPRIT file is available in the folder “completed_parts”. Import a CAD drawing You will start by opening an AutoCAD file in ESPRIT. This drawing has part geometry that you will use to create features. There is other geometry that you do not need, such as the drawing border and title section. You will control the display of the geometry with layers. On the Standard toolbar, click Open. Browse and select the following file: drawing.dxf In the dialog, click Options and make sure ‘File Unit’ is Metric. Click OK to close the Options dialog. Click Open.
48 |  Get Started with ESPRIT 2010 If the Feature Manager is not displayed, press F2. If the Property Browser is not displayed, press Alt+Enter (if necessary, drag the Property Browser below the Feature Manager). Turn off layers to hide elements This drawing already has layers that were created in AutoCAD. When you imported the drawing, you imported the layers as well. Layers let you hide and show different aspects of your drawing. When elements of any type are placed on a layer, you can turn off that layer to hide all elements on that layer. The elements are temporarily hidden, not deleted. You can turn the layer back on at any time to show the elements. The CAD drawing has elements that you do not need for machining operations, such as the drawing border and title box. You can hide these elements so you only see the geometry for the part. On the ‘Layers and Planes’ toolbar, click the Layers icon.
Working with Features   | 49 Uncheck all layers except ‘Default’, ‘Visible (ISO)’, and ‘Hidden (ISO)’. Create and activate a new layer You need to create a new layer for the features you will create. The active layer is displayed with a red box around it. All new elements are created on the active layer. When a new layer is created, it is automatically set as the active layer. • In the Layers dialog, click New • For the layer name, type ‘Features’ and click OK • Close the dialog
50 |  Get Started with ESPRIT 2010 Position the part for machining The origin point in the AutoCAD drawing is not located on the part geometry. To make this part easier to machine, you will move the origin point to the lower left corner of the part boundary since this is a good touch-off location for the machinist. ESPRIT makes it easy to change the origin point without moving the part itself. • On the Edit menu, click ‘Move Origin Point’ • You are prompted to “Select New Origin Point” • Select the snap location at the lower left corner of the part boundary
Working with Features   | 51 Draw dimensions This drawing does not have any dimensions. You will draw some dimensions on the top view of the part to see the depths of the pockets and the holes. You can then use those values to add depth to the features you create. On the Tools menu, click Dimensioning. • Click the Text tab • Make sure ‘Length Unit’ is set to ‘Metric’ • Click the Font button and set the font size to 12 • Click OK to close the Font dialog • Click OK to close the Parameters dialog
52 |  Get Started with ESPRIT 2010 On the Smart toolbar, click Dimensioning. • Click Dimension • In the Status area, select SNAP mode to turn it off • Select a segment on the top and the bottom of the top view • The system displays a preview of the dimension that moves with your cursor • Move the cursor to the left of the geometry and click to place the dimension • Select a segment on the top and a segment at the bottom of a drilled hole • Place the dimension to the right of the geometry • In the same way, add dimensions for the depths of the pockets • Press the ESC key to exit Dimension mode • In the Status area, enable SNAP mode
Working with Features   | 53 Create 3D features from a 2D drawing When a machine shop receives a drawing from a customer, it is useful to be able to use the geometry in the drawing to create 3-dimensional features that can be machined. ESPRIT lets you create features on 2-dimensional geometry and add 3-dimensional properties to them. Create a hole feature On the Smart toolbar, click Features. Click Holes. • Click the arrow button next to ‘Max Diameter’ and select an inner circle from one of the drilled holes • Click OK to create a hole feature that connects all the drilled holes
54 |  Get Started with ESPRIT 2010 Edit the hole feature These holes have a depth of 15 mm and a countersink with a total angle of 90 degrees. Change the view to ‘Isometric’ so you can see the updates to the feature as you add machining properties. • In the Project Manager, select the Hole feature • In the Property Browser, select the value for the ‘Depth’ property • Enter a value of 15 and press Enter • Select the value for ‘Chamfer Diameter’ • Click the arrow button next to the value and then select an outer circle from one of the drilled holes • Change the value for ‘Chamfer Angle’ to 90
Working with Features   | 55 Create chain features for the pocket You will create three features for the pocket: one for the closed boundary of the pocket, one for the rectangular island, and one for the circular island. For features that define a pocket, the cutting side is important because it controls where material is removed (on the inside or outside of the chain). Cutting side is based on the direction of the feature and can be set to Left, Right, or Center. • Change the view back to ‘Top’ • Hold down the Shift key and select a single element in the pocket profile • All connected elements are grouped automatically • Click Auto Chain • The start point for the chain is created in the middle of the longest segment and has a counter- clockwise direction
56 |  Get Started with ESPRIT 2010 • Hold down the Shift key and select a single segment of the rectangular island • Click Auto Chain • Select the circle inside the pocket and click Auto Chain • Select the feature ‘1 Chain’ in the Feature Manager • In the Property Browser, change ‘Cutting Side’ to ‘Left’ and press Enter • Notice that ‘Material Removal’ changes to ‘Inside’ • Select the feature ‘2 Chain’ and change the property for ‘Cutting Side’ to ‘Right’ and press Enter • ‘Material Removal’ for the island feature is ‘Outside’ • Select the feature ‘3 Chain’ and change ‘Cutting Side’ to ‘Right’
Working with Features   | 57 Add depth to the chain features When several elements are selected, only the properties that are common to all the elements can be edited in the Property Browser. Since the features for the pocket all share the same depth, you can update the depth for all three features at one time. • In the Feature Manager, select the three chain features • Change the property for ‘Depth’ to 18 and press Enter Create a chain feature for the open pocket The area located at the upper right of the part is defined as an ‘open’ pocket because it defines a closed boundary that has some edges along a wall and other edges that are open. You can edit the sub-elements of a feature to define edges as open or closed. • Hold down the Ctrl key and select the segments and arcs that define the boundary of the open pocket (the CTRL key lets you continue adding elements to a group) • Click Auto Chain • Change the cutting side of the feature to Left • Change the depth of the feature to 24
58 |  Get Started with ESPRIT 2010 • On the View menu, click Masks • Select ‘Geometry’ to hide the display of the geometric elements (do not close the dialog yet) • In the work area, select an outer edge of the feature • When the entire chain highlights, press the right mouse button to highlight only the edge of the chain • Press the left mouse button to accept this choice • In the Property Browser, change the attribute for ‘Open Edge’ to ‘True’ • In the same way, select the other sub-elements on the outer edge and change the ‘Open Edge’ attribute to ‘True’
Working with Features   | 59 • Change the view to ‘Isometric’ • You can see that the open edges are displayed as dashed lines • In the Masks dialog, select ‘Geometry’ to show the geometric elements and close the dialog Create a chain feature on the inside edge Features along the edges of a part are useful for contouring operations. This chain defines an open profile with the start point and the end point in different locations. After you select the end point of the profile, you need to click the Cycle Stop command to let ESPRIT know that you are finished selecting elements for the chain. • Click Auto Chain • Select the start point shown • Select the angled segment to the left of the start point • Select the end point shown • On the Edit toolbar, click Cycle Stop to create the feature • Change the cutting side to Right • Change the depth to 24
60 |  Get Started with ESPRIT 2010 Create a manual chain on the outer boundary A chain around the boundary of the part can be used for facing and contouring operations. • Click Manual Chain • Use SNAP mode to select the four corners of the part boundary (be sure to select the corners in order) • Change the cutting side so that material removal is on the outside of the boundary • Change the depth of the feature to 30 XX To see the features more clearly you can mask the geometry.
Milling on a Standard Mill   | 61 Milling on a Standard Mill ESPRIT has very strong capabilities in 2.5D milling, providing both ease-of-use and a high level of control over every aspect of a milling operation. The intent of this project is to teach you the process for creating standard milling operations using the standard milling technology in ESPRIT. For this project, you will learn how to use the commands on the SolidMill Traditional toolbar to mill a part on a 2-1/2 axis mill. You will learn: • About SolidMill Traditional machining technology and machining cycles • How to create a milling tool • How to create features for milling operations • How to create a stock model • Techniques to quickly remove stock material • Two pocketing techniques: high-speed and standard • Drilling techniques for hole patterns and a milled hole • Simulation with Stock Automation SolidMill Machining Technology 56 Saving Machining Technology..60 Feeds and Speeds..............................60 Milling Clearances............................ 62 Depths of Cut........................................ 64 SolidMill Traditional Machining Cycles......................................................66 Prerequisites.......................................67 Open the part file...........................67 Create a milling tool....................68 The Tool Manager..............................68 Create milling features................72 Create a stock model................... 79 Remove excess material...............81 Cut the pockets and slot...........88 Mill and drill the holes.............. 95 Simulate milling operations.... 99
62 |  Get Started with ESPRIT 2010 SolidMill Machining Technology 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
Milling on a Standard Mill   | 63 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.
64 |  Get Started with ESPRIT 2010 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. As parameters are selected, the interface updates to show only the parameters you need. Options that are not used are hidden. If the user changes a parameter, the interface updates to show or hide a different set of parameters.
Milling on a Standard Mill   | 65 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.
66 |  Get Started with ESPRIT 2010 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. XX 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.
Milling on a Standard Mill   | 67 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 XX 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 that involve the Z-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.
68 |  Get Started with ESPRIT 2010 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. This is usually the top of the workpiece, but other situations may apply. Sometimes the top of the feature is below the top of the work piece (for example, holes in the floor of a pocket). The only time that clearance is not measured from the top of the feature is if the starting depth is a
Milling on a Standard Mill   | 69 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. XX 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.
70 |  Get Started with ESPRIT 2010 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.
Milling on a Standard Mill   | 71 • 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.
72 |  Get Started with ESPRIT 2010 SolidMill Traditional Machining Cycles All SolidMill Traditional machining cycles are displayed on the SolidMill Traditional toolbar and on the Machining menu under SolidMill Traditional. To display the SolidMill Traditional toolbar, click ‘Switch to SolidMill’ on the Smart toolbar and then click SolidMill Traditional. Facing - Removes a flat portion of stock material based on a feature that matches the stock perimeter. SolidMill Facing quickly removes material at the depth (or depths) you specify with simple linear passes followed by a final contouring pass around any islands to provide a uniform amount of stock on wall areas. The linear and contouring passes are combined into a single operation to save you time and to guarantee a consistent amount of stock on floors and walls. Pocketing - Removes material inside a closed boundary. Within a single pocketing operation, you have the option to create separately definable phases for roughing, wall finishing, and floor finishing passes that each let you use a different tool. When a pocket or face profile feature is chosen, the operation automatically finds any subordinate islands within the feature boundary. Trochoidal Pocketing - Removes material inside a closed boundary using the fastest possible feed rates. Trochoidal Pocketing quickly roughs parts at a constant material removal rate and provides multiple levels of control over tool motion pattern, feed rates, and cutter load. Although developed for high-speed machining, Trochoidal Pocketing brings benefits to any type of machine by providing a more constant tool load and a better surface finish. Contouring - Creates vertical or tapered cuts along the contour of a selected profile. Within a single contouring operation, you have the option to create separately definable phases for roughing and finishing. The same tool is used for both roughing and finishing, although you can define different incremental depths for finishing passes as well as different speeds and feeds. Rest Machining - Creates an operation to remove material remaining from previous operations. A rest machining operation can be applied to any existing SolidMill Traditional operation. The previous operation becomes the “parent” operation and the rest machining operation applied to it becomes the “child” operation. The child operation inherits many of the settings from the parent operation. The parent operation is used as the basis for calculating the areas to machine. Drilling - Creates a drilling operation. Several types of drilling cycles are supported, including canned cycles. Spiraling - Creates either spiral or helical cutting passes based on the selection of a feature with a circular shape or a PTOP feature. Threading - Creates a standard threading or single-point threading operation using basic milling technology. Manual Milling - Creates rapid or feed moves based on manually selected elements or coordinate locations. Manual Milling creates a tool path on the centerline of the tool without compensation. Wire Frame Milling - Creates a milling operation based on wire frame geometry. This command lets you create a simple freeform milling operation from planar geometry. Two separate profiles are used. One profile is swept along the other to create a 3-dimensional shape for the toolpath.
Milling on a Standard Mill   | 73 Open the part file On the Standard toolbar, click Open. Browse and select the following file: milled_part.esp. Set the view to ‘Isometric’. If the Project Manager is not displayed, press F2. Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. The files are also available for download from ESPRITWeb » File Library » ESPRIT 2010. All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set to “Metric”. If you would like to review and simulate the machining operations from this lesson, the completed ESPRIT file is available in the folder “completed_parts”.
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99239843 esprit-get-started

  • 2. Get Started with ESPRIT 2010 Copyright © 2009 DP Technology Corp. All rights reserved. U.S. Patent No. 6,907,313. Other U.S. patents pending. Information is subject to change without notice. No part of this manual may be reproduced, transmitted, translated in any form or by any means, graphic, electronic, or mechanical, including photocopying, recording, taping, or by any information storage or retrieval system, without written permission from DP Technology Corp. The software described in this document may only be used or copied in accordance with the terms of the furnished license agreement and/or non-disclosure agreement. It is illegal to copy the software onto any medium except as specified in the license or non-disclosure agreement. All DP Technology Corporation software products contain integrated security programs and/or plug-in modules that are required for the software license to properly operate. It is a violation of the DP Technology Corporation copyrights and U.S. Copyright law to disable or attempt to disable or remove or otherwise operate the software without the security programs and/or modules installed. Any software not supplied by DP Technology Corporation which is intended to allow the operation of the software without the required plug-in security module and/or integrated security programs is a copyright violation. ESPRIT is a registered trademark of DP Technology Corp. All brand or product names or proprietary file types mentioned in this document are trademarks or registered trademarks of their respective holders. Contact the appropriate companies for more information regarding trademarks and registration. DP Technology Corp. 1150 Avenida Acaso Camarillo, California 93012 USA Tel: +1 805 388 6000 Fax: +1 805 388 3085 www.dptechnology.com Printed in the United States of America
  • 3. Contents Welcome to ESPRIT 2010 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Installing ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ESPRIT Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ESPRIT Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 The ESPRIT Graphical User Interface (GUI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Opening and Storing Files in ESPRIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Selecting Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Controlling the Display of Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Working with Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Geometry commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Work Planes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Draw 2D Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Working with Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Types of Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Creating and editing features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Feature Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Work Planes assigned to features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Import a CAD drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Position the part for machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Draw dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Create 3D features from a 2D drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Milling on a Standard Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 SolidMill Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 SolidMill Traditional Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
  • 4. Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Create a milling tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Create milling features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Remove excess material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Cut the pockets and slot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Mill and drill the holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Simulate milling operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Turning on a Standard Lathe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 SolidTurn Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 SolidTurn Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Create a turning tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Create turning features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Create lathe stock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 Rough the face and the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Drill on the center line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Rough and finish the groove on the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Contour the OD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Rough and finish the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Groove the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Thread the ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145 Perform the cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Simulate turning operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Burning on a 2-axis Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 SolidWire Machining Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 SolidWire Gold Machining Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Open the part file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Set the EDM Machine Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Create EDM features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Create a stock model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 Contour the group of holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
  • 5. Contour the die openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Sort EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Simulate wire EDM operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Using CAD files from other systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 AutoCAD files (*.dxf, *.dwg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 IGES files (*.igs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 ACIS files (*.sat) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Parasolid files (*.x_t, *x_b) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 SolidEdge files (*.par, *.psm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 SolidWorks (*.sldprt, *.sldasm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 STEP files (*.stp, *.step) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184 STL files (*.stl) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 CATIA files (.model, .catpart, .exp, .dlv) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 UG files (*.prt) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Pro/E files (.prt.*, .prt, asm.*, .asm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 Inventor files (*.ipt, *.iam) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 ESPRIT Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187 Attributes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188 Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190 Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191 Workspace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192 File Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
  • 6.
  • 7. Welcome to ESPRIT 2010   | 1 Welcome to ESPRIT 2010 ESPRIT has all the power you need to machine any part... ESPRIT is a high-performance computer-aided manufacturing (CAM) system for a full range of machine tool applications. ESPRIT delivers powerful full-spectrum programming for 2-5 axis milling, 2-22 axis turning, 2-5 axis wire EDM, multitasking mill-turn machining, and B-axis machine tools. ESPRIT’s high-performance capabilities include machining any part geometry (solid, surface, or wireframe), universal post processing to format G-code for virtually any machine tool, and solid simulation and verification with dry runs rendered in dynamic solids for optimal part quality and consistency. ESPRIT’s multitasking component provides powerful capabilities for driving mill-turn machines, multi-axis lathes, and Swiss-style machine tools. ESPRIT provides synchronization of simultaneous cutting cycles using any combination of turrets and spindles for milling or turning, factory-certified post processors for all the leading multitasking machine tools, and dynamic solid simulations for dry run verification of the machining processes. Get Started with ESPRIT will teach you all the basics of how to machine your parts, plus show you advanced techniques to help you get the most out of ESPRIT. Installing ESPRIT................................ 2 ESPRIT 2010 System and Component Requirements........................................... 2 Hardware Key........................................... 2 Install ESPRIT from the DVD......... 3 Use ESPRIT................................................. 3 ESPRIT Support................................... 4 Phone Support........................................ 4 ESPRIT Help on the Web.................. 5 Software Maintenance Contract (SMC).............................................................. 5
  • 8. 2 |  Get Started with ESPRIT 2010 Installing ESPRIT ESPRIT 2010 System and Component Requirements The installation program verifies all requirements before proceeding. If the system does not meet requirements, the installation will abort until the system complies. Existing users should review their computer systems to be sure that they comply with the latest ESPRIT installation and system requirements. The following are minimum hardware requirements for ESPRIT 2010: • 1 GHz 32-bit (x86) processor or greater1 • RAM requirements of a minimum of 1 GB • 128 MB SVGA video card (1024 x 768) • 40 GB hard disk drive • 3 GB of free hard drive space • DVD-ROM drive • Parallel or USB port (required for ESPRIT security) ESPRIT requires certain operating system components to be installed to function properly. These are prerequisites of installing ESPRIT. These components must be installed prior to installing ESPRIT. Systems failing to meet these criteria will cause the ESPRIT installation to fail. • Microsoft® Windows® XP SP323 or Windows® Vista™ or Windows® 73 • Microsoft® Internet Explorer version 6.0 or greater 1 Processor must support the SSE2 instruction set. 2 ESPRIT 2010 will be the last version of ESPRIT supported on Microsoft® Windows® XP. 3 ESPRIT is compiled as an x32 bit application. When run on an x64 OS ESPRIT will be run as x32 bit. Hardware Key Plug your ESPRIT locking device, normally a hardware key (security dongle) provided by DP Technology, into the appropriate USB or parallel port on your computer. If you have a parallel port security dongle, plug it into the primary parallel port (LPT1) at the back of your computer. Do not plug it into a serial port. ESPRIT will not function if the security dongle is not inserted correctly. Take special care to protect your security dongle from loss or damage. It is an integral component of the software and your license. The only device you may attach to the back of a parallel security dongle is a parallel printer. Important: Do not plug any tape backup systems, portable CD-ROMs, DVD players or recorders, Zip drives, multi-function office systems (all-in-one printer/fax/scanner/copier devices) into a parallel security dongle. These will damage your hardware key. If your security dongle becomes damaged, your ESPRIT software will not work until a replacement security dongle and new password can be shipped to you at your expense. Security dongle replacement is not covered by Software Maintenance Contracts. Lost or stolen security dongles are your responsibility. Please check with your insurance carrier to be sure your business insurance has them covered for the full value of your ESPRIT software.
  • 9. Welcome to ESPRIT 2010   | 3 Install ESPRIT from the DVD Please set your computer’s date correctly before installing ESPRIT and do not change the date thereafter. Important: An incorrect date can damage the security module and render ESPRIT inoperative. Your ESPRIT software will not work again until a replacement security module and new password can be shipped to you. 1. Download and install the latest Windows® service packs. 2. Disable any anti-virus software. 3. Open the file “ESPRIT_ReadThisFirst.pdf” on the DVD. 4. Follow the instructions to perform a new installation of ESPRIT 2010 or to upgrade from a previous version of ESPRIT. Use ESPRIT ESPRIT is a single instance application and does not support multiple instances. ESPRIT does not limit the number of instances running, but you may experience unexpected and undesirable results in choosing to run more than one instance of ESPRIT at the same time. Double-click the ESPRIT icon on your Windows desktop Or, From the Windows Start menu, select All Programs » DP Technology » ESPRIT. Other ESPRIT menu items: NC Editor: NC file editing tool Settings Manager: Saves the ESPRIT configuration to allow it to be backed up or transferred to another machine. KnowledgeBase: Database setup and management
  • 10. 4 |  Get Started with ESPRIT 2010 ESPRIT Support The DP Technology web site provides a wide variety of information about the company and its products. You can access the web site at: http://www.dptechnology.com For support issues, please send an e-mail to: support@dptechnology.com Phone Support Contact your reseller first. Resellers of ESPRIT give specialized information related to the custom solution they provided to you. This is the best place to start. If you do not have a reseller, contact the nearest DP Technology office. Corporate Offices 1150 Avenida Acaso Camarillo, CA 93012 USA Tel: +1 805 388 6000 Fax: +1 805 388 3085 dptechnology.com Midwest USA 10275 West Higgins Road Suite 420Rosemont, IL 60018 USA Tel: +1 847 297 8100 Fax: +1 847 297 8107 dptechnology.com Eastern USA 8535 Cliff Cameron Drive Suite 112 Charlotte, NC 28269 USA Tel: +1 704 594 9551 Fax: +1 704 594 9802 dptechnology.com DP Japan Level 28, Shinagawa InterCity Tower A 2-15-1 Konan, Minato-ku Tokyo 108-6028 Japan Tel: +81 3 6717 2896 Fax: +81 3 6717 4545 dptechnology.jp DP China 458 North Fu Te Road Building No. 2, 1F Wai Gao Qiao F. T. Z. Shanghai 200131 China Tel: +86 21 5868 3696 Fax: +86 21 5868 2803 dptechnology.cn DP Europe “Le Thèbes” 68 Allée de Mycénes 34000 Montpellier France Tel: +33 4 67 64 99 40 Fax: +33 4 67 64 99 41 dptechnology.fr DP Germany Sommerleite 1 D-96 148 Baunach Germany Tel: +49 9544 98756-0 Fax: +49 9544 98756-29 dptechnology.de DP Italy Via Iacopo Nardi 2 50132 Florence Italy Tel: +39 055 2342286 Fax: +39 055 2347858 dptechnology.it
  • 11. Welcome to ESPRIT 2010   | 5 ESPRIT Help on the Web Get the most current information about ESPRIT, new product features and enhancements, latest releases, post processors, advanced tips, and creative solutions. The ESPRITWeb is a family of websites dedicated to serving the needs of the ESPRIT community. Register for the ESPRITWeb at: http://www.dptechnology.com/ew • The ESPRITWeb home page is the central point for the ESPRIT online user community. It contains up-to-date information on all ESPRIT products and includes links to all other ESPRIT online areas. • Discussion is a discussion group that provides you with an open forum for discussion on any topic related to ESPRIT. Ask questions and share your ideas, solutions, and experiences with other ESPRIT programmers. • Technical Bulletins is a web-based library of technical information and tips about ESPRIT, including a library of ESPRIT@Work technical training guides for SolidMill, SolidTurn, SolidWire, Post Processor, and ESPRIT API. • SupportWeb is a web-based three-step technical support system. Start by using the Frequently Asked Questions (FAQs) to find a solution to your problem. If your initial FAQ search does not answer your question, search the solution database for answers. Finally, if you have not found your solution in either of these places, you can submit your question to our technical support engineers directly from the web and subsequently via e-mail.File Library is a web-based library of post processors, macros, and other data files useful to ESPRIT programmers. The ESPRITWeb is only available to registered ESPRIT users who have an active Software Maintenance Contract (SMC). For more information on SMC, go to http://www.dptechnology.com and click on the link to Professional Services. We look forward to hearing your comments and suggestions on how we can improve the DP Technology website. Send your comments via e-mail to ESPRIT@dptechnology.com or even better, post your message on the Discussion group. Software Maintenance Contract (SMC) Our goal is to build successful ESPRIT users. We believe the best way to do this is through the SMC program. Participants receive... • Unlimited phone support • Continuous ESPRIT software and documentation upgrades • ESPRIT de Corps Newsletter, our informative and technical newsletter • Opportunity to participate in and gain from cutting edge field testing • 24-hour web access to the DP Help Center and FTP site • Invitation to ESPRIT World Conference For more details on the DP Technology SMC, please call 1+ 805 388 6000.
  • 12. 6 |  Get Started with ESPRIT 2010
  • 13. ESPRIT Fundamentals   | 7 ESPRIT Fundamentals Before you begin the lessons in this guide, you should familiarize yourself with how to work with part files in ESPRIT. As a native Windows-based application, the ESPRIT interface and its menus and toolbars should look familiar to you. This chapter introduces the ESPRIT work environment and explains how to work with ESPRIT part files. You will learn: • How to use ESPRIT menus and toolbars • How to open and store ESPRIT files • How to select, or group, elements using various selection modes such as HI, SNAP, and SUB-ELEMENTS • How to control the display of elements with views, masks, and layers XX Before beginning to use ESPRIT, you should have a working knowledge of your computer, the Microsoft® Windows® operating system and its conventions. You should know how to use a mouse and standard menus and commands. To review these techniques, refer to the documentation for Microsoft® Windows®. The ESPRIT Graphical User Interface (GUI)......................................8 Menus............................................................9 Default Toolbars...................................10 The Smart Toolbar..............................10 Other Toolbars........................................ 11 Displaying the XYZ Axis and the UVW Axis...................................................... 11 Opening and Storing Files in ESPRIT.......................................................13 Creating a New File...........................13 Opening an Existing File................14 Saving a File............................................14 Selecting Elements..........................15 Selecting Elements in the Work Area................................................................15 The Group Command.........................15 Selection Modes...................................16 Deselecting Elements.......................19 Selecting Items in the Project Manager.......................................................19 Controlling the Display of Elements................................................ 20 Shaded and Wireframe Displays.20 Views........................................................... 20 Pan, Zoom, and Rotate the View.21 Masks...........................................................23 Layers..........................................................23
  • 14. 8 |  Get Started with ESPRIT 2010 The ESPRIT Graphical User Interface (GUI) Let’s start by taking a look at the ESPRIT screen. This window is displayed when you create a new file or open an existing one. The ESPRIT window contains: 1. Menus and default toolbars along the top of the screen. You can select commands from the menus or from toolbars. 2. A graphic work area where you can view your work. This is the largest area of the screen. 3. The Prompt area, at the bottom left of the screen, displays prompts that tell you what to do next. Always pay attention to what the prompt is telling you. 4. The Status area, at the bottom of the ESPRIT screen, provides dynamic information about the current work environment. As you select commands or move the cursor, the information is constantly updated. ESPRIT also provides two specialized windows that provide additional information about the parts you are working on and provide an excellent way to manage your work. 5. The Project Manager consists of a tabbed set of windows that list every feature, every cutting tool, and every operation in the current session. The Project Manager lets you manage, sort, and reorder these items. To view the Project Manager, press the F2 key or click Project Manager on the View menu. 1 2 3 4
  • 15. ESPRIT Fundamentals   | 9 6. The Property Browser displays the specific properties of any item selected in the graphic work area or the Project Manager. The types of properties displayed depend on the type of item selected. You can view and change individual properties for the selected item. To view the Property Browser, click Properties on the View menu or hold down the Alt key as you press Enter. Menus Commands are located on eight menus. Most of the menu commands are also available on the toolbars. • File: Open an existing file or create a new one. Save files that have changed. • Edit: Copy or delete items, move the origin point or change the orientation of an imported model. • View: Set the display of the work environment. • Create: Draw new geometry and dimensions, create features, surfaces, or solids. • Machining: Set up the machine definition, create cutting tools, create and simulate machining operations. • Tools: Set the system unit, create macros, load add-in programs, and personalize ESPRIT. • Window: Create new windows and arrange the display of multiple windows. • Help: Access the online help files or learn about your current version of ESPRIT. 5 6
  • 16. 10 |  Get Started with ESPRIT 2010 Default Toolbars The default toolbars are located near the top of the ESPRIT screen. 1. The Standard toolbar has file management commands that let you create, open, save, and print files. This is also where you can find the Copy command when you want to copy elements in the work area. 2. The View toolbar has several commands that let you control the display in the work area, such as zooming and rotating the view plus commands that let you choose whether to display parts in shaded or wire frame modes. 3. The Edit toolbar gives you selection tools that let you filter the types of elements that can be selected or automatically select (group) multiple elements from the selection of a single element. 4. The Layers and Planes toolbar has commands for creating and selecting work planes, layers, and view planes. The Smart Toolbar Use the Smart toolbar to quickly display and hide ESPRIT toolbars based on the type of work you want to do. The first three icons on the toolbar relate to the machining modes in ESPRIT: milling, turning, and wire EDM. If you click “Switch to SolidMill”, the toolbar is updated to display commands that let you create milling tools and operations. If you click “Switch to SolidTurn”, the milling commands are hidden and new commands display that let you create turning and mill/turn operations and tools. If you want to create geometry, just click the Geometry icon to activate the Geometry group of toolbars. If you click Milling Tools, the geometry toolbars are hidden and milling tool commands are displayed. All visible toolbars activated from the Smart toolbar will always be shown in the same position so you never have to hunt for a command. 1 2 3 4
  • 17. ESPRIT Fundamentals   | 11 Other Toolbars In addition to the Smart toolbar, you can display other toolbars. To display other toolbars: • On the View menu, click Toolbars... and then select a toolbar from the list. Any toolbar that has a check mark next to the name is already displayed on the screen. • Right-click on any visible toolbar and select the toolbar you want to display • To show toolbars for machining operations, select the machining type on the Machining menu, such as SolidMill Traditional, and then select the machining type again on the secondary menu. To hide a toolbar: • On the View menu, click Toolbars... and select a toolbar that has a check mark next to the name • Right-click on a toolbar and select the toolbar you want to hide • To hide a machining toolbar, right-click on the toolbar and select Hide To move a toolbar, place the cursor on the double line at the top or to the right of the toolbar and drag it to a new location. When you drag a toolbar near the edge of the screen, it will automatically snap to the edge. Instructions that describe how to create your own toolbars or customize existing toolbars are available in ESPRIT Help. Press F1 to display the help and then click “Customize” in the index. If you would like to customize the Smart toolbar, click “Smart Toolbar Add-In” in the index. Displaying the XYZ Axis and the UVW Axis You can display two types of axes in the work area: XYZ Axis: The global axis positioned at the global origin point UVW Axis: The local axis of the current work plane The display of the two axes is controlled on the View menu.
  • 18. 12 |  Get Started with ESPRIT 2010 The XYZ axis shows the position of the part model in relation to the global axis. The UVW axis shows the origin and orientation of the current work plane. You will learn more about work planes in the lesson “Working with Geometry”.
  • 19. ESPRIT Fundamentals   | 13 Opening and Storing Files in ESPRIT When you start a new session in ESPRIT or create a new file, you are given the choice of starting with a blank file or basing your new work session on a predefined template. The <Blank Document> option opens a new file that uses the ESPRIT defaults. A template file contains user-defined elements and settings for the way you machine parts at your company. You can create templates that include regularly used tools, machine setup configurations, simulation settings, repeated geometry, and KnowledgeBase settings. As you become more familiar with ESPRIT, you can create templates that make it easier and faster to work on similar types of jobs. As a new user, select <Blank Document> and click OK. The commands on the File menu or the icons on the Standard toolbar (located near the upper left of the ESPRIT screen) are used to manage part files. The display of the template dialog is controlled by the “Display Template Dialog” option on the Input page of the Options dialog, available on the Tools menu. By default, the template dialog displays. For more information about how to create and use template files, please refer to the ESPRIT help. Creating a New File Clicking the New command closes the current file so that you can begin work on a new file. If changes have been made to the current file, ESPRIT will prompt you to save those changes before the file is closed.
  • 20. 14 |  Get Started with ESPRIT 2010 Opening an Existing File Clicking the Open command lets you open native ESPRIT files (.esp extension), native 2D and 3D files from other CAD systems such as SolidWorks or Pro/E, stereolithography (STL) files, and translated files such as IGES and STEP. Since ESPRIT is based on the Parasolids kernel, it is adept at opening a variety of solid model files. After you click Open, you can use the “Files of type” pulldown to list only files with a specific extension. This makes it easier to browse for the file you want. If the file you’re looking for has an unlisted extension, select “All Files”. XX The list of available file formats is based on the licensed options. For example, if your license does not allow you to open CATIA files, this option will not display in the “Files of Type” pulldown. Saving a File After working in ESPRIT, you’ll want to save your work so you can retrieve it later. The Save command stores the current file as a native ESPRIT file or as another type of CAD format. ESPRIT files are saved with a “.esp” file extension. If you want to convert the file to a different file format, select the “Save as type” pulldown and then select a file extension.
  • 21. ESPRIT Fundamentals   | 15 Selecting Elements One of the most important tasks in any CAD/CAM system is the ability to select a variety of elements in the part file. A single part file may include one or more solid models, wireframe geometry, surfaces, and toolpath. In addition, you must have the ability to select individual components of an element, such as edges on a solid model or the endpoint of a line. Selecting Elements in the Work Area Elements in the work area can be selected individually, as a group or by type of element. • Use your mouse to select an individual element in the work area • To select more than on element, hold down the Ctrl key as you select elements or drag a selection box over a group of elements • To select a group of connected elements, hold down the Shift key as you select an element Use the Selection Filter to select elements by type. If Geometry is chosen, you will only be able to select geometry elements in the work area. When you are finished, remember to set the Selection type back to All. The Group Command If you want to select all elements that fit specific selection criteria, you can use the Group command on the Edit menu. The Group command lets you select all elements using the following criteria: • Element type • Color • Layer • Work Plane
  • 22. 16 |  Get Started with ESPRIT 2010 After you identify the selection criteria, click OK to automatically select all elements that meet those criteria. Selection Modes Five selection modes are provided in the status area at the lower right of the screen: • HI (highlight) mode • SNAP mode • SUB-ELEMENTS mode • INT (intersection) mode • GRID mode When a mode is grayed out, that means the mode is disabled. Click on a mode to enable or disable it. HI Mode When HI mode is enabled, ESPRIT always asks you to confirm element selections. This allows you to select from elements that are close to, or even on top of, each other. For example, you can use HI mode to select a solid model, an edge on that model, or feature created from a solid model.
  • 23. ESPRIT Fundamentals   | 17 When HI mode is enabled, ESPRIT will prompt “Is this the correct choice” and highlights an element near the selection point. If this is not the correct element, answer No by pressing the right mouse button. ESPRIT will highlight the next closest element. In this example, you want to select the feature but a segment is highlighted instead. You would click the right mouse button until the feature highlights. When the correct element is highlighted, answer Yes by pressing the left mouse button.
  • 24. 18 |  Get Started with ESPRIT 2010 SNAP Mode When SNAP mode is enabled, the cursor recognizes the midpoints and endpoints of lines and segments and the center points of circles and arcs as valid point selections. With SNAP enabled, the cursor changes to: when you hover over the end of a segment or arc when you hover near the midpoint of a segment or arc when you hover over the center point of a circle or arc SUB-ELEMENTS mode When SUB-ELEMENTS mode is enabled, you can select the individual sub-elements of solid models or features in the work area. For example, you can select the faces, faces loops, or edges of a solid model. You can also select the sub-elements of features. The selection of sub-elements is extremely useful for selecting the individual faces on a solid model that you want to machine. The Grouping Properties command relies on the selection of sub-elements to automatically group faces for several types of features: Holes, Pockets, Draft Feature Recognition, Turning Profiles, and FreeForm features. INT Mode When INT mode is enabled, the cursor recognizes the intersections of segments, lines, arcs, and circles as valid point selections. With INT set on, the cursor changes immediately to and remains as the INT cursor until an intersection is chosen. The cursor exits INT mode immediately after an intersection is chosen.
  • 25. ESPRIT Fundamentals   | 19 GRID Mode ESPRIT uses the grid configuration settings from the Options dialog box (from the Tools menu, select Options and then the Input tab). This lets you select from a defined invisible array of screen locations in response to prompts for points, angles, distances, and so on. You may want to set the grid spacing to match your part drawing values. Deselecting Elements To deselect all items simply click anywhere in a blank area of the work area. Selecting Items in the Project Manager Features and machining operations can be selected directly in the Project Manager. Most of the time, this is much easier than selecting these items in the work area. When a feature or operation is selected within the Project Manager, the same item highlights in the work area.
  • 26. 20 |  Get Started with ESPRIT 2010 Controlling the Display of Elements ESPRIT provides a variety of methods that let you control how your parts are displayed. Shaded and Wireframe Displays For solids and surfaces, you can set the display to shaded or wireframe mode. Shaded Wire: Creates a shaded image with wireframe. The display of the wireframe is light source dependent. Wireframes will appear in different colors and/or disappear depending on the part orientation with respect to the light. Silhouettes are not supported, only true edges. Shaded: Creates a shaded image. Has no effect on geometry elements. You can also shade the simulation of cutting operations. Hidden Wireframe: Displays visible solids, surfaces, and geometry as wireframe depending on the orientation of the part. Elements that would normally be hidden by a shaded view are not displayed. Wireframe: Displays all solids, surfaces, and geometry as wireframe. Views ESPRIT provides several standard view orientations. When you change from one view plane to another, the display in the work area rotates to the new view orientation and the display automatically zooms to fit all elements within the screen. You can control the rotation animation speed on the Workspace tab of the Options dialog (available on the Tools menu).
  • 27. ESPRIT Fundamentals   | 21 You can also store your own view orientations. Pan, rotate or zoom the view to the orientation you prefer and then create a new view to store the view for later use. Pan, Zoom, and Rotate the View Commands on the View toolbar let you fit, zoom, pan and rotate the display of your part in the work area. However, it is faster to use the mouse and keyboard to modify the view. Fast Rotate Hold down the Ctrl key and the middle mouse button, or scroll wheel, and move the mouse to quickly rotate the view. If you hold the mouse button down over an axis or geometry element, the view will rotate about that element. Alternatives • Click the Rotate command on the View toolbar • Hold down the Ctrl key and press the up or down keys to rotate 15° around the horizontal axis • Hold down the Ctrl key and press the right or left arrow keys to rotate 15° around the vertical axis • Hold down the Alt key and press the right or left arrow keys to rotate 15° around the normal axis • Hold down Shift+Ctrl and press the up or down arrow keys to rotate 90° around the horizontal axis • Hold down Shift+Ctrl and press the right or left arrow keys to rotate 90° around the vertical axis Zoom Spin the scroll wheel forward to zoom in. Spin the scroll wheel backwards to zoom out. The zoom takes place from the location of the cursor on the screen. Alternatives • Use the zoom commands on the View toolbar: Zoom, Zoom Previous, Zoom Dynamic • Hold down the Shift key and press the up or down arrow keys to zoom in or zoom out
  • 28. 22 |  Get Started with ESPRIT 2010 Smart Zoom Hold down the Shift key and the middle mouse button, or scroll wheel, and move the mouse forward to zoom in or move backwards to zoom out. With Smart Zoom, the zoom takes place from the center of the model regardless of the position of the mouse. That way, the model is always visible when you zoom. Pan Hold down the middle mouse button, or scroll wheel, and move the mouse right, left, forward, or backward to pan the view. Alternatives • Click the Pan command on the View toolbar • Press the right, left, up, or down keys Keyboard Shortcuts Press F5 to redraw the screen. Press F6 to fit all visible graphic elements on the screen. Press F7 to switch to a top view. Press F8 to switch to an isometric view.
  • 29. ESPRIT Fundamentals   | 23 Masks The Masks command on the View menu lets you hide the display of specific types of elements. Press Ctrl+M to display the dialog. Items with a check mark are displayed. Select any items you want to hide to remove the check mark. All elements of that type will be hidden in the work area. To display the elements again, select the item in the dialog. Layers Layers are very useful for controlling the display of different types of elements in a complex part file. For example, you can set up different layers for machine components, the initial part stock or casting, the finished part, roughing tool paths and finishing tool paths, or any other type of geometry. When new elements are created, they are placed on the active layer. Layers can be turned on or off to hide or show the different aspects of your part. The elements are not deleted, just temporarily hidden. You can turn a layer back on at any time. Elements can be placed on a different layer by first selecting one or more elements and then changing the “Layer” property in the Property Browser.
  • 30. 24 |  Get Started with ESPRIT 2010
  • 31. Working with Geometry   | 25 Working with Geometry A basic requirement of any CAD/CAM system is to provide functions that allow the creation of 2-dimensional and 3-dimensional geometry. For machinists, the ability to create geometry to aid in the creation of proper tool path is critical. ESPRIT provides functions to create two types of geometry: unbounded and bounded. Unbounded geometry has no end point or start point, such as an infinite line, or the start point and end point are the same, such as a circle or ellipse. Bounded geometry is limited to a start point and end point, such as a line segment or arc. Some geometric elements are neither bounded or unbounded, such as points, rectangles, and polygons. In addition, ESPRIT lets you trim or extend geometry, or add fillets and chamfers to corners. The intent of this lesson is to teach you the basics of creating 2-dimensional geometry in ESPRIT. You will learn: • About the commands for creating geometry • About work planes and how to modify their location and orientation • How to draw lines, rectangles, points, and circles • How to trim geometry and fillet corners • How to draw a hole pattern from an array of points Geometry commands.................... 26 Unbounded Geometry...................... 26 Bounded Geometry.............................27 Entering Values....................................27 Geometry creation modes............ 28 Work Planes........................................ 28 Saving a work plane.........................29 Draw 2D Geometry......................... 30
  • 32. 26 |  Get Started with ESPRIT 2010 Geometry commands Geometry commands are available on two toolbars: Unbounded Geometry and Bounded Geometry. Unbounded Geometry The Unbounded Geometry toolbar displays automatically when you click Geometry on the Smart toolbar. Point: Creates a point using a reference element or entered values. The user can enter XYZ coordinate values, select grid points, or choose a reference element to create a point: on a Snap location (end point, midpoint, or center point), at the intersection of two elements, at a specified distance along an element, or at a specified distance and angle from a reference location. Line 1: Creates a line from one reference element. The line can be created through a point, tangent to a circle or arc, or parallel to another line, segment, or axis. Line 2: Creates a line from two reference elements. The line can be created between two points, tangent to circles or arcs, or perpendicular to another line through a specified location. Circle 1: Creates a circle from one reference element. The circle is centered at a specified location or created concentric to another circle. Circle 2: Creates a circle from two reference elements. The circle is created through or tangent to two elements or Snap locations. Circle 3: Creates a circle from three reference elements. The circle is created through or tangent to three elements or Snap locations. The radius is calculated from the three locations. Ellipse 1: Creates an ellipse centered about a point or Snap location. The user is prompted for the center point, angle of major axis, major radius, and minor radius. Ellipse 3: Creates an ellipse from three points or Snap locations. The user is prompted for the center point, a point that defines the angle of the major axis and the major radius, and a point anywhere on the ellipse. Fillet/Chamfer: Creates an arc (fillet) or segment (chamfer) between two reference elements. Depending on the selected geometry, the elements are either trimmed or extended to the end points of the fillet or chamfer. Keep: Keeps the portion of an element between two reference elements and trims the rest. This command can also be used to convert an arc to a circle, a segment to a line, or a bounded ellipse to an unbounded ellipse. Trim: Trims the portion of an element between two reference elements. Point Array: Creates multiple points at evenly spaced intervals. The user can specify the number of points to create in a linear array, circular array, or grid array. In addition, the user can choose to automatically create a PTOP feature from those points at the same time. Horizontal/Vertical Line: Creates a line parallel to the X-axis (horizontal) or the Y-axis (vertical) at a specified distance.
  • 33. Working with Geometry   | 27 Rectangle: Creates a rectangle or cube from two points or Snap locations. When the reference points lie on the same plane, a rectangle is created from four separate segments. When the reference points lie on different planes, a cube is created from twelve separate segments. Polygon: Creates a closed shape with any number of sides centered about a point or Snap location. Bounded Geometry To display the Bounded Geometry tool bar, click ‘Bounded Geometry’ on the Create tool bar. Most of the commands are the same except that you can create segments instead of lines and arcs instead of circles. Segment 1: Creates a segment from one reference element. The segment can be created through a point, tangent to a circle or arc, or parallel to another line, segment, or axis. The user specifies the length and angle. Segment 2: Creates a segment from two reference elements that define the start and end points. The segment can be created between two points, tangent to circles or arcs, or perpendicular to another line, segment, or axis. Arc 1: Creates an arc from a center point, a radius value, and start and end angles. Arc 2: Creates an arc with a specified radius through or tangent to two reference elements. Arc 3: Creates an arc from three reference elements that define the start point, a point on the arc, and the end point. Ellipse 1: Creates an open ellipse centered about a point or Snap location. The user is prompted for the center point, angle of major axis, major radius, minor radius, start angle, and end angle. Ellipse 3: Creates an ellipse from three points or Snap locations. The user is prompted for the center point, a point that defines the angle of the major axis and the major radius, and an end point. The second point selected also defines the start point of the ellipse. Entering Values Each geometry command displays a series of messages in the prompt area (located at the lower left corner of the screen). The messages typically prompt you to select a reference element in the work area, such as a center point for a circle or an end point for a line, and then prompt you to input a value, such as a radius or distance. You can accept the displayed value by pressing the Enter key or you can type a new value. As soon as you begin typing on the keyboard, an input box displays.
  • 34. 28 |  Get Started with ESPRIT 2010 You can type the value or you can enter a mathematical expression to calculate the value, such as SQR(PI*3) or 10/3. Geometry creation modes When a geometry command is clicked on the toolbar, its mode of geometry creation is activated. The mode stays active until you press the Escape key or click another command. For example, if you click the Circle 1 command, you can create one circle after another. Work Planes When geometry is created, it is drawn on the current work plane. Work planes let you draw geometry on a plane other than the default XYZ plane. The location and orientation of the current work plane is shown by the UVW axis. To display the UVW axis, click ‘UVW Axis’ on the View menu. ESPRIT provides three work plane orientations, all starting at the system origin point: • XYZ: U, V, and W share the same orientation as X, Y, and Z. Geometry is drawn on the XY plane. • ZXY: U, V, and W are aligned along Z, X, and Y respectively. Geometry is drawn on the ZX plane. • YZX: U, V, and W are aligned along Y, Z, and X respectively. Geometry is drawn on the YZ plane. In ESPRIT, the tool axis is always aligned along the W, or Z, axis. Users have the ability to create their own work planes in any orientation and location using the commands on the ‘Modify Work Plane’ tool bar. This tool bar displays automatically when ‘Geometry’ is clicked on the Smart tool bar.
  • 35. Working with Geometry   | 29 Work Plane from Geometry: Creates a work plane from selected elements that define a plane. Any of the following can be selected: two intersecting lines or edges of a surface or solid, a line and a point not on that line, three points not on the same line, a circle. The first element selected defines the U axis, the second element defines the V. Parallel Work Plane: Moves the UVW axis incrementally according to the U, V, and W values you enter. Follow the prompts at the lower left of the screen. If the UVW has the same orientation as the XYZ axis, Parallel Work Plane works the same as Translate Work Plane. Translate Work Plane: Moves the UVW axis incrementally according to the X, Y, and Z values you enter and according to the orientation of the XYZ axis. Follow the prompts at the lower left of the screen. Rotate Work Plane: Rotates the UVW axis any angle about a selected line or segment. Rotate UVW: Rotates the UVW axis any angle about the U, V, and W axis. Symmetry Work Plane: Moves the UVW axis symmetrically with respect to a selected plane. You can select elements to define the mirror plane (see Work Plane from Geometry) or use an existing plane as the mirror plane. To do so, type the word “name” and then enter the name of the plane you want to use. XX After a work plane is repositioned, you can use it immediately. The position of the elements you create will be based on the new location and orientation of the UVW axis. Saving a work plane To save the current position of the UVW, open the Work Planes dialog (press F10) and click New. Enter a name for the new plane and click OK. When “Include View” is checked, the same name and orientation is added to the list of View Planes so you can change to that view at any time. The view is created with the ‘W’ of the UVW axis pointing out towards you so that you can create elements on the UV (or XY) plane. An asterisk (*) displays after the new plane name in list for both Work Planes and View Planes to indicate that the work plane includes a view.
  • 36. 30 |  Get Started with ESPRIT 2010 Draw 2D Geometry In this lesson you will learn to draw points, lines, and circles and become familiar with how to trim elements. You will draw the geometry using the dimensions in this drawing. All dimensions are in millimeters. Create a new ESPRIT document You will start with a new document that does not have any geometry at all. Open ESPRIT or, if ESPRIT is already running, click New. Make sure System Unit, on the Tools menu, is set to Metric. Set the view to ‘Top’. Make sure SNAP mode and HI mode are active.
  • 37. Working with Geometry   | 31 Draw the part boundary as a rectangle The outer boundary of the part is the perfect shape for using the Rectangle command. The Rectangle command requires the entry of two point locations that define the opposite corners of the shape. You will learn how to enter a point location when no points exist in the document. On the Smart tool bar, click Geometry. • Click Rectangle . • You are prompted to “Select First Reference Point”. Select the origin point located in the middle of the screen. • You are prompted to “Select Second Reference Point”. You do not have a second point, but you do know that the part boundary measures 120 mm wide by 90 mm high. • Type the letter N to indicate there is no point and press the Enter key. • You are prompted to “Enter X Value”. Type the number 120 and press Enter. • You are prompted to “Enter Y Value”. Type the number 90 and press Enter. XX You could also enter all the values for a point location in the input box as a single string. For example, n;120;90.
  • 38. 32 |  Get Started with ESPRIT 2010 Draw the boundary lines for the pocket The edges of the pocket are offset from the part boundary by 5 mm. Now that you have the boundary geometry, you can use it as a reference for additional geometry. You will use the segments in the boundary to create parallel lines. • Press F6 to fit the rectangle in the window. • Click Line 1 . • You are prompted to “Select Reference Element”. Select one of the segments. • You are prompted to “Enter Distance”. Type 5 and press Enter. • You are prompted to select an offset direction of “Up, Down, Left, or Right”. Digitize inside the boundary.
  • 39. Working with Geometry   | 33 Trim the pocket boundary • Click Keep . • Select a line by digitizing it inside the pocket boundary since this is the portion of the line you want to keep. • Digitize the other three lines in the same way so that all the lines are trimmed. • You are again prompted to select a reference element. Select another segment in the boundary. • This time the distance defaults to 5, so just press Enter. • Again digitize inside the boundary. • Follow the prompts to create the next two lines for the pocket.
  • 40. 34 |  Get Started with ESPRIT 2010 Add more detail to the pocket The upper portion of the pocket is 35 mm across. There is also an angled line that starts 45 mm above the bottom of the part boundary. • Click Line 1 . • Select the left pocket segment and enter a distance of 35. • Digitize to the right of the selected segment. • Select the bottom segment of the part boundary and enter a distance of 45. • Digitize above the selected segment.
  • 41. Working with Geometry   | 35 Draw the angled line With Line 1 still active, click INT mode to activate it. • Move the cursor over the intersection of the two lines you just created and click to select the intersection. • You are prompted to “Enter Angle”. Type -10 and press Enter. • Click ‘Select’ and then select the horizontal line. Press the Delete key since you do not need this line anymore.
  • 42. 36 |  Get Started with ESPRIT 2010 Fillet the pocket corners All the corners of the pocket have a 6 mm fillet except for the intersection of the angled line, which is sharp. • Click Fillet/Chamfer . • In the dialog, set the Radius to 6. • Select the segments at each corner, digitizing on the side of the segment that is inside the pocket boundary. • Change the Radius to 0. • Select the angled segment to the right of the intersection. • Select the vertical segment above the intersection.
  • 43. Working with Geometry   | 37 Draw the first point for the hole pattern From the drawing, you know that one circle is positioned 8 mm away from the top right corner of the part boundary. You also know the width and height of the part, so you can calculate the location for the first circle. Click Point . In the dialog, select ‘Cartesian/Center’. For the X value, enter 120-8 (width minus the offset). For the Y value, enter 90-8 (height minus the offset). Set Z to 0 and click Apply to create the first point.
  • 44. 38 |  Get Started with ESPRIT 2010 Draw an array of points The holes in the hole pattern are evenly spaced 64 mm horizontally and 30 mm vertically. The easiest way to create a hole pattern is to use the Point Array command to create the center points. • Click Point Array . • In the dialog, select ‘Grid’. • Set ‘Number’ to 2 horizontally and 2 vertically. • Set ‘Distance’ to -64 horizontally and -30 vertically. Negative values are used because you want to create the array below and to the left of the point you just created. • Set ‘Angle’ to 0 horizontally and 90 vertically. • Select the first point of the hole pattern.
  • 45. Working with Geometry   | 39 Draw the hole pattern The last step is to draw the 7 mm diameter holes using the points you created. • Click Circle 1 . • Select a point. • You are prompted to “Enter Radius”. Type 7/2 and press Enter. • Select another point and press Enter to accept the default radius. Create the other two circles in the same way. • Press the Escape key to exit the Circle 1 command.
  • 46. 40 |  Get Started with ESPRIT 2010
  • 47. Working with Features   | 41 Working with Features Features are an integral component to the machining functions in ESPRIT and serve several purposes: • They describe the shape of the parts you want to machine. ESPRIT uses standard manufacturing terms for features such as pocket, hole, profile, face, and so on. In this way, a set of features can describe the shape of an entire part. • Features contain machining properties that control where material removal should occur. These properties include cutting depths, draft angles, cut direction, entry and exit points, and lead-in/lead-out points to name a few. • When a feature (or features) is selected before a machining command is clicked, ESPRIT will automatically load the machining properties from the selected feature onto the operation technology page. This saves time and prevents the errors caused by entering values manually. • Features help automate machining processes because they provide a single source of information about how to cut a part. Any number of machining operations can be associated with a single feature. Associated tool paths are easily updated whenever a feature is modified. The intent of this lesson is to introduce the user to the importance of features in machining operations and to provide an introductory lesson on how to create 2-dimensional features from the geometry in a drawing and modify those features to add 3-dimensional properties for machining. You will learn: • About the different types of features • Commands for creating and editing features • Properties assigned to features • Work planes assigned to features • How to create 3-dimensional features from a 2D drawing Types of Features............................42 Chain Feature........................................42 PTOP Feature..........................................42 Feature Set..............................................42 Custom Object.......................................42 Creating and editing features.43 Creating features................................43 Editing features...................................44 Feature Properties.........................45 Work Planes assigned to features 46 Prerequisites.......................................47 Import a CAD drawing..................47 Position the part for machining 50 Draw dimensions...............................51 Create 3D features from a 2D drawing...................................................53
  • 48. 42 |  Get Started with ESPRIT 2010 Types of Features When a feature is created, it is classified as one of the following: Chain Feature An individual feature is considered to be a chain feature. A chain feature could be the boundary around a part, a simple pocket, or a path constructed of wire frame geometry. A chain feature defines the start location, direction, and end location for a cutting path. Chain features are quite simple and are used when you want the cutter to follow a defined path. Typically, these are contouring or profiling operations. In most cases, the tool can be centered on the chain feature or offset to the right or left. PTOP Feature A PTOP (point-to-point) feature defines a path connecting a series of holes or points. PTOP features are typically used for drilling operations and can also be used for manual milling. The tool will follow this path to drill each hole. PTOP features contain information about the depth and diameter of holes along the path as well as information about chamfers and counter bores. Feature Set A collection of individual features that comprise an area to be machined is considered a feature set. Feature sets are represented by a folder in the Feature Manager. A feature set is typically a Pocket feature that has sub-pockets or islands or it can be a Part feature containing all features found within a part boundary. Custom Object All EDM features created with the Draft Feature Recognition command are custom objects. Custom Objects also have an associated Feature Type that designates the feature as a Draft Conic Feature (2- axis) or Ruled Feature (4-axis).
  • 49. Working with Features   | 43 Creating and editing features Features are created using the commands on the Features toolbar. To display the toolbar, click Features on the Smart tool bar. Two toolbars display: Create Features and Edit Features. Creating features Features are created from commands on the Create Features toolbar. Manual Chain: Creates a chain feature from manually selected elements or point locations. This command can also be used to re-open a chain for editing. Auto Chain: Creates a chain feature automatically from elements that form a closed or open shape. The feature can be created from grouped elements or a manually selected start point, the next element in the chain, and an end point. Manual PTOP: Creates a PTOP feature from grouped or manually selected circles or point locations. Holes: Automatically recognizes holes on a solid model using criteria that defines the allowable range of diameter values. Face Profiles: Creates a profile feature from any combination of solid faces, face loops, solid edges, or wire frame geometry. Face Profiles also processes any holes within the selected face like the Holes command, using the allowable range of hole diameters defined in Feature Parameters. Pocket: Recognizes pockets, and any internal islands, found within a closed boundary and creates features on them. A Pocket feature can be created from a solid model, a face or face loop on a solid model, or a chain feature. Feature Parameters: Defines the parameters used for automatic hole recognition in the Holes and Face Profiles commands and the recognition of milled holes in the Pocket command. An additional setting controls the creation of multiple pockets when the Pocket function is used. Part Profile: Creates geometry or, optionally, a chain feature at the intersection of the UV plane of the UVW axis and a selected solid, NURB surface, or composite. For solid models, a cross-section is created at the UV plane. For NURB surfaces and composites, the geometry marks the silhouette of the part projected along the W axis onto the UV plane. Turning Profiles: Analyzes a part to find OD, ID, or face projection profiles and generates a profile for use in turning operations. A turning profile can be created from a solid model, solid faces, surfaces, surface composite, or STL model. The calculated profile can be created as a chain feature or as individual geometric elements. Draft Feature Recognition: Creates a 2-axis or 4-axis EDM feature automatically from a solid model, grouped wire frame geometry, or solid faces. This command is only available when the machining mode is set to SolidWire. Gear: Creates a chain feature of an inner or outer involute gear from specified gear data.
  • 50. 44 |  Get Started with ESPRIT 2010 Cam: Creates a chain feature of a cam profile based on values provided by the user. Editing features The Features tool bar also displays commands you can use to edit features. Insert Point: Inserts a point in an existing PTOP feature. New Start: Changes the start location on a chain feature to any element defined in the original chain. Remove from PTOP Feature: Removes a point from a PTOP feature. Move Back: Removes any number of elements, from last to first, on an existing chain or PTOP feature. This command is available only when the Manual Chain function is active. Modify Sharp Corner: Places arcs on corners (non-tangent junctions) of a chain feature. Arcs can be applied to the entire chain or any portion of a chain. Modify Internal/External Corners: Analyzes a chain or EDM feature to find and identify all corners, then automatically applies a user-defined corner style to those corners. A corner style can be applied to all corners, internal corners only, external corners only, clockwise corners, or counter clockwise corners. Find Shortest Path: Optimizes the travel distance between points in a PTOP or Hole feature. Reverse: Reverses the direction of a curve, chain feature, or PTOP feature. Commands to edit EDM features Several commands on the Edit Features toolbar are designed specifically for EDM features. Taper Change - Inserts a pivot or gradual taper change into a draft conic feature. Add Match Line - Adds a new synchronization line to a 4-axis ruled feature. Remove Match Line - Deletes a synchronization line from a 4-axis ruled feature. Add Slug Retention Profile - Adds small slots or grooves to an EDM die feature to prevent a slug from staying in the die during a punching operation. Remove Slug Retention Profile - Removes slug retention profiles from EDM die features. Add Extra Cut-off - Adds an extra break point to an existing EDM feature at a user-defined location and distance. Remove Extra Cut-off - Removes an extra break point that was previously added to an EDM feature.
  • 51. Working with Features   | 45 Feature Properties The Property Browser displays all the properties of a selected item. These include general properties such as color, layer, and element type plus any machining properties. Features always have machining properties. To display the Property Browser, hold down the Alt key as you press the Enter key (Alt+Enter) or select Properties on the View menu. In addition to properties for the entire feature, each feature also has properties for each sub- element such as the position of each point in a PTOP feature, the length of segments in a chain feature, plus attributes that show whether an edge is open or closed. You can highlight sub- elements in a selected feature using HI mode. To edit a feature property, click on the value to the right of the property and make your change. In this way, you can create a feature from 2D geometry and quickly give it 3D properties by adding depth and draft angles.
  • 52. 46 |  Get Started with ESPRIT 2010 Work Planes assigned to features Each time a new feature is created, a work plane is assigned to it automatically. The assigned work plane property affects the orientation of the tool for milling and turning operations placed on that feature. It has no effect on the orientation of the wire in EDM operations. You can view the work plane property in the Property Browser. ESPRIT assigns only one work plane to each feature, regardless of the complexity of the feature. If you try to delete a work plane associated with an existing feature, ESPRIT protects you from accidentally deleting the work plane by displaying a warning that your action is not allowed.
  • 53. Working with Features   | 47 Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. The files are also available for download from ESPRITWeb » File Library » ESPRIT 2010. All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set to “Metric”. If you would like to review and simulate the machining operations from this lesson, the completed ESPRIT file is available in the folder “completed_parts”. Import a CAD drawing You will start by opening an AutoCAD file in ESPRIT. This drawing has part geometry that you will use to create features. There is other geometry that you do not need, such as the drawing border and title section. You will control the display of the geometry with layers. On the Standard toolbar, click Open. Browse and select the following file: drawing.dxf In the dialog, click Options and make sure ‘File Unit’ is Metric. Click OK to close the Options dialog. Click Open.
  • 54. 48 |  Get Started with ESPRIT 2010 If the Feature Manager is not displayed, press F2. If the Property Browser is not displayed, press Alt+Enter (if necessary, drag the Property Browser below the Feature Manager). Turn off layers to hide elements This drawing already has layers that were created in AutoCAD. When you imported the drawing, you imported the layers as well. Layers let you hide and show different aspects of your drawing. When elements of any type are placed on a layer, you can turn off that layer to hide all elements on that layer. The elements are temporarily hidden, not deleted. You can turn the layer back on at any time to show the elements. The CAD drawing has elements that you do not need for machining operations, such as the drawing border and title box. You can hide these elements so you only see the geometry for the part. On the ‘Layers and Planes’ toolbar, click the Layers icon.
  • 55. Working with Features   | 49 Uncheck all layers except ‘Default’, ‘Visible (ISO)’, and ‘Hidden (ISO)’. Create and activate a new layer You need to create a new layer for the features you will create. The active layer is displayed with a red box around it. All new elements are created on the active layer. When a new layer is created, it is automatically set as the active layer. • In the Layers dialog, click New • For the layer name, type ‘Features’ and click OK • Close the dialog
  • 56. 50 |  Get Started with ESPRIT 2010 Position the part for machining The origin point in the AutoCAD drawing is not located on the part geometry. To make this part easier to machine, you will move the origin point to the lower left corner of the part boundary since this is a good touch-off location for the machinist. ESPRIT makes it easy to change the origin point without moving the part itself. • On the Edit menu, click ‘Move Origin Point’ • You are prompted to “Select New Origin Point” • Select the snap location at the lower left corner of the part boundary
  • 57. Working with Features   | 51 Draw dimensions This drawing does not have any dimensions. You will draw some dimensions on the top view of the part to see the depths of the pockets and the holes. You can then use those values to add depth to the features you create. On the Tools menu, click Dimensioning. • Click the Text tab • Make sure ‘Length Unit’ is set to ‘Metric’ • Click the Font button and set the font size to 12 • Click OK to close the Font dialog • Click OK to close the Parameters dialog
  • 58. 52 |  Get Started with ESPRIT 2010 On the Smart toolbar, click Dimensioning. • Click Dimension • In the Status area, select SNAP mode to turn it off • Select a segment on the top and the bottom of the top view • The system displays a preview of the dimension that moves with your cursor • Move the cursor to the left of the geometry and click to place the dimension • Select a segment on the top and a segment at the bottom of a drilled hole • Place the dimension to the right of the geometry • In the same way, add dimensions for the depths of the pockets • Press the ESC key to exit Dimension mode • In the Status area, enable SNAP mode
  • 59. Working with Features   | 53 Create 3D features from a 2D drawing When a machine shop receives a drawing from a customer, it is useful to be able to use the geometry in the drawing to create 3-dimensional features that can be machined. ESPRIT lets you create features on 2-dimensional geometry and add 3-dimensional properties to them. Create a hole feature On the Smart toolbar, click Features. Click Holes. • Click the arrow button next to ‘Max Diameter’ and select an inner circle from one of the drilled holes • Click OK to create a hole feature that connects all the drilled holes
  • 60. 54 |  Get Started with ESPRIT 2010 Edit the hole feature These holes have a depth of 15 mm and a countersink with a total angle of 90 degrees. Change the view to ‘Isometric’ so you can see the updates to the feature as you add machining properties. • In the Project Manager, select the Hole feature • In the Property Browser, select the value for the ‘Depth’ property • Enter a value of 15 and press Enter • Select the value for ‘Chamfer Diameter’ • Click the arrow button next to the value and then select an outer circle from one of the drilled holes • Change the value for ‘Chamfer Angle’ to 90
  • 61. Working with Features   | 55 Create chain features for the pocket You will create three features for the pocket: one for the closed boundary of the pocket, one for the rectangular island, and one for the circular island. For features that define a pocket, the cutting side is important because it controls where material is removed (on the inside or outside of the chain). Cutting side is based on the direction of the feature and can be set to Left, Right, or Center. • Change the view back to ‘Top’ • Hold down the Shift key and select a single element in the pocket profile • All connected elements are grouped automatically • Click Auto Chain • The start point for the chain is created in the middle of the longest segment and has a counter- clockwise direction
  • 62. 56 |  Get Started with ESPRIT 2010 • Hold down the Shift key and select a single segment of the rectangular island • Click Auto Chain • Select the circle inside the pocket and click Auto Chain • Select the feature ‘1 Chain’ in the Feature Manager • In the Property Browser, change ‘Cutting Side’ to ‘Left’ and press Enter • Notice that ‘Material Removal’ changes to ‘Inside’ • Select the feature ‘2 Chain’ and change the property for ‘Cutting Side’ to ‘Right’ and press Enter • ‘Material Removal’ for the island feature is ‘Outside’ • Select the feature ‘3 Chain’ and change ‘Cutting Side’ to ‘Right’
  • 63. Working with Features   | 57 Add depth to the chain features When several elements are selected, only the properties that are common to all the elements can be edited in the Property Browser. Since the features for the pocket all share the same depth, you can update the depth for all three features at one time. • In the Feature Manager, select the three chain features • Change the property for ‘Depth’ to 18 and press Enter Create a chain feature for the open pocket The area located at the upper right of the part is defined as an ‘open’ pocket because it defines a closed boundary that has some edges along a wall and other edges that are open. You can edit the sub-elements of a feature to define edges as open or closed. • Hold down the Ctrl key and select the segments and arcs that define the boundary of the open pocket (the CTRL key lets you continue adding elements to a group) • Click Auto Chain • Change the cutting side of the feature to Left • Change the depth of the feature to 24
  • 64. 58 |  Get Started with ESPRIT 2010 • On the View menu, click Masks • Select ‘Geometry’ to hide the display of the geometric elements (do not close the dialog yet) • In the work area, select an outer edge of the feature • When the entire chain highlights, press the right mouse button to highlight only the edge of the chain • Press the left mouse button to accept this choice • In the Property Browser, change the attribute for ‘Open Edge’ to ‘True’ • In the same way, select the other sub-elements on the outer edge and change the ‘Open Edge’ attribute to ‘True’
  • 65. Working with Features   | 59 • Change the view to ‘Isometric’ • You can see that the open edges are displayed as dashed lines • In the Masks dialog, select ‘Geometry’ to show the geometric elements and close the dialog Create a chain feature on the inside edge Features along the edges of a part are useful for contouring operations. This chain defines an open profile with the start point and the end point in different locations. After you select the end point of the profile, you need to click the Cycle Stop command to let ESPRIT know that you are finished selecting elements for the chain. • Click Auto Chain • Select the start point shown • Select the angled segment to the left of the start point • Select the end point shown • On the Edit toolbar, click Cycle Stop to create the feature • Change the cutting side to Right • Change the depth to 24
  • 66. 60 |  Get Started with ESPRIT 2010 Create a manual chain on the outer boundary A chain around the boundary of the part can be used for facing and contouring operations. • Click Manual Chain • Use SNAP mode to select the four corners of the part boundary (be sure to select the corners in order) • Change the cutting side so that material removal is on the outside of the boundary • Change the depth of the feature to 30 XX To see the features more clearly you can mask the geometry.
  • 67. Milling on a Standard Mill   | 61 Milling on a Standard Mill ESPRIT has very strong capabilities in 2.5D milling, providing both ease-of-use and a high level of control over every aspect of a milling operation. The intent of this project is to teach you the process for creating standard milling operations using the standard milling technology in ESPRIT. For this project, you will learn how to use the commands on the SolidMill Traditional toolbar to mill a part on a 2-1/2 axis mill. You will learn: • About SolidMill Traditional machining technology and machining cycles • How to create a milling tool • How to create features for milling operations • How to create a stock model • Techniques to quickly remove stock material • Two pocketing techniques: high-speed and standard • Drilling techniques for hole patterns and a milled hole • Simulation with Stock Automation SolidMill Machining Technology 56 Saving Machining Technology..60 Feeds and Speeds..............................60 Milling Clearances............................ 62 Depths of Cut........................................ 64 SolidMill Traditional Machining Cycles......................................................66 Prerequisites.......................................67 Open the part file...........................67 Create a milling tool....................68 The Tool Manager..............................68 Create milling features................72 Create a stock model................... 79 Remove excess material...............81 Cut the pockets and slot...........88 Mill and drill the holes.............. 95 Simulate milling operations.... 99
  • 68. 62 |  Get Started with ESPRIT 2010 SolidMill Machining Technology 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
  • 69. Milling on a Standard Mill   | 63 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.
  • 70. 64 |  Get Started with ESPRIT 2010 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. As parameters are selected, the interface updates to show only the parameters you need. Options that are not used are hidden. If the user changes a parameter, the interface updates to show or hide a different set of parameters.
  • 71. Milling on a Standard Mill   | 65 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.
  • 72. 66 |  Get Started with ESPRIT 2010 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. XX 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.
  • 73. Milling on a Standard Mill   | 67 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 XX 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 that involve the Z-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.
  • 74. 68 |  Get Started with ESPRIT 2010 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. This is usually the top of the workpiece, but other situations may apply. Sometimes the top of the feature is below the top of the work piece (for example, holes in the floor of a pocket). The only time that clearance is not measured from the top of the feature is if the starting depth is a
  • 75. Milling on a Standard Mill   | 69 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. XX 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.
  • 76. 70 |  Get Started with ESPRIT 2010 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.
  • 77. Milling on a Standard Mill   | 71 • 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.
  • 78. 72 |  Get Started with ESPRIT 2010 SolidMill Traditional Machining Cycles All SolidMill Traditional machining cycles are displayed on the SolidMill Traditional toolbar and on the Machining menu under SolidMill Traditional. To display the SolidMill Traditional toolbar, click ‘Switch to SolidMill’ on the Smart toolbar and then click SolidMill Traditional. Facing - Removes a flat portion of stock material based on a feature that matches the stock perimeter. SolidMill Facing quickly removes material at the depth (or depths) you specify with simple linear passes followed by a final contouring pass around any islands to provide a uniform amount of stock on wall areas. The linear and contouring passes are combined into a single operation to save you time and to guarantee a consistent amount of stock on floors and walls. Pocketing - Removes material inside a closed boundary. Within a single pocketing operation, you have the option to create separately definable phases for roughing, wall finishing, and floor finishing passes that each let you use a different tool. When a pocket or face profile feature is chosen, the operation automatically finds any subordinate islands within the feature boundary. Trochoidal Pocketing - Removes material inside a closed boundary using the fastest possible feed rates. Trochoidal Pocketing quickly roughs parts at a constant material removal rate and provides multiple levels of control over tool motion pattern, feed rates, and cutter load. Although developed for high-speed machining, Trochoidal Pocketing brings benefits to any type of machine by providing a more constant tool load and a better surface finish. Contouring - Creates vertical or tapered cuts along the contour of a selected profile. Within a single contouring operation, you have the option to create separately definable phases for roughing and finishing. The same tool is used for both roughing and finishing, although you can define different incremental depths for finishing passes as well as different speeds and feeds. Rest Machining - Creates an operation to remove material remaining from previous operations. A rest machining operation can be applied to any existing SolidMill Traditional operation. The previous operation becomes the “parent” operation and the rest machining operation applied to it becomes the “child” operation. The child operation inherits many of the settings from the parent operation. The parent operation is used as the basis for calculating the areas to machine. Drilling - Creates a drilling operation. Several types of drilling cycles are supported, including canned cycles. Spiraling - Creates either spiral or helical cutting passes based on the selection of a feature with a circular shape or a PTOP feature. Threading - Creates a standard threading or single-point threading operation using basic milling technology. Manual Milling - Creates rapid or feed moves based on manually selected elements or coordinate locations. Manual Milling creates a tool path on the centerline of the tool without compensation. Wire Frame Milling - Creates a milling operation based on wire frame geometry. This command lets you create a simple freeform milling operation from planar geometry. Two separate profiles are used. One profile is swept along the other to create a 3-dimensional shape for the toolpath.
  • 79. Milling on a Standard Mill   | 73 Open the part file On the Standard toolbar, click Open. Browse and select the following file: milled_part.esp. Set the view to ‘Isometric’. If the Project Manager is not displayed, press F2. Prerequisites The files for this lesson are available on the ESPRIT DVD in the ‘Get Started’ folder. The files are also available for download from ESPRITWeb » File Library » ESPRIT 2010. All dimensions in this lesson are in millimeters. Make sure “System Unit” on the Tools menu is set to “Metric”. If you would like to review and simulate the machining operations from this lesson, the completed ESPRIT file is available in the folder “completed_parts”.