AT472 test 1 2.

5 axis machining operations

Instructions for the exam:

 Save the Part file from Brightspace test 1 on your desk top or a folder and open the file
using CATIA.
 Create a Machining process.
 The material of the part is aluminum, the tooling is carbide, and the CNC machine used
is the Haas VF1 (VF1 tool catalog).
 Use Whitney feed and speed calculator to calculate safe feed and speed parameters.
 Simulate your operations and use the analyze function to make sure that the part is
machined to the design parameters (part is green, any yellow in the part would indicate
that you either forgot an operation or there is an offset from the part programmed).
 Save your files using Safe Management function and submit the part and process files
on Brightspace. This is very important. I won’t be able to open your files if you don’t do
this correctly as a result your grade for the exam would be a zero!

Tips
 I used a 2” facemill, ¼ “end mill, and a 1/8” end mill, but other options are available in
the VF-1 tool catalog.
 Start with a Face milling operation.
 Use the largest diameter end mill that you can use that can still cut the corner radii
(measure the corner radii using the CATIA measurement function).
 Radial step over: always use the Step over ratio option. Maximum step over is .5D of the
end mill.
 Axial step over: always use the Maximum depth of cut option. Maximum cut depth is .
5D of the end mill.
 Macros: Activate all macros and copy Approach and Retract macros to the other
macros.
 Approach and retract macros feed-rate is 50% of the calculated machining speed.
 Always try to come in from the outside of the stock material and enter the stock
material at a reduced speed.
 For pocketing operations create macros that either use a circular or ramp style
approach. If you have to come in straight down than you have to reduce your Approach
speed to 20% of the machining speed.
 Analyze your final simulation and double check FEED/SPEEDS, Step-overs and Macros.