Task 2

AIM
The aim of the task is to practice creation of milling program for 3D part using a CAM software.

You will learn:

1. Using the CAM software to prepare the NC programs for 3D parts.

2. Tool path types for different machining scenarios.
3. Tool selection.
4. Cutting parameter definition.
5. Program checking with Siemens NX software.

Software
CAD/CAM software: Siemens NX or Audodesk Fusion 360.

Helping materials
NX 3D CAM tutorials in NX (Manufacturing Tutorials), NX help system in Siemens’ website (just push
“F1”!), help materials on Autodesk web site if Fusion is used, videos on youtube, forums.

Procedure
1. Import geometry
2. Analyze the geometry – inner radiuses, pocket size, dimensions, holes, etc. What are the
operations needed? Which tools are needed? What are the dimensions of the tools?
3. Define part and blank
Bounding block can be used for blank definition. Leave 2 mm of material on all sides to be cut (blank
offset).
4. Material of part is steel S355 5. Define coordinate systems
Processing from different sides is required, define several coordinate systems, z-axis defining the
spindle orientation.
6. Choose suitable tools
Select the tools and suitable cutting parameters from a tool catalog (e.g. Dormer Tools, InovaTools,
Sandvik Coromant, etc.)
a. Keep in mind that the tool with the same diameter uses different cutting parameters for
roughing and finishing.
 b. To select the suitable tools and parameters, a real tool selector or a tool catalogue should
be used. For example: https://www.sandvik.coromant.com/en-
gb/tools/coroplustoolguide
c. Choose tools so that the machining time is minimal (the biggest tool that fits to the
geometry).
d. In the final machining operation, tool diameter is chosen by part inner corner size.
Remember: final tool radius has to be less than part corner radius – only then tool path
that cleans the part corners has arc -type movements.
7. Define required machining operations with the correct operations sequence
a. Roughing operations (remove most of the material, leave only a thin layer (value from tool
catalogue, usually < 5% of tool diameter) for finishing).
b. Finishing operations.
c. Drilling operations (center drilling and final drilling operations).
d. Chamfer cutting operations, if needed.
8. Tool paths:
a. Tool paths are created using of Siemens NX CAM (or Fusion 360) software.
b. Tool paths must be technologically correct.
c. In wall finishing operations, tool paths must have small arcs in corners (otherwise
surface defect will occur).
d. Feed rate and spindle speed must be defined according to different cutting
conditions (tool size, depth of cut, etc), based on tool catalogue.
e. In finishing operations, engage and retract moves must be with arcs (radius can be
equal with the tool diameter).
f. In finishing, climb cutting must be used.
g. Moving cutter vertically into material: with helical movement or using ramping
(angle from the tool catalog).

9. Check the program

Simulate (verify) the program, check thickness by color.
10. Write the report
General remarks:
• Work starts with part analysis – CAM engineer has to know the dimensions of the part to plan
the operations and to choose the appropriate tools.
• The material to be machined is regular carbon steel (S355) - it is important for selection of the
tools and the machining parameters from a tool catalogue.
• No parts can be milled with one set-up, i.e. from one side only. Use different coordinate
systems to define different set-ups. All surfaces of the parts must be machined.
• For finishing operations leave the stock as suggested in the tool catalogue. If the catalogue is
not suggesting the value, use 5% of finishing tool diameter.
• If some surfaces cannot be machined, don’t machine them, but explain the reasons in the
report and give suggestions how to deal with the surfaces.
• Define tool dimensions based on tool catalogue data, use realistic tool dimensions (e.g. it is
not realistic to use milling cutter for cutting steel with diameter of 1 mm, that has length 100
mm).
• First, think about sequence of cutting operations: which operations need to be accomplished
before the others.
• Try to use as few set-ups as possible. Every set-up is additional cost and a source of errors.
• Think about how the part can be fixed to the machine table. However, considering the clamps
and fixtures in your programs is not required this time, just mention this aspect in the report.
• If the part is a thin shell, e.g. a bottle, you don’t have to remove the material from inside (five
sides is enough).
• In case of questions, don’t hesitate to contact the supervisor.
• You can only improve the grade if the score was <50%, and you will get 10% less points when
submitting the task the second time.

Report
Correctly formatted work includes:
1. Title page, Table of contents, Goal of work, Operations drawings, Tool table, Operations and their
sequence, Remarks and comments, Summary.

2. Model data: version number, some drawing views to visualize the part.

3. Blank specification.

4. Part setup information. How the part is fixed on CNC table, where is the coordinate system?
5. Tool data from the catalogue that has been used. Tool set-up list. Example:
Tool number Tool id in catalogue Tool Type Rough/Finish Diam Corner rad
T01 S785 End mill R 12 0
T02 S385 Ball mill F 6 3
T03 D112 Drill 8 0
 T04 D112 Drill 3 0
6. List of operations.
Example
Operation Operation Tool Spindle speed, Feed, mm/min Ap/Ae
type RPM
01-Rough Roughing T01 3550 1220 6/2
02-Finish Finishing T02 5500 1550 0,5/0,6
03-Drill Drilling T03 120 30
04-Drill Drilling T04 350 20
7. Summary and conclusions.

Common mistakes
The most common mistakes that can do in this task are as follows:

• The tools are not numbered.

• There is some material left uncut.
• Cutting parameters (F and S) are not defined.
• The cutting parameters seem to be a bit weird – too small feed per tooth or otherwise unrealistic
(they are not based on calculations or catalog data).
• In roughing, the cutter moves straight down. It would be much better if it could ramp or go
helically.
• In finishing operations, the toolpath must have arcs in right angled corners, otherwise surface
defects will occur.
• In finishing operations, the tool has to go into contact (and also afterwards go out of the contact)
with the wall using an arc (in case of linear movement visible surface defect will be on the
surface).
• No stock left in roughing for the finishing operation.
• Used operation is not the best operation for finishing, it is designed for roughing.
• Unreasonable operations, most of the time only air is milled.
• Too much material is removed (vertical step size too large).
• The report does not fulfill the requirements or there is no report.
• Illogical order of operations.