Turning Tutorial - Stub Axle

In this tutorial you will learn how to machine the turning part above using the following steps:

Job Setup

Facing

Turning Profile

Profile Grooving

Cylindrical Thread

Cutting Off the Part

Before proceeding, open the part StubAxle.SLDASM into HSMWorks.

The files used in this manual can be found in the examples folder in the folder where
HSMWorks is installed. Typically, this is something
like C:\Program Files\HSMWorks\examples\

The file for this tutorial is an assembly and contains the final component as well as the stock shape we start
from.
Job Setup
We begin with setting up common job parameters.

Open the HSMWorks operation manager by clicking .

Right-click on StubAxle Operation(s) and select New Job....

Job

Select Turning or Mill/Turn for the Job type under the Job group.

Stock

In the group Stock, change the Stock Definition from Automatic to From Solid.

Next, select the component Stock^StubAxle<1> as the stock by either:

o In the model window, right-click on the model.

o Choose Select Other.

o From the list, select Stock^StubAxle<1>.

or:

o In the model window click the in front of StubAxle to expand the Assembly tree.

o Select the Stock^StubAxle<1> component feature.

Your selection should look like this:

Model

In the group Model, right-click in the selection field and choose Clear Selections.

Next, select the component StubAxle<1> as the surfaces by either:

o In the model window, click on the model.

o In the model window click the in front of StubAxle to expand the Assembly tree.

o Select the StubAxle<1> component feature.

Work Coordinate System (WCS)

Select Use Model & Orientation for the Tool Orientation Selection.

Click on the WCS Orientation box and select Front Plane in the Assembly tree to define the

location of the work coordinates. Ensure Top Center is selected as WCS Origin.

Change Home Position to 5mm to ensure all movements start out of the stock limits.

Click at the top of the property manager.

Click the strategy Turning Face on the CAM toolbar. This creates a new operation and opens

the Property Manager where you can edit the individual parameters controlling the toolpath, as

well as selecting the actual geometry to machine.

The property page is divided into number of groups, and in this tutorial we will go through each one by one
changing the necessary settings in each group as we go along.

Tool

Press

This opens the Tool Library where you can select from existing tools in a library or define a new tool.

Add a new tool with default dimensions:

Press

In the Insert tab, select a 80deg Diamond - Shape C - as insert for general turning. Leave the rest

of the parameters by default (Name should be CNMT09T308)

In the Holder tab, select a -5deg side (both) holder - Style L - for general turning. Leave the rest

of the parameters by default.

Press the OK button to create your new tool.

Press to select the tool for your operation and close the tool dialog.

Geometry
By default, the facing operation machines the whole front side of the stock. This is exactly what we need in
this operation so there is no need to define any confinement or model.

Radii
When activating the Radii tab, a preview of the radius limits will be shown:
 Preview of the radius limits for the facing operation.

Leave the default values.

Passes
The parameters in this group controls how the actual facing toolpath is laid out.

Enable Multiple passes:

Multiple passes

Set Number of Stepovers:

Start Calculation

Click at the top of the property manager. The resulting toolpath will look like this:
Turning Profile
The next operation will be machining the profile of the part to remove most of the excess material. To do
this, we will use the Turning Profile strategy with the same tool used in the previous operation.

Click the strategy Turning Profile on the CAM toolbar. This opens the Property Manager and

you will see the following groups.

Tool
The previous tool #1 - CNMT09T308 should still be selected. We will leave all settings in this group
unchanged.

Geometry
We want to machine a bit further than the backside of the part, to clean the cutting-off area and the fillet. A
confinement has to be defined to extend the operation over the part limits.

Enable the Confinement group.

Set Backside Stock Offset:

5mm

Passes
Turning Profile
The parameters in this group controls how the actual profile toolpath is laid out.

Disable Allow grooving:

Allow grooving

Enable Roughing Passes:

Roughing Passes

Set Maximum Roughing Stepdown:

2mm

Enable Finishing Passes:

Finishing Passes
 Set Maximum Stepover:

0.5mm

Start Calculation

Click at the top of the property manager. The resulting toolpath will look like this:
Profile Grooving
Next we need to machine the central groove and to clean the corners/angles since the previous operation
left material in these areas due to the corner radius of the insert used. It is possible to do that in one single
operation using the Turning Profile Groove strategy to remove the excess material.

Click the strategy Turning Profile Groove on the CAM toolbar. This opens the Property

Manager and you will see the following groups.

Tool

Press to open the Tool Library.

Press to add a new tool.

In the Insert tab, select Grooving in the Type drop-down list. Select a Square Shape for the tool

tip and enter the following values:

o Groove width = 2.5mm

o Width = 2.2mm

o Corner radius = 0.25mm

Leave the rest of the values by deafult.

In the Holder tab, increase the Cutting width up to 50mm (we are going to use the same tool for

the parting operation).

Press the OK button to create your new tool.

Press to select the tool for your operation and close the tool dialog.

Geometry
We only want to remove the material the previous operation did not remove.

Enable Rest Machining:

Rest Machining
 Passes
Turning Profile Groove
This group controls how the grooving toolpath will be calculated.

Enable Roughing Passes:

Roughing Passes

Set Maximum Roughing Stepdown:

1mm

Enable Finishing Passes:

Finishing Passes

Set Maximum Stepover:

0.2mm

Start Calculation

Click at the top of the property manager. The resulting toolpath will look like this:
Cylindrical Thread
The next operation will be to machine an external thread (M20x2.5) in the front part of the stub axle. We will
use the Turning Thread strategy to generate the toolpath for the threading operation.

Click the strategy Turning Thread on the CAM toolbar. This opens the Property Manager and

you will see the following groups.

Tool

Press

This opens the Tool Library where you can select from existing tools in a library or define a new tool.

Add a new tool for the threading operation:

Press

In the Insert tab, select Threading in the Type drop-down list. Select ISO Triangular Full

Profile as Shape for the insert. Set the Thread pitch to 2.5mm (M20x2.5). Leave the rest of the

values by default.

In the Holder tab, select a Straight Threading holder with the default values.

Press the OK button to create your new tool.

Press to select the tool for your operation and close the tool dialog.

Geometry
Threads
Select the area of the part where the thread operation will be performed.
Confinement
The thread do not cover the whole selected area, so we have to define a confinement for the operation.

Enable the Confinement group.

Set Frontside Stock Offset:

2mm

Set Backside Stock Offset:

-5mm

Passes
Turning Thread
Use these settings:

Ensure Thread Type is set to Right handed.

Set Thread Depth:

2mm

Set Number of Stepdowns:

Verify that the tool thread pitch is set in the field Thread Pitch:
 2.5mm

The thread does not end in a groove, so ensure the option Fade Thread End is enabled to fade out

the thread at the end.

Start Calculation

Click at the top of the property manager. The resulting toolpath will look like this:

Disable the option Toolpath Occlusion in the View menu to see the threading toolpath going through the
stock.
Cutting Off the Part
The last operation will be cut off the part. We will use the same tool as for the grooving operation.

Click the strategy Turning Part on the CAM toolbar. This opens the Property Manager and

you will see the following groups.

Tool

Press

Select tool #2 - turning grooving used with the Turning Profile Groove1 operation.

Press

Start calculation

Click at the top of the property manager. The resulting toolpath will look like this:

To verify the toolpath use the stock simulation, right click on the Job node in the Operation Manager and

select Stock Simulation (All). Press the Start button and watch the stock simulation up to the final
stock shape.
 Stock Simulation

Click to exit the Stock Simulation.

Congratulations! You have completed this tutorial.