Automated Drill in CimatronE Version 8
Product Fact Sheet
For Internal Use
Automated Drill in CimatronE Version 8
Marketing and Technical Aspects
Table of Contents
What is it? ....................................................................................................................... 3
Typical Uses ................................................................................................................ 3
Automated Drill Advantages ........................................................................................ 4
Objection handling ....................................................................................................... 5
Automated Drill Post Processor Implementations ............................................................ 7
Multiple Cycles ............................................................................................................ 7
Multiple Tools .............................................................................................................. 8
Mixed Drill and Mill (Gun-Drilling)................................................................................. 9
GPP2 and Automated Drill ......................................................................................... 10
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What is it?
The Automated Drill is an advanced newly designed drill programming application,
integrated (free of charge) into CimatronE NC solution starting from version 8.
Automated Drill supports 2.5-5-axis manufacturing as well as gun drilling, and reduces
drill programming time by up to 80%. Automated Drill is also meant to replace the use of
QuickDrill.
The application is able to recognize and sort hundreds of holes in only seconds, and
automatically assign the appropriate drilling sequence for each hole type. The
application's unique stock recognition capabilities take into consideration the stock
existing above the hole, before it is drilled. It then assigns the appropriate drilling
sequence for such holes. This is useful in places where drilling is performed before the
milling operation is complete, and results in unprecedented time saving and elimination
of user errors.
Unlike other systems that offer users a pre-defined set of drilling sequences, Cimatron's
Automated Drill is also an adaptive system, offering a user friendly interface to define
any drilling sequence on-the-fly. The user-defined drilling sequences are automatically
saved in the system for future use on similar holes, saving hours of programming time.
Typical Uses
Automated Drill comes to address the needs of several types of users and NC
applications:
-
Plate machining. In molds (and to a lesser extent in dies), the plates require a
lot of drilling, from different directions. A typical plate of a complex mold will have
several hundred holes that must be drilled.
-
5-Axis Production. Drilling the holes in a full 5-Axis part can be very complex
and time consuming without the proper automation. With Automated Drill 5-Axis
drill capabilities, every hole may have its own orientation (e.g., holes drilled
around a cylinder or a conic shape). Automated Drill features a powerful 5-Axis
Drill solution that complements the Cimatron 5-Axis Mill solution for the 5-Axis
Production market.
-
2.5-Axis Production. Prismatic parts produced with discrete manufacturing
techniques often contain a large number of holes, from multiple directions.
-
Gun Drilling. When very deep holes must be drilled (e.g., for mold cooling
channels), special machines and drills are often used in a process known as
3
“Gun Drilling”. This is actually a special milling technique, where the drill process
is simulated through milling, with adjustable feed control.
Automated Drill Advantages
Automated Drill should be positioned to new and existing users as a best-in-class drilling
application, seamlessly integrated with other CimatronE NC manufacturing procedures,
such as 3X-Mill, 2.5X-Mill or 5X-Production.
Automated Drill unique advantages include the following:
-
Automatic recognition of hundreds of holes, with complex shapes, within
seconds, either in a single direction (3X Drill) or in all directions (5X Drill).
-
The hole recognition algorithms takes into consideration both geometric and nongeometric properties of the holes (e.g. threads and clearance).
-
Seamless integration with the Mold and Die Design applications. Each catalog
part (e.g. Screw) added to the Assembly automatically creates the required hole
and adds the relevant non-geometric data.
-
Full associativity to the model.
-
Full synchronization with the Drawings and the Table of Holes (Drafting).
-
Automated sorting of holes into groups based on their shape, with full user
control where necessary.
-
Automated assignment of drilling sequences to holes, yet with full user control.
-
Recognition and handling of two-sided holes.
-
Combination of regular drilling and gun-drilling (simulated drill).
-
Knowledge of Stock Remaining. This unique advantage supports perfect
handling of holes that are located inside pockets where milling has not been
completed yet. It provides seamless integration of the drill process into the full
manufacturing process of the part.
-
Adaptive Intelligent Drill, where the system actually learns the preferred drill
sequences associated with each hole type. In later parts, similar holes can be
automatically assigned the proper drill sequence. That way, productivity grows as
the system “learns” the working methods of the user.
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Objection handling
The Automated Drill application has been developed as part of CimatronE version 8.
Obviously, there are more features that can and will be developed to push productivity
and usability even higher.
Cimatron is committed to continue the evolution of Automated Drill in version 9 and in
subsequent versions.
Several points that may be raised as objections for the Automated Drill applications:
The definition of drill sequences is too complex, and is not worth it for a few holes
-
With training, that definition is not all that complex. The basic definition is no
more complex than specifying the list of tools you wish to use for that hole, and
where you want them to operate (start and end depth).
-
The definition only needs to be done one time per type of hole. Later on, the
system uses the same sequence for similar holes. Therefore, after a few weeks
of work, all your standard holes, which make the great majority of the holes
needed, are fully defined.
-
One expert engineer can define the drill sequences for all users. That way,
knowledge is spread throughout the organization and consistent work methods
are being applied.
Automated Drill does not support a pre-hole pocket (for holes on slanted
surfaces)
-
Indeed, that option is not available yet in version 8. Cimatron is committed to
deliver it in the next minor version (version 8.x) in order to perfect the integration
between drilling and milling.
-
A temporary work-around can be applied, by defining the pocket on the machine
as one of the predefined canned cycles. That way, the “canned pocket” can be
part of any drill sequence.
Gun Drilling leaves a lot to be desired
-
Version 8 supports basic gun drilling, including handling of intersecting holes.
Additional features and options will be added in future versions.
-
Note that only a few percent of the holes are drilled with gun drilling (mostly
cooling channels in some shops). Even without all options, the existing gundrilling solution, combined with the automated hole recognition and the regular
drilling, bring great productivity improvements.
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What about Hole Attributes from other Software
-
Indeed, the ability to use hole attributes from external data (e.g., CATIA 5 files)
inside the drilling application can simplify the process and reduce errors.
-
Cimatron is working on the solution together with its Data-Interface vendors, and
is committed to bring a complete solution to the import of hole (and other)
attributes in the next software version.
Do I need to have my Post-Processor redone?
-
Automated Drill brings a lot of new functionality into a single drill procedure.
Multiple tools, multiple cycle types and Gun-drilling are the notable changes. This
presents potential challenges to existing Post Processors.
-
Starting with version 8 Service Pack 1, an option is available at the PostProcessing dialog to break every multi-tool and multi-cycle procedure to multiple
separate procedures in the post-processor. With that option, each PP procedure
only contains one cycle type, like the old drill. Gun drilling motions are also
broken to a separate PP procedure. Using that option, existing PP may be
safely used with Automated Drill.
-
Note – this option only “breaks” the Automated Drill procedure to separate
procedures in the post-processor, not inside CimatronE.
-
For users who wish to have the entire Automated Drill procedure posted as a
single procedure, existing post-processors must be verified and typically modified
to support the new options. For instance, an existing PP may not execute well a
“Tool Change” command in the middle of a drill procedure (since it was not
designed or tested for it). PP verification is especially important in 5X Drill.
-
It is strongly advised to use the “break to multiple procedures” option for existing
GPP or IMS post-processors. Cimatron cannot be responsible for the well being
of the machine or the work parts if that option is not used with existing PP.
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Automated Drill Post Processor Implementations
This discussion assumes the use of a GPP-based Post Processor, and will use GPP
terminology. However, the implications and changes are similar for IMS developers.
The discussion is only relevant for post processing of Automated Drill without the use of
the “break to multiple procedures” option.
Multiple Cycles
With Automated Drill, it is possible to have different cycle types inside each procedure
(regular drill only has one cycle type per procedure). If that happens in the middle of a
procedure, it means that the previous cycle must be turned off and a new cycle turned
on.
The following table shows a typical list of blocks that will be created by the Automated
Drill application in such a case. It does not show all the blocks that may be produced –
only the relevant ones.
Block
Comment
BEGINNING OF PROC
Beginning of procedure information bloc
… other blocks
Tool change, origin change, etc.
CYCLE (on)
First cycle, first hole
CYCLE
Second hole
…
More holes
CYCLE (off)
End of first cycle
CYCLE (on)
Second cycle, first hole
…
More holes
CYCLE (off)
End of second cycle
END OF PROCEDURE
End of drill procedure
Notes:
1. This table shows a procedure with two cycle types. In practice, there may be
more cycle changes inside the procedure.
2. Automated Drill always turns the previous cycle off before turning the next one
on.
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Multiple Tools
One of the greatest benefits of Automated Drill is that it applies a full drilling sequence to
each hole. With (almost) no exception, that sequence uses multiple tools (e.g., one for
the center drill and several for the hole itself).
With CimatronE manual drill, each such tool was used in a separate procedure. With
Automated Drill, they are all used in the same procedure. That requires multiple tool
changes inside each Automated Drill procedure.
Automated Drill optimizes the order of operations in order to minimize the number of tool
changes (non-productive time). But still , several tool changes may occur inside the
procedure.
The following table shows a typical list of blocks that will be created by the Automated
Drill application and have to be processed by the post-processor. It does not show all the
blocks that may be produced – only the relevant ones.
Block
Comment
BEGINNING OF PROC
Beginning of procedure information bloc
TOOL CHANGE
First tool for drill
CYCLE (on)
First hole
CYCLE
Second hole
…
More holes
CYCLE (off)
End of this cycle
TOOL CHANGE
Second tool
CYCLE (on)
First hole
…
More holes
CYCLE (off)
End of this cycle
END OF PROCEDURE
End of drill procedure
Notes:
1. This table shows a procedure with two tools. In practice, there may be many
more tool changes inside the procedure.
2. Automated Drill always turns the cycle off before doing a tool-change, and then
turns it on again.
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3. There may also be multiple cycles using the same tool (in which case there will
be multiple cycle “on/off” pairs between tool changes).
4. Like in regular drill, there are no linear motions inside the Automated Drill
procedure to lead the tool to the first point after each tool change. These
“connections” must be handled by the post-processor (especially critical in 5X
drill).
Mixed Drill and Mill (Gun-Drilling)
Gun-drilling does not use machine canned cycles. In fact, it is a milling operation, where
the tool is driven into the hole using carefully controlled feed rates (in order not to break
the tool when hitting material or getting out of the material).
If a single Automated Drill procedure contains both regular holes (done with canned
cycles) and gun-drilling holes, then the toolpath will contain both CYCLE blocks and
LINEAR MOTION blocks in the same procedure. This new situation must be properly
handled by the post-processor.
The following table shows a combination of canned cycles and gun-drilling inside the
same procedure. Tool changes were added too (it is unlikely that the same drill will be
used for both types of drills).
Block
Comment
BEGINNING OF PROC
Beginning of procedure information bloc
TOOL CHANGE
First tool for drill
CYCLE (on)
First cycle, first hole
…
More holes
CYCLE (off)
End of first cycle
TOOL CHANGE
Second tool (for Gun-drilling)
LINEAR MOTION (fast)
Position tool above hole
LINEAR MOTION (fast)
Descend closer to hole
LINEAR MOTION (feed)
Start gun-drilling
FEED
Optional change feed rate in the middle
LINEAR MOTION (feed)
More drilling…
…
More feed rate changes and drilling motions
LINEAR MOTION (fast)
Come up out of the hole and above it
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TOOL CHANGE
Third tool
CYCLE (on)
Second cycle, first hole
…
More holes
CYCLE (off)
End of second cycle
END OF PROCEDURE
End of drill procedure
Notes:
1. The TOOL CHANGE blocks are not mandatory. Simulated drill may be used with
regular tools too (if the user chooses to do so).
GPP2 and Automated Drill
GPP2 is designed to fully support the Automated Drill application in CimatronE version
8, as listed below:
-
Multiple cycles within the same procedure are supported. Of course, the postprocessor has to correctly process the cycle “on” and “off” blocks.
-
Each multi-tool procedure is broken inside GPP2 to multiple procedures, each
with a single tool. This applies to Automated Drill as well as to any other multitool procedure.
-
GPP2 has a rich and flexible mechanism to apply connections before and
between holes, as defined by the DF2 and EX2 program. This covers the
connections after tool changes, as well as connections between cycles (if
necessary) and between canned cycles and simulated drill segments. Like every
GPP2 post-processor, it must comply with the GPP2 connection mechanism.
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