Contents

Tubes Manufacturing – Flex3D Tubes Plus....................................................4

Design of Tube Part .................................................................................4

1. Tube Creation .............................................................................4

2. Chamfer Tube ............................................................................8

3. Perforation Properties(Drill Tube) ...............................................9

4. Limit Tube ................................................................................115. View (hide backlines).....................................................................136. Dimension/Measurement Note........................................................137. Section tube....................................................................................14

8. Surface Map .............................................................................15

9. Cut Tube ...................................................................................16

10. Modify technology .....................................................................18

11. Modify Order ............................................................................18

12. Cutting Sense and Compensation ............................................19

13. Lead In .....................................................................................19

14. Micro-Joints ................................................................................21

15. Modify Clearance .....................................................................22

16. Simulate Cut ............................................................................2317. Settings...........................................................................................24

a. Position the axes ........................................................................24b. Tube cut machines configuration......................................................24c. System graphic configuration dialogue.............................................28

18. New (to go to Fabrication module) ............................................30

Fabrication Order (OF module) ..............................................................30

19. Import tubes part ......................................................................31

20. Make nestings ...........................................................................3221. Generate CNC Program...................................................................3322. Common Cut setting (default) and Non Common Cut setting........3523. Inverse and Rotate setting..............................................................37

Nestings for tube parts ..........................................................................39

1. Machining of cut nesting ...........................................................39

2. Saving to generate CNC ............................................................40

3. Return to Fabrication Order .......................................................40Appendix 1 - First time usage......................................................................41Appendix 2 - Tutorial of a Tube module......................................................43

1. Creating a tube...............................................................................432. Nesting tubes..................................................................................50

Appendix 3 - SAT file handling.....................................................................61

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Lantek Flex3D Tubes Plus

Tubes Manufacturing – Flex3D Tubes PlusTubes Plus module provides a manufacturing process to produce parts from tube materials. The 2-steps approach of design and nesting/machining allows the maximum material utilization and flexible automation of this manufacturing process.

Design of Tube Part This is the CAD module for the tube part. It consists of an intuitive environment and a great number of functionality that helps in the design process. It is totally parametric and at any moment of the process, one can change whatever parameter of the previous operations without redoing the whole steps again. At any moment, it can also show the tool that is acting on the operation. The menu option is made available by placing the mouse cursor over the said operation and right clicks the mouse button.

The user should start with the Tube toolbar and 2D Draw toolbar .

Now you could start design the tube part…

1.Tube Creation

It should begin to define the tube base (material, format) and the machine (the showed options are the existing ones in Expert's database) in order that ultimately the software could generate CNC's program correctly.

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In term of tube types, there are 5 types of predefined pipe formats, as shown below for information.

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The user could do the Operations on Tubes

Quick Note on Tube Cut Machine – tubes module settings and install machines

Additional note on the Web and Flange which affect the extremes of the tube part (Web is for top-down or vertical and Flange is for left-right or horizontal).

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The example with Web End as 30 degree and Flange Start with 45 degree. They will create the chamfer on the tube part but the chamfers are only used for nesting and will be machined in the Nesting module. On the tube part design, the user cannot machine the extreme ends.

Note the left extreme end is the Web End of 30 degree and the right extreme end is the Flange End of 45 degree.

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2.Chamfer Tube

Chamfers the tube based on the parameters entered in the chamfer properties dialogue.

The chamfer can be done from an attack angle or a partial chamfer can be done from two values.

The chamfer parameters can be modified subsequently by means of the properties command of the tube tree that appears on the left of the work area.

Chamfer Partial Chamfer

Chamfer properties dialogue

This dialogue enables you to create a new chamfer or modify the parameters of an existing one.

Operation parameters

Operation ID: chamfer operation identifier in the tube tree. Fibre: specifies the part, within the tube thickness, which serves as a reference to

do the chamfer, either to define the attack angle in the normal chamfer or to specify the two values that make up the partial chamfer. GO

Start/End: if this option is active, the chamfer is done at the start of the tube.

Chamfer definition

A chamfer can be done from an attack angle or a partial chamfer can be done from two values. In both cases, the parameters take the model coordinate system as the reference.

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Chamfer: you have to specify the attack angle of the plane that forms the chamfer in respect of the XY plane. as well as the rotation angle of that plane in respct of the X axis.

Partial chamfer: the chamfer is defined from the values assigned to the parameters Dist. X and Dist. Z as well as the rotation angle on the X axis.

To create a new chamfer press the button add. The operation ID cannot exist in the tube operations tree. To modify the parameters of a previously created chamfer press the button apply.

Fibre

Specifies the part, inside the tube thickness, that serves as a reference for the creation of the tube or to define other operations

There are three possibilities:

Inner: the reference point is included in the tube thickness. The position of this point is determined by means of the parameter average position relative to interior that indicates, in percentage terms, the relative position of the point in respect of the inner edge of the tube.

Inside: reference point in respect of the inner edge of the tube. Outside: reference point in respect of the outer edge of the tube.

3.Perforation Properties(Drill Tube)

Makes a hole in the tube based on the parameters entered in the perforation properties dialogue

The perforation may be round, rectangular or obround in shape. You can also perforate with 2D geometries imported from MEC files and with projected geometries.

The perforation parameters can be subsequently modified using the command properties in the tube tree that appears on the left of the work area.

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Perforation properties dialogue

This dialogue enables you to make a hole in a tube or modify the parameters of a previously created one.


Operation ID: perforation operation identifier in the tube tree. Translate in X and Y: position of the perforation on the tube surface in respect of

the XY plane of the model coordinate system.

In the case of round, rectangular or obround perforations they determine the central axis of the tool.

In the case of imported geometries they determine the displacements on X and Y to be added to the original poition of the geometries.

Rotation about X, Y and Z: rotation angle of the perforation in respect of the three axes.

Transpierce: if this option is active, the perforation transpierces the tube.

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Drill definition

Round: defined by means of a diameter. Square: indicate the width (length X) and the height (length Y). Obround: indicate the width (length X) and the height (length Y). Import 2D Geo: enables you to make a perforation by importing a 2D geometry in

MEC format and taking as reference the model coordinate system. Projected: makes a perforation from the 2D geometry previously selected and that

will be projected on the tube surface. The XY plane of the working coordinate system is taken as a reference.

To create a new perforation press the button add. The operation ID cannot exist in the tube operations tree. To modify the parameters of previously created perforation press the button apply.

4. Limit Tube

Limits the current tube with another tube based on the parameters entered in the limit properties dialogue.

The limiting tube may be cylindrical or rectangular.

The parameters of the operation may be modified later using the command properties in the tube tree that appears on the left of the work area.

Limit properties dialogue

This dialogue enables you to limit the current tube with another tube or modify a previously limited tube.


Operation ID: limit operation identifier in the tube tree. Fibre: specifies the part, within the tube thickness, which serves as a reference to

determine the diameter (when limiting with a cylindrical tube) or to determine the height and base (when limiting with a block). GO

Start/End: if this option is active, the tube is limited from the start.

Cylinder/block definition

The limiting tube can be a cylinder or a block. In both cases:

Dist. X, Dist. Z: position of the tube axis in respect of the XZ plane. Rotation: rotation angle in respect of the X axis. Attack angle: angle in respect of the XY plane. Cylinder

o Diameter: diameter of limiting tube. (*) Block

o X length: width of limiting tube. (*) o Z length: height of limiting block. (*)

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o Corner radius: radius of the rounded corner that forms the rectangular base of the block.

o Rotation: rotation angle in respect of the Y axis.

(*) The reference for determining these parameters depends on the fibre selected. The thickness of the limiting tube is considered to be the same as that of the original tube.

To create a new limitation press the button add. The operation ID cannot exist in the tube operations tree. To modify the parameters of a previously created limitation press the button apply

The type of cut can be customized to grain of the tube (e.g. Outside, Inside and Inner)There are two types of Limit Tube (cylinder or rectangular). The parameters of the positioning are the same, except in cylinder cut requires diameter and rectangular cut requires X/Y and corner radius.

Cylinder limit tube: The cylinder diameter determines the curve at limit tube.

Rectangular Limit Tube: The dimension and the corner radius determine the shape at limit tube. The block rotation parameter will also determine the end result of the limit tube.

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5.View (hide backlines)The view menu provides 3 functions.

The Hide back line is especially important when they are varies holes and display the holes on the reverse facing side will mix up and complicate the view. It is especially so when try to make adjustments to hole such as the lead-ins etc.

The 2D view is to provide a static view of the tube part when it is in 2 dimension. The combination of 3D view and then 2D view could provide user an added way to verify that the operations on tubes are according to his requirements and design.

6.Dimension/Measurement NoteTo measure and show Dimension note on the tube part to ensure precise placements and positioning.

Example: Dimension or measurement between two points.

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Dimension from edge

Dimension of 2 points

Angle Dimension 2 edges

Angle Dimension 2 points

Arc Dimension

Point Dimension

Delete

Show/Hide Dimension Note

Configure Dimension

Show back lines

2D

Hide back lines


7.Section tubeThis feature will cut a section of the tube.

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8. Surface Map

Projects the 2D geometry selected on the XY plane of the working coordinate system on the tube.

The parameters for this operation are defined using the surface map properties dialogue

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Surface map properties dialogue

This dialogue enables a 2D geometry to be projected on the surface of the tube, taking as a reference the XY plane of the working coordinate system. To do this, the 2D geometry must have been selected.

Moreover, in the case of rectangular tubes the Z axis of the working coordinate system must be perpendicular to one of the faces.

It presents the following parameters:

Operation ID: map operation identifier in the tube tree.

Geometry

Discretisation value: length of the discretisation segment in the projection and in the cut operation. The default value for this parameter corresponds to the value assigned to the surface map operation discretisation value parameter in the cut parameter dialogue. GO

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Note: if the XY plane of the working CS coincides with the XY plane of the model CS, the projection is done by following the positive direction of the Z axis of the model CS.

The position of the geometry depends on the active system of coordinates in every moment. Only it is necessary to introduce the parameter of discretisation (this is due to the fact that all the geometries that pass of 2D to 3D are represented by means of small segments)

9. Cut Tube

Defines the cutting operation on the tube based on the machine selected.

The cutting parameters for that machine are shown in the cut properties dialogue. These parameters can be modified subsequently by means of the properties command of the tube tree that appears on the left of the work area.

By default Flex3D shows the cut parameters stored in the dependent materials list for the machine selected, that is to say, the material/thickness dependent configuration.

If it cannot find the right values on the list (material and thickness of the current tube), then it shows the parameters specified in the cut technology configuration for that machine.

Once the cut operation has been defined use the save command on the file menu, which stores the information about the operation in a file with the extension M3D. The name of the cut file will be the same as that of the tube modeling.

Moreover, if the post-processor is installed for the active machine, a numerical control file is generated with the extension dependent on the machine used and which will be stored in the directory \Flex3D\CNC.

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Up to this moment, all the operations that we have done are operations on the design of the pipe, that is to say still not real cut that has been generated on the pipe. With this operation the cut will be simulated and the paths of the same will be generated.

Once executed, the application will mark in red the contours, and that is the machining of the cuts would be realized in the pipe.

Until the user does not save the file, the application will not generate the program CNC for the chosen machine. This will be done in transparent form to the user.A series of sub-functions exist inside this operation:

Cut properties dialogue

This dialogue shows and enables you to modify the cut parameters for the machine selected:

Cutting edge: determines if the cut is done on the outer or inner edge of the tube. Chamfer: determines if the material that forms the thickness of the tube is

chamfered. Technology type: cut or mark. Cut order: enables you to specify the cut order to be followed by the machine :

o From: starts on the contour closest to the starting point, continues to the right and returns from the left. Always leaves for the end any cut on the left edge of the tube.

o Left to right o Right to left

Stating point: coordinates of the initial location of the cutting head. Technology values :

o Speed: of the cutter (metric_units/minute). o The compensation can be indicated wither by a radius or compensation

value, or by a compensation index. Lead-in values : the lead-ins can be set automatically using the following

parameters: o Lead-in position: point on corner or middle point of of the discretised

segment. o Lead-in length

Other parameters : o Clearance for rapid motions: rapid displacement distance. o Cut discretisation value: length of the cut segments. o Operation identifier: identifier that defines the cut operation in the tube

tree.

Note: Once the cut operation has been defined, if any changes are made to the tube properties or to any of its operations it will be necessary to delete the cut operation and define it again.

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10. Modify technology

This command enables you to configure and modify the technology type to be applied to each cut and mark contour, as well as tool compensation using the cut values modification dialogue.

To activate this dialogue you just have to click on the contour required.

Cut value modification dialogue

This dialogue enables you to specify the following parameters for the contour selected:

Technology type: this option indicates the technology type to be used on the contour, it can be:

o Standard cut o Standard mark o Laser pulse cut o User technology (n)

Cutter compensation: determines whether there is compensation and its parameters:

o Deactivated: no cutter compensation carried out (by default). o Left/right: compensation will be carried out on the side of the contour

specified.

Index: compensation index for the contour selected.

Value: radius or value for compensation for the contour selected.

Speed: cutter speed in the contour selected (metric_units/minute).

The default values for the parameters index, value and speed are those specified in the command cut tube.

11. Modify Order

This command enables you to view or modify the specified contour cut order in the tube cutting operation.

To modify the order, click on the contour you want to cut first and then successively on all the contours, until you have established a new cutting order.

It modifies the order in which the different geometries are going to be cut in the pipe. The system provides a default order chosen in the settings. It always begins for the geometry more to the left side (nearer to the origin of coordinates) except the last one, then it moves towards the right and ultimately it returns back to the first one (the left most).Choose the first one and then proceed with the rest. Whenever we want to begin again, it is necessary to return to choose the Modify Order option.

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12. Cutting Sense and Compensation It could modify the cutting direction sense. It could also modify the compensation settings (off, left or right).

13. Lead In

This operation enables you to insert new lead-ins as well as view, modify or delete those created earlier. The lead-ins are always parallel to the X axis of the model CS.

To insert a lead-in just click on the contour at the point you want to make the insertion.

To delete a lead-in you have to click on the contour containing it.

The configuration of the lead-ins (length and position) can be modified by clicking the right button of the mouse on the work area using the cut lead-in values dialogue

To indicate the entry point of cut of the laser. The placement of lead-in is flexible and intuitive.

Cut lead-in values dialogue

This dialogue enables you to configure the following parameters:

Auxiliary operations: these operations affect all the contours. o Modify defined lead-ins length: this option establishes a new length for all

the lead-ins that are already defined, assigning them as a new value the parameter lead-in length.

o Delete defined lead-ins: deletes all the lead-ins defined up to now. o Create outstanding lead-ins automatically: automatically creates lead-ins

for those contours in which they still have not been defined. Lead-in length: length of lead-in segment. Lead-in position

o Picked point o Near corner point: lead-in on corner of discredited point. o Middle point: lead-in on middle point of discredited segment.

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Therefore I mark with the mouse the place and then with the right mouse button, I modify the default parameters. It can create them automatically as they have been defined in the Settings.

There is also the automatic lead-in.

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Please note that the second option (‘Also in projected’) should be checked when the geometry is to be imposed upon the tube part via the Surface Map function – then the automatic lead-in would be applied in that situation as well.

14. Micro-Joints

This command enables you to add micro-joints to the cut or mark contours.

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To do this, you have to click the left button of the mouse on the micro-joint insertion point inside a contour.

You can modify the size of the micro-joint segment as well as carry out other operations by clicking the right mouse button on the work area using the micro-joint values dialogue

Micro-joint values dialogue

This dialogue enables you to modify the size of the micro-joint segment using the micro-joint length parameter.

Moreover, the following auxiliary options can be carried out:

Delete defined micro-joints: deletes the existing micro-joints on all the contours. Show micro-joints: shows the ends of each micro-joint.

We can define zones in the contour that are not going to be cut.

With the right mouse button, we modify the length. It is used especially when the pipe is going to be cut at different zones, in order that the scrap parts do not break.

15. Modify Clearance It serves to detect collisions. They are in use for controlling the lead-in that is not on cylindrical pipe. When the machine turns the pipe to cut another geometry, if the cut head does not have sufficient clearance from the surface, it may hit against the pipe.

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With the right button of the mouse, we will be able to choose the distance of lead-in and that of the lead-out of the laser head.

16. Simulate Cut

This command simulates the tube cutting operation.

The type of simulation is configured using the cut simulation dialogue

Cut simulation dialogue

This dialogue presents the following buttons, which show the different steps of the simulation:

Goes to initial contour.

Undoes the simulation of the last contour.

Simulates the next contour in the order specified.

Simulates from the current contour to the end.

You can also configure the type of simulation using the parameters button that activates the cut simulation parameters dialogue

It allows the simulation the cut of the different geometries. We can go forward and backward.

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In addition, we can choose the type of simulation.

Cut simulation parameters dialogue

This dialogue enables you to set the cut and mark simulation mode:

Only edges : the simulation is limited to cuts or marks. Edges and axes : the simulation includes in addition to the cut marks, the axes

that represent the position of the cutting head. Head simulation : makes the cut with a simulation of the head and its movements

over the part.

Finally, the check box Simulate rapid enables you to view the rapid displacements between different operations carried out on the tube.

17.Settingsa. Position the axes

This is a functionality that is used to facilitate the generation of more complex cutting. It allows the axes to be place at various points of the part and allows subsequent changes as the need arises.

It has different options:

Axes on one of the faces of the piece.

Transformation of the axes.

Axes in the center of the model.

Position of the axes in the minimal box that contains the pipe.

4 predefined views of the pipe.

b. Tube cut machines configuration

This dialogue enables you to establish the configuration of the tube cut machine selected from the list, as well as to install a new one.

If you select to install a new machine, the machines dialogue will be initiated. Once you have selected a machine, the following buttons are activated to establish

your configuration:

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o Cut technology configuration o Cut simulation configuration o Material /thickness dependent configuration

You select the cutting machine you are going to use when you create the tube.

By default, Flex3D tries to make the cut using the values stored in the list of dependent materials for that machine, that is to say, material/thickness dependent configuration.

If it cannot find the right values in the list (material and thickness of current tube), then it makes use of the parameters specified in the cut technology configuration for that machine.

Machines dialogue

This dialogue enables you to add new machines to those currently installed as well as uninstall machines installed earlier.

To do this, just select from the list of Machines available the one you want to install and establish its configuration, or select from the list of Machines installed the one you want to uninstall (unless it is the active machine, in which case it cannot be uninstalled).

Cut parameters dialogue

This dialogue enables you to determine the following parameters for the machine selected:

Cutting edge : determines if the cut is made on the outer or inner edge of the tube.

Chamfer : determines whether the material that forms the thickness of the tube is chamfered.

Technology type : cut or mark. Cut order : enables you to specify the cut order to be followed by the machine,

with the following possibilities : o From : starts on the contour closest to the starting point, continues to the

right and comes back from the left. Always leaves for the end any cut on the left edge of the tube.

o Left to right o Right to left

Starting point : co-ordinates of the initial location of the cutting head. Technology values :

o Feed rate : of the cutting tool (metric units/minute). o The compensation can be indicated either by means of a radius or

compensation value, or by means of a compensation index. Lead-in values : the lead-ins can be defined automatically using the following

parameters: o Lead position: point on corner or middle point of discredited segment. o Lead-in length

Other parameters : o Clearance for rapid motions : rapid displacement distance.

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o Cut discretization value : length of cut segments. o Surface Map operation discretization value : length of segments

discretized in 2D geometry map.

Compensation

Once you have configured a machine in Flex3D Tubes, the corresponding CP file is copied from the base. The name could be “PSFHKW02_1.CP1”.

The compensation value would be applied to the tube cutting.

To illustrate more clearly the result, I have set the compensation radius value as “15”. The result on the following hole is shown.

It shows that now the defined “compensation” value for Tube machine is now being applied to the cutting compensation and cutting path.

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Now I also show the whole tubes (hole, two extremes).

To move on to nesting, the result is also evident on the system compensation.

On the Material Thickness Dependent Data, the compensation data works in similar way.

Material/thickness dependent parameters dialogue

This dialogue enables you to establish the configuration of the cut parameters on the basis of the material used, as well as the thickness of the tube for the machine selected.

To do this, it presents a material/thickness list in which you can carry out a number of operations :

New : presents the cut parameters dialogue, which enables you to add a new configuration depending on the material and thickness selected.

Modify : initiates the cut parameters dialogue, which enables you to modify the cut parameters of the material/thickness pair selected.

Delete : deletes the material/thickness pair selected. Copy : makes a copy of the material/thickness pair selected. Order : puts the list in alphabetical order.

Note: The wild card character * indicates any material.

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c. System graphic configuration dialogue

This dialogue enables the following parameters to be configured:

Automatic orientation when WCS changed : when this option is active, each time you change the CS you automatically get a view of the model corresponding to the XY plane of the new CS.

Automatic view mode when changing module : this option changes from render mode to only 2D mode when you change from the box or tube module to the 2D drawing module.

Highlight current solid : in the box module this option enables you to highlight the face of the module you select in the box tree .

It also enables you to determine the colors for the different elements that may appear in the work area:

WCS and Grid color : working coordinate system and grid color if grid mode is active.

Highlight 2D color : color of 2D entities selected on any plane. 2D entities in XY plane color: color of 2D entities on active plane. 2D entities in other planes color : color of 2D entities on another plane that is not

the active one. Option color : color of 2D entities from which you have to select one. These

entities are the result of 2D operations in which two solutions are possible, as in the

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case of Segment or Straight line from parallel line and distance, Circumference from 2 points and radius and Modify edges.

Background color : work area background color. Background color for printing 2D special entities color : color of the 2D entities used in the tube module to carry

out surface map. Cut simulation color : if you use cutting technology. Mark simulation color : if you use marking technology. Highlight solid color : in the box module, color of the face of the model selected in

the box tree. Cutting head color Rapid color : in the tube module, color of the panning of the tool between different

cuts or marks. Drag punches color : in the box module, color of the punches and press punches

when dragged on the face of the model until their location is determined.

The default colors can also be restored.

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18. New (to go to Fabrication module) Use ‘New’ to allow access to all module. Then choose ‘Fabrication Order (OF module)’ . Here you could import the tube parts designed in this section of Design of Tube Part.

Fabrication Order (OF module) The user will base on project or customer order to create a Fabrication Order for tubes parts.

This could be consider the main work environment to gather all the relevant tube parts, and get them nested on the tube material and finally to generate the corresponding CNC program for the specific tube cutting machine.

First step is to select and then New or Open to proceed…

a. Start a new job b. Pick job from job list

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19. Import tubes part From the selection list, the user could pick the tube parts relevant for the current fabrication. The list of tube parts will be shown on the Part List for user to enquire for additional information.

See in Appendix A the first time usage

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20. Make nestings After a tube material (profile bases) is selected and displayed,

the system will do the automatic make nesting of tube parts of the whole Fabrication Order on the tube material.

Once the tube part is nested in the Fabrication Order, it could move on to Nesting for Tube Parts to can handle multiple types of tube-parts (with different profile bases).

Status of tube operations could be

The tube parts are nested

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Square tube type with its individual tube-part


21. Generate CNC ProgramThe CNC Program is generated for the specific tube cutting machine.

As the above step of make nesting is done, then move on to Nesting for Tube Parts module to generate the CNC (right mouse click on the nest-tube icon)…

After ensuring the machining is done via Cut Nesting , the save button will help to generate the CNC.

Notepad is a common software that can be used to open the generated CNC file.

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The operator will place the designated tube material correctly and then the cutter will follow the CNC instructions to machine on the tube material.

Note: when you open tube-nest from Fabrication Order, then when you close the window, the system will go back to Fabrication Order.

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22. Common Cut setting (default) and Non Common Cut setting

By default, the tube part has been set with common cut – that means there is no distance to the prior and subsequent tube parts in the nest.

On the Part List, with right mouse click will show a submenu, allowing user to choose the Common Cut settings.

The following setting means not using common cut and thus will apply the ‘offset between Parts’

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The result could be as shown below.

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23. Inverse and Rotate setting

While designing tube part, there are two configurable properties – ‘Rotatable’ and ‘Reversible’.

Then when in Tube Nesting, at Part List, there will be available the Rotation menu (when the tube part is defined as Rotatable and Reversible).

The definitions are as follow:Rotate = 180º about z axisInverse = 180º about x axis

Reverse or inverse means the same thing here.

An example given here to show difference in Automatic Nesting with Rotate/Revert settings and when the Rotate/Revert settings are unchecked (not used).

a. With Rotate/Revert settings

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b. Without Rotate/Revert settings

By right mouse click on the part tree, there is also an option to manually rotate or inverse a particular tube part in the nest.

The effect is only on that individual tube part.

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Nestings for tube parts The Nesting for tube parts could be considered a step in Fabrication Order or could also be used as a standalone function to do nesting and machine for a single tube type (Fabrication Order gives options for multiple tube types). The following will just describe the nesting and machining as part of the Fabrication Order process.

Note: There is a manual nesting option as well ( ) to move individual tube part up

and down the tree structure and then rebuild the nesting .

1. Machining of cut nesting

The user could proceed to generate the cutting tube operations via the Cut Nesting option

. Once the machining is done, the simulation options – simulate nesting cut option

and simulate cut head option – would be made available.

The reload tube parts option allows for the machining of tube parts to be removed so

that another machining could be done. If require, the automatic nesting option could also be done again.

Simulate Cut

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It allows the simulation the cut of the different geometries. We can go forward and backward.

In addition, we can choose the type of simulation.

2. Saving to generate CNC

As describe above in the Fabrication Order section, the save option will initiate the generation of the CNC program. I.e.

After ensuring the machining is done via Cut Nesting , the save button will help to generate the CNC. (refer to item 3 of Fabrication Order section).

3.Return to Fabrication Order

Note: when you open tube-nest (Nestings of tube parts ) from Fabrication Order, then

when you close the window , the system will go back to Fabrication Order.

Appendix 1 - First time usage (relevant steps)

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Start with Formats creation

Build the Bases

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Build the Profile bases inventory

Appendix 2 - Tutorial of a Tube module41


1.Creating a tube

First, we click on this button:

Image1.-Tubes module button

A side bar will be opened at the right of the screen. Then we click the first button of that bar, the “Create tube” button.It will appear a dialog like this:

Image 2.-“Create tube” dialog

We have to choose a reference name, a base tube, a machine and a length.

For example, in this case we don’t have any base tube selected, so we push the “…” button.

It will appear a dialog like this:

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Image 3.-Tube bases saved on the database at the moment

We are going to suppose that we do not have any base saved on the database. So we must create a new base. We click on the “New” button and it will appear a new dialog like this:

Image 4.-“New” tube base dialog

For this new base we will need:

-A reference name

-A format

-A material

We will suppose we have neither of them.

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First, we will choose the format. So we click the button “…” and a new dialog will appear:

Image 5.-Tube formats saved on the database at the moment

Once again, we will suppose we don’t have any format saved on our database. So we will create a new one. Then we click on “New” and this dialog will be shown:

Image 6.-Edit format dialog

On this window we can select between different types of tubes, rounded, squared, triangular… or we can create our own type drawing and selecting a 2D geometry and pushing the last button, the one that has a pencil on it.

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In our case we have chosen a rounded tube, selected its dimensions and write a name for it. Then we push “Save”. So we return to the last window. Now we can see that this format is now saved on the database.

So we have a format, then we’re going to select it. So we click “Select”.

We go back to this window:

Image 7.- “New” tube base dialog

We have no material, so we are going to create one. For that we select <new> from the “Material” combo box. It will appear a dialog like this:

Image 8.-New material

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We add a new material with the ID “Steel”. Select its parameters and then select it. So now, we have all that we need to create a profile base:

Image 9.-“New” tube base dialog

We select a reference name and then press “Ok”.

Image 10.- Tube bases saved on the database at the moment

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Now we have a base saved on the database. So we select it and then go back to this window:

Image 11.-“Create tube” dialog

Then we select a machine for cutting the tube, the length of the tube and a reference name for it. So we click “Ok”. This is the result:

Image 12.-A simple tube

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If you go to the operation tree, right click on the first item and then go to “Properties”, it will be open a dialog like this:

Image 13.-Tube properties

In this dialog we have a button with “CC” on it. This button is for selecting common cut options. This, and the “Rotatable” and “Reversible” check boxes, will be very useful later to make the nesting and optimize a base tube, if we want to let it.

For our example we have selected both check boxes and all the common cut options will be true. Then we save the tube on the database just clicking on “Save” button.

Now we are going to make a simple drilling operation on the tube. For that, we select the forth right side bar button. Select “Round drill”, diameter 7, 100 mm on “X Translation” and “Entire solid” on “Drill depth” button. Then we add the drill. Result is like this:

Image 14.-Round drill on tube

We have many options for cutting the tube, make drillings, chamfers, etc. In our case we save the tube again for later try the tube nesting.

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2. Nesting tubes

For making nesting for tubes first click “New” on the main window. Then click this button:

Image 18.-Nesting tubes module

A new right bar will appear. Now, we click on the first button of this bar: “Create Nesting Tube” button. It will appear a new dialog window like this:

Image 15.-A new tube nesting creation

On this dialog we have, as usual, to put a reference for the tube nesting we are going to create, select the machine to cut it and the base tube.

Here we have two options, create a new tube just for this nesting or select it from an inventory base. We are going to select this second option, so we click on “…” button. It will appear a dialog like this:

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Image 16.-Tube bases inventory

We suppose we do not want to use any of the profile bases stored on the database and we will create a new one. So we click on button “New”. A dialog like this will be shown:

Image 17.-Creating new tube bases in the inventory

We just have to fill three fields:

-Profile: Here we select the profile base we created at first for the tube.

-Length: This is the length of our base tube, from which the tube will be cut.

-Quantity: This is the number of tubes of that type and length that we have on the inventory.

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Then press “Ok” and “Select” our material from the inventory. Then press “Ok” again and our base tube will be shown:

Image 18.-A tube base for nesting

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The pink part symbolizes the rotatory axis. This is configurable for this nesting, on the last button of the right bar and for the machine, on the machine options.

Image 19.-Rotatory axis configuration for the piece

Image 20.-Rotatory axis configuration for the machine

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Now, we are going to import a part to nest. For that we click on the third button of the right bar. A window like this will be shown:

Image 21.-Import part to nesting

On this window, we can see the entire piece which has the same base as the base nesting and a graphical representation of them. For our case we select the only part we have, put 7 on the “Quantity” field and then click “+”. Then click “Ok”.

If we now click on the second button of the right bar we can see all the pieces we have to nesting, in our case:

Image 22.-Pieces for nesting

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On this window, if we make right double clicking we have useful information as tube properties, quantity, common cut properties and the possibility of delete or block the tube and a list view for the pieces.

If we click on the forth button of the right bar we can configure the offsets of the nesting.

Image 23.-Nesting configuration

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If we click on “Automatic nesting” button on the right bar we will obtain something like this:

Image 24.-A single tube nesting

A useful option for distinguish between tubes is to do on menu ToolsSystem settingsGraphicsMain viewer buttonSelect another color on “Part secondary”.

We can configure the order of the pieces manually using these buttons:

Image 25.-Buttons for putting in order the pieces

Using the first and the second one we can move the selected piece up or down through the tree until have the piece on the position we want to.

The third button is for rebuilding the nesting and so to see graphically the changes.

Save this and it will be stored on the database.

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Now, if you click on the “Cut nesting” button you will do this to the nesting. Then the button on the bottom of this one will be activated and clicking on it you could see the cutting simulation:

Image 26.-Cut simulation

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Suppose a more complicated nesting. Let’s create another tube of length 250 of the same base as first. Once we have the tube, we go to the operation tree and right click on the only icon and then click on “Properties”.

Then check both “Rotatable” and “Reversible” check boxes and on the graphical “Cutting extreme” icon a web start angle of 20. Also check all the options for common cutting.

Image 27.-Cutting the extreme of a tube

Then click on “Ok” and save all.

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Now create a new nesting as we did last time and on “Import part” dialog just select the two pieces with distinct quantities for them:

Image 28.-Importing parts for a tube nesting

Then press “Ok”. If we click on “Part list” button on the right bar we will see this:

Image 29.-A tube nesting part list

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Now we make the “Automating nesting” and this is the result:

Image 30.-A tube nesting with two kinds of tubes

As you can see, we have introduce 5 tubes with a hole at the first of the nesting and 3 tubes with a gradual cut and the nesting have placed it at the best position.

This is what would be happen if we would not check the gradually cut tube as rotatable and reversible and haven’t check the common cut options.

Image 31.-A tube nesting with two kinds of tubes without using common cut

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Appendix 3 - SAT file handlinga. The Tube Part could be saved as SAT file.

This allows user to keep a backup copy of the Tube Part.

b. The SAT file containing a Tube Part could also be imported into the software

The Body type should be ‘Tube’.

The file select window allows user to choose the required Tube Part SAT file.

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The Tube Part is loaded in its raw format as follow:

Then the next step is to analyse the Tube Part properties (using Select

Base Face option ).

The proper tube material thickness is then detected and thus able to recognise the tube properties.

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The end result is the loaded Tube Part – where all the machining could be achieved based all holes and the two extreme ends. Since the Tube Part was not created from scratch in the software (it is read in from SAT file), the operations information such as perforation and chamfer operations are not recorded or created.

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flex3d tubes manufacturing manual 081208

Documents

tube module

tube parts

tube toolbar

tube creation

tube materials

chamfer tube

limit tube

section tube