Happy CAMing with ZW3D: FIFA World Cup Trophy

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Happy CAMing with ZW3D: FIFA World Cup Trophy

Made of gold with a malachite base, the FIFA world cup trophy was the most shining attraction in this summer. Though the 2018 World Cup was over, our passion for soccer never ends. As a soccer fan and engineer, let’s learn the FIFA World Cup programming to enjoy the fun of programming and soccer.

Figure1 FIFA World Cup_副本.png

Figure 1   World Cup

This article will focus on 5 Axis finishing processes after finishing rough machining.  

Step1: Create the 5axis semi-finishing process by 5X Sidecut command, take the part as a feature, and define a cutter as D4R2, as shown in Figure 2.

Figure 2   Create a 5X Semi-finishing Operation_副本.png

Figure 2   Create a 5X Semi-finishing Operation

Step2: Set key parameters. 

Primary Parameters: Set Surface thick to 0.1mm and Max Cut Depth to 1mm.

Axis Control Parameters: Set Guide Type to Cylinder, and set Guide Rule Guide Normal, as shown in the following figure.

Figure3   Set Key Parameters_副本_副本.png

Figure3   Set Key Parameters

Step3: After the parameters definition, we can directly calculate the operation to generate the tool path. The result is as follows.  

Figure4   Semi-finishing Tool Path_副本.png

Figure 4   Semi-finishing Tool Path

Step4: Duplicate the semi-finishing operation to create the 5X Sidecut finishing process.

Figure5   Create a 5X Finishing Operation by Duplication.png

Figure 5   Create a 5X Finishing Operation by Duplication

Step5: Just modify one primary parameter, set Surface Thick to 0, and then calculate finishing operation.

Figure6   Finishing Tool Path_副本.png

Figure 6   Finishing Tool Path

Step6: Next, let's carve a few words (start's name or team name) on this cup. Back to CAD level then draw a sketch, such as "ZW3D". Then wrap the curves to the surface to get the following result.

Figure 7   Wrap Curves_副本.png

Figure 7   Wrap Curves

Step7: In ZW3D, we could use the 5X Drive Curve operation to engrave these words. Add part as one feature, and then select curves as profile feature with Part type, as shown in the image below. Define tool as D1.

Figure 8   Define 5X Drive Curve Operation.png

Figure 8   Define 5X Drive Curve Operation

Step8: Turn off Lead-In and Lead-Out. Set other parameters to default. The tool path is shown below.

Figure 9   Tool Path of Lettering_副本.png

Figure 9   Tool Path of Lettering

Step9: Let's simulate the whole process by Solid Verify command.

Figure 10   Solid Verify_副本.png

Figure 10   Solid Verify