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This is an extract of the full manual, which is over 55 pages, full colour, and bound. Visit or call REA today: www.f1inschools.org.au/go/FastTrack 1300 554 503
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Contents
1. 2. Acknowledgements and copyright notice ................................................................................................................ 2 Introduction to this tutorial as a fast-track to CATIA V5 ........................................................................................... 3 2.1. 2.2. 2.3. 2.4. 3. Tutorial plan ...................................................................................................................................................... 4 Checklist of requirements to complete the tutorial ......................................................................................... 5 Conventions used in this tutorial ...................................................................................................................... 5 Options for self-help and further learning ........................................................................................................ 6
3.2. 4.
Design using CATIA V5 ............................................................................................................................................ 11 4.2. 4.3. 4.4. CATIA V5 workbenches ................................................................................................................................... 13 The REA Fast-Track product ............................................................................................................................ 15
Fast-Track Maths Boost-Quiz | Cartesian coordinate system ................................................................................ 17 4.5. 5. Practise using Imagine and Shape................................................................................................................... 19
Modify the REA Fast-Track Car (Courtesy Team NASA) .......................................................................................... 25 5.1. Redesign the side pods ................................................................................................................................... 30
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Method A: Indent the side pods vertically .............................................................................................................. 31 Method B: Split the side-pods horizontally ............................................................................................................ 33 Redesign the front aerofoil ............................................................................................................................. 35
5.2.
Method A: Sharp and thin front aerofoil ................................................................................................................ 36 Method B: Beam-breaker ....................................................................................................................................... 38 5.3. Reshape the rear aerofoil ............................................................................................................................... 39
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Extension Exercise 1: Designing an Imagine and Shape Car from Nothing ............................................................ 53
Re-Engineering Australia Foundation Ltd. Level 9, 423 Pennant Hills Road, Pennant Hills NSW 2120 Australia.
Fast-Track to CATIA V5, REA, Re-Engineering Australia, Zero to Collaboration in Seconds!, REA-ssure, the Re-Engineering Australia Foundation Logo, and other associated logos are trademarks of Re-Engineering Australia Foundation Ltd. All rights reserved.
F1 in Schools: F1 in Schools, F1iS, Formula 1 in Schools, the F1 in Schools challenge, and the associated logos are trademarks of F1 in Schools.
Formula 1: F1, Formula 1, Formula One, and the associated logos are trademarks of Formula One Licensing BV. CATIA V5: CATIA V5, CATIA, CATIA User Companion, Dassault Systmes, DS Campus, and the associated logos are trademarks of
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Dassault Systmes.
Reproduction
This document may not be reproduced, in part or in whole, without prior approval of Re-Engineering Australia Foundation Ltd. This includes, but is not limited to, class reproduction of the tutorial in schools.
Acknowledgements Acknowledgements and thanks are extended to Team N.A.S.A. (2008) of Noosa District State High School, Qld, Australia for contributing their design modelling to the Fast-Track Car design.
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This document, all its contents (including images, text, procedures) are copyright 2009, Re-Engineering Australia Foundation Ltd.
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In this course, the trainee will redesign a basic model so to create their own unique car. The trainee will then be guided through self-evaluation and quality assurance, before finally preparing their design for possible machining on a computer numerical controlled (CNC) router.
of the car. This way, in a class setting, all trainees will create their car, rather than being guided to create the same car many times.
The course is oriented with manufacturing in mind, just as professional designers must consider. The trainee is always thinking ahead to any manufacturing constraints or freedoms. The trainee is taught to envisage the car within the limitations of the balsa wood blank, and methods employed in manufacturing. Any CNC router with
The skills taught in this course are not limited to F1 in Schools, and the trainee should use the skills learned as building blocks to continued knowledge of the CATIA V5 design system, and all CAD systems generally. This course
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is an introductory guide, and several extension-exercises are available. Additionally, to learn more about CATIA V5 see Re-Engineering Australias CATIA V5 Instruction Guide for F1 in Schools.
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compatible machining capabilities could be used, however Re-Engineering Australia recommends, and this tutorial
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Throughout the course, the trainee is guided to express innovation and ingenuity by prompts to create a unique part
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trainees should feel confident that they can begin working on Re-Engineering Australias CATIA V5 Instruction Guide
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Introduction to Computer Aided Design and CATIA V5s interface. Introduction to how the REA Fast-Track Car is designed.
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Modify the car to a custom shape. Step-by-step examples are given at each stage; although The trainee is encouraged to use their imagination.
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RACE CAR
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Use CNC router
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Wheels
Product Tree
Status Bar
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CATIA V5 Start Menu: Where you can change the active workbench and toolbar set Menu Bar: all operations can be accessed through the menu bar, but its often faster by clicking on a toolbar Working space: this blue area is where you can work on the part or product open Compass: defines the 3 axis that the geometry is located on (3 Dimensional Part = 3 Axis compass) Side, Bottom and Floating Toolbars: these items will change depending on the active workbench, and they contain all the needed tools to work on the part. In the tutorial, the icon will be included with the in-text reference to help identify the icon. Status Bar: often shows a helpful hint as to what you need to do next Product Tree: contains all the geometry you see on screen. This tree is how CATIA V5 structures your data. It will contain all the open products, parts, processes, drawings etc. You can expand the tree to show every line, point and face if you want (but it will become very long) o The Product Tree represents all the actions that have been applied to the model. CATIA V5 maintains these actions, and you can return to previous actions and redefine them. This is a very powerful feature of CATIA V5. Be aware that if you change actions and items in the middle of the product tree, all the actions and items below that change, and that reference that change may behave differently. Anytime that the product tree is edited, all items between the edit and the bottom of the tree are updated to take the edit into account. Sometimes, this will result in warnings when an action is no longer possible (perhaps you deleted a surface that was used later), and other times it might result in different or unexpected results.
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Bottom Toolbars
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Compass Side Toolbars
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4.3.
Rear aerofoil
Balsa Block
Car body
Engine chamber
4 Wheels
Side pods
The Axles: Located at the front and rear of the car, these axles locate the wheels. The Axle grommets: these four grommets push into each axle hole at the front and rear, and these are what the axles actually touch. If the axles were to be running on the balsa wood, they would have high friction and the car may not run as fast as possible. The Wheels: these four REA standard wheels push onto the axles. The wheel design matches the wheels that are supplied by Re-Engineering Australia that will be used on the car. The REA Fast-Track Car: The car body is made up of several surfaces and includes: o o o o Side Pods: the protruding sides of the car, which are required by the rules and regulations; Front aerofoil: the front wing, which has to be within width, depth and height rules and regulations; Rear aerofoil: similarly to the front wing, has to be within regulations, often is used to provide lift to the rear of the car; Engine chamber: the body that surrounds the CO2 cartridge, where the power to propel the car down the track comes from.
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The Balsa Block: represents the balsa wood block that the car will be machined from, at the end of the tutorial. All cars must be made from a single block of balsa wood, of a size and specification within the rules and regulations. The Balsa Block part conforms to these rules , and is identical to the block that can be purchased from Re-Engineering Australia. Note that it includes a groove under the car, and it includes the CO2 chamber hole at the rear of the car, where the CO2 gas cylinder will be located. This means these two features are fixed and cannot be changed.
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2 Axles
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Front aerofoil Page 15
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Machining Fixture
4 Axle Grommets
4.4.
CATIA V5 operates in 3-dimensional space. In order to properly define the 3D objects within the infinite 3D space, an origin is selected. Once this global origin is defined (in the CATIA V5 part), all other points are referenced from this origin. CATIA V5, along with other 3D CAD suites, uses a 3-axis coordinate system, defining width, depth, and height. This is known as the Cartesian coordinate system, and is globally used as the +z +y
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+z B O +y A +x
most common method of defining objects in 2D or 3D space. The Cartesian coordinate system
defines the three axes as x, y, and z. Typically, x is length, y is depth, and z is height. The axes intersect at the origin.
+x
Any point is defined as the distance from the origin, with respect to the 3 axes, and is presented as (x, y, z). For example:
The origin O is (0, 0, 0), since it is 0 units along the x, y, and the z axis; A point A is (3, 1, 2), since it is 3 units along x, 1 units along y, and 2 units
A point B is (-2, 5, -1), since it is -2 units along x, 5 units along y, and -1 units along the z axis.
Note that point B is actually lower than O in space (it is -1 units along z), but it appears higher in the representation below. This is because its impossible to accurately represent 3D space on the 2D page. Follow the dotted lines with your eye, and you will see that point B is negatively along 2 x units, positively along 5 y units and negatively along 1 z
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units.
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Open the Balsa Block in a new window. In the product tree, right-click REA Fast-Track BalsaBlock, select BalsaBlock Object, select Open in New Window
Notice that the balsa block has oriented itself to the standard axes. The compass shows the positive x, y, and z
Determine the length of the Balsa Block along the x-axis. Click the measure tool
In the measure dialogue box, ensure that Measure Between icon is selected
What is the length of the Balsa Block? Find out under the x-component in the measure between dialogue box! It should be 223mm.
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Length (x-axis)
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Click the back edge of the balsa black, and click the front edge.
Measure Between
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Compass x-axis component Measure tool
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Click the point at the origin, and then click point A. The measure between dialogue box will indicate the distance from the origin, and it will be shown in terms of (x, y, z) already!
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All components
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A has only two components other than 0. It looks like (0, __, __). B has three components and no components are 0; all three are positive! It looks like (__, __, __). C also has three components and no components are 0! It looks like (__, __, __).
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Measure tool
c)
Repeat clicking the origin point, and then finding the location of B and C, and record the coordinates.
This method, of defining points from the balsa block origin, is exactly how the car is machined from the real balsa block in the router. Its important that you get your head around how the origin of the balsa block is the centre of the CO2 cartridge hole... and more importantly that the origin of the balsa block defines the origin of the entire machining operation, later!
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Note!
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The Fast-Track to CATIA V5 training car will be shown in the CATIA V5 working space,
inside a semi-transparent block. The wheels that are attached to the car are a part of the standard REA Wheel set. The semi-transparent block represents the balsa wood block which the car is machined from. Step 2:
To get a better look at the car, hide the balsa block and fixture.
a) b) c)
In the product tree, find REA Fast-Track BalsaBlock Right-click on the balsa block, select Hide/Show
Look around the design and examine the wheel systems. A reminder of the CATIA V5 display controls:
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Pan view
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Rotate view Zoom view
or
or
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1. Hold mid-mouse button 2. Click left-mouse button (but do not hold) 3. Move the mouse up/down to zoom .
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1. Hold mid-mouse button 2. Hold left-mouse button 3. Move the mouse to rotate the screen.
Remember that the view can be reset to show the car at a standard zoom by selecting fit all in
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Also notice that the Imagine and Shape Tools Palette has opened, which includes the tools you need to change the shape of the side pods. The previous section outlines each of these tools and how to use them.
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Tip!
Hourglass Indent (Method A)
Modify the shape of the side pod to your choice. A couple of examples are shown for inspiration, one indenting the sides, the other splitting it horizontally.
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Important!
This tutorial is designed to guide you through the modification of the REA Fast-Track Car. At each stage, including this step of redesigning the side pods, the tutorial includes two different methods, with step-by-step guides to help you create one of the designs below. > Depending on your confidence, you may choose to: ignore the choices below; attempt one of the methods on your own; or work through the following pages, after choosing either Method A or Method B (Chisel Split) (Method B)
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Regularly unhide the balsa blank (in the Product Tree, Right-click BalsaBlock..., and choose Hide/Show).
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Remember to always work within the boundaries of the balsa blank, and the rules of the F1 in Schools challenge.
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Method A: Indent the side pods vertically You may choose to indent the shape of the side pods. This design shows some sleek curves along the sides of the car, forming an hour-glass effect when the car is viewed from the top. Step 1: a) b) c) d) Use the rotate tool, and rotate the four centre faces about the X-axis about 45. Rotate the screen, and zoom in slightly so the right side pod is easily visible On the Imagine and Shape Tool Palette, select Rotatation Select the Face filter Click the first face, then holding Ctrl, click the other three faces Note that the selected faces are bordered red, and the face the mouse is hovering over is bordered orange. The current selection is orange, and the active selection is red. e)
On the compass, find the arc leading from Z to Y this is the arc that is rotating about the X-axis
Compass Arc
f)
Click-and-hold on that arc, and drag the mouse around the circle towards the car body, about 45, then release the mouse
Step 2:
Use the translate tool, and move the two centre vertical lines into the car body.
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a)
On the Tool Palette, select Translation Select the Line Filter Click the first line, then holding Ctrl, click the second line Note the compass has assumed a relative rotation to the face you are working with.
Z-axis
b) c)
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Rotate tool
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Faces
Face filter
Lines
d)
Reset the compass to a standard position by clicking Reset Compass on the Tool Palette
e)
On the compass, click-and-hold on the Z-axis and drag the mouse into the body, about half-way to the middle
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Completed
Tip!
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After reviewing the design changes, it is easy to make further modifications! Re-open the surface for further modification by double-clicking Body surface in the product tree.
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Line selection Z-axis Faces
Line filter
On the compass, click-and-hold the Z-axis and drag the mouse into the body, about two-thirds to the middle
Step 2:
Use the translate tool, and move the four middle faces outwards of the body.
a) b) c)
Click the first face, then holding Ctrl, click the next three faces
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d)
On the compass, click-and-hold on the Z-axis, and drag the mouse out of the body enhancing the split side pod
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Z-axis
Step 3:
Escape from the surface modifier and review the design changes.
Tip!
After reviewing the design changes, it is easy to make further modifications! Re-open the surface for further modification by double-clicking Body surface in the product tree.
1. Press ESC (on the keyboard) twice to escape the surface modifier Step 4: a) Show the Balsa Blank. In the Product Tree, find BalsaBlock...
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If the cars side pods protrude outside of the balsa block, then the car will be impossible to machine. Using the CATIA V5 display tools (such as rotate), check if the side pods are protruding out of the semi-transparent balsa block. Step 5: a) b) c) If the car protrudes out of the Balsa Blank: Double-click Body Surface to re-enter the surface editor Re-select the translation tool and face filter
Protruding face
Select the four protruding faces, and move them into the body until they do not protrude (along the Z-axis)
d)
When the faces do not protrude out of the Balsa Blank, press ESC twice to escape the surface modifier
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e)
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(Original)
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Lift (Method A) Sweeping (Method B)
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This area is inaccessible from the side of the car, and is not machinable.
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Warning!
The conventional method of generating a pressure difference involves creating the well-known aerofoil crosssectional tear-drop shape. The distinct requirements of the aerofoil include: Rounded front lip; Near-flat under-side; Rounded top-side; and Sharp trailing edge.
Typical Aerofoil These features result in airflow being split above and below the wing. Due to principals of conservation of mass, the body of air must move uniformly around the aerofoil (the air particles must rejoin the flow with the same particles that they were split from). Due to the shape of the upper surface, and the face that the air particles must rejoin with the same particles they split from, the air must travel a longer distance than the under-side, and consequently the air above the wing must flow faster.
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A different approach to generating lift involves using the wing with a positive angle of attack. This can be related to a conventional ceiling fan. While a ceiling fan spins, it pushes air downwards due to the angle of the fans blades. The same concept can be applied to aerofoils, where the wing would be angled downwards, and as the wing moved through the air, a thrust force would be exerted downwards, and the equal-andopposite lift force would result. Of the following wings, select the wing that would be best for: 1. Generating lift 2. Generating down-force
At this point, Bernoullis Principle shows that a difference in airflow speeds results in a difference in pressures between the two faces of the wing. The different in pressure creates an aerodynamic force upwards. It is this force that pulls the wings upwards lift!
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WING B
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Positive Angle of Attack WING C
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WING A
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The use of aerofoils to generate lift forces has been successfully used and extensively documented for several centuries. There are two distinct methods of using aerofoils to generate lift: creating a pressure difference between the lower and upper faces of an aerofoil; or angling the aerofoil at a positive angle of attack towards the air flow, which generates downwards thrust.
CATIA V5 is not just a Computer Aided Design software package, but rather a Computer Aided Design, Manufacturing and Engineering suite. Now the Fast-Track car has been redesigned, its time to physically machine the car from real balsa wood.
CATIA V5 should have been installed correctly on the computer youre using, however because CATIA V5 will soon be creating code to physically machine the car, its very important to ensure that the installation of CATIA V5 on your computer is correctly set up to be compatible with the CNC Router to be used. Step 1: a) Save all open CATIA V5 documents.
If the REA Fast-Track product is currently open from earlier in the tutorial, then click File and select Save In the Save Management dialogue box, notice that all open files are listed (including the product, car, wheels, axles, axle grommets, etc).
b) c)
Click the row with name REA Fast-Track product.CATProduct Check that the location is your working directory If location is not your working directory, click Save-As, then save in your working directory.
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d) e) f)
Click Save
Click Propagate directory... Click OK CATIA V5 will save all the open documents in your working directory.
g) Step 2: a)
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Click File, select Close until you see the Star/Cosmos background of CATIA V5 Open the REA Fast-Track Machining process On the CATIA V5 menu bar, click File, Select Open
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Management
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d) Step 3:
a)
b) c) d)
Select Machining Select the Output tab Under Post Processor and Controller Emulation Folder, ensure that Cenit is selected
e)
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Working directory PPPAR folder Generate NC Code in Batch Mode
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ENSURE you select the folder above the PPPAR folder. You must select the parent folder of PPPAR.
f)
Click OK
g)
Scroll the options window down, and check that under Tool Path Files, NC Code output and NC Documentation Location, that Extention: NC Click OK to save the options
h) Step 4: a)
Generate the NC code for the router. Under the NC Machining Tools toolbar, select Generate NC Code in Batch Mode
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Scroll down
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Match these values, then go to next tab
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Select CARPOST.PPPAR Click Execute, then wait for the command screen to finish creating the NC code
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Select None, then go to next tab
Follow the REAssure instructions to check the new NC code generated in the previous step
Instead of using CATIA V5 to generate the NC code for the manufacturing process, its also possible to use QuickCAM. This is software developed by Denford (who also manufacture the microrouters available from Re-
A guide to using QuickCAM for the F1 in Schools program is available from Re-Engineering Australia, and through the REA Supportal (rea.webexone.com).
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Engineering Australia).
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