Task description Autocorrection program – Manufacture of a stamp

Create cutout stamp.

There are several conditions to be observed for automatic calculation of error-free milling paths (cutout paths) using TTrack . AutoCorrection:

• the graphic paths must consist of closed contours. Open sections are not allowed.
• the graphic paths may contain no errors such as crossovers or gaps.
• all graphic paths from one layer are always used for the calculation in AutoCorrection.

Create program.

Should there still be data of the last work in the program, then save these using File . Save or Save under. After this delete all the data memory using File . New.

Load data. Load the file AHSoft.SLD (or another suitable graphic) using File . Open.

Set working limits. Set your working area inLayout . Limits using measurements of X=40mm x Y=30mm.

Calculation of milling path.

Select the layer with the graphic data, here Layer 0. Select TTrack . Autocorrection . ACorr2D3D and select the setting according the figure Autocorrection 2D/3D.

Suggestion for a tool application in brass (MS58).

 Settings for Autocorrection 2D/3D.

Following the start of calculation you receive the milling paths for an embossed stamp (comp. Graphics).

Export milling data.

You can issue the milling paths calculated in Autocorrection directly without detours using TLayer Export. The program opens the export menu. Select for example, DIN/ISO here.

View DIN/ISO data.

You can view the saved DIN/ISO data using the Texteditor. For this select Extras . TextEdit. Select the generated DIN/ISO file and open it with OK.

There are several conditions to be observed for automatic calculation of error-free milling paths (cutout paths) using TTrack . AutoCorrection:

• the graphic paths must consist of closed contours. Open sections are not permitted.
• the graphic paths may contain no errors such as crossovers or gaps.
• all graphic paths from one layer are always used for the calculation in AutoCorrection.

Adjust program and create drawing. Should the data of the latest work still be in the program then save these. After this delete all data memory using  File . New.

Draw all required contours. The overall Mould depth is 4.5mm. The dashes of the numerals are to be kept at a height of 2.3mm above the base (2.2mm from above). The surrounding rectangle applies as base at the depth of 4.5mm. The Mould is to be generated at 30°.

Section through the Mould.

Calculate milling data.

First, the pocket is generated at a depth of 2.2mm (surface relief face for the dashes). After this the numerals in the area 2.2mm – 4.5mm are made available. Finally, the surrounding rectangle is re-milled.

Tools used

Generate pocket at a depth of 2.2mm. For the pocket, a rectangle offset outward at the angle and milling depth is required. For this, in the tool input, for example, for T1 and incised depth 4.5mm of the res. radius, 2.7mm can be selected. Less the tip radius of 0.1mm this results in a necessary offset of 2.6mm. It is sensible, for the last step of processing, to leave a small chip standing, in order that no step is visible in the shoulder through possible tool tolerances. For this an offset of 0.1mm is envisaged here. The rectangle is marked and copied into an empty layer using Layout . Copy in Layer. The offset outward in the target layer is calculated using operat. Contour offset. Offset: 2.5mm Direction: outward Calculation: mitre cut Contour: delete original The pocket is calculated in TTrack . Autocorrection . ACorr2D3D using the outward offset rectangle. Tool: W3 with incised depth 2.2mm Correction process: 2D+3D Clearance process: line-shaped, 0° Milling tracks: surface relief and recessed. The calculated milling paths are saved in a graphic layer (here layer#8) using TLayer > TargetLayer.

Cut out numerals. The numerals are to be embossed in the range from above 2.2mm down to a depth of 4.5mm. For this, the cutout calculation takes place initially as for a stamp with an incised depth of 2.3mm (= 4.5mm – 2.2mm). After this, the milling paths are offset downwards by a surface relief  offset of 2.2mm. The graphic on the relief surface is already available for the numerals. The rectangle must, however, still be converted. The rectangle is marked and copied into an empty graphics layer using Layout . Copy in Layer. The offset outward in the target layer is calculated using operat . Contour offset. Offset: 1.23mm Direction: outward calculation: mitre cut Contour: delete original The numerals are copied in using Layout . Copy from Layer. Using the graphic, the milling paths are calculated for 3 tools in TTrack . Autocorrection . ACorr2D3D. Tool: W1, W2, W3 with incised depth 2.3mm Correction process: 2D+3D Clearance process: line-shaped, 0° Milling tracks: surface relief + recessed. The milling paths in TLayer depths of cut are offset downwards with a surface relief depth of 2.2mm. The other settings remain unchanged. The calculated milling paths are saved in a graphics layer (here, for example, Layer#9) using TLayer > TargetLayer.

Re-mill rectangle. The rectangle is re-milled to the complete depth using 2 tools. For this the rectangle has yet to be converted to the final dimensions. The rectangle is marked and copied into an empty graphics layer using Layout . Copy in Layer. The offset is calculated outward in the target layer using operat . Contour offset. Offset: 2.6mm Direction: outward Calculation: mitre-cut Contour: delete original. With the graphic the milling paths are calculated for 2 tools in TTrack . Autocorrection . ACorr2D3D. Tool: W1, W2 with incised depth 4.5mm Correction process: 2D+3D Clearance process: no clearance track Milling tracks: surface relief and recessed.

Export milling data. The milling paths are exported using File . direct milland selection of layer #8, #9 and #10 (the layer with data which is not to be exported must be switched to “white”). Note: the milling paths (tool application, sequence, 3D graphic etc.) can be monitored using ExportAids.

There are several conditions to be observed for automatic calculation of error-free milling paths (cutout paths) using TTrack . AutoCorrection:

• the graphic paths must consist of closed contours. Open sections are not permitted.
• the graphic paths may contain no errors such as crossovers or gaps.
• all graphic paths from one layer are always used for the calculation in AutoCorrection.

Adjust program.

Before calculation the data should be appropriately available or must be reworked using the program functions. For a circular stamp it is sensible to place the processing zero point centrally. Adjustment takes place using Layout . Limits.

Note: An existing graphic (e.g. imported data) can be placed centrally very easily using centre frame and centre graphic.

Inserted graphic.

The imported graphic AK (from DXF) consists of a series of individual curve segments which have to be combined. This is a typical image for DXF data, which have been saved using lines and arcs. The import of DXF data is always to be viewed critically. Unfortunately DXF, as pure character format , takes no notice of possible processing. The graphic must be converted into closed contours using process . Combine tracks.

For join tracks, the setting close up to error = 0.000 mm is sensible for general work. This automatic process attempts, over several steps, to join line segments into closed contours. It is only when the data contains larger errors (crossovers, overlapping, gaps  > 10mm), that the process fails and the remaining paths must be joined manually. The paths can be joined in the menu edit  (join posn).

Font.

For a milling offset calculation an outline font is required. Outline fonts in HCAM../iSIGN+3D are all fonts, which begin with F.. or imported TrueType-/ Type1 fonts. Here the font F1000219.HZE(DIN1451 mean) has been used. This typeset has a very small surface relief width and is suitable for special marking stamps.

All paths to be jointly corrected in one layer. In Layer #0 we have saved all paths to be corrected jointly . The graphic for a stamp has been mirrored completely in the X – direction using Layout . Layout . mirror 2D.

Milling path calculation.

The milling paths are first calculated for a flat 3D stamp. The projection on the cylinder takes place later with data export. For the milling path calculation select one after another Layer #0 and TTrack . AutoCorr . ACorr2D3D. 3 tools were selected for the calculation: #50 (FrS = 0.02mm); #51 (FrS = 0.08mm); #52 (FrS = 0.2mm). The tools are loaded in ACorr2D3D . Tool-Block from the file CutoutTool.ToolWZB.

Tools: 1 = #50; 2 = #51; 3 = #52. Automatically adjusted with loading of the tools in Tool-Block . open.

Following the calculation the milling paths are presented in the tool colours. You can monitor the milling paths using TLayer MillGraphic . Graphic MillingTrack.

TLayer MillGraphic, overall picture.	Zoom ‘AK’. Only the finest tool (yellow) still reaches all contours.

In Zoom TLayer MillGraphic it can be seen clearly which parts are reached (processed) using the individual cutter radii:

Data export.

The milling paths calculated for a surface stamp can now be exported to the machine. There are 2 paths available for the data export:

• Direct export using AutoCorrection . TLayer Export (recommended). The direct export is recommended as subsequently only milling is still to be carried out.
• Saving in one layer and export via File . direct mill . Export. Further aids and combinations are available on the export using direct mill. Here, for example, additional recessed/embossed engravings can be saved in other layers. Export then takes place in layer sequence. In the example CircularStamp.SLD the milling paths are saved in Layer #8.

Return and select File . direct mill (or the aid direct mill auto in CAD). In the export selection the layers which are to be exported must be switched to colour, the layers not to be exported to white through clicking-on. In the example Layer #0 is clicked-on and is thus marked white (inactive). The other layers remain in their colours. With Export you obtain the export selection.