Working with the Heat Map (Geometry Analysis)
You can direct aPriori to display your part in the Component Viewer in the form of a heat map. Each of the part’s GCDs is filled in with a color that indicates the value range, for the GCD, of a specified metric.
To enable the heat map, click the Geometry Analysis tool,
, in the Component Viewer tool bar. Your part is displayed as a heat map, and the Geometry Analysis bar graph appears.
, in the Component Viewer tool bar. Your part is displayed as a heat map, and the Geometry Analysis bar graph appears.
The bar graph includes a dropdown menu, labelled Criterion, which lists the heat map metrics. If you select, for example, the metric General Area Removal Rate, each GCD in the heat map is filled in with a color that indicates the rate of removal for finishing operations assigned to that GCD. If more than one finishing operation is assigned to the GCD, the color indicates the average rate across operations. Warmer colors (like orange and red) indicate higher values; cooler colors (like green and blue) indicate lower values.
Note: The Design to Cost tool for presents the same types of machinability issues as the Heat Map, but in a format that is more user-friendly for casual users who are not experts in machining. See the aPriori User Guide for more information.
Following are some of the heat map metrics (see the aPriori User Guide for a complete list of metrics, as well as information on configuring the Heat Map):
• General Area Removal Rate: rate at which the finishing operation for the indicated GCD removes material from the GCD’s surface, in unit area per unit time. Removal rate depends on feed, speed, tool diameter, and contact width. Cycle time increases as removal rate decreases—see Operation Cycle Time and Cut Time Calculations.
If the heat map indicates that removal rate for a GCD or group of GCDs is lower than you think it should be, consider making one or more of the following adjustments:
o Increase speed for the GCD(s). See Requested Tool Cutting Speed in Surface Finishing Milling Options.
o Modify the tool diameter. A larger tool diameter can increase removal rate, but it can also decrease corner accessibility, rendering certain operations infeasible. A smaller tool diameter can sometimes make a more efficient operation feasible. See Requested Tool Diameter in Surface Finishing Milling Options.
o Modify operation assignment, either by directly assigning an operation to the GCD(s), or else by modifying setups or thresholds. See Modifying Machining Operation Assignments.
• General Volume Removal Rate: rate at which the hole-making operation for the indicated GCD removes material from the part, in unit volume per unit time. Removal rate depends on feed and speed. Cycle time increases as removal rate decreases. If the heat map indicates that removal rate for a GCD or group of GCDs is lower than you think it should be, consider increasing feed or speed. See Requested Feed per Tooth and Requested Tool Cutting Speed in Surface Finishing Milling Options.
• Contouring Removal Rate: rate at which the contouring operation for the indicated GCD removes material from the GCD’s surface, in unit area per unit time. Removal rate depends on feed, speed, tool diameter, and contact width. Cycle time increases as removal rate decreases—see Operation Cycle Time and Cut Time Calculations.
If the heat map indicates that removal rate for a GCD or group of GCDs is lower than you think it should be, consider making one or more of the following adjustments:
o Increase speed for the GCD(s). See Requested Tool Cutting Speed in Surface Finishing Milling Options.
o Modify the tool diameter. A larger tool diameter can increase removal rate, but it can also decrease corner accessibility, rendering certain operations infeasible. A smaller tool diameter can sometimes make a more efficient operation feasible. See Requested Tool Diameter in Surface Finishing Milling Options.
o Modify operation assignment, either by directly assigning an operation to the GCD(s), or else by modifying setups or thresholds. See Modifying Machining Operation Assignments.
• Side Mill Area Removal Rate: rate at which the side milling operation for the indicated GCD removes material from the GCD’s surface, in unit area per unit time. Removal rate depends on feed, speed, tool diameter, and contact width. Cycle time increases as removal rate decreases—see Operation Cycle Time and Cut Time Calculations.
If the heat map indicates that removal rate for a GCD or group of GCDs is lower than you think it should be, consider making one or more of the following adjustments:
o Increase speed for the GCD(s). See Requested Tool Cutting Speed in Surface Finishing Milling Options.
o Modify the tool diameter. A larger tool diameter can increase removal rate, but it can also decrease corner accessibility, rendering certain operations infeasible. A smaller tool diameter can sometimes make a more efficient operation feasible. See Requested Tool Diameter in Surface Finishing Milling Options.
o Modify operation assignment, either by directly assigning an operation to the GCD(s), or else by modifying setups or thresholds. See Modifying Machining Operation Assignments.
• Side Mill Length to Diameter Ratio: Tool length divided tool diameter. This ratio affects side-milling feasibility. See Working with Features to Review.
If side milling would be appropriate, but the heat map indicates that this value is too small for side milling, check the PSO information entries to see if this caused side milling to be infeasible. If so, you can assign side milling either explicitly or by changing thresholds or setup axes. See Easy Side Milling Length to Diameter Ratio and Maximum Side Milling Length to Diameter Ratio in Machining Node Process Setup Options.
• Facing Area Removal Rate: rate at which the facing operation for the indicated GCD removes material from the GCD’s surface, in unit area per unit time. Removal rate depends on feed, speed, tool diameter, tool path, and contact width. Cycle time increases as removal rate decreases—see Operation Cycle Time and Cut Time Calculations.
If the heat map indicates that removal rate for a GCD or group of GCDs is lower than you think it should be, consider making one or more of the following adjustments:
o Increase speed for the GCD(s). See Requested Tool Cutting Speed in Surface Finishing Milling Options.
o Modify the tool diameter. A larger tool diameter can increase removal rate, but it can also decrease corner accessibility, rendering certain operations infeasible. A smaller tool diameter can sometimes make a more efficient operation feasible. See Requested Tool Diameter in Surface Finishing Milling Options.
o Modify operation assignment, either by directly assigning an operation to the GCD(s), or else by modifying setups or thresholds. See Modifying Machining Operation Assignments.
• Time Tool Machines Air: percentage of engagement time that is non-chipmaking time, that is, percentage of time during which the tool is engaged (spinning) that the tool is not in contact with the GCD surface (see Operation Cycle Time and Cut Time Calculations). If the heat map indicates that this metric is too high, consider reducing tool diameter—see Requested Tool Diameter in Surface Finishing Milling Options.
• Cutting Speed Reduction Factor: percentage by which the recommended speed is reduced due to limitations of the current machine. aPriori reduces the speed used for calculating removal rate, when aPriori’s recommended speed exceeds the machine’s speed capabilities. If the heat map indicates that the reduction factor is high, consider explicitly selecting a machine that supports higher speeds.
• Cycle Time: time to perform the assigned operation on the indicated GCD. If the heat map indicates that the cycle time is high, examine other metrics for the indicated GCD, such as removal rate and tool diameter, or consider modifying operation assignment.
• Surface Finishing Tool Diameter: diameter of the tool selected for the assigned operation on the indicated GCD. If the heat map indicates that this value is too small for a GCD or group of GCDs, consider increasing tool diameter, either directly with a process setup option (See Requested Tool Diameter in Machining Node Process Setup Options) or indirectly by activating a setup that provides a better angle on the GCDs corners.
• The heat map also contains an item, Features to Review, which applies to features that have been assigned to Features to Review or General Mill Finishing. See Working with Features to Review.