I think you are really minimizing the cost of 3R tooling. Hideously expensive is the understatement of the week!!
But it's darn repeatable and fun to work with if you can swallow the price.
But back to the question at hand. This could be completed with either sinker or wire EDM. You would...
If the material is exhibiting a cold creep condition it may be changing shape after the machining process. Talk to a materials specialist and they may be able to describe this condition to you.
I would think you could post it in Catia and just look at the code. It has to be in the correct format. Therefore just copy it and modify and use as necessary.
Another way to accomplish this is to have a program written to make a 1 inch helix. Use cutter comp to comp your tool on. You can...
You are assuming that if you calculate the Hertzian stress and then back that out to a torque value for the clamp that the ham fisted operator will torque the clamp to your spec's.
Why not just add a soft copper shim between the round bar and the v-block? The copper will deflect and the round...
Google "tapping titanium"
There is a boat load of info out there......
Also, consult your favorite local tooling rep. There are some amazing taps out there for this material.
You are looking for additional relief in the flute compared to a 'regular' tap. You WILL pay extra for taps specific...
Well, in that case I can't help you a bit....
But, here's something to think about. Is UG primarily a CAD package or a CAM package???
Me thinks its a CAD package. That being said, the functionality of any CAM add on should be an interesting proposition indeed.
Good Luck!!!
Are you using a CAM software package?? Many CAM programs have some feature that will accomplish this for you.
If you are writing your own code by hand you could do something like this:
G1X8.F200.
G1X8.5F40.
G3X9.0Y0.5I8.5Y0.5F40.
G1Y1.0F40.
G1Y8.0F200.
G1Y8.5F40.
G2X8.5Y9.0I8.5J8.5F40...
Here is the link to the Siemens 840D retrofit. I think this may be what you are looking for. They are claiming to be able to run up to 248 axes with this controller.