mat_mt11050_g

Multi-Axis Techniques

Student GuideMay 2007

MT11050 — NX 5

Publication Numbermt11050_g NX 5

Proprietary and restricted rights notice

This software and related documentation are proprietary to UGS Corp.

Copyright 2007 UGS Corp. All Rights Reserved.

All trademarks belong to their respective holders.

2 Multi-Axis Techniques — Student Guide mt11050_g NX 5

Contents

Course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Course description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Student responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Class standard for NX parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Class part naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Seed part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Workbook overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Classroom system information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Student and workbook parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

WAVE Geometry Linker in Manufacturing . . . . . . . . . . . . . . . . . . . . 1-1

The WAVE Geometry Linker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Geometry types used by the Geometry Linker . . . . . . . . . . . . . . . 1-4Edit links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Broken links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Delete parent geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Delete linked geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Activity: Create an assembly for WAVE . . . . . . . . . . . . . . . . . . . 1-10Link procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13Activity: Create WAVE geometry . . . . . . . . . . . . . . . . . . . . . . . . 1-14Simplify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Simplify Body procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17Activity: Simplify Body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18Activity: Other modeling techniques . . . . . . . . . . . . . . . . . . . . . 1-20

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24

Advanced Cavity Milling topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cut Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Activity: Cut Levels parameters . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Cut patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Activity: Zig-Zag cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

In-Process Work Piece for Cavity Milling . . . . . . . . . . . . . . . . . . . . . . . 2-11Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide 3

Contents

Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Activity: Level Based In-process Workpiece (IPW) . . . . . . . . . . . 2-14Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-18Activity: Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . . . . . . . 2-19Cavity Milling stock options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22Activity: Blank Distance option . . . . . . . . . . . . . . . . . . . . . . . . . 2-23

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Activity: Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Steep Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Activity: ZLEVEL_PROFILE_STEEP Operations . . . . . . . . . . . . . . . . . . 3-9Activity: Z-Level Profile Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13Z-Level Cutting Between Levels (aka Gap Machining) . . . . . . . . . . . . . 3-17Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fixed Contour overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2More on Flow Cut drive methods . . . . . . . . . . . . . . . . . . . . . . . . . 4-6Activity: Create Fixed Contour operations . . . . . . . . . . . . . . . . . . 4-9Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Activity: Mill Area geometry groups . . . . . . . . . . . . . . . . . . . . . 4-16Trim Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20Activity: Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Introduction to four and five axis machining . . . . . . . . . . . . . . . . . 5-1

Multi-Axis Machining concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Activity: Operations at other than 0,0,1 tool axis . . . . . . . . . . . . . 5-4

Define the center of rotation for a rotary axis . . . . . . . . . . . . . . . . . . . . 5-10Activity: Main and local MCS in multi-axis applications . . . . . . 5-12Activity: Main and local MCS in multi-axis applications . . . . . . 5-17

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

Five Axis Z Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Z Level Five Axis Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Tool Axis tilt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Activity: Creating a Z Level Five Axis operation . . . . . . . . . . . . . 6-7Activity: Changing the Maximum Wall Height . . . . . . . . . . . . . . . 6-9More Tool Axis tilt options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Activity: Away from point tool axis tilt . . . . . . . . . . . . . . . . . . . . 6-12Activity: Away from curve tool axis tilt . . . . . . . . . . . . . . . . . . . 6-15Activity: Away from multiple curve tool axis tilt . . . . . . . . . . . . . 6-18

4 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

Contents

Optimized cut levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21Activity: Optimized cut levels . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25

Sequential Mill basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Sequential Milling overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3Sequential Milling terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4Define the Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11Multiple Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

Activity: Basic Sequential Milling techniques . . . . . . . . . . . . . . 7-14More on Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27Activity: Sequential Milling of a multi-surfaced floor . . . . . . . . . 7-28

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Sequential Mill advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Tool axis control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Activity: Sequential Mill Five-Axis fan motion . . . . . . . . . . . . . . . 8-8Standard and nested loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-17Activity: Sequential Mill – using loops . . . . . . . . . . . . . . . . . . . . 8-18Activity: Remove excess stock from a closed wall . . . . . . . . . . . . 8-21Activity: Use looping to remove excess stock . . . . . . . . . . . . . . . 8-28Additional Sequential Mill options . . . . . . . . . . . . . . . . . . . . . . . 8-30

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-34

Variable Contour – basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3Terminology used in variable contour . . . . . . . . . . . . . . . . . . . . . . 9-5Variable Contour vs Fixed Contour . . . . . . . . . . . . . . . . . . . . . . . 9-6Drive methods for Variable Contouring . . . . . . . . . . . . . . . . . . . . 9-7Activity: Overview of Variable Contour options . . . . . . . . . . . . . 9-12Tool axis control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15Activity: Point and Line tool axis types . . . . . . . . . . . . . . . . . . . 9-19

Activity: Normal to Part and Relative to Part . . . . . . . . . . . . . . . . . . . . 9-26Activity: Special tool axis and non part geometry . . . . . . . . . . . . 9-31Activity: The Interpolated tool axis . . . . . . . . . . . . . . . . . . . . . . 9-38

A comparison of Variable Contour vs. Sequential Milling . . . . . . . . . . . 9-46Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-49

Variable Contour – advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3Activity: Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . 10-4Geometry selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11Automatic Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12Activity: Floor selection and Automatic Wall . . . . . . . . . . . . . . . . . . . . 10-13


Contents

Tilting the tool axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16Activity: Tilting the tool axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19Activity: Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-23Activity: Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . 10-24Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31Activity: Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . 10-37Activity: Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . . . . 10-38Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43

Projection Vectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Zig-Zag Surface machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Advanced surface contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1


Course overview

Course descriptionThe Multi-Axis Machining course teaches the use of the Manufacturingapplication for creating 4 and 5-axis milling tool paths. You will learn aboutthe Variable Contour and Sequential Mill operation types that are designedfor multi-axis machining. You will also learn about the tool axes that areavailable within Variable Contour and Sequential Mill operations.

Intended audienceThis course is intended for Manufacturing Engineers, NC/CNC programmersand anyone with the desire to learn how to create four and five axis tool paths.

PrerequisitesThe required prerequisites for the course are NX ManufacturingFundamentals or the CAST equivalent. Any additional experience in creatingmulti-axis tool paths is an asset in taking this course.


Objectives

ObjectivesAfter successfully completing this course, you will be able to perform thefollowing activities in NX:

• choose between Variable Contour and Sequential Mill operation types

• choose the best type of tool axis for creating various multi-axis tool paths

• develop multi-axis machining practices

• develop NX multi-axis programming practices

Student responsibilities• Be on time.

• Participate in class.

• Focus on the subject matter.

• Listen attentively and take notes.

• Enjoy the class.


Course overview

Class standard for NX partsThe following standards are used in this class. Standardization allows usersto work with others parts while being able to predict the organization of thepart file. All work should be performed in accordance with these standards.

Class part naming

This class uses the following file naming standard:

Where the student is requested to save a part file for later use, the initialsof the student’s given name, middle name, and surname replace the courseidentifier "***" in the new file name with the remainder of the file namematching the original. These files should reside in the student’s personaldirectory.

The arrow symbol

The arrow symbol (→ ), represents that you choose an option, thenimmediately choose another option. For example, Tools→OperationNavigator→Tool path→Replay means:

• put the cursor on Tools on the main menu bar

• press mouse button #1 to display the pull-down menu.

• slide the cursor down to Operation Navigator (continuing to press mousebutton # 1)

• slide the cursor down to Tool path

• slide the cursor down to Replay

• release mouse button #1


Class standard for NX parts

Layers and categories

There are standard layer assignments and category names in each of thepart files. They are as follows:

Layers 1-100, Model Geometry (Category: MODEL)

Layers 1-14, Solid Geometry (Category: SOLIDS)

Layers 15-20, Linked Objects (Category: LINKED OBJECTS)

Layers 21-40, Sketch Geometry (Category: SKETCHES)

Layers 41-60, Curve Geometry (Category: CURVES)

Layers 61-80, Reference Geometry (Category: DATUMS)

Layers 81-100, Sheet Bodies (Category: SHEETS)

Layers 101 - 120, Drafting Objects (Category: DRAFT)

Layers 101 - 110, Drawing Borders (Category: FORMATS)

Layers 121 - 130, Mechanism Tools (Category: MECH)

Layers 131 - 150, Finite Element Meshes and Engr. Tools (Category: CAE)

Layers 151 - 180, Manufacturing (Category: MFG)

Layers 181 - 190, Quality Tools (Category: QA)

Colors

The following colors are preset to indicate different object types.

Object Color UsedSolid Bodies GreenSheet Bodies YellowLines and Arc(non-sketch curves)

Green

Conics and Splines(non-sketch curves)

Blue

Sketch Curves CyanReference Curves(in sketches)

Gray

Datum Features AquamarinePoints and Coordinate Systems WhiteSystem Display Color Red


Course overview

Seed partSeed parts are an effective tool for establishing customer defaults or anysettings that are part dependent (saved with the part file). This may includenon-geometric data such as:

• sketch preferences

• commonly used expressions

• layer categories

• user-defined views and layouts

• part attributes

How to use this manualIt is important that you use the Student Guide in the sequence presentedsince later lessons assume you have learned concepts and techniques taughtin an earlier lesson. If necessary, you can always refer to any previous activitywhere a method or technique was originally taught.

The format of the activities is consistent throughout this manual. Steps arelabeled and specify what will be accomplished at any given point in theactivity. Below each step are action boxes which emphasize the individualactions that must be taken to accomplish the step. As your knowledge of NXincreases, the action boxes may seem redundant as the step text becomes allthat is needed to accomplish a given task.

Step 1: This is an example of a step.

This is an example of an action box.

Choose Edge Lengths, Corner for the creation method.

The general format for lesson content is:

• Presentation

• Activity

• Summary

While working through lesson activities, you will experience a higher degreeof comprehension if you read the Cue and Status lines.

At the start of each class day you will be expected to log onto your terminaland start NX, being ready to follow the instructor’s curriculum. At the end ofthe day’s class you should always exit NX and log off the terminal.


Workbook overview

Workbook overviewThe workbook contains a project that requires you to apply the knowledgethat you learned in the class and in the Student Activities. The projects donot contain detailed instructions as do the Student Activities.

The intent of the projects is to allow you to apply the skills taught in thiscourse. At any point when you are not making progress, ask your instructorfor help.


Course overview

Classroom system informationYour instructor will provide you with the following items for working inthe classroom:

Student Login:

User name:

Password:

Work Directory:

Parts Directory:

Instructor:

Date:

Student and workbook parts

The parts for this class are stored in the class Parts directory. There are twodirectories located in the Parts directory, the Student_parts and workbook.

The Student_parts directory contains the parts that you will use whenworking on activities in the Student Manual.

The workbook directory contains the parts that you will use when workingon the project within the workbook.

System privileges

You do not have the system privilege to modify any of the part files. If youattempt to do so, you will get a message saying that the file is Read Only.However, this does not restrict you from working with these files.


1Lesson

1 WAVE Geometry Linker inManufacturing

Purpose

In this lesson, you will learn different methods available for creatingmachining geometry, using the WAVE (What If Alternative ValueEngineering) Geometry Linker, that is associated to the designer’s originalgeometry.

Objective

Upon completion of this lesson, you will be able to:

• Use the WAVE Geometry Linker to create associative, linked geometry.

• Make modifications to linked geometry.

• Use a "base part" to control the manufacturing setup.

• Build a simulated casting solid body using the Wave Geometry Linker.

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide 1-1

1

WAVE Geometry Linker in Manufacturing

The WAVE Geometry LinkerThe WAVE Geometry Linker is used to associatively copy geometry from acomponent part in an assembly into the work part. The resulting linkedgeometry is associated to the parent geometry. Modifying the parent geometrywill cause the linked geometry in the other parts to update.

The WAVE Geometry Linker is available with a Manufacturing Bundlelicense. It does not require a NX WAVE license.

Different types of objects can be selected for linking, including points, curves,sketches, datums, faces, and bodies. The linked geometry can be used forcreating and positioning new features in the work part.

The Wave Geometry linker is accessed by choosing Insert→AssociativeCopy→WAVE Geometry Linker from the menu bar.

1-2 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

1


• The At Timestamp option lets you specify where the linked object is placedin the feature list. When turned off, any new features added altering theparent geometry will be reflected in the linked geometry. When turned on,new features added after the link was created will not be affected.

• Blank Original lets you blank the original geometry so that the linkedgeometry in the work part will be easier to work with while the assemblyis displayed.

• Create Non-Associative option will create a broken link. The geometrywill be created in the work part but will not be associated to the parentgeometry.


1


Geometry types used by the Geometry Linker

Several different types of geometry can be used in the WAVE application.

• Points

• Curves/Strings

• Sketches

• Datums

• Faces

• Regions of Faces

• Bodies and Mirrored Bodies

When selecting geometry to copy, you should consider how permanent thegeometry will be. If you copy as little geometry as possible to do the job,performance will be improved but updates will be less robust when the parentgeometry is altered.

For example, if you copy individual curves to another part, the link may notupdate correctly if one of the curves is deleted. Conversely, if you copy anentire sketch, curves may be removed or added and the link will update.


1


Edit links

Links may be edited by choosing Edit→Feature→ Parameters in the ModelNavigator and selecting a linked feature. Linked features have an Edit dialogbox similar to the one below.

When this dialog box is displayed, the cursor is active in the graphic windowallowing new parent geometry selection for the link being edited. The newparent geometry must be the same type as the old geometry (curve, datum,solid body, etc.)

• Parent indicates the parent geometry type. If the feature was linked, butthe link has been broken, the parent is shown as a Broken Link.

• Part shows the name of the part where the parent geometry is located. Ifthe parent geometry is located in the current work part, the part namegiven is Work Part.

The dialog box information updates when you select new parentgeometry, which you can do at any time.


1


• At Timestamp allows you to specify the timestamp at which the linkedfeature is placed. If toggled on, the list box will display the features in theparent part. One of these features may be selected from the list to specifya new timestamp location for the linked feature being edited. If toggledoff, all features in the parent part will be reflected in the linked feature.

• Break Link lets you break the association between the linked feature andits parent. This means that the linked feature will no longer update if itsparent changes. You can later define a new parent by selecting geometrywith the cursor.

• Replacement Assistant allows replacement of one linked object withanother (cannot be used on linked sketches or strings).

• Flip Face Normal reverses the normal of the face selected.

• An Extracted feature (intra-part) can be converted to a Linked feature(inter-part) by selecting the appropriate option and selecting new parentgeometry from another component in the assembly.

Depending on the geometry type of the feature being edited, other optionsmay appear on the dialog box.

When editing links and selecting new parent geometry, it may be easierto temporarily work in an exploded view to distinguish between theexisting linked geometry and the new parent geometry.


1


Broken links

A link may become broken for several of the following reasons:

• The parent geometry is deleted.

• The path from the linked geometry to the parent part is broken. This canoccur if the component part containing the parent geometry is deletedor substituted.

• If the parent is removed from the start part reference set that definesthe linked part.

• If you deliberately break the link (e.g., using Edit Feature or the Breakoption on the WAVE Geometry Navigator dialog box).

Newly broken links

When a link breaks for an indirect reason (i.e., any reason except the last onelisted above), the link is identified as newly broken until you accept it. Youcan accept newly broken links from the WAVE Geometry Navigator dialogbox or the Edit during Update dialog box.

After a link is accepted, its status is changed to broken until a new parent isdefined.


1


Delete parent geometry

To prevent unintentional deletion of the parents of linked geometry, a messagewill warn you if a delete operation would cause inter-part links to break. Thisapplies to operations using Edit→Feature→Delete, Edit→Delete, and ModelNavigator→Delete while the parts containing the linked geometry are loaded.

• The Information option provides details about the links that will bebroken in an Information window.


1


Delete linked geometry

Linked geometry is created as a feature and can be deleted by choosingEdit→Feature→Delete (or choosing the Delete Feature icon).

Linked bodies may also be deleted by choosing Edit→Delete. If you choosethis method, you will not have an opportunity to verify child features beforethey are removed.

Assemblies and WAVE

The WAVE Geometry Linker only works in the context of an assembly. Anassembly link must exist between two part files before a WAVE link can beestablished.


1


Activity: Create an assembly for WAVE

In this activity, you will create an assembly structure for later use with theWAVE Geometry Linker. Remember that WAVE only works in the contextof an assembly.

This activity uses a hypothetical company that has been awarded a contractto machine a mixer housing.

The customer has supplied a NX solid model of the designed part. Sincehigh-production quantities are needed, the customer has decided to make thepart as an aluminum casting. This will reduce significantly, the amount oftime spent machining. Unfortunately, the customer has not supplied a solidmodel of the casting which we will need to create. Using WAVE, you willcreate a simulated casting model that is associated with the original geometry.

For the casting body, it will be necessary to remove the seven drilled holes,and add .250" machining stock on the inlet, outlet and mixer tube faces. Alsonote that the ring groove will not exist on the casting body.

All machined faces have 1/4" of added stock. Once the modeling changesare made, you will drill all holes and machine the ring groove into themixer outlet face, since the casting process was not accurate enough for thetolerances required.

Step 1: Create a new part.

On the Standard toolbar, click New .

Notice that the dialog box has several tabbed pages.


1


Click the Model tab. Expand the Units list and select Inches.

On the Model page, select the Assembly template.

This template will provide the standard Layer settings andCategory Names as defined for this class.

In the New File Name group, in the Name input box, replacethe default name with ***_mixer_mfg , where *** representsyour initials. Ensure Folder is set to your “home” folder.

Saving parts to your home is standard practice for this class.Parts that you create must be saved in a folder to which youhave read and write permissions.

Click OK.

Step 2: The Add Component dialog box appears. This will allow you toadd the part we are going to work on.

In the Part group, click Open .

Select mixer_body from the parts folder, then choose OK.

In the Add Component dialog box, expand the Settings groupand change Name to mixer; select SOLID from the ReferenceSet pulldown.

Click OK.

Step 3: Examine the current assembly structure.

Click the Assembly Navigator tab in the Resource Bar.

Clicking once on the tab temporarily displays the AssemblyNavigator by sliding it to the left over the graphics display.

Double-clicking on the tab displays the Assembly Navigatorin a separate window which can then be moved and docked.

There are currently two parts in this assembly. The top levelcontrol part is ***_mixer_mfg, while mixer_body is the singlecomponent. Currently, only the component contains any geometry.

The next step will be to create a new component that will containthe WAVE casting body.

Step 4: Create an empty component.


1


Choose Assemblies→Components→Create New from themenu bar.

OK the Class Selection dialog box.

Expand the Units list and select Inches.

On the Model page, select the Model template.

In the File Name group, in the Name input box, replace thedefault name with ***_mixer_casting.

Ensure Folder is set to your “home” folder.

Click OK.

In the Create New Component dialog box, change thecomponent name to casting.

Click OK.

A new component, named CASTING, is displayed in theComponent Name column of the Assembly Navigator. The nameof the part file is ***_mixer_casting. You may need to displaythe Component Name column by right-clicking and selectingColumns→Component Name.

Step 5: Save the assembly.

Click Save on the toolbar.

When you save an assembly, all modified components belowthe work part are saved as well.


1


Link procedure

You use the Insert→Associative Copy→WAVE Geometry Linker dialog boxto create associated objects between part files. The linker allows you tocopy geometry downward into component parts, upward into higher levelassemblies, or sideways between components within an assembly. As youbuild your Mixer assembly you will use the sideways functionality.

To create linked geometry:

• Arrange your assembly display so that the part containing the geometryto be copied is visible, and the geometry of interest is selectable.

• Change Work Part to the part that is to receive the linked copies.

• Change your roll to a higher level of design functionality.

• Choose Insert → Associative Copy →WAVE Geometry Linker.

• Use the linker dialog box to filter the type of object(s). You may selectseveral objects of different types.

• Choose Apply to make copies and remain in the Selection dialog box, orOK to copy objects and exit the dialog box.


1


Activity: Create WAVE geometry

In this activity, you will practice using the geometry linker. You will createa WAVE linked copy of the mixer body, then perform modifications to thatcopy to simulate a casting.

Step 1: Prepare the assembly.

If necessary, open the ***_mixer_mfg assembly part and thenthe Assembly Navigator.

Choose Start → Modeling.

Select the component ***_mixer_casting in the AssemblyNavigator, right-click and select Make Work Part.

The mixer body changes to the color Dark Faded Green. This isa visual clue that geometry is no longer in the current modelinghierarchy.

Step 2: Select the System Defaults Role tab and drag the Essentials withfull menus icon to the graphics screen.

Choose Insert→Associative Copy→Wave Geometry Linker.

It is possible to link types of geometry other than solid bodies.Curves, Sketches, and Datum Planes are also commonly linked.

Set Type to BODY in the WAVE Geometry Linker dialogbox.

Select the mixer body.

Click OK.

Step 3: Modify the display of the linked casting.

There are now two identical bodies, lying in the same model space;the component body and the linked copy. It can be difficult todetermine one from the other, it will be necessary to clarify thedifferences. First, you will remove the original body from thedisplay. Then, you will change the display of the linked body.

In the Assembly Navigator right-click over the***_mixer_casting component, and choose Make DisplayedPart.

In the graphics window change the view orientation and shadestatus if required.


1


Choose Edit→Object Display.

Select the linked body and choose OK.

Using Edit Object Display is a powerful method ofdifferentiating between bodies that are similar inappearance.

In the Basic group, change Color to Yellow.

Choose OK in the Edit Object Display dialog box.

Step 4: Make the top-level part the displayed part, then save the workin progress.

At this point no physical difference exists between the mixer bodyand the mixer casting. They do have a visual difference. In the nextactivity, you will perform modeling changes to the mixer casting.

In the Assembly Navigator, right-click on the***_mixer_casting component, choose DisplayParent→***_mixer_mfg.

In the Assembly Navigator, right-click on ***_mixer_mfg,choose Make Work Part.

Click on the red check mark in front of Mixer_body and theyellow casting will remain on the screen.

Click on the red check mark in front of ***_mixer_casting andit will leave the screen.

Click on the grey checkmark in front of mixer_body and theoriginal model will appear.

Click on the grey checkmark in front of ***_mixer_castingand it will appear, but will blend completely with the originalmodel. This will be changed in the next activity.

Click Save .


1


Simplify

Simplify is a powerful modeling tool that can be used to satisfy a wide rangeof needs in developing models that are associative, but somewhat different.

Simplify provides a method of removing faces. This process must be able toextend surrounding faces to "heal the wound" where the faces have beenremoved.

Uses of Simplify:

• Remove "machined" features for preparing an as cast part from a bodythat is not appropriately constructed for link At Timestamp, or from abody whose features are not accessible.

• Remove details such as holes and blends for finite element analysis.

• In casting tooling work, core and pattern preparation in parts where theregions were not modeled separately. Simplify can often be used bothto remove interior faces, for patterns, and to remove exterior faces, forcores (if the system cannot heal wounds left by core removal, the patterndesigner must extract regions and sew core-print faces to obtain a corebody).

• Preparing a body for export to a supplier who need only be concerned withthe exterior envelope. Interior faces are removed using simplify, then thesimplified part is linked into a new part for export to the supplier. Thelinked part has no "knowledge" of interior features in the original, but itcan still be updated by the owning company if the parent body changes.


1


Simplify Body procedure

You will use the Simplify Body function to remove holes from your mixercasting body.

To simplify geometry:

• Choose as a retained face, one that will not be simplified away.

• Select Automatic Hole Removal.

• Set the size for the Hole Dia Less Than parameter.

• Choose Apply to perform simplification.

• Acknowledge the simplify notice.


1


Activity: Simplify Body

In this activity, you will practice using Simplify Body as a tool to reduce thecomplexity of a linked solid body.

Step 1: Make the CASTING component the work and displayed part.

If necessary, open your ***_mixer_mfg assembly part and thenopen the Assembly Navigator.

Right-click on the ***_mixer_casting component and chooseMake Displayed Part.

Step 2: Perform a Simplify Body operation on the seven bolt holes on theoutlet face and mixer tubes.

Choose Start→Modeling if required.

Choose Insert→Direct Modeling→Simplify.

The Simplify Body dialog box is displayed.

The cue line reads: “Select retained faces.”


1


Select any face on the body that will not be removed when theholes are removed.

Select Automatic Hole Removal.

Specify .500 in the Hole Dia Less Than field and press thereturn key.

Click Apply in the Simplify Body dialog box.

The Simplify Body information window gives the number of facesremoved and retained (in this case 7 faces are removed, 108 facesremain).

Dismiss the Simplify Body information dialog box by choosingOK.

Click Cancel in the Simplify Body dialog box.

Click Save .


1


Activity: Other modeling techniques

Previously Simplify Body was used to remove unwanted geometry from theLinked casting body. Now, you will explore other ways to modify a linkedbody. The first option explored is Extrude.

Step 1: Make the CASTING component the work and displayed part.

If necessary, open your ***_mixer_mfg assembly part and thenopen the Assembly Navigator.

Click on the ***_mixer_casting component, choose MakeDisplayed Part.

Step 2: Use Extrude to fill in the ring groove.

Choose Start→Modeling.

Choose Insert→Design Feature→Extrude.

The Extrude dialog box is displayed.

If required, on the Selection Intent toolbar change the typefilter to Face and change the curve rule to Face Edges.


1


Choose the bottom face of the ring groove, as shown below.

In the Limits group, set End to Until Extended and select theoutlet face.

Set Boolean to Unite.

OK the Extrude dialog box.

Step 3: Use the Offset Face option to add machining stock.

In this step, you will add machining stock to the inlet and outletfaces, as well as the mixer tube faces.

From the menu bar choose Insert→Offset/Scale→Offset Face.

In the Offset Faces dialog box, type 0.250 for the Offset value.

Select the inlet and outlet faces, and the two mixer tube faces.


1


Choose OK.

The modeling changes are complete. It will be difficult to visualizethose changes in shaded mode, without a further display changeto the casting.

Step 4: Change the translucency of the casting.

To make it easier to visually distinguish the original designed partfrom the casting, you will make the casting model translucent.

If necessary, turn on Shaded mode.

From the menu bar choose Edit→Object Display.

Select the body and choose OK.

Slide the Translucency bar to 50% and choose OK.

If the solid body does not become semi-transparent, choosePreferences→Visualization Performance, and turn offDisable Translucency, located on the General Settings tabunder Session Settings.

Step 5: Make ***_mixer_mfg the work part, and compare the two solidbodies.

To fully realize the extent of the changes made, you will displayboth the original and the linked body together.


1


Open the Assembly Navigator.

Right-click on the CASTING component and choose DisplayParent→***_mixer_mfg.

In the Assembly Navigator, double-click on ***_mixer_mfg tomake it the work part.

Examine the two models.

The CASTING component has stock added on the machined faces.All drilled holes have been removed, as well as the ring groove.

This is only one potential method for creating a simulated castingbody. Other methods and techniques could also have been used.However, this method is fully associated to the original, so that ifthe original body changes, the casting body will update also.

At this stage, NC/CNC programming, using the CASTINGcomponent as the BLANK, could now begin.

Choose File→Close →Save All and Close.


1


SummaryThe WAVE Geometry Linker provides an efficient method to associativelycopy geometry used for machining from a component part in an assembly intoa work part. The machining geometry is modifiable for manufacturing needsbut does not change the original design intent.

In this lesson you:

• Used Assemblies to enable "Best Practices" for modeling in manufacturing.

• Created a WAVE solid body that is associatively linked to the original.

• Modified the WAVE geometry to simulate a casting for machining.


2

Lesson

2 Advanced Cavity Milling topics

Purpose

This lesson teaches you how to use additional Cavity Milling options to createtool paths. You will also use Geometry Parent Groups to machine CavityMilling geometry.

Objective


• Utilize advanced Cavity Milling options

• Create and modify Geometry parent groups for Cavity Milling

• Create and modify Cut Levels

• Utilize the In-Process Work Piece


2

Advanced Cavity Milling topics

Cut LevelsCavity Milling cuts geometry in planes or levels.

The advantage to this approach is that tool paths remain relatively short, dueto minimum tool path movement, which is performed in layers.

The disadvantage is that when machining geometry that is close to horizontalmore stock may remain than desired. See the diagram below.

The closer the geometry approaches horizontal, the more stock that remains.Through the use of Cut Level parameters, you can reduce the amount of stockthat remains by reducing the depth of cut in these near level areas.

Use Cut Levels in the Cavity Mill dialog box to access the Cut Levelsdialog box.

The Cut Levels dialog box serves these primary functions:

• Create, delete or modify Ranges

• Modify Cut Levels within Ranges

To reduce the amount of additional stock, a new range can be added. TheDepth per Cut in that Range only is modified.

In the next activity, you will use various Cut Level parameters.


2


Activity: Cut Levels parameters

In this activity, you will replay an operation and review the various CutLevels. You will then modify the range to allow the tool to cut without anywarning messages.

Step 1: Open, rename the part file, and enter the Manufacturingapplication.

Open the part file base_mfg_2.

Rename the part ***_base_mfg_2 using the File → Save Asoption on the menu bar.

Choose Start → Manufacturing.

Step 2: Activate the Operation Navigator.

Choose the Operation Navigator tab from the Resource Barand expand the BASE_MALE_DIE parent group.

In the Operation Navigator, verify the Program Order view isactive.

Step 3: Generate the operation.

Double click on the CAVITY_MILL operation in the OperationNavigator to Edit the operation.

Generate the operation.


2


A warning message states that the Tool cannot fit into level 14.

At this level, the part and blank geometry are identical, the tracegenerated for the part and blank geometry are the same; thereforeno geometry is available for machining. You will now alter the cutlevels to eliminate the warning message.

OK the warning message.

Refresh or hit F5 to remove the path display.

Step 4: Edit the Bottom of Range #1.

The first step is to remove the warning from this operation bychanging the cut range.

Click Cut Levels from the Path Settings group in theCavity Mill dialog box.

Large and small plane symbols appear. The large plane representsthe Range, and the small planes are the Levels within the Range.Some Ranges do not have any additional levels.


2


At the very top of the dialog box, there are three buttons fordefining ranges. The Auto Generate (1) button defines rangesthat will align with planar horizontal faces. The User Defined (2)button defines ranges by selection of the bottom plane for eachnew range. The Single (3) button defines the cut range based onpart and blank geometry.

In the Cut Levels dialog box, click (beneath Range 1,Level 1) once.

The color changes for the active planes, and the Range number andLevel numbers change to Range 2, Levels 2-7.

Click until Range 4, Levels 12-14 is highlighted, and theRange Depth value is 3.25.

This is where we want to stop machining at, but there is one moreRange left.

Click one more time and Range 5, Levels 15-16 arehighlighted, and the Range Depth value will read 3.75. Now

click Delete Current Range and delete Range 5.

OK the Cut Levels dialog box.


The operation successfully generates without warning messages.

OK to the Cavity Mill dialog box.

Save the part file, but do not close the file.


2


Cut patternsIn the Path Settings Group, Cut Pattern determines the pattern the cutterwill use when machining the part.

The Cut Patterns are as follows:

Zig-Zag machines in a series of parallel straight line passes. Climbor conventional cut directions are not maintained since the cut directionchanges from one pass to the next.

Zig always cuts in one direction. The tool retracts at the end of eachcut, then positions to the start of the next cut.

Zig with Contour also machines with cuts going in one direction.However, contouring of the boundary is added between passes, before andafter the cut motion. The tool then retracts and re-engages at the start ofthe contouring move for the next cut.

Follow Periphery offsets the tool from the outermost edge that isdefined by Part or Blank geometry. Internal islands and cavities will requireIsland Cleanup or a clean up Profile pass.


2


Follow Part creates concentric offsets from all specified Part geometry.The outermost edge and all interior islands and cavities are used to computethe tool path. Climb (or Conventional) cutting is maintained.

Trochoidial cut pattern uses small loops along a path (resembles astretched-out spring). This is a useful cut pattern in high speed machiningapplications when constant volume removal needs to be maintained.

Profile follows a boundary using the side of the tool. For this method,the tool follows the direction of the boundary.


2


Activity: Zig-Zag cut pattern

In this activity, you will use the Zig-Zag cut pattern to cut the part.

Step 1: Open the part file and start the Manufacturing application.

Continue using the part from the previous activity,***_base_mfg_2.

If necessary, choose Start →Manufacturing.

Step 2: Edit an existing operation to change the Cut Pattern.

In the Operation Navigator, double-click on the CAVITY_MILLoperation.

In the Cavity Mill dialog box, in the Path Settings group, select

Zig-Zag for the Cut Pattern.


2



Click Generate .

The tool path is generated.

Step 4: Change the Cutting options.

In the Path Setting group in the Cavity Mill dialog box, click

Cutting Parameters .

The Cut Parameters dialog box is displayed. Options available arebased on the selected Cut Pattern.

Click the Strategy tab, then type 45.0 in the Degrees field.

Click Display Cut Direction .

An arrow indicates the applied Cut Angle.

You may need to refresh the screen in order to see the CutDirection Arrow.

OK the Cut Parameters dialog box.


Click Generate to generate the operation.

Click Verify .

Use 3D Dynamic verification to analyze the results.

The Zig-Zag cut pattern does not have a stepover on every pass,resulting in a less than desirable tool path.

Cancel the Tool Path Visualization dialog box.

Change the Cut Pattern to Zig with Contour.


2



Choose Generate to generate the operation.

Verify the tool path, using the 3D Dynamic option.

This time the tool path is more efficient in the method of cleaningup the corners.

Save the part.


2


In-Process Work Piece for Cavity MillingTo make the various Cavity Milling operations as efficient as possible,you must determine what has been machined in each previous operation.Variables such as cutting tool lengths and diameters, draft angles andundercuts, fixture and tool clearances, will affect the amount of materialthat each operation may leave.

The material that remains after each operation is executed is referred toas the In Process work piece or IPW.

The remaining material (IPW) can be used for input into a subsequentoperation which may be used for additional roughing. To use the previousIPW, tool path generation must be done sequentially, from the first operationto the last, within a certain geometry group.

Two methods for creating the In Process work piece are available:

1. 3D IPW

2. Level Based IPW


2


Level Based IPW

Level Based IPW uses the 2D cut regions from the previous Cavity Millingand/or Z-Level operation to identify and machine the remaining (Rest)material.

• Must be Cavity Mill or Z-Level operations.

• Must be under the same Geometry Group.

• Must have the same Tool Axis.


2


Use 3D

Use 3D uses a 3D internal definition to represent the remaining material.All milling operations can produce a 3D IPW. Using 3D is the correct IPWoption if you are also using other types of operations to remove material fromthe blank. For example, if your cavity milling operation follows a surfacecontouring operation, then you must use the 3D IPW.


2


Activity: Level Based In-process Workpiece (IPW)

In this activity, you will machine the part using three different cutter sizes.You will start with a cavity mill operation and activate the use of the LevelBased IPW by using the REST_MILLING operation type and generate themultiple operations.

You will make three operations, all using the same WORKPIECE andMILL_AREA. Planning ahead when programming will lead you to make anduse Geometry groups

Step 1: Open level_based_mfg and start the Manufacturing application.

Rename the part ***_level_based_mfg using the File → SaveAs option on the menu bar.


Click the Operation Navigator tab on the Resource Bar.


2


Step 3: Display the Geometry View in the Operation Navigator andexpand the objects.

Click Geometry View on the Operation Navigatortool bar, then expand the MCS_MILL , WORKPIECE, andINSIDE_MILL_AREA parent groups.

In this case, Cavity Mill will use only the MILL_AREA to containthe tool to inside of the pockets, rather than the entire part.

Step 4: Create the first operation.

From the Manufacturing Create toolbar, click Create Operation

.

Make sure Type is set to mill_contour and select CAVITY_MILL

.

Set the following location specifications:

Program PROGRAMTool EM-1.25Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

For Name type CM_ROUGH_1 and click OK.

No additional parameters are going to be changed in this operation.

Click Generate to generate the tool path.

Click OK to accept the path.

Step 5: Create the second operation.

On the Manufacturing Create toolbar, click Create Operation

.

Make sure Type is set to mill_contour and click Rest Milling

.


2


Set the following location options:

Program PROGRAMTool EM-.75Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

Name the operation RM_ROUGH_2 and click OK.

Click Generate .

A Tool Path generate message is displayed.

Click OK.

The Information Window appears because the tool cannot fit intosome of the areas of the part, namely the square corners.

Dismiss the Information Window, and OK to accept the path

Step 6: Create the third operation.


.

Make sure Type is set to mill_contour and click Rest Milling

.

Set the following location options:

Program PROGRAMTool EM-.5Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

Name the operation RM_ROUGH_3 and click OK

No additional parameters are going to be changed for this activity.

Click Generate .

Again the Tool Path generate message comes up and states thatwarning have been generated. Click Cancel this time, as we knowthat there are square corners in our model which cannot be cut.


2


Click OK to accept the path.

Step 7: Verify the Tool Path.

Display the Program View in the Operation Navigator and expandthe objects.

Right-click the Program → Tool Path→ Verify.

Verify the tool path, using the 3D Dynamic option.

Save and close the part file.


2


Pre-Drill Engage and Cut Region Start Points

Pre-Drill Engage and Cut Region Start Points are used in the following:

Operation Where Found

Cavity Mill Non Cutting Moves – Start/DrillPoints

Corner Rough Non Cutting Moves – Start/DrillPoints

Rest Milling Non Cutting Moves – Start/DrillPoints

Z-Level Processors Non Cutting Moves – Start/DrillPoints

Profile 3D Non Cutting Moves – Start/DrillPoints

Face Milling Processors Non Cutting Moves – Start/DrillPoints

Planar Mill Processors Non Cutting Moves – Start/DrillPoints

Plunge Mill Points in Path Settings

Pre-Drill Engage Points

Operations normally determine where they start.

You can use the Pre-Drill Engage Points option to specify where you wantthe tool to start cutting. With this option, the tool moves to the pre-drilledengage point you specify, then to the specified cut level. It then moves to theprocessor generated start point and generates the remainder of the tool path.

Region Start Points

Region Start Points allows you to specify cut start points for each region ina multi-region cavity. When you use circular engages, this option can avoidengages into pocket corners by selecting either Mid Point or Corner in theDefault Region Start pull down.


2


Activity: Pre-Drill Engage Point

In this activity, you will edit the current operation to use a Pre-drilled EngagePoint to start your tool path and to use a Region Start Point. The Pre-drillEngage Point is a hole that has been previously drilled and is representedby a modeled hole in the BLANK. The Cut Region Start point will be anInferred Point on the model.

Step 1: Open the part form_mold_mfg and start the Manufacturingapplication.

From the menu bar, select File→Open.

Select form_mold_mfg, then choose OK.

Rename the part ***_form_mold_mfg using the File → Save Asoption on the menu bar.



Choose the Operation navigator tab from the Resource Bar.


Step 3: Edit an existing operation.

Double-click the CM_ROUGH operation.

The Cavity Mill dialog box is displayed. You will now define a pointthat represents a hole which has been previously drilled.

Step 4: Define a Pre-drill Engage Point for this operation.

In the Path Settings group, click Non Cutting Moves .

Click the Start/Drill Points tab and expand the Pre-Drill Pointsgroup.

Click the Point Constructor and select the arc center ofthe drilled hole in the Blank that we are going to engage into.

OK the Point dialog box.

Expand the List and verify that a value of 5.2500, 2.5000, and3.1250 is present.


2


Expand the Region Start Points group.

Click Point Constructor and select the Mid Point of theedge shown here.

OK the Point dialog box.

Expand the List and verify that a value of 4.4575, 2.5000, and.2000 is present.

Click the Engage tab.

In the Closed Area group, select Plunge for the Engage Type.

OK the Non-Cutting Moves dialog box.


2


Step 5: Generate the tool path.

Click Generate to create the tool path.

Notice that all levels start at the Pre-Drill Engage Point in thecenter of the part, then move to the start point which is determinedby the processor.

Click Verify .

In the Tool Path Visualization dialog box, set Display (underMotion Display) to Current Level.

Click Play .

You may want to slow the animation speed down.

OK the Tool Path Visualization dialog box.

OK to accept the operation.

Save and Close the part.


2


Cavity Milling stock options

Stock options for Cavity Milling are found on the Cut Parameters dialog box.This dialog box is activated by selecting the Cutting button found on theCavity Mill operation dialogs.

Some of the stock options are as follows:

Part Side Stock adds stock to the individual walls of the part.

Part Floor Stock adds stock to the floor.

Check Stock is the distance that the tool will stay away from the checkgeometry.

Trim Stock is the distance that the tool will stay away from the trim boundary.

Blank Stock is stock applied to Blank geometry.

Blank Distance applies to Part geometry. This is an offset distance whichcan be used for a casting or forging.


2


Activity: Blank Distance option

In this activity, you will learn how to set the Blank Distance for a core typepart. The MCS, Part geometry and Program Name have already been createdfor you.

Step 1: Open a new part file, rename and start the Manufacturingapplication.

Open the part file horn_mfg.

Rename the part ***_horn_mfg using the Save As option onthe menu bar, where *** represents your initials.


Choose the Operation Navigator tab from the Resource Bar.


Step 2: Create an operation utilizing Blank Distance as a part offset.


.

The Create Operation dialog box is displayed.

Set Type to mill_contour.


2


Select Cavity Milling .

Set the following:

• Program: ROUGH_WITHOUT_CASTING

• Use Tool: EM-.375-.06

• Use Geometry: WORKPIECE

• Use Method: MILL_FINISH

Name the operation CM_.20_BLANKDISTANCE.

Click OK.

The Cavity Milling dialog box is displayed.

Step 3: Verify the Part Geometry selection.

For Specify Part click Display .

Note that the Part geometry is displayed.

Note that no Blank geometry has been selected and cannot bedisplayed.

Step 4: Specify Operation settings.

In the Path Settings group, set Cut Pattern to Follow Part.

Set Global Depth per Cut to .125.

Click Cutting Parameters .

The Cut Parameters dialog box is displayed.

Click the Strategy tab if required.

In the Cutting group, set Cut Order to Depth First.

In the Blank group, set Blank Distance to .20.

Click OK.

The Cavity Mill dialog box is displayed.


2



Click Generate to create the tool path.

Click OK.

The tool path cuts all of the core geometry.

Notice that the tool path follows the part contour since you usedthe Blank Distance option rather than selecting other geometry(such as a solid block) to represent the Blank shape.

In this case, you specified that the Blank was near-net-shape with.200" stock overall.

Choose OK to accept the tool path.



2


SummaryThe Cavity Milling module provides efficient and robust capabilitiesof removing large amounts of stock, primarily in cavity and core typeapplications.

The following functions are available in Cavity Milling:

• Use of the In-Process work piece for accurate removal of material usingdifferent size cutting tools

• Cut levels to precisely control depths of cut

• Cut patterns to control direction and method of removing stock


3

Lesson

3 Z-Level Milling

Purpose

This lesson is an introduction to the Z-Level operation type, which is usefulwhen profiling steep areas. You can also isolate specific areas that you wantto cut or avoid cutting within a Z-Level operation.

Objective


• Understand the uses of Z-Level milling.

• Create milling operations using the Z-Level operation type.

• Understand the meaning and use of steep and non-steep areas of geometry.


3

Z-Level Milling

Z-Level MillingZ-Level Milling is designed to profile bodies or faces at multiple depths. Itwill cut steep areas (the steepness of the part at any given area is defined bythe angle between the tool axis and the normal of the face) or the entire part.

The following Z-Level operation types are available:

• CORNER ROUGH - Cavity milling with a reference tool that can beused with or without the In Process Work piece; uses existing referencetool

• ZLEVEL_PROFILE - uses the Profile Cut Method without the SteepAngle being set

• ZLEVEL_CORNER - Z-Level milling that uses an existing referencetool; and compliments flowcut machining

Part geometry and Cut Area geometry can be specified to limit the area tobe cut. If cut area geometry is not defined, then the entire part is used asthe cut area.

1. Create new Geometry

2. Select or Edit the Part Geometry

3. Select or Edit the Check Geometry

4. Select or Edit the Cut Area Geometry

5. Select or Edit the Trim Boundaries Geometry


3

Z-Level Milling

Many of the option settings found in Z-Level Milling are the same as in otheroperation types. A description of some of these options are as follows:

Geometry

• Part geometry consists of bodies and faces which represents the Part aftercutting

• Check geometry consists of bodies and faces which represent clamps orobstructions that are not to be machined

• Cut Area geometry represents the areas on the Part to be machined; itcan be some or all of the part

• Trim geometry consists of closed boundaries which indicate where materialwill be left or removed; all Trim boundaries have tool positions on only

During tool path generation, the geometry is traced, steep areas and traceshapes are determined, cut areas are identified and a tool path is generatedfor all cut depths specified.


3

Z-Level Milling

Activity: Z-Level Milling

In this activity, you will generate tool paths using Z-Level Milling. Z-Levelis designed to profile an entire part or steep areas that were previously leftby the roughing operations.

Step 1: Open the part file and enter the Manufacturing application.

Open the part base_mfg_3.

Rename the part ***_base_mfg_3 using the File → Save Asoption on the menu bar.

Start the Manufacturing application if necessary.


Choose the Operation Navigator tab from the Resource Barand change to the Program Order View.

Expand the BASE_MALE_DIE group.

Step 3: Create a Z-Level operation.

Click Create Operation on the Manufacturing Createtool bar.

Make sure Type is set to mill_contour.

In the Operation Subtype group, click ZLEVEL_PROFILE

.


3

Z-Level Milling

In the Location group set the following parameters:

• Set Program to BASE_MALE_DIE.

• Set Tool to EM_1.25_.25.

• Set Geometry to WORKPIECE

• Set Method to MILL_FINISH

• Name the operation zlevel_finish.

Click OK.

The Zlevel Profile dialog box is displayed.

Step 4: Change the Depth of Cut.

For ease of viewing turn model shading off.

In the Path Settings group, set Global Depth per Cut to 0.100.

You will now change the cut levels. You will stop cutting materialat the top of the bottom face. The default is the bottom face ofthe part.

Click Cut Levels .

The Cut Levels dialog box is displayed, and plane symbols appearon our part which represent Ranges and Levels.


3

Z-Level Milling

Select the Downward icon and observe the Range change andthe highlighted area move down on the model.

Index to the 4th range and click Delete Current Range .

Choose OK.




3

Z-Level Milling

Step 6: Verify the Program that you have created.

Click Toolpath Verification to examine the tool pathresults.

Choose OK to accept the operation.

Save and Close the part file.


3

Z-Level Milling

Steep AngleThe steepness of the part at any given area is defined by the angle betweenthe tool axis and the normal of the face. The steep area is the area where thesteepness of the part is greater than the specified Steep Angle. When theSteep Angle is toggled on, areas of the part with a steepness greater than orequal to the specified Steep Angle are cut. When the Steep Angle is toggledoff, the part, as defined by the part geometry and any limiting cut areageometry, is cut.


3

Z-Level Milling

Activity: ZLEVEL_PROFILE_STEEP OperationsIn this activity, you will create a ZLEVEL_PROFILE_STEEP operation tomachine all of the steep geometry located within the cavity. You will use theGeometry Parent Group, WORKPIECE that contains all of the Part geometry.The tool path will cut only within the Steep areas specified.


Open the part steep_form_mfg.

Rename the part ***_steep_form_mfg using the File→ SaveAs option on the menu bar.

Enter the Manufacturing application.


Choose the Operation Navigator tab from the Resource Barand change to Geometry View.

The MCS_MILL Parent Group is displayed in the OperationNavigator.

Expand the MCS_MILL and WORKPIECE Geometry ParentGroups.

The CM_ROUGH operation is listed in the Operation Navigatoralong with a MILL_AREA that will be used in our activity.


3

Z-Level Milling

Change the view of the Operation Navigator to the ProgramOrder View.

Step 3: Create the ZLEVEL_PROFILE operation.

Select Create Operation from the Manufacturing Createtoolbar.

The Create Operation dialog box is displayed.

Select mill_contour from the Type pull down, if required.

In the Operation Subtype group, select ZLEVEL_PROFILE

.

Set the following:

• Program: INTERIOR-PROGRAM

• Tool: EM-.500-.06

• Geometry: MILL_AREA

• Method: MILL_FINISH

Click OK.


In the Geometry group, click Edit (beside Geometry).

In the Mill Area dialog box, click Display next to SpecifyPart.

The entire part highlights.

In the Mill Area dialog box, click Display next to SpecifyCut Area.

Only the inside faces highlight.

Click OK to return to the Z-Level Profile dialog box

Step 4: Set the Steep Parameter and Depth of Cut.


3

Z-Level Milling

In the Path Settings group, click the Steep Containment pulldown and select Steep Only.

The Angle option appears and is defaulted to 65 Degree.

Set Global Depth per Cut to .125.


Click Generate and generate the tool path.

Choose OK to save the operation.

Step 6: Verify the tool path

With Program Order View on in the Operation Navigator,right-click on INTERIOR-PROGRAM→Tool Path→Verify

The Tool Path Visualization dialog box is displayed.

Click the 3D Dynamic tab.

Select Suppress Animation near the bottom of the dialog box.

Click Forward to Next Operation .

The system prepares a display of what our stock looks like afterthe two operations, but we do not need to watch the step by stepmaterial removal.

Notice the areas cut by the tool paths. Many of theareas near the blends were not machined so that anotheroperation with a more appropriate tool radius could be used.Remember that the Steep Angle was set to 65 degrees andmay need to be changed.


Save the part file, but do not close as you will be using it inthe next activity.

Minimum Cut Length

Minimum Cut Length enables the elimination of short tool path segmentsthat may occur in isolated areas of the part. Moves shorter than this valueare not generated.


3

Z-Level Milling

Depth Per Cut

Depth Per Cut allows the specification of the maximum depth per cut ina range. Cut depths are calculated that are equal and do not exceed thespecified Depth Per Cut value.

Cut Order

Z-Level Milling determines cut traces by shape. Shapes can be profiled byDepth First in which each shape is completely profiled before beginning toprofile the next shape. Shapes can also be profiled by Level First in which allshapes are profiled at a particular level before cutting each shape at thenext level.

This is an example of Depth First in which the right raised area was cut first,then the cutter was picked up and the left side was then cut and then theoperation went around the base till completion.


3

Z-Level Milling

Activity: Z-Level Profile MillingIn this activity, you will create a Z-Level Profile operation to machine thegeometry of the island within the cavity. You will create a Mill Area GeometryGroup that contains the geometry necessary for machining the island. Thetool path will cut only within the area that has been specified.

Step 1: Create the Geometry Parent Group.

Continue using ***_steep_form_mfg.

Select Create Geometry from the Manufacturing Createtool bar.

The Create Geometry dialog box is displayed.


In the Geometry Subtype group, click Mill_Area .

If necessary, set the Geometry Location to WORKPIECE.

Enter ZLEVEL_AREA as the Name.

Click OK.

The Mill Area dialog box is displayed.

Click Specify Cut Area .

The Cut Area dialog box is displayed.


3

Z-Level Milling

Select the interior island geometry as shown. Having themodel in a top view will aid in the selection process.

Make sure that the system you are using has the Preference→ Selection Multi-Selection set to Rectangle for the MouseGesture, and Inside for the Selection rule.

Click OK.

To briefly review —– you have created a Geometry Parent Group,named ZLEVEL_AREA which contains the geometry of the island.This Geometry Group will be used in the ZLEVEL_PROFILEoperation.

You will now create the operation.

Step 2: Create the ZLEVEL_PROFILE Operation.

On the Manufacturing Workpiece toolbar, select Create

Operation .

In the Operation Subtype group, click ZLEVEL_PROFILE

.


3

Z-Level Milling

Set the following:

Program: INTERIOR-PROGRAM

Tool: EM-.500-.06

Geometry: ZLEVEL_AREA

Method: MILL_FINISH

Click OK.

The ZLEVEL_PROFILE dialog box is displayed.

The Part geometry is displayed. It was specified in theWORKPIECE Parent Group.

In the Geometry group, select Cut Area and choose Display

.

The Cut Area geometry is displayed. It was specified in theZLEVEL_AREA Parent under the WORKPIECE Parent Group.

Change the Global Depth per Cut to .15.



3

Z-Level Milling





3

Z-Level Milling

Z-Level Cutting Between Levels (aka Gap Machining)Z-Level cutting between levels, commonly referred to as Gap Machining,creates extra cut levels (2) when gaps occur due to the occurrence of non-steep(1) areas. This avoids the creation of separate Area Milling operations or,in some cases, the use of extremely small depths of cut to control excessivescallop heights in non-steep areas.

Resultant tool paths from Gap Machining produce uniform scallops,regardless of the angle of steepness, incorporating fewer engages and retracts,producing a more consistent surface finish.

Stepover option

Stepover pertains to machining the gap areas.

When used with the default Use Depth of Cut parameter, the stepovermatches the depth of cut of the current cut range.


3

Z-Level Milling

Max Cut Traverse option

Max Cut Traverse defines the longest distance that the cutting tool feedsalong the part when not cutting.

Sequencing of Gap and Z-Level tool paths

Z-Level and gap tool paths are sequenced and ordered as follows:

• Z-Level tool path is machined from the top-down and uses the sameconnection methods as it would without the Cut Between Levels option

• When a gap is discovered, the gap is cut, cutting continues until anothergap is found or the cut is complete at that level.

Z-Level Gap machining is activated from the Cut Parameters dialog box byselecting the Connections tab and selection of Cut Between Levels. Modify theparameters on that dialog box as needed.

Additional information on Z-Level Gap Machining can be found in theon-line documentation from within the NX Help pull down.


3

Z-Level Milling

Activity: Z-Level Gap MachiningIn this activity, you will activate Gap Machining option in an existing Z-Leveloperation.


Choose File → Open → male_cover_mfg.

Rename the part ***_male_cover_mfg using the File → SaveAs option on the menu bar.


If necessary, display the Operation Navigator in the ProgramOrder view.

Step 2: Replay an existing Z-Level operation.

Double-click on the ZLEVEL_PROFILE operation for editingpurposes.


Click Replay .


3

Z-Level Milling

The tool path is displayed. Note the non-steep areas and thenumerous engage retracts that occur.

The operation does a fairly good job of machining the steepgeometry but does not machine the non-steep area very well. Youwill now turn on the Cut Between Levels (Gap Machining) optionto completely finish machine the part in one complete operation.


The Cut Parameters dialog box is displayed.

Click the Connections tab.

Turn On the Cut Between Levels option.

Set the Stepover to Constant.

Change the Distance to 0.15.

ChooseOK.



3

Z-Level Milling


The non-steep areas are now machined as well as the steep areasof the part.




3

Z-Level Milling

SummaryThis lesson was an introduction to Z-Level milling, which is used whenprofiling steep areas (the steepness of the part at any given area is defined bythe angle between the tool axis and the normal of the face). This operationtype is useful in minimizing the amount of scallop or cusps that remainson the part.

In this lesson you:

• Created an operation using Z-Level Profile operation types.

• Reviewed and generated operations using Z-Level operationsincorporating Steep options.

• Reviewed and generated operations using Z-Level operationsincorporating Cut Between Levels (Gap machining).


4

Lesson

4 Fixed Contour operation types

Purpose

This lesson will show you how to create a Fixed Contour operation usingseveral of the options and concepts that are unique to Fixed Contourmachining. You will also review the steps necessary to create various ParentGroups that will aid you in the selection of geometry and cutting tools. FixedContour operations are generally used for creation of tool paths used to finishthe contoured areas of a part.

Objective


• Use the Fixed Contour Area Milling and Flow Cut Drive methods tocreate tool paths

• Create Geometry Groups used for Fixed Contouring operations

• Choose the most appropriate drive method for a Fixed Contour operation

• Apply the more advanced concepts of Fixed Contour operations forcreating tool paths


4

Fixed Contour operation types

Fixed Contour overviewFixed Contour operations are used to finish areas formed by contouredgeometry. Fixed Contour tool paths are able to follow complex contours bythe control of tool axis, projection vector and drive methods. Tool paths arecreated in two steps. The first step generates drive points from the drivegeometry. The second step projects the drive points along a projection vectorto the part geometry.

The drive points are created from some or all of the part geometry, or can becreated from other geometry that is not associated with the part. The pointsare then projected to the part geometry.

The tool path is created on the selected part surfaces by projecting pointsfrom the drive surface in the direction of a specified projection vector. If partsurfaces are not defined, the tool path can be created directly on the drivesurface.

Terminology used in Fixed Contour operations

• Part Geometry - is geometry selected to cut.

• Check Geometry - is geometry selected that is used to stop tool movement.

• Drive Geometry - is geometry used to generate drive points.

• Drive Points - are generated from the drive geometry and projected ontothe part geometry.

• Drive Method - method of defining drive points required to create a toolpath. Some drive methods allow the creation of a string of drive pointsalong a curve while others allow the creation of an array of drive pointswithin an area.

• Projection Vector - used to describe how the drive points project to thepart surface and which side of the part surface the tool contacts. Theselected drive method determines which projection vectors are available.

The projection vector does not need to coincide with the tool axisvector.

Drive methods for Fixed Contouring

The Drive method defines the method of creating drive points.

Each drive method contains a series of dialogs that are displayed uponselection.


4


Area Milling drive method

The Area Milling drive method allows you to specify a cut area for tool pathgeneration.

Cut Area(s) may be defined by selecting surface regions, sheet bodies, orfaces. They can be selected in any order.

If you do not specify a Cut Area, the processor will use the selected partgeometry (excluding areas not accessible by the tool) as the cut area.

Surface drive method

The Surface Area drive method allows you to create an array of drivepoints that lie on an orderly grid of faces, and must share a common edge;they must not contain gaps that exceed the Chaining Tolerance definedunder Preferences (Preferences→Selection→Chaining Tolerance). Trimmedsurfaces can be used to define drive surfaces as long as the trimmed surfacehas four sides.

Tool Path drive method

The Tool Path drive method allows you to define drive points along the toolpath of a Cutter Location Source File (CLSF) to create a similar tool path.

Radial Cut drive method

The Radial Cut drive method allows you to generate drive paths perpendicularto and along a given boundary, using a specified Stepover distance, Bandwidthand Cut Type. This method is useful in creating cleanup operations.

Flow Cut drive method

Flow Cut drive methods allows you to generate drive points along concavecorners and valleys formed by part surfaces. The direction and order of theflow cuts are determined using rules based on machining best practices.

Text drive method

Text drive methods allows you to generate drive paths based on text createdfrom drafting notes.

User Function drive method

The User Function drive method creates tool paths from special drivemethods developed in User Function code.

Geometry groups associated with Fixed Contour operations

There are three different Geometry groups available for use in Fixed Contouroperations. They are:


4


• The MILL_GEOM group which allows part, blank and check geometry.

• The MILL_BND group which also allows part, blank, check and trimand floor boundary geometry.

• The MILL_AREA group allows part and check but not blank geometry. Italso allows for the specification of Cut Areas ,Wall and Trim geometry.

Fixed Contour operations are generally used to finish contoured types ofgeometry.


The Fixed Contour operation types are:

• FIXED_CONTOUR - Generic Fixed Contour operation type. Allowsselection of various drive methods and cut types. Use when other FixedContour operation types are not applicable.

• CONTOUR_AREA - Uses Area Milling drive method. Ideal forcutting specific areas of part geometry for semi finish or finishing cuts.

• CONTOUR_AREA_NON_STEEP - Controls how steep you can cut up anddown due to cutter issues.

• CONTOUR_AREA_DIR_STEEP - Allows steep areas to be cut with respectto the direction of cut.

• CONTOUR_SURFACE_AREA - Uses Surface Area drive methodwhere orderly rows and columns of faces (grids) are available.

• STREAMLINE - Operation is new for NX5 and will be covered in a laterlesson.

• FLOWCUT_REF_TOOL - Operations have 4 main operations: 1)Flowcut Single Pass, one pass down a groove. 2) Flowcut Multiple Pass,Multiple passes down a groove. 3) Flowcut Multiple Pass Reference Tool,uses previous tool to control ares to be cut. 4) Flowcut Smooth, usessmooth loops to exit and engage.


4


• PROFILE_3D - Generates a profile pass utilizing three dimensionalcurves, edges, faces, existing boundaries or points. Machines at a givenZ-depth offset with respect to the geometry type selected.


4


More on Flow Cut drive methods

The Flow Cut drive method allows the specification of Climb, Conventional,or Mixed cut directions for single pass operations.

The Climb and Conventional options allow the climb or conventional methodfor all cutting passes in the operation. If a steep side can be determined, thesteep side is used to calculate the Climb or Conventional cut direction. If asteep side cannot be determined, the cut direction is determined internally.

The Mixed option allows for the internal calculation of the cut direction.


4


Flow Cut drive method using Cut Area and Trim Boundary Geometry

The Flow Cut drive method allows Cut Area geometry to be defined the sameway as the Area Milling drive method. Concave valleys are analyzed withinthe cut area as well as concave valleys formed by the cut area and partgeometry. Valleys formed by the cut area and check geometry are excluded.

Trim boundaries:

• Are defined as an “On” condition

• Are defined as “Trim Inside” or “Trim Outside”.

• Can be used to further constrain cut regions.

• Can be multiple for needed control.

• Can have stock added.

Flow Cut Reference Tool Drive Method

Flow Cut Reference Tool drive method uses the previously used tool diameterto determine the width that needs to be cleaned up with multiple passes atuser defined stopovers. The user can control order of cuts, amount of overlapand any steep containment.

Flow Cut options

Maximum Concavity controls where Flow Cuts are created based on theAngle of Concavity that is defaulted to 179 degrees.

Minimum Cut Length allows the removal of short cut motion, defaulted to avalue of .030

Hookup Distance allows you to eliminate small gaps in the cut motiondefaulted to a value of .030

Cut Type is either Zig, Zig Zag or Zig with Lifts.

Stepover Distance allows you to specify the distance between passes,defaulted to .100.

Sequencing enables you to determine the order in which the cut passes areexecuted.

Inside-Out starts in the center and moves to the outside with the passes.

Outside-In starts on the outside passes, and works to the center.

Steep Last starts the cut motion from non-steep side to the steep side.

Steep First starts on the Outside of the steep to the outside of the non-steep.

Inside Out Alternate cuts a Flow Cut valley from the middle to the outside.


4


Outside In Alternate cuts a Flow Cut valley from outside towards the middle

Reference Tool Diameter lets you specify the diameter of the tool from theprevious operation on this part of the part.

Overlap Distance enables you to extend the width of the area defined by theReference Tool Diameter along the tangent surfaces.

Steep enables the use of steepness to control the cut regions and their cutdirections.

Much additional information on Flow Cut can be found in the Help →Documentation NX5 Help Library → Manufacturing → ManufacturingMilling → Fixed and Variable Contour → Fixed Only → Flow Cut DriveMethods and then choose the area of interest.


4


Activity: Create Fixed Contour operations

The following activity creates simple Fixed Contour rough and finishoperations. You will first review a Cavity Milling operation that was used torough the majority of the part. You will then create Contour Area operationsthat will semi-finish and finish the part. Finally, you will use Flow Cutoperations, using a Reference Tool, to remove stock that remained fromprevious operations.

Step 1: Open the part file, rename and enter the Manufacturingapplication.

Open the part male_cover_mfg_3.

Save As ***_male_cover_mfg_3 .

Enter theManufacturing application and display the OperationNavigator in the Program Order.

Step 2: Review the Cavity Milling roughing operation.

This part file contains a Cavity Milling operation that rough cutsthe part.

Highlight the ROUGH_CM operation, right-click Tool Path andselect Verify.

Click the 3D Dynamics tab

Select the Suppress Animation check box.

Click Forward to Next Operation .


4


After a momentary pause, the system will show the 3D Dynamicsdisplay

Note that a number of .250 steps were left in the material as aresult of the specified Cut Level. Also, .050 Floor and Side Stockwere specified in the operation.


You will create a Fixed Contour operation to semi-finish machinethe part.

Step 3: Create a Fixed Contour operation to semi-finish the part.


Operation .


In the Operation Subtype group, click CONTOUR_AREA

.

In the Location group, set:

• Program to MALE_COVER

• Tool to BALLMILL-1.00

• Geometry to WORKPIECE

• Method to MILL_SEMI_FINISH

Enter the Name as semi_rough_fc.

Choose OK.

The Contour Area dialog box is displayed.

In the Geometry group, next to Specify Part click Display

and check geometry.

In the Drive Method group, click Edit .

The Area Milling Drive Method dialog box is displayed.


4


In the Drive Settings group set or verify the following options:

• Pattern to Parallel Lines

• Cut Type to Zig Zag

• Stepover to Tool Diameter

• Percent to 25

• Cut Angle to Automatic

Click OK.

Generate the tool path.

OK to accept the operation.

Step 4: Create a Fixed Contour finishing operation using the ContourArea operation type.

On the Manufacturing Workpiece toolbar, click Create

Operation .

In the Operation Subtype group, click CONTOUR_AREA

.

In the Create Operation dialog box, set the following:




• Method to MILL_FINISH

For Name type finish_fc.

Click OK.

The Contour Area dialog box is displayed.

In the Drive Method group, choose Area Milling.


4


The Area Milling Method dialog box is displayed.

Set the following options:

• Pattern to Follow Periphery

• Tool motion to Outward

• Stepover to Scallop

• Height to .002

• Stepover Applied to On Plane.

Choose OK.


Your tool path should look similar to the above.


Step 5: Create a Flow Cut finishing operation.

The tool could not fit into some areas of the part geometry becauseof tool size. You will use a Flow Cut operation and a smaller toolto remove uncut areas.


4



Operation .

The Create Operation dialog box appears.

In the Operation Subtype group, click FLOWCUT_REF_TOOL

.

In the Location group, set:




• Method to MILL_FINISH

Enter the Name as flow_fc.

Click OK.

The Flowcut Reference Tool dialog box is displayed.

Note that on the dialog box there is no Drive Method label sinceFlow Cut is the Drive Method.

Step 6: Change the Reference Tool setting.

You will change the Reference Tool setting. The previous tool usedwas a 1.00 diameter tool.

Expand the Reference Tool group.

Enter 1.00 in the Ref. Tool Diameter value field.

Leave the Overlap distance set to .03. The amount of overlap withthe previous operation may change due to size of cutters and yourcompany preferences.



4


Click Generate .

Note that the area being cut is in reference to the 1.000 ReferenceTool diameter.

Choose OK.

Save and Close the part.


4


Cut Area

In the previous activity, we attacked the entire part with our operations forsemi-finish and finishing. Now we are going to break our part down intosmaller pieces. This may be due to machine time consideration or other shopdriven reasons.

If an area of our part requires numerous machining operation on any givenarea, then a separate Geometry Group should be made under the CreateGeometry group. We are going to create our Cut Area as a Geometry Group.

We will break our part down to an even smaller machining area by using aTrim Boundary in the next activity.

Only faces and sheet bodies can be selected for Cut Area geometry. TheFeatures option allows surface regions (groups of faces or sheet bodies) forselection purposes.


4


Activity: Mill Area geometry groups

This activity will demonstrate how to create and use a MILL_AREA geometrygroup in an operation. You will Replay and examine the results of an existingoperation. You will then create a MILL_AREA geometry group consisting offaces and will modify the inheritance of the operation to use the MILL_AREAparent.

Step 1: Open the part file, rename it, and enter the Manufacturingapplication.

Open the part male_cover_mfg_2.

Rename the part ***_male_cover_mfg_2 using the File→ SaveAs option on the menu bar.

Choose Start → Manufacturing .

Change the Operation Navigator to the Geometry View.

Expand the MCS_MILL and WORKPIECE geometry groups.

Step 2: Replay the current operation.


4


Highlight the FC_FINISH_RIBS operation, right–click andselect Replay.

This Fixed Contour operation machines the entire part. This is notthe desired result.

In the next steps, you will create a MILL_AREA geometry group tolimit the machining to just the two ribs protruding from the part.

Refresh the graphics screen.

There are at least three ways to refresh the screen:

1. Right–click→ Refresh

2. Press the F5 button

3. From the top menu bar, choose View→ Refresh

Step 3: Create the MILL_AREA geometry group.

On the Manufacturing Create toolbar, click Create Geometry

.

If necessary, change the Type to mill_contour.

Set the Geometry Subtype to MILL_AREA .

In the Location group, set Geometry to WORKPIECE.

In the Name field, type two_ribs.


4


Click OK.

The MILL_AREA dialog box is displayed.

Step 4: Define the Cut Area geometry.

Click Cut Area .

At this time, it will make it easier to select the rib faces byselecting the Assembly Navigator Tab and unchecking thered check mark in front of the male_cover_stock, bolt_5 andthe male_cover_mach_plate components. This will preventthe selection of faces that are not part of the Workpiece.

Rotating the model to a top view would let you do arectangular box selection of the faces in the two areas.

Choose the faces of the ribs, as shown.

When finished selecting the faces, choose OK.

When using the rectangular selection method, you mayaccidentally select some of the faces in the bottom face. Theywill not be machined so they can be left in the Geometrygroup, or they can be de-selected by holding down the Shiftkey and pick them again.

Choose OK again to accept the dialog box.

Step 5: Change the inheritance of the operation.

You will move the FC_FINISH_RIBS operation, so that theoperation will machine only the faces specified.


4


Click and drag the FC_FINISH_RIBS operation so that itresides under the TWO_RIBS Parent Group, then release themouse click.

Highlight the FC_FINISH_RIBS operation, right-click, selectGenerate from the pop-up menu.

The tool path is generated and cuts the faces selected in theMILL_AREA group.


Save the part file, but do not close, as we will use it in thenext activity.


4


Trim Boundary

A Trim Boundary is like any other boundary except it can control the toolpath and prevent the generation either inside or outside of the boundary.

A Trim Boundary can be part of the Mill Area Geometry group, or as anaddition to the operation. Does the area in question require multiplemachining will determine where it should be placed.


4


Activity: Trim Boundaries

In this activity, you will create a trim boundary inside of a MILL_AREAParent Group and will then generate the corresponding operation.

Step 1: Continue using the part file.

Continue using ***_male_cover_mfg_2.

Step 2: Create a Trim Boundary.

Change the view to TOP.

Change the Operation Navigator to the Geometry View.

You will now edit the operation.

Double-click on the TWO_RIBS geometry.

Click TRIM .

The boundary you will create will be developed using cursorlocation points.

For Filter Type click Point Boundary .

Change the Point Method to Cursor Location.

Notice that the Trim Side setting is defaulted to Inside. Thismeans that the area inside of the Trim Boundary will not bemachined. Changing to Outside would allow for machining onlyinside of the Trim Boundary.

Using four screen position points create a trim boundarysimilar to the one shown below.

Only four points are needed, as the boundary processor will closethe shape for you.


4


Choose OK to return to the main dialog box.


Generate the tool path for the FC_FINISH_RIBS operation andexamine the results.

Any tool path that falls within the Trim boundary is removed. Thisis because our Trim Side was set to Inside.



4


SummaryThis lesson introduced you to Fixed Contour operations that gives you theability to machine complex contour geometry with numerous options.

In this lesson you:

• Created Area Milling and Flow Cut operations.

• Made extensive use of the MILL_GEOM and MILL_BND parent group.


4

5

Lesson

5 Introduction to four and fiveaxis machining

Purpose

This lesson introduces the application of machining parts utilizing 4 and5 axis machining principles.

Objective

At the conclusion of this lesson, you will be able to:

• Create tool paths for 4-axis positioning and contouring operations.

• Properly place the MCS for multi-axis operations.


5

5

Introduction to four and five axis machining

Multi-Axis Machining conceptsThe majority of what NC/CNC programmers term as "multi-axis" can actuallybe considered fixed axis machining. The spindle axis, on some machines, isnot normal to the Z direction of the machine tool and the actual machiningdoes not force a change in any motion of the rotary axis. This case considersusing the rotary axis for positioning mode only.

Programming of this type of operation is relatively simple, once youunderstand some of the more basic concepts of multi-axis machining. Someconcepts for considerations are:

• NX always requires a tool axis; if one is not specified, the default tool axisis equal to the Z of the MCS (sometimes referred to by the vector of 0,0,1)

• Fixed-Axis machining with a tool axis other than (0,0,1) involves settingthe tool axis to the proper orientation

• When performing multi-axis machining, never assume the tool axis iscurrently correct; always make sure you specify the proper tool axis if itis not 0,0,1

• Prior to rotation of the table to a new position, verify the tool has beenretracted far enough to clear the part/fixture during rotational moves

• It is a recommended practice to return the tool axis back to (0,0,1) at theend of the operation. Clearance Planes are also suggested.


5


Activity: Operations at other than 0,0,1 tool axis

In this activity, you will machine the top and two angled areas of a sleevecollar used in a yoke mechanism. All necessary Parent objects have beencreated and the part has been previously roughed. The operations which youwill create will finish mill the top and two angled faces of the part.

Step 1: Open an existing part file and enter the Manufacturing application.

Open the part file, collar_mfg_setup_1.

Choose Start→Manufacturing.

Click the Operation Navigator tab .

The Operation Navigator and the part are displayed.


5


Step 2: Create the finishing operation.

The operation, ROUGHING, already exists to rough the pad atthe top of the part. You will now create the operation to finishthat particular pad.

Click Create Operation .

Choose FACE_MILLING_AREA as the operation type.

Choose the following Parent objects:

Program FIXED_AXISTool EM-1.00-0Geometry TOPMethod MILL_FINISH

Note that the geometry parent contains a face that describesthe top of the part.

Also note that the tool used in this operation is a 1.00" diameterend mill with 0" corner radius.

Type top_face in the Name box.

Click OK.

The FACE_MILLING_AREA dialog box is displayed.

Select Follow Periphery from the Cut Pattern list..

Type 50 in the Perecnt box.

Generate the operation and then choose OK from the DisplayParameters dialog box.

The generated tool path is displayed.

Click OK to accept the operation.

Step 3: Verify the results.

You will now verify the results by using Tool Path Visualization.

If required, change to the Program Order View of the OperationNavigator.


5


Highlight the FIXED_AXIS program object.

Click Verify Tool Path .

In the Tool Path Visualization dialog box click the 2D Dynamictab.

Click Play .

Two operations will be replayed. The first operation is usedfor roughing, the second is the finish operation that you justcreated.

Verifying the operation indicates the tool path to be acceptable,you will now continue with the next operation.

Click Cancel.

Step 4: Create the first angled-face operation.

You will copy and rename the existing operation, TOP_FACE, touse as a template for creating the next operation.

Right-click TOP_FACE and choose Copy.


5


RIght-click TOP_FACE again and choose Paste.

A copy of the previous operation is created, with the nameTOP_FACE_COPY. You will now rename the operation toANGLE_FACE_1.

Right-click TOP_FACE_COPY and choose Rename, typeINSIDE_CHAMFER.

You will now change the geometry parent object.

Double-click the INSIDE_CHAMFER operation.

Select INSIDE_CHAMFER from the Geometry list.

Choose OK.

Choose Generate.

Choose OK on the Display Parameters dialog box.

The Operation Parameter Error dialog box is displayed.

This dialog box is informing you that the operation will notwork unless the tool axis is set normal to the floor axis. Youwill now redefine the tool axis normal to the floor.

Choose OK from the Operation Parameter Error dialog box.

As described earlier, there is always a defined tool axis. In thiscase, the tool axis is the same as the Z of the MCS. You will nowchange the tool axis to one that is normal to the floor plane of theINSIDE_CHAMFER geometry parent object.

Expand Tool Axis.

Select Specify Vector from the Tool Axis list

Click Specify Vector.


5


Select the angled face as shown in the following figure.

Choose OK until the FACE_MILLING dialog box is displayed.


Click OK to save the operation.


Use Verification to verify your tool path (refer to Step 3 fordetailed instructions).

Step 6: Create the second angled face operation.

You will use the copy/paste features of the Operation Navigator tocreate the third finish operation.

Highlight the INSIDE_FACE operation.

Right-click→ Copy.

Right-click→Paste.

Change the name of the new operation toOUTSIDE_CHAMFER.

Edit the operation by doubling-clicking onOUTSIDE_CHAMFER.

Select OUTSIDE_CHAMFER from the Geometry list.

Choose Specify Vector from the Tool Axis list.


5


Click Inferred Vector .

Select the angled face as shown in the following figure.

Click Generate.

Choose OK on the FACE_MILLING_AREA dialog box to savethe operation.


Use Verification to verify the tool path.

Close the part file without saving.


5


Define the center of rotation for a rotary axisTo machine about a rotary axis, the position of the rotary axis must bedefined. There are two methods to accomplish this:

• Place the WCS/MCS at the center of axis rotation. For a 4 or 5 axismachine tool, position the Main MCS at the center of rotation of the 4thor 5th axis.

• Designate the MCS as a geometry group, consisting of both a Main andLocal MCS. This is used by the NX/POST post processor as either fixtureoffsets or machine tool zero data.

Place the MCS at the center of axis rotation

Position the part on the fixture in a normal position. Place the MCS at thecenter of rotation of the fourth axis.

At the machine tool, the operator will then set the rotary table center asthe zero point.

Advantages:

• Simplest method to use and deploy

• Considerably less work for the NC/CNC programmer

Disadvantages:

• Output in created program does not match output or dimensions on partprint

• Adjustment of fixtures may require some type of reprogramming

Designate the MCS as a geometry group, consisting of both a main andlocal MCS

The programmer designates the purpose of the coordinate system as eitherMain or Local in the geometry group. When post processing, using the localMCS, the data of the Main and Local coordinate system are used and theoutput will then match the print dimensions.

If the coordinate system is designated Local, then a special output parametercan be specified for the coordinate system. The options available are:

• None

• Use the Main MCS

• Fixture Offset

• CSYS rotation


5


The default setting is Fixture Offset. The designated option setting is thenpassed to the post processor, along with the Main and Local coordinate systemto output the appropriate fixture offset values (G54...G59). The post processorneeds to be modified for this action to occur.

Advantages:

• Output in the program matches the part print

• Fixture adjustments can be solved by changing the Main and Localdesignation

Disadvantages:

• Programmer needs to understand the complexities associated with use ofthe Main and Local coordinate system and the options provided

• May be more confusing for machine operators

• Machine tool post processor must be set up to obtain the correct output

The following activity will address using a Main and Local MCS.


5


Activity: Main and local MCS in multi-axis applications

In this activity, you will use the Main and Local MCS. The the main and localMCS have been created for you. The Main MCS is set at the machine zero.When you list the tool paths, the output is based on the Local MCS. Whenyou post the program, the output of the tool paths, with their respective X,Y, and Z values, are based upon the Main MCS.


Open the part file t_stone_mfg_assm.

Save the part as ***_t_stone_mfg_assm.

If necessary, choose Start→Manufacturing.

Step 2: Examine the Local and Main coordinate systems.

If required, change to the Geometry view of the OperationNavigator.


5


Expand the WORKPIECE group object and all subsequentobjects contained within the WORKPIECE parent.

You will notice that the WORKPIECE parent contains threedifferent MCS coordinate systems. You will now examine eachone.

Double-click on the MCS_MAIN group object.

The MILL_ORIENT dialog box is displayed.

Expand the Details arrow to see the Coordinate SystemPurpose options.

Note that the Coordinate System Purpose selected is Main.

Choose OK.

Double-click on the MCS_000 group object.

TheMILL_ORIENT dialog box is displayed.

Expand the Details arrow to see the coordinate system purposeoptions.

Note that the Coordinate System Purpose selected is Local, theSpecial Output is set to Use Main MCS, and the Fixture Offsetis set to 1.

Choose OK.


Expand the Details arrow if necessary arrow to see thecoordinate system purpose options.

Note that the Coordinate System Purpose selected is Local, theSpecial Output is also set to Use Main MCS, and the FixtureOffset is set to 2.


5


Choose OK.

You will now list the tool paths for the existing operations that usethe Local MCS and observe that the X, Y and Z values are outputfrom the Local MCS.

Step 3: Examine the tool path listing.

Highlight the FM_001 operation, replay and list the tool path.

Highlight the FM_002 operation, replay and list the tool path.

You will now post process the operations and note that the X, Yand Z values are based on the MAIN MCS.

Step 4: Post process the existing operations and examine the output.

Change to the Program Order view in the Operation Navigator.

Highlight the T_STONE parent group.

Click Postprocess .

Using the Browse button under Available Machines, browseto your parts directory and select the mcs_purpose.pui postprocessor.

Choose OK.

Choose Apply on the Postprocess dialog box.


5


If necessary, choose OK to the Path Out of Date dialog box.

The posted output is displayed.

Notice the values for the X, Y and Z axes.

Cancel the Postprocess dialog box.

Step 5: You will now modify the local MCS so the output is from the localMCS.

Change to the Geometry view of the Operation Navigator.

Edit theMCS_000 parent group and change the Special Outputto Fixture Offset.

Choose OK.

Repeat the above step action item for MCS_90 .

Choose OK.

Change to the Program Order view of the Operation Navigator.

Highlight the T_STONE parent group.

Click Postprocess .

The Postprocess dialog box is displayed.


5


If necessary, browse to your home directory and select themcs_purpose.pui postprocessor.

Choose OK.



If necessary, choose OK to overwrite Output File dialog box.


Notice the values for the X, Y and Z axes and compare with thepreviously posted output. The tool path is now output from thelocal MCS.



5


Activity: Main and local MCS in multi-axis applications

In this activity, you will use the Main and Local MCS.. The main and localMCS have been created for you. The Main MCS is set at the machine zerowould be. When you list the tool paths, all have the same X, Y, and Z valuessince they are based on the Local MCS. When you post process the program,the output of the three tool paths, with their respective X, Y, and Z values, arebased upon the Main MCS.


Open the part file mcs_local_main.

Save the part as ***_mcs_local_main.

If necessary, choose Start→Manufacturing.

Step 2: Examine the Local and Main coordinate systems.

If required, change to the Geometry view of the OperationNavigator.


5


Expand the WORKPIECE group object and all subsequentobjects contained within the WORKPIECE parent.

You will notice that the WORKPIECE parent contains fourdifferent MCS coordinate systems. You will now examine eachindividual one.

Double-click on the MCS_MAIN group object.

The MCS dialog box is displayed.

Expand the Details arrow.

Note that the Coordinate System Purpose selected is Main.

Choose OK.




Note that the Coordinate System Purpose selected is Local andthat Special Output is set to Use Main MCS.

Choose OK.






5


Choose OK.




Choose OK.

You will now list the tool paths for the existing operations thatuse the Local MCS and observe that the X, Y and Z values arethe same for each one.

Step 3: Examine the tool path listing.

Highlight the PROFILE_000 operation, replay and list thetool path.



Note that all the X, Y and Z values are the same.

You will now post process the three operations and note thatthe X, Y and Z values are based on the MAIN MCS.

Step 4: Post process the existing operations and examine the output.

Change to the Program Order view in the Operation Navigator.

Highlight the TT1346-AA parent group.

Click Postprocess .

Using the Browse button under Available Machines, browseto your parts directory and select the mam_mcs_mill.pui postprocessor.

Choose OK.



5




%N0010 G40 G17 G90 G70N0020 G91 G28 Z0.0:0030 T00 M06N0040 G00 G90 G53 X37.775 Y20.4 B0.0 S764 M03N0050 G43 Z-17.5 H00N0060 Z-17.9N0070 Z-18.4N0080 G01 Z-18.5 F1.4 M08N0090 G03 X37.575 Y20.5 I.2 J.15N0100 G01 X37.5N0110 X36.5 F1.5N0120 Y19.5N0130 X38.5N0140 Y20.5N0150 X37.425N0160 G03 X37.225 Y20.4 I0.0 J.25N0170 G00 Z-17.5N0180 G00 X29.6 Y27.775 B0.0 S764 M03N0190 Z-17.9N0200 Z-18.4

Notice the values for the X, Y and Z axes.

You will now modify the local MCS by adding fixture offsets andwill re-post the operations.

Cancel the Postprocess dialog box.

Step 5: Modify the Local MCS by adding fixture offsets and re-postingthe operations.

Change to the Geometry view of the Operation Navigator.

Edit the MCS_000 parent group, type 1 for the Fixture Offsetand change the Special Output to Fixture Offset.

Repeat the above step action item for MCS_90 and MCS_180parent groups, using 2 as the fixture offset for the MCS_90parent group and 3 as the fixture offset for the MCS_180parent group.

Choose OK.

Change to the Program Order view of the Operation Navigator.

Right-click the program TT1346–AA and choose Generate.

ClickOK as needed until you return to the Operation Navigator.

Highlight the TT1346-AA parent group.


5


Click Postprocess .

The Postprocess dialog box is displayed.

If necessary, browse to your home directory and select themam_mcs_mill.pui post processor.

Choose OK.



If necessary, choose OK to overwrite Output File dialog box.


%N0010 G40 G17 G90 G70N0020 G91 G28 Z0.0:0030 T00 M06N0040 G00 G90 G54 X1.7 Y.4 B0.0 S764 M03N0050 G43 Z.5 H00N0060 Z-.4N0070 G01 Z-.5 F1.4 M08N0080 G03 X1.5 Y.5 I.2 J.15N0090 G01 X.5 F1.5N0100 Y-.5N0110 X2.5N0120 Y.5N0130 X1.5N0140 X1.35N0150 G03 X1.15 Y.4 I0.0 J.25N0160 G00 Z-.4N0170 Z.5N0180 G00 G55 X1.7 Y.4 B0.0 S764 M03N0190 Z-.4N0200 G01 Z-.5 F1.4N0210 G03 X1.5 Y.5 I.2 J.15N0220 G01 X.5 F1.5N0230 Y-.5

Notice the values for the X, Y and Z axes and compare with thepreviously posted output. Also note the G54, G55 and G56 that isused for fixture offsets.



5


SummaryThe majority of "multi-axis" machining can actually be considered to beplanar or fixed axis in nature. The spindle axis, on some machines, is notnormal to the Z direction of the machine tool and the actual machining doesnot force a change in rotation of the rotary axis. Designation of tool axis andMCS is crucial to perform this type of work.

In this lesson you:

• Performed planar type machining at a tool axis other than (0,0,1).

• Specified the MCS at the center of rotation for multi-axis machining.


6

Lesson

6 Five Axis Z Level

Purpose

The Z Level Five Axis operations allow you to create Z level operations withthe addition of four and five axis options. These operations can then beutilized for roughing and finishing multi axis and deep wall parts.

Objective


• Create five axis Z Level operations

• Create Z Level operations utilizing tool axis tilt options.

• Optimize Z Level Cut Depths.


6

6

Five Axis Z Level

Z Level Five Axis OverviewZ Level Five Axis applies a tool axis to the Z Level tool path. Z Level FiveAxis tool paths are planar Z Level paths, the tool axis tilt is applied to thepath. Z Level Five Axis can apply the tool axis tilt using several methods.


6

Five Axis Z Level

Tool Axis tilt

The following tool axis tilt options are available:

• Away From Part

• Away From Point

• Toward Point

• Away From Curve

• Toward Curve

Tilt Angle

The Tilt Angle can be set by using Specify or Automatic.

The Automatic Tilt angle is determined using the Maximum Wall Height andthe Part Safe Clearance. The Maximum Wall Height is the distance fromthe tool tip, along the tool axis that the wall is encountered. In the examplebelow, if the Maximum Wall Height is set to 1.5 the holder will avoid thegeometry using the 1.00 diameter of the holder plus the Part Safe Clearance.


6

Five Axis Z Level

This tool path was generated using an Maximum Wall Height of 1.00. The toolrests on the part surface but the tool holder interferes with the part geometry.

The same operation generated with a Maximum Wall Height of 2.00. Noticethat the tool leans over so the first diameter of the holder doesn’t collidewith the part. The Part Safe Clearance is the clearance distance for theholder. The large diameter still collides because the Maximum Wall Heightstill needs to be adjusted.


6

Five Axis Z Level

The same operation generated with an Maximum Wall Height of 3.00. Noticethat the tool tilts so the large diameter of the holder doesn’t collide withthe part.

Setting the Maximum Wall Height smaller can keep the tool from tiltingexcessively when your cuts aren’t going to cause interference.


6

Five Axis Z Level

Activity: Creating a Z Level Five Axis operation

In this activity, you will create a Z Level Five Axis operation. You will use anAway From Part tool axis with an Automatic tool axis tilt.

Step 1: Open and rename an existing part file.

Open the file zl_multi_axis_2_setup_1.

Rename the part to ***zl_multi_axis_2_setup_1.


The necessary Parent Groups (i.e. Geometry, Machine,Program and Method) have already been created for you.

Step 2: Create a Z Level Five Axis operation.

Choose Start→Manufacturing.


If necessary, change the Type to mill_multi-axis.

Click ZLEVEL_5AXIS .

Set the Parent objects as shown:

Program 1234Tool BN-10Geometry MILL_AREAMethod MILL_FINISH


6

Five Axis Z Level

Type away_part in the name box.

Click OK.

The Z Level 5 Axis dialog box is displayed.

The Tool Axis Tilt is set to Away From Part.

The cutting tool is 30 mm long, the tool holder is an additional30 mm. The tool will cut just over 56 mm deep, you will set theMaximum Wall Height to 60. Sixty is the total length of the tooland holder.

Type 60 in the Maximum Wall Height box.


Click Generate .

Orient your view to the left view and observe the tool axis. Thetool axis is tilted far enough to clear the entire tool holder.

Step 4: Verify the tool path and examine the tool axis.

Click Verify .

Change the Animation Speed to 3.

Click Play .

Click OK.

The tool axis tilts away from the part so that the entire tool holder clearsthe part geometry.

Click OK to return to the operation.



6

Five Axis Z Level

Activity: Changing the Maximum Wall Height

In this activity, you will create a Z Level Five Axis operation. You will use anAway From Part tool axis with an Automatic tool axis tilt. You will apply asmaller Maximum Wall Height.

Step 1: Create another Z Level Five Axis operation.




Set the Parent objects as shown;

Program 1234Tool BN-10Geometry MIL_AREAMethod MILL_FNIISH

Type max_wall in the Name box.

Click OK.

The Z Level 5 Axis dialog box is displayed.

The Tool Tilt Axis is set to Away From Part.The cutting tool is 30 mm long, the first step of the tool holder isan additional 15 mm. The tool will cut 50 mm deep so we will setthe Maximum Wall Height to 45. Forty-five is the total length ofthe tool and the first step of the holder.

Type 45 in the Maximum Wall Height box.

Step 2: Change the Cut Levels

Click Cut Levels .

Type 50 in the Range Depth box.

Click OK.

This tool path is set shallower to demonstrate the new tool axis.


6

Five Axis Z Level


Click Generate.

Right-click in the graphics screen and choose Orient view→Left.

Step 4: Verify the tool path and examine the tool axis.

Click Verify .

Change the Animation Speed to 3.

Click Play .

The tool axis tilts away from the part so that only the first step of the toolholder clears the part geometry. If the path was cut to the depth in theprevious operation the tool holder would collide with the part geometry.




6

Five Axis Z Level

More Tool Axis tilt options

In the previous activities you used an Away from part tool axis tilt and anautomatic angle. The following activities will examine some other tool axistilt options. These options include Away from part, Away from point, Towardpoint, Away from curve and Toward curve. All of the tool axis tilt optionsallow an Automatic or a Specified angle.

Tool Axis tilt methods

• Away from part — Tilts away from the part geometry at an angle relativeto the MCS Z axis.

• Away from point — Tilts away from the specified point at an angle tothe MCS Z axis.

• Toward point — Tilts toward the specified point at an angle to the MCS Zaxis.

• Away from curve — Tilts away from the curve or curves at an angle tothe MCS Z axis.

• Toward curve — Tilts toward the curve or curves at an angle to the MCSZ axis.


6

Five Axis Z Level

Activity: Away from point tool axis tilt

In this activity, you will machine the outside vertical walls of the part. TheAway from point tool axis tilt will be used.

Step 1: Continue using the ***_zl_multi_axis_2_setup_1.prt part andcreate a new operation.






Type point in the Name box.

Click OK to create the operation.


6

Five Axis Z Level

Step 2: Specify the tool axis tilt options.

Choose Away from point from the Tool Axis Tilt list.

Select the arc at the top of the part to select the arc center.

Click Specify from the Tilt Angle list.

Type 30 in the Degrees box.

Step 3: Generate and verify the tool path.

Click Generate .


6

Five Axis Z Level

Right-click in the graphics screen and Orient view to the top.

Click Verify .

Click Play .

The tool axis is tilted 30 degrees from the ZM axis about thepoint that was selected.


The tool axis is tilted away from the point along the curved portionof the part but also continues to rotate along the linear sectionof the part.



6

Five Axis Z Level

Activity: Away from curve tool axis tilt

In this activity, you will machine the outside vertical walls of the part. TheAway from curve tool axis will be used. You will use a single curve to controlthe tool axis. The tool axis will tilt away from the curve at the specified angle.

Step 1: Continue using the***_zl_multi_axis_2_setup_1 part and create anew operation.






Type curve in the Name box.



Click Format→Layer Settings.

Type 51 in the Work box.


6

Five Axis Z Level

Click OK.

You will select the line to control the tool axis tilt.

Choose Away from curve(s) from the Tool Axis Tilt list.

Select the curve as shown below.




Click Generate .


6

Five Axis Z Level

Right-click in the graphics screen and select Orient View→Top.

The tool axis tilts away from the selected curve at the anglespecified from the ZM axis.

Click Verify .

Click Play .




6

Five Axis Z Level

Activity: Away from multiple curve tool axis tilt

In this activity, you will machine the outside vertical walls of the part. TheAway from curve tool axis will be used. You will select multiple curves tocontrol the tool axis tilt.

Step 1: Continue using the***_zl_multi_axis_setup_1 part and create anew operation.




Set the Parent objects as shown;


Type multi_curve in the Name box.



6

Five Axis Z Level


Choose Away from curve(s) from the Tool Axis Tilt list.

Select the curves as shown below.




Click Generate .

Right-click in the graphics screen and select Orient→Top.

Click Verify .


6

Five Axis Z Level

Click Play .


The tool axis is tilted away from the arc along the cylindrical faceand away from the line along the planar face.



6

Five Axis Z Level

Optimized cut levelsOptimized adjusts the depth of cut to help maintain a more consistent on partspacing and scallop height. Optimized creates additional cuts as the slopechanges from steep or near vertical to shallow or flat. The maximum cutdepth does not exceed the Global Depth per Cut value.


6

Five Axis Z Level

Activity: Optimized cut levels

In this activity, you will machine around the fins of the part. The Away frompart tool axis tilt will be used. You will generate the path using constant cutdepths. Then you will optimize the cut levels and generate a new tool path.

Step 1: Open the impeller_zlevel_setup_2 part.




Program 1234Tool EM-3.0_BNGeometry MIL_AREAMethod MILL_SEMI_FINIISH

Type optimize in the Name box.

Click OK to create the operation


Choose Away from part from the Tool Axis Tilt list.




6

Five Axis Z Level

Step 3: Specify the cut levels.

Click Cut Levels .

Type 3.0 in the Global Depth per Cut.

Click OK.


Click Generate .

Click Verify .

Move the Animation Speed slider bar to 3.

Click Play .

The tool axis is tilted 3 degrees from the ZM axis away fromthe part geometry and the cut depths are constant.


Step 5: Optimize the cut levels to leave more consistent stock.

Click Cut Levels .


6

Five Axis Z Level

Choose Optimized from the Cut Levels list.

Click OK.


Click Generate .

Click Verify .

Click Play .

The tool axis is tilted 3 degrees from the ZM axis away from thepart geometry. The cut levels are closer together in the flatterareas of the part.




6

Five Axis Z Level

SummaryZ Level 5 Axis operations utilize tool axis tilt allowing shorter tools to beused. The tool axis is applied using ball nose cutters to planar cut levels.These cut levels are perpendicular to the Machine Coordinate System

You can now create 5 Axis Z Level operations and incorporate;

• Several tool axis tilt options.

• Constant and Optimized cut levels.


6

7

Lesson

7 Sequential Mill basics

Purpose

Sequential Mill operations allow you to machine contoured parts bycutting from one surface to the next in a sequence of moves referred to assuboperations. These suboperation types allow the flexibility to completelycontrol cutter movements to obtain desired results.

Objective


• Use Sequential Mill operations to create multi-axis tool paths

• Create Sequential Mill rough and finish operations


7

7

Sequential Mill basics

Sequential Milling overviewSequential Milling operations are used to finish cut part edges using lineartool motion. You can area machine using Sequential Mill, however, the areais limited to an offset from a single drive surface or a single part surface(or both).

Sequential Mill also provides tool axis control capabilities in maintaining atool position relative to drive and part geometry, recognizing multiple checksurfaces.


7


Sequential Milling terminology

The following terms pertain to Sequential Milling:

• Part surface controls the bottom of the tool

• Drive surface controls the side of the tool

• Check surface controls the tool stopping position

In the above illustration, the tool is in contact with the Part, Drive and Checksurfaces. The bottom of the tool follows the Part surface, the side of the toolfollows the Drive surface until the tool contacts the Check surface.

Several dialogs are used in Sequential milling. The operation starts with theSequential Mill dialog where you set global parameters and progresses tosuboperation dialogs that control each suboperation.


7


Global operation parameters

When you create a new Sequential Mill operation you first see the SequentialMill dialog where global operation parameters are set.

The Sequential Mill dialogbox -

Allows you to:

• Add stock to all drive andpart surfaces

• Specify a MinimumClearance value to be usedin Engage and Retractsuboperations

• Add Corner Control

• Specify Path Generationwhich determines whetherthe tool path is output foreach suboperation

• Multi-axis output

After creating or editing an operation, you choose End Operation eithergenerate the tool path, or save the operation without tool path generation.


7


Suboperations

After you set the Sequential Mill operation options you can create asuboperation to control tool motion.

Suboperations are individual tool motions. The four different types ofsuboperations are Engage, Continuous Path, Point to Point and Retractmotion.

Normally, you will use these suboperations in sequential order.

• Initially, specify an Engage move

• Then, specify Continuous Path motions

• At the end of the tool path, specify a Point to Point

• And then a Retract move


7


The Engage Motion

The Engage Motion suboperation defines where the tool initially contactsthe part. This is usually the first suboperation dialog box which you willencounter.

To create an Engage Motion suboperation you must

• Specify the Engage Method

• Specify a Reference Point

• Specify Geometry including Part, Drive and Check

Other options are also available.


7


The Continuous Path Motion dialog box

After engaging the part, the tool motion is determined by a series ofContinuous Path Motion (CPM) suboperations.

Each tool move requires specific Drive, Part and Check geometry:

• Drive geometry controls the side of the cutter

• Part geometry controls the bottom of the cutter

• Check geometry stops the cut movement

The cutter moves along the drive and part geometry until it reaches checkgeometry.


7


Point To Point Motion

The Point to Point motion enables you to create linear, non-cutting moves. Itis used to move the tool to another position where continuous path motionscan then continue. You may or may not need to use this dialog box whencreating Sequential Mill operations.

To create a Point to Point suboperation you must define the Motion Method


7


Retract Motion

The Retract Motion dialog box enables you to create a non-cutting move fromthe part to the avoidance geometry or to a defined retract point. It is similarto the Engage Motion.

To create a Retract Motion suboperation you must specify the Retract Method.


7


Define the Check Surfaces

When you are creating a Continuous Path Motion or Engage suboperations,you must define one or more Check Surfaces.

By default, the Check Surface for one suboperation becomes the Drive Surfacefor the next suboperation. This often saves you from having to specify theDrive Surface. The Part Surface, is by default, the same for each suboperationthroughout the tool path. This also saves you from having to specify thePart Surface. Normally, you only need to specify the Check Surface in eachsuboperation.

Before you specify the part, drive, and check geometry, you must indicatewhere the tool will stop. You have four possible choices:

• Near Side indicates that the tool will stop when it reaches the closest sideof the specified part relative to the current tool position

• Far Side indicates that the tool will stop when it reaches the farthest sideof the specified part relative to the current tool position

• On indicates that the tool will stop when its center axis reaches the edgeof the specified part relative to the current tool position

• Ds-Cs Tangency and Ps-Cs Tangency indicates that the tool will stop whenit is at the position that the drive (or part) surface is tangent to the checksurface

-

You must initially specify a tool Reference Point position to determine the sideof the drive, part, and check geometry for tool placement. This establishesdirection only.

Once you specify the Reference Point, you can specify the tool startingposition as the Near Side, Far Side, or On the Drive, Part, or Check geometry.


7


Multiple Check Surfaces

In a Continuous Path Motion command the cutter moves along the Drive andPart Surface until it reaches a Check Surface.

If you specify more than one Check Surface (multiple check surfaces), motioncontinues until the tool reaches the first of the possible stopping positions.

You can define up to five Check Surfaces for each Continuous Path Motionsuboperation. After you have defined the first Check Surface, you areautomatically prompted to define the next Check Surface.

The following activities will familiarize you with Sequential Mill operations.


7

7


Activity: Basic Sequential Milling techniques

In this activity, you will use basic interactions necessary to create SequentialMilling operations. You will drive a tool around a simple part, create severalsuboperations, and establish Drive, Part, and Check geometry used in thevarious operations.

Step 1: Open and rename an existing part file and then enter theManufacturing application.

Open the part file box_mfg.

Rename the part to ***_box_mfg.


The necessary Parent Groups (i.e. Geometry, Machine,Program and Method) have already been created for you.

Step 2: Create a Sequential Milling operation.

Choose the Create Operation icon



7


Click Sequential_Mill .

Set the Location objects as shown and name the operationSM_1:

Program BASIC_SMTool EM-1.00-0Geometry WORKPIECEMethod MILL_FNIISH

Choose OK.

The Sequential Mill dialog box is displayed.

This dialog box allows the input of basic global parametersthat are active throughout the operation (unless changed inan suboperation).

Click Display Options.

Choose 3-D from the Tool Display list.

Choose OK.

The global parameters are now set.

The Sequential Milling dialogs behave somewhat differentlythan other operation dialogs that you are normally familiarwith.

Choosing OK from the main dialog box results in thesuboperation dialog box being displayed. This is where theactual programming process takes place.

Choose OK from the Sequential Mill dialog box.

The Engage Motion suboperation dialog box is displayed. Bydefault, the suboperation dialog box is set to Engage.

To properly determine the tool’s current location for NearSide/Far Side, establish a Pt to Pt motion as the firstsuboperation.

Choose Pt to Pt from the Engage list.

The dialog box changes to match Point to Point motion.

You will now establish the tool position, specifying both theposition of the tool and the tool axis.


7


Choose Point, Tool Axis from the Motion Method list.

The Point Constructor dialog box is displayed.

Select the existing point:

Choose OK.

The Vector dialog box is displayed.

Click ZC Axis

Choose OK.

The Point to Point suboperation is complete. By choosing OK,the suboperation will be placed in the sub-op list and you willbe ready to create the next suboperation.

Choose OK.

You will now define the Engage component.

Change Pt to Pt to an Engage suboperation.

The Engage Motion dialog box is displayed.

This dialog box requires Drive, Part and Check geometry.Additionally, you may specify an engage method.

You will specify the geometry first and then the Engage method.


7


Click Geometry.

The Engage Geometry dialog box is displayed.

You will now select the Drive geometry.

Select the face as shown.

The geometry selection on the dialog box advances to Partgeometry.

You will now select the Part geometry.


7


Select the bottom of the pocket as the Part geometry.

The geometry selection on the dialog box advances to Checkgeometry.


7


Select the face, as shown below, as the Check geometry.

As soon as the last geometry is selected, the dialog box revertsto the Engage Motion suboperation.

You will now specify the Engage motion.

Click Engage Method.

The Engage Method dialog box is displayed.

Choose Vector Only from the Method list

The Vector Constructor dialog box is displayed.

Change Inferred Vector to By Coefficients.


7


Key in the following values:

I=-1.000

J= 1.000

K=-1.000

Choose OK.

Key in 0.500 in the Distance field of the Engage Method dialogbox.

Choose None from the Clearance Move list.

Choose OK twice.

The second suboperation, 2 Eng, is created. The tool side is nowpositioned tangent to Drive and Check geometry and tangentto the Part geometry with the bottom of the tool.

You will now create a Continuous Path Motion suboperation.

The arrow displayed at the bottom of the tool indicates thedirection of the next cut.


7


Notice the defaults for Drive Surf and Part Surf.

The Drive Surf is set to the Previous ds (drive surface). The PartSurf is set to the Previous ps (part surface). It will be necessaryto set the Check surface.

Choose the Check Surfaces button.

The Check Surfaces No. 1 dialog box is displayed.

You are now ready to select the Check surface. As soon as thesurface is selected, the dialog box advances to Check SurfaceNo. 2. It is important to specify any changes to the dialog boxbefore the surface is selected.

The current Drive surface is tangent to the next surface thatthe tool will drive to. You will change the stopping position toDrive Surface/Check Surface Tangency.

Change the Stopping Position to Ds-Cs Tangency.


7


Select the Blend face as shown.

There will not be a second Check surface to select.

Choose OK in the Check Surface dialog box.

Choose OK in the Continuous Path Motion dialog box.

The third suboperation, 3 cpm, has been created. You will nowcreate another CPM suboperation.

The processor has automatically forwarded the Drive surface tothe previous Check surface. It has also kept the previous Partsurface as the new Part surface.

The Direction of Motion Vector setting is correct.

You need to choose a new Check surface.


7



The object type of face is correct as well as the StoppingPosition of Ds-Cs Tangency.

Select the face as shown.

Choose OK in the Check surface dialog box.


The suboperation, 4 cpm, is now placed in the dialog box list.

Sequential Mill is now ready for the next suboperation. Onceagain, the defaults are correct. You only need to choose a newCheck surface.


This time, the Stopping Position of Ds-Cs Tangency is incorrect.You will change it to Far Side, so that the tool is completely offthe Part surface, prior to stopping.


7


Change the Stopping Position to Far Side.

Select the surface as shown below.

Choose OK in the Check Surface dialog box.


The suboperation, 5 cpm, is now placed in the dialog box list.

The machining operation is complete. You will now retract thetool a safe distance from the work piece.

Change the suboperation from Cont. Motion to Retract.

The Retract Motion dialog box is displayed.

Choose the Retract Method button.

The Retract Method dialog box is displayed.


7


Change the Method from None to Vector Only.


Change Inferred Vector to By Coefficients.


I= 1.000

J= -1.000

K= 1.000

Choose OK.

Key in 0.500 in the Distance field of the Retract Method dialogbox.

Choose OK.

Choose OK in the suboperation dialog box.

The suboperation, 6 Ret, is now placed in the list.

The tool retracts to the clearance plane. Programming of thewall is complete. The End Operation button will complete theprocess.

Choose the End Operation button.

To observe the tool path, refresh the screen and display thetool path.

In the graphics window, right-click→Refresh.


7


Choose Redisplay Tool Path from the End Operation dialogbox.

The tool path is displayed.

Choose OK from the End Operation dialog box.



7


More on Check Surfaces

In the previous activity, you used the same Part surface for each ContinuousPath Motion suboperation. The suboperation ended after the tool movedalong the Drive surface to the Check surface. The Check surface then becamethe Drive surface for the next suboperation and the Continuous Path Motiondialog box anticipated this choice by selecting Previous Check Surface as theDrive surface at the beginning of each Continuous Path Motion suboperation.

It is also possible to exchange the Part surface for the next Check surface.One consideration that should be made when exchanging the Check surfaceas the new Part surface is the Stopping Position..

In the following activity, the Drive and Part surfaces, as well as the Checkgeometry will change throughout the operation as you generate the tool path.You will see that the Check surface in a current suboperation can become thePart surface, as well as the Drive surface, in the next suboperation. You willalso see that the processor is able to anticipate your choice for Drive and Partsurfaces in Continuous Path Motion suboperations, so that you only need tospecify the Check surface(s).


7


Activity: Sequential Milling of a multi-surfaced floor

In this activity, you will machine a floor that is flat, sloped, and curved. Thepart requires that you re-specify the part surface when the floor surfacechanges.

Step 1: Open a new part, rename and begin a Sequential Mill operation.

Open the part file sq_3 and rename it to ***_sq_3.

Choose Start →Manufacturing.

Click the Operation Navigator tab from the resource bar.

In the Operation Navigator, Replay the operation namedDEMO.

You will now create an operation identical to the operationwhich you just replayed.

Step 2: Create the Sequential Mill operation.

Click Create Operation.

If necessary change the Type to mill_multi_axis.

Click SEQUENTIAL_MILL .


7


On the Create Operation dialog box, set:

Program MULTI-FLOOR-PROGTool EM_.75_.125Geometry WORKPIECEMethod MILL_FINISH

Type fin-poc-walls in the Namebox.

Click OK.


Clear the Multiaxis Output check box.


The Display Options dialog box is displayed.

Choose 3-D from the Tool Display list

Select 9 from the Path Display Speed slider.

Click OK.

The global parameters are now set and you are ready to beginthe Sequential Milling process.

Click OK and continue to the Engage Motion dialog box.

Step 3: Specify an Engage motion.

You will now create a vector that will be used for engaging the part.


The Engage Method dialog box is displayed.

Change the Method to Vector Only.


Click XC Axis

Click Revere Direction

Click OK.

Type 0.500 in the Distance box.

Click OK to return to the Engage Motion dialog box.


7


Select Point from the Reference Point Position list.

Select the point as shown.

Click OK .


7


Click the Geometry button and specify the Drive and Partsurfaces as shown.

(1) Drive Surface

(2) Part Surface

(3) Check Surface (add .250 stock)

Specify .250 Stock for the Check surface, prior to selectingthe surface.

You must enter any Stock value and change the StoppingPosition status before you select the Check Surface.


7


Click OK.

The tool moves from the Clearance plane to the position justspecified.

The tool direction arrow shows the current direction of motion.Throughout this activity, change the direction arrow whenevernecessary so that it points in the intended cut direction.

Step 4: Specify Continuous Path motion.

Sequential Mill expects the next Drive surface to be the previousDrive surface, and the next Part surface to be the previous Partsurface.

Drive Surf Previous dsPart Surf Previous ps

For the remainder of this activity, you will be prompted to changethe Drive and Part surfaces only if the processor does not correctlyselect the proper surface. Each suboperation will require you toselect a new Check surface.

Click Check Surfaces.

Change the Check Stock to 0.

Change the Check surface Stopping Position to Ps-CsTangency.


7


Specify a new Check surface as shown.

Return to the Continuous Path Motion dialog box and click OK.

The tool moves to the new position.

Note the status of the Part Surface to previous Check surface.


7





Note that the Sequential Mill processor did not change thestatus of the Drive or Part surfaces.

Specify the Check surface Stopping Position as Near Side.


7





Note that the Sequential Mill processor expects that the nextPart surface will be the previous Part surface.

Specify the Check surface Stopping Position as Ds-CsTangency.


7





Note that the status of the Drive or Part surfaces did notchange.

Specify the Check surface Stopping Position as Near Side.


7





Note the status of the Drive or Part surfaces did not change.

Specify the Check surface Stopping Position as Ps-CsTangency .


7


Specify a new Check surface.



Note the status of the Drive and Part surfaces changed.

Specify the Check surface Stopping Position as Ps-CsTangency.


7


Specify a new Check surface as shown below.



The status of the Drive or Part surfaces did not change.

Specify the Check surface Stopping Position as Far Side.


7





Change Cont. Path to Retract.

The Retract Motion dialog box is displayed.

Change the Retract Method to Vector Only .


7


Click XC Axis

Change the Distance to .200.

Return to the Retract Motion dialog box and click OK.

The tool retracts to the Clearance Plane.

Choose End Operation and then OK to save the operation.

The entire tool path is displayed.



7


SummarySequential Milling operations allow complete control of cutter movement andare useful in the finish machining of complex, multi-axis geometry. The moreexperienced programmer will use Sequential Milling techniques to simplifythe creation of complex tool paths.

The following functions are used in Sequential Milling applications:

• Selecting of specific tool axis.

• Specifying tool starting and stopping positions based on contact with Part,Drive, and Check surfaces.


8

Lesson

8 Sequential Mill advanced

Purpose

Some of the more advanced features of Sequential Milling allow for multiplepasses and control of the tool axis. These options allow for increased flexibilityfor roughing and finishing operations.

Objective


• Use standard and nested loops for creating roughing and finishing passes.

• Completely control the tool axis in 3, 4 and 5-axis applications.


8

8

Sequential Mill advanced

Tool axis controlIn Sequential Mill, you define the tool axis by first specifying 3, 4 or 5-axistool positioning which is found on the Engage and Continuous Path Motiondialogs.

3-axis allows you to specify the ZM axis or a fixed vector.

4-axis allows the tool to remain perpendicular to a specified vector and can befurther adjusted by:

• Another vector - projected PS (or DS) Normal

• A "ring" height on the tool - tangent to PS (or DS)

• An angle - at angle to PS (or DS)

Project Part Surface (or Drive Surface) Normal indicates that the tool axis iscalculated by rotating the surface normal by a lead or lag angle, projectingthe resulting vector onto a plane perpendicular to the specified Perpto Vector,and then rotating it in that plane by a specified angle. This option causes thePerpto Vector and the Next Cut Direction buttons to appear.

Tangent To PS (or DS) indicates that the side of the tool is tangent to thedesignated surface while the tool axis remains perpendicular to the specifiedPerpto Vector.

At Angle To Ps (or Ds) indicates the tool axis maintains a fixed angle withthe designated surface normal while remaining perpendicular to the specifiedPerpto Vector.

5-axis allows the tool axis to :

• Remain normal, parallel or angled to the Part or Drive surfaces

• Fan between surfaces

• Pivot from a point


8


5–Axis Tool Axis ControlVariable Contour Sequential Mill

Toward or Away From Point Thru Fixed PointNormal to Part Normal to PSNormal to Drive Normal to DSSwarf Drive Parallel to PS

Parallel to DSRelative to Drive At Angle to DS

At Angle to PS– Tangent to PS– Fan– Tangent to DS

Normal To Ps (or Ds) causes the tool axis to remain perpendicular to thespecified surface. This generally involves keeping the center of the bottomof the tool in contact with the surface. Optionally, you can offset the contactpoint from the bottom center of the tool.

(1) Surface normal at contact point

(2) “new” contact point

Parallel to Ps (or Ds) causes the side of the tool to be kept parallel to thesurface rulings at the contact point. A ring on the tool must be specified toindicate where the side of the tool must touch the surface.


8


(1) Drive Surface ruling

(2) Ring height

(3) Part Surface

Tangent to Ps (or Ds) causes the side of the tool to be tangent to the specifiedsurface while the tool axis stays perpendicular to the current direction ofmotion. You must specify a ring height.

(1) Drive Surface

(2) Ring height

At Angle to Ps (or Ds) causes the tool axis to maintain a fixed angle (Tilt) withthe surface normal and a fixed angle with the current direction of motion(a Lead or Lag angle).

(1) Tool Axis

(2) Lead

(3) Lag

(4) Direction of motion

Fanning is an even distribution of tool axis change from the start to the stopposition. This can be useful, for example, when the tool is canted at eitheror both positions.


8


(1) Final Tool Axis

(2) Check Surface

(3) Check Surfacecontact point

(4) Part Surface

(5) 5–Axis Fanning


8


Thru Fixed Point indicates that the tool axis always lies along the line joiningthe tool end tip and a user-defined point. Use the Point Constructor dialogbox to define the point.

(1) User defined pivot point

(2) Check Surface

(3) Drive Surface

(4) Part Surface


8


Activity: Sequential Mill Five-Axis fan motion

In this activity, you will create a Sequential Milling operation to finish thewalls of a pocket on an aircraft structural component.

Step 1: Open, rename and examine the part file.

Open the part file spar_mfg.

The spar is cut from a forged block of aluminum and is held inplace by clamps along the slits that run the length of the blockon either side. Dowel pins are used to locate the block.

The orange material represents the "window frame" portionof the block. Small tabs run from it to the part to secure itduring machining.

This part has been partially machined. You will first examinethe machining progress made to this point.

Rename the part ***_spar_mfg.


Click the Operation Navigator tab from the toolbar.

Highlight the SIDE_1 program.object..

Right-clickTool Path, and choose Verify


8


Select the 3D Dynamic tab from the Tool Path Visualizationdialog.

Click the Play Forward button from the bottom of the dialog.

The In-Process work piece of the part is represented. You willbegin machining the left most pocket in the part.

Click OK on the Tool Path Visualization dialog.

Step 2: Create the Sequential Mill Operation.

Click Create Operation from the Manufacturing Create toolbar.

The Create Operation dialog is displayed.

Click mill_multi-axis from the Type list.

Click Sequential_Mill as the subtype.

Set the Parent objects as follows:

Program FINISH_1Tool EM-.5–.130–CARBIDEGeoemtry PART_AND_BLANKMethod MILL_FINISH

Type SM_FINISH_WALLS_POCKET_1 in the Name box.


8


Click OK.

The Sequential Mill dialog is displayed.

Step 3: Set Tool Display options and create a Point to Point Motion.


The Display Options dialog is displayed.

Choose 3-D from the Tool Display list and change the PathDisplay Speed to 9.

Click OK twice.

The Engage Motion dialog is displayed.

You will now establish the tool location and axis by using aPoint to Point suboperation.

Change the motion from Engage to Pt to Pt.

The corresponding dialog changes to match Point to Pointmotion.

You will now establish the tool position, specifying both theposition of the tool and the tool axis.

Choose Point, Tool Axis from the Motion Method list..

The Point Constructor dialog is displayed.

Select the following point for the base point.

The Vector Constructor dialog is displayed.

Click ZC Axis .

Click OK to accept the tool axis.


8


Click OK to accept the first suboperation.

The first suboperation, 1 ptp, is created and inserted into thesuboperation list.

Step 4: Create the Engage Motion.

You will now define the Engage component.

Change Pt to Pt to Engage.



The Engage Method dialog is displayed.

Choose Vector Only from the Method list.

The Vector Constructor dialog is displayed.

Choose By Coefficients from the Type list


I= 0.000

J= –1.000

K= –.500

Click OK.


8


Key in 2.00 in the Distance field of the Engage Method dialog.

Click OK.

Click Geometry button from the Engage Motion dialog.

The Engage Geometry dialog is displayed.

You will first create a temporary check plane as the Drivegeometry using the Three Points option for plane creation.

In the Engage Geometry dialog, change the Type from Face toTemporary Plane.

Click Point and Direction .

Select the control point as shown.

Select the linear edge to define the vector as shown.


8


A temporary plane is displayed.

Click OK.

The dialog advances to Part.

Choose Face from the Type list..


8


Select the bottom face of the pocket as the Part geometry.

Select the wall face as the Check geometry.

After selecting the Check geometry, the Engage Motion dialogis displayed. Before proceeding any further you will want tochange the Tool Axis to 5-axis fan motion.

Choose 5-axis from the Tool Axis list.

The Five Axis Option dialog is displayed. Notice that theMethod defaults to Fan, which is acceptable in this instance.

Click OK in the Five Axis Options dialog.

Click OK to create the Engage suboperation.

You are now ready to create the first Continuous Path Motion.


8


Step 5: Create the first Continuous Path Motion.

The radii in the pocket corners are slightly larger than the toolradius and allows the opportunity to drive the corner fillet withless tool chatter.

Continuous Path Motion is the default as the next suboperationtype. You will need to choose the fillet as the next Check surface.

Change the Drive Surface to Previous Cs.

In the Continuous Path Motion dialog, click the CheckSurfaces button.

In the Check Surfaces dialog, change the Stopping Position toDs-Cs Tangency.

Select the corner fillet surface as shown.

Click Left in the Direction list.

Click OK in the Check Surfaces dialog.


8


Click OK in the Continuous Path Motion dialog.

The tool drives into the corner and suboperation 3 is created.

Click the Check Surfaces button.

Select the next surface in line.

Choose OK until the next suboperation is created.

Step 6: Finish the operation.

Continue to drive around the inner wall of the pocket, usingthe next surface in line as the new Check surface.

When you reach the original surface that you used for engagingthe part, drive a temporary plane selected like the originaltemporary plane. This should prevent any scallops from beingleft on the wall.

Retract the tool from the pocket and end the operation.

Save the part file.

You finish machined the wall of the pocket. One of the wallsof the pocket is at an extreme closed angle. Extra stock wasleft on that wall.

In a future activity, you will use Sequential Mill loopingfunctionality, with five-axis motion, to remove the excessivestock.


8


Standard and nested loops

Standard loops

Loops are modified copies of an original tool path. They are copies of a portionof a tool path that are repeated to remove extra stock.

Creating loops

The Loop option is located in any of the Motion dialogs (Engage, Retract,Continuous Path, or Point to Point) under the Options → Loop Control.

• Before you begin the creation of a loop, the tool should be in the properposition within the operation (where you want the tool to start repeatingfrom).

• You can specify Loop Stock. This is the stock that is applied to thegeometry within the loop. It is removed as the looping routine progresses.

• To end the loop, you should be in the desired position within the operationand then stop the loop. Choose Options→Loop Control→Start/End andchange to End.

• The tool path is then recomputed by adding the loop Stock and movingtoward the part in a specified number of steps. The path will display inthe graphics window.

• You can also create an operation without a loop. You can later edit theoperation and then add the loop.

Nested loops

A Drive surface and a Part surface loop within the same suboperation or alater suboperation is considered a nested loop (one inside of another).

If the Ds loop and the Ps loop are started within the same suboperation, youmust determine whether you want the Ds loop or the Ps loop to be cut first.The Nesting Status option defines this for you. This option is only availableafter both the Ds and Ps Start/End Parameters are defined.

The next activity will familiarize you with some of the basic concepts oflooping within Sequential Mill.


8


Activity: Sequential Mill – using loops

In this activity, you will replay and examine Sequential Mill loopingoperations.

Step 1: Open a new part file and replay an existing operation.

Open the file sq_3_loop.


From the Operation Navigator, Replay the FINWALLS toolpath.

The tool path makes several passes toward the part walls andfloors. You will now examine the loop settings.


8


Double-click on the FINWALLS operation.

Note that the Multiaxis Output option is selected.

Click OK.

The Point to Point Motion dialog is displayed.

Click OK.


Normally, you start the looping process from within this dialog.

Click Options.

The Other Options dialog is displayed.

Click Loop Control.

The Loop Control dialog is displayed.

Note the Ds and PS loop settings.

These settings will create five passes, each pass will remove.050 stock.

Click OK three times to return to the Continuous Path Motiondialog.

On the Continuous Path dialog, Click Options, then LoopControl to check the Loop Control status. They are set toContin.

Click OK twice to return to the Continuous Path Motion dialog.

Step 2: End the loop.

On the Continuous Path Motion dialog, double-click on thesuboperation 11 Ret.

The tool path updates to the current location.

On the Retract Motion dialog, click the Options button, thenthe Loop Control button to check the loop status. They areset to End.

Step 3: Start the looping process.

Click OK three times until the Loop Debug Options dialog isdisplayed.


8


On the Loop Debug Options dialog, click OK.

The tool begins to cut as specified.

Choose End Operation, then choose OK from the End Operationdialog to save the operation and return to the OperationNavigator.

The entire tool path is now displayed.

Close the part.


8


Activity: Remove excess stock from a closed wall

In this activity, you will use the looping functionality of Sequential Mill toremove the excess stock on a undercut wall. You will make a copy of theprevious operation that you created and modify that operation for doinglooping activities.

Step 1: Copy a previous Sequential Mill operation.

Open the part file***_spar_mfg (or choose from Window onthe toolbar)

If necessary, change the view of the Operation Navigator tothe Program Order View.

Expand the SIDE_1 and FINISH_1 Program objects.

Right-click SM_FINISH_WALLS_POCKET_1 and choose Copy.

Right-click PM_FINISH_BOSSESand choose Paste.

Right-click→ Rename to change the operation name toSM_SEMI-FINISH_WALLS_POCKET_1.

Step 2: Edit the operation.

You will want to edit the operation which you just copied andrenamed. You will be using most of the same defaults as in theprevious operation. However, some parameters will change.

Double-click SM_SEMI_FINISH_WALLS_POCKET_1 .


Change the Global Stock on Drive Surfaces to .030.

Change the Global Stock on Part Surfaces to .030.

Click OK on the Sequential Milling dialog box.

Scroll down to the bottom in the suboperation list.

Highlight the 12 Ret suboperation.

Hold down the shift key, scroll back up in the dialog box andchoose the 4 cpm suboperation.


8


Click the Delete button and confirm the choice in the messagedialog box.

There should now be three suboperations remaining in thesuboperation list — a Point to Point; an Engage, and a CPM.

Since this operation will leave stock on the wall and the toolradius is nearly the size of the corner fillet, the corner filletradii will not be selected. When stock is added to the fillet,it becomes impossible for the tool to reach its designatedtangency point.


8


Step 3: Edit the suboperation 3 cpm.

Double-click on suboperation 3 in the suboperation list box.

Note that in order to edit a suboperation, simply highlightingthe operation will not place it in edit mode. A double-clickon the suboperation is necessary. When successful, the word"editing" will appear following the suboperation name.


Change the Stopping Position to Near Side.

Select the undercut wall as shown.

Click OK on the Check Surfaces dialog box.

Click OK to accept the modified CPM suboperation.

Since there are not any more suboperations to edit, SequentialMill automatically switches to Insert mode.

Step 4: Create additional suboperations.

You will now create the additional suboperations, necessary tofinish the undercut area of the pocket.



8


Select the wall as shown below.

Click OK on the Check Surfaces dialog box.

Click OK to create the suboperation.

The suboperation is created. You will now position the cutter tothe middle of the Check surface which you previously selectedand then will retract the tool.


Click Temporary Plane from the Type list.

Click Point and Direction .


8


Select the control point as shown.

Select the linear edge to define the vector as shown.

A temporary plane is displayed.


8


Click OK in the Check Surface dialog box.

Click OK to accept the suboperation.

Change the motion type to Retract.

Click the Retract Method button.

Change the Method from None to Vector Only.

Choose By Coefficients from the Type list.

Key in the following values to create the vector:

I = 0.0

J = –1.0

K = 1.0

Click OK in the Vector Constructor dialog box.

Key in 1.0 in the Distance field.

Click OK in the Retract Method dialog box.

Click OK to accept the suboperation.

The suboperation, 6 Ret, is created.


8


Click End Operation.

Click OK in the End Operation dialog box.

Save the part file.


8


Activity: Use looping to remove excess stock

In this activity, you will edit the previous operation, modify the operation byusing the looping option, which will create a series of passes for stock removal.

Step 1: Edit an existing operation.

Continue using ***_spar_mfg.

In the Operation Navigator, double-click on theSM_SEMI_FINISH_WALLS_POCKET_1 operation.

Click OK in the Sequential Mill dialog box.

Click OK in the Point to Point Motion dialog box to advanceto suboperation 2.

In the Engage Motion dialog box, click the Options button.

Click Loop Control.The Loop Control dialog box is displayed.

Choose Start from the Ds loop parameters.

Key in 0.2 in the Initial stock field and .05 in the Incrementfield.

Click OK.

Click OK on the Other Options dialog box.

Click OK on the Engage Motion dialog box.

Continue to click OK until suboperation 6 Ret is highlighted(Retract Motion dialog box is displayed).

Click Options.

Click Loop Control.

Change the Ds loop parameters from Continue to End.

Click OK on the Loop Control dialog box.

Click OK on the Other Options dialog box.

Sequential Milling is now ready to create the additional looppasses.

Click OK on the Loop Debug Options dialog box.


8


When satisfied with the additional passes, Click End Operationon the Point to Point Motion dialog box.

Click OK in the End Operation dialog box.

Visually examine the output using Visualization.

Save and close the part.


8


Additional Sequential Mill options

The following are Sequential Mill options that you have not used in theactivities. You can review these options with your instructor or on your own.

Replace geometry globally

Replace Geometry Globally, replaces faces, curves and temporary planes byother faces, curves and temporary planes throughout the operation.


8


This option is located on the Sequential Mill dialog box.


8


Sequential Milling best practices

Engaging:

• Use a reference point that is near the startup geometry

• When using the Fan tool axis, use Tangent to Drive

• Use the Direction Move option on the Engage Geometry dialog box whenthe tool can move to more than one location or if the tool is not close tothe surface

• Remember that the Direction Move is applied first to the Drive, second tothe Part, and last to the one or more Check surfaces

• Use Side Indication on the Engage Geometry dialog box when the toolis on or overlaps a surface

You should imagine the tool moving initially after you specify the Drivesurface. Then, if you need to specify a direction for the Part surface, do sofrom the imagined position. Then imagine the tool moving to the new positionif you need to specify a Direction Move for the Check surface.

Continuous Path:

• If the Drive and Part surfaces are flat and long, reduce the Maximum Step(on the Other Options dialog box)

• When using a Fan tool axis, reduce the Maximum Step (on the OtherOptions dialog box)

• When using a Fan tool axis around curved geometry, limit the motion to60 degrees

Looping:

• Start a loop on an Engage or Point to Point Motion suboperation; startinga loop on a Continuous Path Motion suboperation can cause the tool to beout of tolerance

• The last loop suboperation should be a Retract or Point to Point Motionmove

• ifIyou do not want the tool retracting during the loop, be careful in endingthe loop on a Continuous Path Motion suboperation so that the loop endswith the tool in the same position and orientation as at the start of the loop


8


• Use caution when specifying Added Stock to Check Geometry . In a loop,you may want to choose None when you do not use a Check Surface as aDrive or Part surface in the next suboperation. See the following example.

(1) Added stock =Drive

(2) Added stock =None

(3) Start

(4) End


8


SummaryThe more advanced features of Sequential Milling allow for multiple passesand complete control of the tool axis. These options allow for increasedflexibility for roughing and finishing operations. Some of the more advancedfeatures are:

• Looping control allowing for removal of excess stock.

• Fanning tool axis control.

• Complete control of tool positioning.


9

Lesson

9 Variable Contour – basics

Purpose

Variable Contour operations are used to finish areas formed by contouredgeometry. Variable Contour tool paths are able to follow complex contours bythe control of tool axis, projection vector and drive methods.

Objective


• Create multi-axis tool paths by choosing a tool axis that is mostappropriate for the part geometry

• Incorporate complementary programming practices that are necessary formulti-axis machining


9

9

Variable Contour – basics

Variable Contour operationsVariable Contour operations are used to finish areas formed by contouredgeometry by the control of tool axis, projection vector and drive methods.

Tool paths are created through the generation of drive points from the drivegeometry and then projecting those points along a projection vector to thepart geometry.

The drive points are created from part geometry or can be created from othergeometry that is not associated with the part. The points are then projectedto the part geometry.

The tool path output moves the tool from the drive point along the projectionvector until contact is made with the part geometry. The position maycoincide with the projected drive point or, if other part geometry prevents thetool from reaching the projected drive point, a new output point is generatedand the unusable drive point is ignored.

(1) Drive geometry is usedto generate points

(2) Projection vector movesthe tool from the drivepoint, down the projectionvector until it contacts partgeometry

(3) Drive points

(4) Part geometry may keepthe tool from reaching theprojected drive point

(5) Contact point

(6) Cutter location outputis generated

Tool path accuracy

Variable Contour provides several options that help insure the accuracy ofthe tool path. Included are:

• Check geometry to stop tool movement

• Gouge checking to prevent gouging of the part

• Various tolerance options


9


Variable Contour operations can position to existing locations on the partgeometry (which includes the edge of an object), but the tool cannot positionto an extension of part geometry.


9


Terminology used in variable contour

• Part Geometry - Geometry selected to cut

• Check Geometry - Used to stop tool movement

• Drive Geometry - Used to generate drive points

• Drive Points - Generated from the Drive geometry and projected ontopart geometry

• Drive Method - Method of defining Drive Points required to create atool path; some drive methods allow creation of a string of drive pointsalong a curve while others allow the creation of an array of drive pointswithin an area

• Projection Vector - Used to describe how the Drive Points project to thePart Surface and which side of the Part Surface the tool contacts; theselected drive method determines which Projection Vectors are available

The projection vector does not need to coincide with the tool axisvector.


9


Variable Contour vs Fixed Contour

The primary difference between Fixed Contour and Variable Contour lieswith the various methods of tool axis control and the drive methods available.


9


Drive methods for Variable Contouring

Curve/Point drive method

Allows you to define drive geometry by specifying points and curves. Usingpoints, the drive path is created as linear segments between the points. Usingcurves, drive points are generated along the curves.

Boundary drive method

The Boundary Drive Method allows you to define cut regions by specifyingBoundaries and Loops. Boundaries are not dependent on the shape and sizeof the part surfaces while Loops correspond to exterior part surface edges.Cut regions are defined by Boundaries, Loops, or a combination of both.

The boundary members graphically represent the associated tool positionsas illustrated below:

(1) tanto condition (2) on condition (3) contact condition

Spiral drive method

The Spiral Drive Method allows you to define drive points that spiral outwardfrom a specified center point. The drive points are created within the planenormal to the projection vector and contain the center point. The drive pointsare projected on to the part surfaces along the projection vector.

Spiral Drive Method stepovers are a smooth, constant transition outward.This drive method maintains a constant cutting motion and is applicable tohigh speed machining applications.


9


(1) Drive pointsprojected from plane

(2) Projection vector

(3) Center point definesthe center of the spiral,cut starts here

(4) Part surface

(5) Spiral drive

Surface Area Drive Method

Surface Area Drive Method allows you to create an array of drive points thatlie on a grid of drive surfaces. This Drive Method is useful in machining verycomplex surfaces. It provides additional control of both the Tool Axis andthe Projection vector.

(1) Part geometry

(2) other geometry

(3) drive geometry

To generate Drive Points from part geometry, select the surfaces as drivegeometry and do not select any part geometry. The drive points are thengenerated on the drive geometry.

To generate Drive Points from other geometry, select the drive and partgeometry. The Drive Points are then generated on the drive geometry and areprojected onto the part geometry according to the Projection vector.

In either case, the tool axis can follow the drive geometry contour.

The Surface Area Drive method also provides an additional Projection Vectoroption, Normal to Drive, which enables you to evenly distribute drive pointsonto convex part geometries.

The limiting factor of the Surface Area Drive method is that surfaces mustbe arranged in an orderly grid of rows and columns and adjacent surfacesmust share a common edge.


9


(1) columns

(2) rows

(3) common edge

(4) drive surface

Drive geometries mustbe selected in an orderlysequence defining therows

(1) Row 1

(2) Row 2

(3) Row 3

(4) Row 4

Tool Path Drive Method

The Tool Path Drive Method allows you to define drive points along the toolpath of a Cutter Location Source File (CLSF) to create a similar VariableContouring tool path. Drive points are generated along the existing tool pathand then projected on to the selected part surface(s) to create the new toolpath that follows the surface contours. The direction in which the drive pointsare projected on to the part surface(s) is determined by the Projection Vector.

Tool path created usingPlanar Mill, profile cuttype

(1) planar mill tool path

Results of using PlanarMill tool path, projectedon to the contoured partgeometry

(1) part surface

(2) drive point projection

(3) surface contour toolpath


9


When you select Tool Path as the drive method, you must specify an existingCLSF to be used to generate drive points.


9


Radial Cut Drive Method

The Radial Cut Drive Method allows you to generate drive pathsperpendicular and along a given boundary, using a specified Stepoverdistance, Bandwidth and Cut Type. This method is useful in clean-up typeapplications.

(1) selected boundary

(2) tool path

Contour Profile Drive Method

This method is a simple to use drive method to cut the undercut or overcutwalls of a part and is especially effective in machining multi-pocket typeparts. Selection of the bottom of the pocket, setting of various cut parameters,and generation of the operation are the only steps required for use.

User Function Drive Method

User Function Drive method creates tool paths from special drive methodsdeveloped using User Function programming. These are optional, highlyspecialized custom routines developed for specific applications.. Optionsavailable are:

CAM Exit Name is the name of an operating system environment variablewhich contains the path name of the shared library containing the UserFunction Program.

Users Parameters access a user exit specifying parameters for the drivepath. The User Function program associates these parameters with thecalling operation, using the name of the operation as the link.


9


Activity: Overview of Variable Contour options

In this activity, you will review the basic methods that Variable Contouruses to create tool paths. You will observe that some of the Fixed Contouroptions are not available in Variable Contour, as well as some options areonly available in Variable Contour.

Step 1: Open an existing part file.

Open the part file vx_0.


Select the Operation Navigator tab from the toolbar.

Step 2: Review an existing operation.

You will review the options by examining their settings.

In the Operation Navigator, expand the Program namedOVERVIEW and double-click on the operation named REVIEW.

The Variable Contour dialog box is displayed.

Step 3: View the Variable Contour dialog box options.

You will review the option settings on the Variable Contour dialogbox, then you will note the option settings on the Surface AreaDrive Method dialog box. These options are required to createthe tool path.

Click Display next to Specify Part.

Refresh the graphics window .


9


Under the Drive Method label, view the Drive Methods thatare available.

Expand Tool Axis and note the various tool axes which areavailable.

Step 4: View the Surface Area Drive Method settings.

The Surface Area Drive Method is the most commonly usedmethod of creating variable axis tool paths.

Under the Drive Method label, choose Surface Area.

The Surface Drive Method dialog box is displayed.

Click Display next to Specify Drive Geometry.

Note that the top face was selected as the Drive Geometry. TheDrive Points will be generated on this surface and projected tothe part geometry based on the Projection Vector.

Click Display Contact Points.

The surface normals are displayed at each tool contact point.The Surface Area Drive Method is the only Drive Method thatallows you to display contact points.

Choose Cancel.

Step 5: Generate and view the tool path.

You will now create a tool path using the settings which you justreviewed.


9



Close the part file.


9


Tool axis control

The Variable Contour Tool Axes can be grouped based on the geometry thatdetermines the tool axis.

The choice of tool axis depends upon the Drive Method you choose. Forinstance, the Surface Area Drive Method allows you to specify many 4 and 5axis tool positions that are not available by using any other Drive Method.The table which follows shows the various drive methods with permissibletool axis:


9


Drive methodToolAxis Curve/

Point

Spiral Bndry SurfaceArea

StreamlineToolPath

Radial

AwayFrompoint

X X X X X X X

TowardPoint X X X X X X XAwayFromLine

X X X X X X X

TowardLine X X X X X X XRelativetoVector

X X X X X X X

4–axisNorm.To Part

X X X X X X X

4–axisRel. ToPart

X X X X X X X

Dual4–Axison Part

X X X X X X X

Interpolate X X XSwarfDrive X XOptimizedtoDrive

X X

NormalToDrive

X X

RelativeToDrive

X X

4–axisNorm.ToDrive

X X

4–axisRel. ToDrive

X X


9


Dual4–AxisonDrive

X X

SameasDrivePath

X

Point and Line tool axes

The following tool axis types use focal points and can produce 5-axismovements:

Away From Point

Towards Point


9


The following tool axis types use focal lines and can produce 4-axismovements:

Away From Line

Towards Line

Away and Towards refers to a vector direction.

Consideration must be given to machine configuration, part fixturing andamount of swing or tilt of the table and or head when selecting tool axistypes. It is advisable to select the method which minimizes the amount oftable and or head tilt.


9


Activity: Point and Line tool axis types

In this activity, you will replay a series of Variable Contour operations thatuse point and line geometry to control the tool axis.


Open the part file vx_4.

If necessary, enter the Manufacturing application and displaythe Program Order view in the Operation Navigator.


9


Step 2: Replay the operations.

Replay the AWAYLINE operation.

(1) Focal line usedwith tool axis

The tool path is replayed using the tool axis option Away fromLine.

Replay the AWAYPT operation.

(1) Focal point usedwith tool axis

The tool path is replayed using the tool axis option Away fromPoint.

Notice the amount of difference in tool tilt between the twodifferent methods. Proper placement of the focal point and linecan greatly reduce the amount of tool tilt resulting in reducedrisk of head or tool interference with clamps and or fixturing.

Replay the TOWARDLINE operation.


9


Replay the tool path.

(1) Focal line usedwith tool axis

The tool path is replayed using the tool axis option TowardsLine.

Replay the TOWARDPT operation.

(1) Focal pointused with tool axis

The tool path is replayed using the tool axis option TowardsPoint.

Notice the difference in the amount of tool tilt. The methodchosen, towards or away from a point or line, along with theirrespective placement of the geometry being cut, gives youprecise control of the tilt of the tool.



9


Normal Tool Axis

Normal Tool Axis maintains a tool axis that is perpendicular to the partgeometry, drive geometry, or rotational axis (4-axis) at each contact point.This is a preferred method of tool axis control when the contoured geometrythat is being machined does not change radically in shape and or direction.

(1) Normalto partgeometry ateach drivepoint

The following tool axis types use the Normal tool axis:

• Normal To Part

• 4-axis Norm To Part

• Normal To Drive Surf (Surface Area Drive)

• 4-axis Norm To Drive (Surface Area Drive)

The 4-axis type options allow you to apply a rotational angle to the tool axis.This rotational angle effectively rotates the part about an axis as it would ona machine tool with a single rotary table. The 4-axis orientation causes thetool to move within planes which are normal to the defined rotational axis.


9


In the following example, the rotational angle causes the tool axis to leanforward in relation to an otherwise normal tool axis.

(1) axis normal to partgeometry

(2) rotation angle of15 degrees

(3) plane normal torotation axis

(4) axis parallel toplane

Relative Tool Axis

Relative tool axis maintains a tool axis that is perpendicular to the partgeometry, drive geometry, or rotational axis (4-axis) at each contact point andallows the application of Lead or Tilt angle to the tool axis.

You can apply Lead or Tilt to the following tool axis types:

• Relative To Part

• 4-axis Rel To Part

• Relative to Vector

• Dual 4-axis

• Relative To Drive (Surface Area Drive)

• 4-axis Rel To Drive (Surface Area Drive)

Lead and Tilt Angle

Lead Angle defines the angle of the tool forward or backward along the toolpath. A positive Lead Angle leans the tool forward based on the direction ofthe tool path. A negative Lead Angle (lag) leans the tool backwards based onthe direction of the tool path.


9


Tilt Angle defines the angle of the tool, side to side. A positive value tilts thetool to the right as you look in the direction of cut. A negative value tiltsthe tool to the left.

(1) Tool direction(front view)

(2) Tool direction(right view)

(3) Lead

(4) Lag

(5) Normal axis

(6) Negative tilt

(7) Positive tilt

You can specify a Minimum and Maximum angle of movement for the Leadand Tilt of the tool axis.

Unlike a Lead angle, a 4-axis rotational angle always leans to the same sideof the normal axis and is independent of the direction of the tool movement.

The rotational angle causes the tool axis to lean to the right of the partgeometry normal axis in both zig and zag moves. The tool moves withinplanes normal to the defined rotational axis.

(1) axis normal to part geometry

(2) rotational angle of 15 degrees


9


Dual 4-Axis

Dual 4-Axis applies rotational, Lead and Tilt angle to the Zig and the Zagmoves independently.

You can specify a 4-axis rotation angle, a lead angle, and a tilt angle. The4-axis rotation angle rotates the part about an axis as it would on a machinetool with a single rotary table.

In Dual 4-Axis mode, these parameters may be defined separately for Zigand Zag moves.

(1) zig cut

(2) zag cut

(3) zig cut,tool axis

(4) zag cut,tool axis


9


Activity: Normal to Part and Relative to PartIn this activity, you will compare two similar and frequently used tool axes;normal to Part and Relative to Part.


Open the part file vx_0 and enter the Manufacturingapplication.

Step 2: View the tool path.

Note the tool axis in the first pass. The tool axis is Normal to Part,always perpendicular to the part geometry.

Expand the TOOL_AXIS Program Parent Group.

Replay the operation NORM_PART.

You will change the Tool Axis to Relative to Part and comparethe tool paths.

Step 3: Create a tool path using Relative to Part Tool Axis.

Edit the operation NORM_PART.


Expand Tool Axis and choose Relative to Part from the Axislist.

You are prompted to change the Lead and Tilt angles. Use thedefaults of 0°

Choose OK.


9



Compare this tool path to the previous one. Note that the toolpaths are nearly identical. Both tool paths are created usingthe surface normal at each contact point.

Choose Cancel.

Step 4: Use Lead with Relative to Part tool axis.

You will now see the effect of adding a Lead angle to the Relativeto Part tool axis.

Edit the operation REL_PART_LEAD.



You are prompted for Lead and Tilt angle settings.

You will use the specified settings, which are exaggerated sothat you can easily see the angle of Lead.

Choose OK.


9



Note that the tool leans forward as it cuts.

Choose Cancel.

Step 5: Use Tilt with a Relative to Part Tool Axis.

This time you will see the effect of adding a Tilt angle to theRelative to Part tool axis.

Edit the operation REL_PART_TILT.



Under the Tool Axis label, choose, Relative to Part.

You are prompted for Lead and Tilt angle settings.

Note the specified settings.

Choose OK.


9



Note that the tool tilts to the right as it cuts.

Choose Cancel.


Swarf Drive tool axis

Swarf Drive tool axis maintains a tool axis that is parallel to the drivegeometry. The drive geometry guides the side of the tool while the partgeometry guides the end of the tool.

(1) drive geometry

(2) part geometry

The Swarf Drive tool axis should be used only when the drive geometryconsists of ruled surfaces, since the drive geometry rulings define the swarfruling projection vector.


9


This projection vector can prevent the gouging of the drive geometry whenusing a tapered tool as shown by the following:

(1) tool axis projectionvector

(2) swarf rulingprojection vector

(3) ruled drivegeometry

(4) part surface

(5) tapered tool

(6) gouge

(7) drive point

(8) tool position

In this example, a comparison is made between the Swarf Drive ProjectionVector and the Tool Axis Projection Vector. The drive points are projectedalong the specified vector to determine the tool position, showing the ToolAxis Projection Vector method gouging the drive geometry, while the SwarfRuling Projection Vector method results in the tool positioning tangent to thedrive geometry.


9


Activity: Special tool axis and non part geometry

The part in this activity has been partially machined. You are going tocontinue to machine the core for a hub cover used on a four wheel drivevehicle. To maximize the part finish, you will be using a short tool to preventcutter deflection.


Open the part file hub_core_mfg_asmb.

There are two existing sample operations that you will examineand then create like operations. First you will examine thevarious parts which comprise the assembly.

Save the part as ***_hub_core_mfg_asmb.

Step 2: Examine the assembly.

If necessary, enter the Manufacturing application.

Step 3: Examine various operations.

Choose the Operation Navigator tab from the toolbar.

The Operation Navigator is displayed.

If necessary, change to the Program Order view of theOperation Navigator.


9


Examine the various operations.

Note that the HUB-PROJECT-PROGRAM group objectcontains a rough and finish operation.

Change to the Machine Tool view of the Operation Navigator.

Note the various tools that are defined.

Choose the Assembly Navigator tab from the toolbar.

For creating additional operations, it would be somewhat easierfor selection and visualization purposes, to remove from thedisplay, various parts of the manufacturing setup.

Select the red check marks for the screws (soc_hd_screw.5x8),table assembly (compound_table_asmb) and mounting plate(mounting_plate). This will turn off the display of thesecomponents.

Step 4: Create the operations to finish the fluted area of the part.

Choose the Create Operation icon.

If necessary, set the Type to mill_multi_axis.

Choose the VARIABLE_CONTOUR icon.

Set the Parent Groups as follows:

Program: HUB-FINISH

Tool: BALL_MILL-.75

Geometry: WORKPIECE

Method: MILL_FINISH

Name: vc_flute_fin

Choose OK.

The Variable_Contour dialog box is displayed.

Change the Drive Method from Boundary to Surface Area.


9


Choose OK on the Drive Method Information dialog box.

You will now select the drive geometry to control the toolmotion. The part consists of many faces which are irregularin shape and uneven in contour. You will begin the selectionprocess by selection of the outer face of the cylinder that definesthe raw stock.

Make Layer 2 and 5 selectable.

Click Specify Drive Geometry and select the outside faceof the cylinder that represents the stock (1).

Choose OK.

You will now set the direction of cut and its cut area in relationto the overall size of the outside face of the stock geometry.You will also set the Cut Type.

Click Cut Direction .

Cut direction vectors are displayed.


9


Choose the vector as shown (1).

Choose Surface % from the Cut Area list.

Note the system highlight at the top and bottom of the cylinder.

Refresh the screen.

Set the start and end values as shown:

Start step 20End step 55

Choose OK.

Note the area that is now highlighted. The cutter will now belimited to this area which encompasses the flutes.

Change the Cut Type to Zig.

You will now set the tool axis and projection vector.

Click OK.

Change the Tool Axis from Normal to Part to Relative to Drive.


9


Set the Tilt angle to 45.

Choose OK.

Set the Projection Vector to Toward Line.

The Line Definition dialog box is displayed.

Choose the Point and Vector button.

Choose OK on the Point Constructor dialog box (accept thedefaults).


Choose the ZC Axis icon

Choose OK twice.

The Variable_contour dialog box is displayed.

Step 5:



Interpolated tool axis

Interpolate tool axis enables the control of the tool axis at specific points bydefining vectors. It allows for control of excessive change of the tool axis asa result of very complex drive or part geometry, without the construction ofadditional tool axis control geometry (e.g., points, lines, vectors, smoother


9


drive geometry). Interpolate can also be used to adjust the tool axis to avoidoverhangs or other obstructions.

You can define as many vectors extending from specified positions on thedrive geometry as required to create smooth tool axis movements. The toolaxis, at any arbitrary point on the drive geometry, will be interpolated by theuser-specified vector. The more vectors specified, the more control you haveof the tool axis.

This option is available only when using the Curve/Point or Surface Areadrive method.

(1)user-definedcontrollingvectors

(2) excessivetool axischange

(3) smoothertool axismovement

(4) drivesurfaces

(5) tool axisnormal todrive surface

(6)interpolatedtool axis

Interpolated tool axis dialog box options are:

Specify as defines the vectors used to interpolate the tool axis. You candefine as many vectors as necessary to control the tool axis.

Vector defines vectors by first specifying a data point on the drivegeometry and then specifying a vector.

Angle/PS (or DS) defines vectors by specifying a data point on thedrive geometry and then specifying Lead and Tilt angles relative tothe part (or drive geometry) surface normal at the tool contact pointwith the part geometry. Lead and Tilt angles must be within -90 to90 degree range.


9


After you choose OK to accept the desired vector or angle, you can continuedefining data points and vectors until you choose Back in the PointConstructor dialog box. Selecting Back accepts all of the defined vectors andreturns you to the Interpolated Tool Axis dialog box.

Data Point allows you to create, delete and modify vectors used tointerpolate the tool axis.

Add enables you to create new data points. First specify a data pointon the drive geometry and then a vector direction. After specifying thedata point, a vector normal to the drive geometry is displayed.

Remove enables you to delete data points. Use the Arrow Buttonsto highlight the desired data point or select the desired data pointdirectly from the screen and then choose Remove.

Edit enables you to modify the tool axis at an existing data point. Itdoes not allow you to move data points.

Display displays all currently defined data points for visual reference.

Interpolation method determines which algorithm is used to calculate the toolaxis from one drive point to the next.

• Linear interpolates the tool axis using a constant rate of change betweendrive points

• Cubic Spline interpolates the tool axis using a variable rate of changebetween drive points; this method allows a smoother transition betweenpoints

Interpolate displays drive tool axis vectors at each drive point (when Specifyas Vector is used) or drive points and interpolated lead and tilt angle values(when Specify as Angle/PS or Angle/DS is used).

Reselect removes all defined data points.


9


Activity: The Interpolated tool axis

In this activity, you will create an operation using an Interpolated Tool Axis.The tool will start at the rear of the part with a tool axis that is normal andwill then cut to the front of the part, ending with a tool axis that is alignedwith the ZC axis. As the tool moves from the rear to the front, its orientationchanges incrementally along the tool path.

Step 1: Open a part file, rename and enter the Manufacturing application.

Open the part file interpolate_mfg_asmb and rename it to***_interpolate_mfg_asmb.


Choose the Operation Navigator icon from the toolbar.

Step 2: Create a Variable Contour Operation.



Click Variable Contour .


9


In the Create Operation dialog box, set the following:

Program: PROGRAM-AXIS-LIMITS

Geometry: WORKPIECE

Tool: BALL_MILL-1.0

Method: MILL_FINISH

Name: interpolate

Choose OK.


Step 3: Define the Drive Geometry.

Choose Surface Area from the Drive Method list

The Surface Drive Method dialog box is displayed.

Step 4: Specify a Drive Method.

Click Specify Drive Geometry .


9


Choose the surfaces as shown.

Choose OK.

Click Cut Direction .


9


Choose the Cut Direction arrow as shown.

ChooseZig from the Cut Type list.

Expand More.

Type 4 in the Number of Steps box.

Choose Tolerances from the Cut Step list.

Click OK.

Expand Tool Axis.


9


Select Interpolate from the Tool Axis list.

The Interpolated Tool Axis dialog box is displayed.

The default vector arrows show the current tool axis vectordirection.


9


As shown, select the front arrows (using the cursor or theSelection Arrows, select one at a time) and under the DataPoint label, specify Edit→ZC Axis for each vector directionarrow selected.

Each vector now points along the +ZC axis.

Choose OK.

Choose OK to return to the Variable Contour dialog box.


9


Expand Options.

Click Edit Display icon and change the Tool Display to Axis.

Choose OK to return to the Variable Contour dialog box.

Choose the Generate icon.

Notice that the tool starts cutting along the surface normalvector at the rear of the part, gradually changing its axis to thevectors specified at the front of the part, which is parallel tothe +ZC axis.


9


Verify the Interpolate Tool Axis positions.

List the tool path and verify the start and finish tool axis.

By listing the tool path, you can see the tool axis position at thefirst GOTO, is not parallel to the ZC axis. As the tool moves,the tool axis position interpolates and becomes parallel to theZC axis at the last GOTO.

Close the Information window.

Choose OK.

Save the part file.


9


A comparison of Variable Contour vs. Sequential MillingVariable Contour and Sequential Mill operations allow you to specify Drive,Part and Check surfaces. Generally, the Drive geometry guides the side of thetool and the Part geometry guides the bottom of the tool. The Check geometrystops tool movement. Specifying Part and Check geometry is very similar inVariable Contour and Sequential Mill operations.

Part geometry

Variable Contour does not always require that you specify Part geometry.When you do not, Drive geometry is used as Part geometry.

Sequential Mill requires selection of Part geometry. The default selection isthe previous Part geometry.

Drive geometry

Drive geometry is used to create drive points that are projected to the Partgeometry. You may use geometry other than that contained within the model.This "external" drive geometry can be points, curves, a boundary, etc. thatyou select after you choose an appropriate Drive Method.

Drive geometry in Sequential Mill is used to control the side of the toolwithout developing and projecting drive points. Typically, you select a partwall that you want the side of the tool to contact as it follows the Part surface.

Check geometry

Variable Contour does not require Check geometry. Check geometry istypically used to prevent collision and gouging.

Sequential Mill requires selection of Check geometry. The Check geometryis used for tool positioning at the beginning of the next suboperation andfor preventing collision and gouging.

General considerations

The overriding consideration in choosing between Variable Contour andSequential Mill is: "Which method creates the best tool path and is easiestto use."


9


The answer depends upon whether the part model has features that onlyVariable Contour or Sequential Mill can resolve. If both processors arecapable, you should consider the following relative strength of each processor:

Variable Contour Sequential Mill

preferred method for area milling preferred method for linear millingprimary cutting with bottom of tool primary cutting with side of toolnumerous drive methods for toolpath containment

single drive method

numerous cut patterns for specificapplications

no cut patterns other than looping ornested loops

sheet body and surface regiongeometry allowed

temporary plane geometry allowed

constant tool axis can change tool axis during operationedits apply to entire tool path edits apply to part of tool pathbest at convex wall cuts best at overcut and undercut type

wallseasy to create operation numerous steps in operation creationeasy to create multiple depth paths N/A


9


Tool Axis usage

The following table compares tool axis usage in Variable Contour andSequential Mill operations:

Tool Axis UsageVariable Contour Sequential Mill

3 AxisNormal to Part (default) ZM Axis (default)Relative to Vector Vector

4 AxisAway from line (4) / Toward line (4) -4–axis normal to part / 4–axis normalto drive

-

4–axis relative to part -4–axis relative to drive at angle to Drive Surface/at angle to

Part Surfacedual 4–axis on part / dual 4–axis ondrive

-

- tangent to Part Surface- tangent to Drive Surface- project Drive Surface Normal- project Part Surface Normal

5 AxisAway from point thru fixed pointtoward point thru fixed pointnormal to part normal to Part Surfacenormal to drive normal to Drive Surfaceswarf drive parallel to PS /Parallel to DSrelative to drive at angle to DS / at angle to PSinterpolate -same as drive path -user function -- tangent to PS- tangent to DS- fan


9


SummaryVariable Contour operations provide an efficient and robust capability tomachine complex geometry for multiple axes machining processes (4 plusaxis). Numerous types of tool axis control and drive methods, give theNC/CNC programmer the ability to machine the simplest to the most complexof parts. The following features are common to variable contour operations.

• Complete tool axis control that allows for minimal tool and table rotations.

• Numerous drive methods to achieve the simplest to the more complexof surface machining techniques.


9

10

Lesson

10 Variable Contour – advanced

Purpose

This lesson will introduce advanced concepts in conjunction with VariableContour operations.

Objective


• Create Contour Profile tool paths to cut pocket walls.

• use Associative Datum planes to create surfaces and geometric objectsused for creation of start points and initial tool axis


10

10

Variable Contour – advanced

Contour Profile Drive MethodThe Contour Profile Drive Method in Variable Axis Surface Contouringmachines canted walls with the side of the cutter. Variable axis profiling letsyou automatically generate a tool path to machine the walls of a cavity or aregion bounded by floor(s) and wall(s), with the sides of the cutter. Afterselecting the floor, the software can find all the walls that bound the floor.The tool axis is constantly adjusted to get a smooth path. At concave corners,the side of the tool is tangent to both adjacent walls. At convex corners, thesoftware adds a radius and rolls the cutter around to keep the tool axistangent to each corner wall. Contour Profile also allows you to machine wallsthat are not bounded by floors, such as the outside periphery of a part. Thereare two options to control the placement of the cutter against the wall whenyour part has no floors. Either use Follow Wall bottom to follow the peripheryof the wall or use an auxiliary floor that behaves as a real floor.


10


Activity: Contour Profile Drive MethodIn this activity you will use the Contour Profile drive method to machinethe canted walls of the part.


Open the part file spar_mfg.

This part has already been roughed machined as well as thefloor have been finished. All that remains to finish is theinterior walls of the three rectangular pockets.


Step 2: Create a Variable Axis Profiling operation.



Click CONTOUR_PROFILE .


10


Set the group objects as shown:

Program SIDE_1Tool EM-0.5-.13-CARBIDEGeometry PART_AND_BLANKMethod MILL_FINISH

Click OK.

The CONTOUR_PROFILE dialog box is displayed.

Step 3: Selection of Parameters.

As stated earlier, the only requirements necessary to use this drivemethod is the selection of the floor of the pocket, setting variouscutting parameters and generating the operation. You will firstselect the floor of the pocket.

Click Specify Floor .

Choose the bottom of the pocket as shown.


10


Click OK.


10


Click Display next to Specify Wall .

Note that the Automatic Wall parameter is On. The walls,forming the sides of the pockets are automatically detected(even though the floor is a radius). The operation is now readyto be generated, however we need to make multiple passesto keep the cutter from deflecting. You will now select thoseparameters.


The Cutting Parameters dialog box is displayed.


10


Click the Multiple Passes tab.

Select the Multiple Passes on Wall check box.

Type 0.1 in the Wall Stock Offset box..

Choose Passes from the Step Method list.

Type 3 in the Number of Passes box.

Click OK .

You have set the cutting parameters to remove .100 stock inthree equally spaced passes.

Step 4: Generate the operation and examine the tool path.

Click Generate from the CONTOUR_PROFILE dialog box.


10


Examine the tool path.

(1) Tool path prior to stock removal; (2) tool path after stockremoval


10


If time permits, create a second Contour Profile operation tomachine the walls of the next pocket.



10


Geometry selectionCreating a Contour Profile tool path requires Part geometry, Wall geometryand Floor geometry. There are several options that can be used to definethe geometry. You can define the geometry by selecting the geometry or byallowing parts of the geometry to be detected automatically.

Part Geometry

Use Part geometry to specify the complete set of geometry that represents thefinished part. In many cases, roughing and finishing operations are done onsections of the finished part

Floor Geometry

The floor is the geometry that limits the location of the cutter when it is placedagainst the wall. Floor geometry may be specified by selecting geometry fromyour part, from another geometry or in some cases it can be defined for you.

Wall Geometry

Wall Geometry defines the area to be cut. The cutter is first placedagainst the wall, and once a tool axis is established, the cutteris then positioned against the floor. Wall geometry can also beselected manually or in some cases it can be defined automatically.

The following activities will examine some of the possible geometry selectionmethods and combinations.


10


Automatic WallWhen using the Automatic Wall selection you will select the part geometryand the floor geometry and turn on the Automatic Wall option. The wallswill be detected for you.


10


Activity: Floor selection and Automatic WallYou will create a new operation and specify the Part and Floor geometry forthe operation. You will select Automatic for the Wall selection.


Open the part file wedge_mfg.






Set the group objects as shown ;

Program PROGRAMTool EM-.5-.125-CARBIDEGeometry WORKPIECEMethod MILL_FINISH


10


Click OK


Step 3: Specify the Floor Geometry.

Click Specify Floor .

Choose the bottom of the pocket as shown.

Click OK.


10


Click Display next to Specify Walls.

Note that the Automatic Wall parameter is On. The walls,forming the sides of the pockets are automatically detected.The operation is now ready to be generated.



Examine the tool path using Replay or Verify.


10


Tilting the tool axisThe tool axis can be tilted away from the part geometry. Tilting the tool awayfrom the part walls allows cutting without dragging the side to the cuttingtool. Tools with shorter flute lengths may also be used.


10


Activity: Tilting the tool axisYou will copy the previous operation and add a 10 degree tilt to the tool axis.

Step 1: Continue to use the existing part file.

The part file mfg_wedge should be open.

Step 2: Copy and rename the previous operation.

Right-click the operation CONTOUR_PROFILE, choose Copy,right-click the operation again and choose Paste.

Right-click the operation CONTOUR_PROFILE_COPY, chooseRename.

Rename the operation TILT_AXIS

Step 3: Edit the operation and add the tool axis settings.

Right-click the operation and choose Edit.


Choose the Tool Axis Control tab.

Type 10.0 in the Tilt Angle box.


10


Click OK.




The tool path follows the bottom contour of the wall geometrywhile tilting 10 degrees from the walls.


10


Follow Bottom WallThe Follow Bottom Wall option uses the bottom of the selected walls todetermine the floor. The access vector determines the tool axis direction.


10


Activity: Follow Bottom WallYou will create a new operation and specify the part and wall geometry for theoperation. You will select Follow Bottom Wall to detect the floor. Multiple levelcutting is not available for Follow Bottom Wall. Multiple passes are available.





If necessary, choosemill_multi_axis from the Type list.


Set the group objects as shown and select OK.




10


Step 3: Turn off the Automatic Wall option.

Clear the Automatic Wall check box.

Step 4: Specify the Wall Geometry.

Clcik Specify Walls .

Select all of the walls on the outside of the part.

Click OK.

Select Follow Bottom Wall on the CONTOUR_PROFILE dialogbox.

The operation will detect the bottom of the walls to use for floorgeometry. The path could also be offset from the Bottom Wall.





10


The tool path follows the bottom contour of the wall geometrywhile using the wall geometry to guide the tool axis.

The tool path cuts to the bottom of the selected walls. You willedit the operation to apply a depth offset so the cutter cuts deeperthan the part geometry.

Step 6: Add a depth offset for the tool path.

Type .250 in the Tool Position Offset and Generate theoperation.


Step 7: Move the operation to the Unused Items group on the OperationNavigator You will cut the same area of the part using slightlydifferent options.

Highlight the operation CONTOUR_PROFILE_1 and drag itto the Unused Items group.


10


Automatic Auxiliary FloorUse Automatic Auxiliary Floor to define an infinite plane that is perpendicularto the access vector at the bottom of the wall. You define the access vectorto determine which direction the cutter should be positioned with respectto the wall.


10


Activity: Automatic Auxiliary FloorYou create a new operation using the Automatic Auxiliary Floor option. Aftergenerating the operation you will offset the floor and add multiple levels.









Click OK.



10





Click Specify Wall .

Choose all of the walls on the outside of the part.

Click OK.

Select the Automatic Auxiliary Floor check box.

The operation will detect the bottom of the part to use for floorgeometry. Use the Automatic Auxiliary Floor to define an infiniteplane that is perpendicular to the access vector at the bottom of thewall. The path could also be offset from the Automatic AuxiliaryFloor.




10



The tool path follows a plane at the bottom of the geometry whileusing the wall geometry to guide the tool axis.

Multiple depth and multiple passes are available with AutomaticAuxiliary Floor. You can also set a depth offset. In the next stepsyou will add a depth offset and multiple depths.

Step 6: Set a depth offset for the tool path.

Select the Edit Parameters icon next to Automatic AuxiliaryFloor.

In the graphics screen click and drag the cone head to specifyan offset of -.3 and select the Green Check Mark to accept it.


10


Step 7: You will now select multiple floor passes.


Select the Multiple Passes tab.

Select the Floor check box. .

Type 2.00 in the Floor Stock Offset box.



Click OK to return to the CONTOUR_PROFILE dialog box.

Click Generate.


10



10


Step 8: You will also add multiple Wall passes to the operation.



Select the Wall check box. .

Type 0.1 in the Wall Stock Offset box.




Click Generate.


Click Generate.


Step 9: Move the operation to the Unused Items group on the OperationNavigator.


10




10


Auxiliary FloorAuxiliary Floor allows you to select geometry that doesn’t belong to the modelbeing cut to represent the floor geometry. In the following activity you willuse another face to simplify the tool motion for the cut.


10


Activity: Auxiliary FloorYou will create a new operation using the Auxiliary Floor option.







Set the group objects as shown.


Click OK.



10


Step 3: Make the layer containing the auxiliary floor selectable.

Select Format→ Layer Settings , highlight layer 52 and clickSelectable.

Click OK.






Click OK.

Click Specify Auxiliary Floor .

You will select the sheet body as the Auxiliary Floor.


10


Step 6: Generate the operation and examine the tool path



The tool path follows the Auxiliary Floor geometry while using thewall geometry to guide the tool axis.


10










Click Generate.


10


Click OK to accept the operation and tool path.

In this case the Auxiliary floor establishes a smoother tool paththan the Follow Bottom Wall path. It also allows multiple floorpasses.

Step 8: Move the operation to the Unused Items group on the OperationNavigator.



10


Auxiliary Floor and Automatic Auxiliary FloorYou can combine Automatic Auxiliary Floor along with Auxiliary Floor. Theinfinite plane created by Automatic Auxiliary Floor is treated as anotherface in the Auxiliary Floor definition.


10


Activity: Auxiliary Floor and Automatic Auxiliary FloorYou will create a new operation using the Auxiliary Floor and AutomaticAuxiliary Floor.

.











10







Click OK.

Click Specify Auxiliary Floor .

You will select the sheet body as the Auxiliary Floor.


10


Step 5: You will also turn on the Automatic Auxiliary Floor option.

Click Automatic Auxiliary Floor.

Step 6: Generate the operation and examine the tool path



The tool path follows the Auxiliary Floor and the AutomaticAuxiliary floor geometry while using the wall geometry to guidethe tool axis.


10



10










Click Generate.

Click OK to accept the operation and tool path.


10


SummaryVariable Contour operations provide an efficient and robust capability tomachine complex geometry for 4 and 5-axis machining centers. This lessonfamiliarizes you with some the requirements that are necessary to make theprogramming task simpler.


10

AAppendix

A Projection Vectors

The Projection Vector indicates the side of the part surface to be cut. It is alsoused to project drive points from the drive to the part surface.

The following illustration shows a Projection Vector (defined as Away FromLine, i.e. the center line) indicating the side of the part surface to be cut. Italso shows a drive point projected, along the projection vector, from the drivesurface (P1) to the part surface (P2).

(1) projection vector

(2) part surface

(3) drive surface

Note that, in this example, the drive point is projected in the oppositedirection of the Projection Vector arrowhead. The drive point is alwaysprojected toward the part surface along the projection vector but withoutregard to the Projection Vector arrowhead.

A Projection Vector is required for all Variable Contour Drive Methods.

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide A-1

A

Projection Vectors

The following options allow you to define the Projection Vector:

• Specify Vector — fixed projection vectors

• Tool Axis — variable projection vector

• Away from Point — variable projection vector

• Toward Point — variable projection vector

• Away from line — variable projection vector

• Toward line — variable projection vector

• Normal to Drive — surface area drive method only

• Swarf Ruling — surface area drive method only

• User Function

Specify Vector – Fixed Projection Vectors

I, J, K define the vector by keying in values relative to the origin of the WorkCoordinate System.

Line End Points by defining two points, selecting an existing line, or defininga point and a vector.

2 Points by using the point Constructor to specify two points. The first pointdefines the tail of the vector; the second point defines the arrowhead of thevector.

Tangent to Curve defines a vector tangent to a selected curve. Specify apoint on the curve, select an existing curve, and select one of two displayedtangent vectors.

A-2 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

A

Projection Vectors

Spherical Coordinates defines a fixed vector by keying in two angular values,designated as Phi and Theta. Phi is the angle measured from +ZC and rotatedin the ZC-XC plane from ZC to XC. Theta is the rotation angle about the ZCaxis from XC to YC.

(1) Phi

(2) Theta

Variable contour projection vectors

Tool Axis define a projection vector relative to the existing tool axis. Whenusing tool axis, the vector always points in the opposite direction of the toolaxis vector.

Away From Point creates a projection vector extending away from a specifiedfocal point toward the part surface. Useful in machining the inside spherical(or sphere like) surfaces where the focal point is the center of the sphere.

Towards Point creates a projection vector extending from the part surface toa specified focal point. Useful in machining the outside spherical (or spherelike) surfaces where the focal point is the center of the sphere.

Away From Line creates a projection vector extending from a specified line tothe part surface.

Towards Line creates a projection vector extending from the part surface toa specified line.

Surface area drive method projection vectors

Normal to Drive define projection vectors relative to the drive surface normals.

Swarf Ruling allows you to define the projection vector parallel to the swarfrulings of the drive surfaces when you use a swarf drive tool axis. It should beused only when the drive surfaces are equivalent to ruled surfaces, since thedrive surface rulings define the swarf projection vector.


A

Projection Vectors

The Swarf Ruling projection vector can prevent gouging the drive surfacewhen using a tapered tool as illustrated below:

(1) Tool Axis ProjectionVector

(2) Swarf RulingProjection Vector

(3) Ruled Drive Surface

(4) Part Surface

(5) Tapered Tool

(6) gouge

(7) drive point

(8) tool position

The above figure compares the Swarf Ruling projection vector to the Tool Axisprojection vector (the Tool Axis projection vector is the reverse of the Tool AxisVector). Drive points are projected along the specified vector to determine thetool position. When using the Tool Axis projection vector, drive points areprojected along the tool axis (at an angle to the drive surface), causing the toolto gouge the drive surface. When using the Swarf Ruling projection vector,drive points are projected along the drive surface swarf rulings causing thetool to position tangent to the drive surface.

A-4 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

A

Projection Vectors

The following is a summary table showing the types of projection methodsavailable for each tool axis. The x indicates that the Projection Methodis not available.

Projection MethodsTool AxisFixedVector

ToolAxis

Toward/ AwayPoint

Toward/ AwayLine

NormDrive

SwarfRule

Away From Point XToward Point XAway From Line XToward Line XRelative To Vector XNormal to Part XRelative to Part X4–axis Normal to Part X4–axis Relative to Part XDual 4–Axis on Part XInterpolate XNormal to Drive XSwarf DriveRelative to Drive4–axis Norm to Drive4–axis Rel to DriveDual 4–Axis on DriveSame as Drive Path X X


A

B

Appendix

B Zig-Zag Surface machining

Zig-Zag Surface machining is designed for machining a single trimmedsurface. Zig-Zag Surface also provides the capability to offset the tool fromholes trimmed in the surface (by the radius of the tool plus any specifiedstock).

You can specify a tool path direction or accept a system generated tool pathdirection. Either Zig or Zig-Zag cut types are available.

(1) trim

(2) specifycutdirectionby selectingdirectionarrows

Zig-Zag Surface tool paths are generated in parallel passes. The drivepoints are generated on the surface to be machined. You can control thenumber of input points by a chordal deviation (adjusting the step tolerance)in the direction of cut. This is the allowable deviation from the surface.Scallop height controls the distance between parallel passes according to themaximum height of material (scallop) you specify to be left between passes.This is affected by the cutter definition and the curvature of the surface.

Zig-Zag Surface also provides gouge check so that the system can check forviolation of the surface.

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide B-1

B

C

Appendix

C Advanced surface contouring

Projection

Mathematics of Projection:

• Place tool end at drive point

• Project tool along projection vector

• Tool stops when making contact with part

• If necessary, adjust the tool axis and repeat the above steps until thetool axis is satisfied

• Add more intermediate drive points to satisfy the Intol/Outol with the part

(1) drivepoint

(2)projectionvector

(3) toolposition

(4) part

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide C-1

C

Advanced surface contouring

Projection and Steep Surface:

• ΔX = Δd/sin Δd/

ΔX becomes large if is very small (steep surface)

• The source of Δd is the chordal deviation of the drive path

(1) drivepath

(2) drivepoint

(3) Δd

(4) Δx

(5)

C-2 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

C


Projection and Material Side:

• Surface contouring does not have explicit definition of material side forpart geometry, only the drive surface has explicit material side

• Material side of the part is determined implicitly by the projection vector

(1) drive point

(2) projectionvector

(3) focal point

(4) A

(5) B

(6) C

(7) away frompoint

(8) all othercases

• In the case of Area Milling Drive (no projection vector), the tool axis vectoris used to decide Material Side

Tool axis

Definition of Lead/Tilt angles:

(1) lead

(2) tilt

(3) tool axisvector

(4) referencevector

(5) cut vector

(6) tool axis

• Begin with cut vector, rotate it toward the Reference vector 90°- degrees

• Then rotate around the cut vector degrees (counter clockwise)

• Reference vector is the surface normal relative to the part/drive or avector which is relative to a vector


C


Definition of 4-axis rotation angle:

(1) rotation angle

(2) perpendicular plane

(3) tool axis

(4) projected tool axis

(5) 4–axis vector

• Compute tool axisvector without 4–axisconstraint first

• Project this toolaxis vector onto theperpendicular plane ofthe 4–axis vector

• Rotate the projectedtool axis vectoralong 4–axis vector

(counterclockwise)

The unconstrained tool axis vector could be:

• Normal to Part / Drive

• Relative to Part / Drive


C


Interpolated tool axis algorithm:

(1) data point 1; (2) data point 2

(3) data point 3; (4) data point 4

(5) grid cell

• divide the whole parameter (u,v)space for the drive surfaces by a19x19 grid

• compute the tool axis at each gridpt using the data pts weighted bythe inverse of the distance square

• inside each grid cell, calculate thetool axis vector as the linear/splineinterpolation of the tool axis vectorat the four corners.

Drive surface

Remap of drive surface:

Remap algorithm:


C


(1) trimmed face; (2) underlinedsurface

• merge the exterior edges of thetrimmed face to 4 sides

• re-proportion the parameters ofthe exterior edges according to arclength

• use the arc length proportionaledge parameters to construct thenew (u’,v’) space for the trimmedface (Coon’s mapping).

• align the multiple drive surfacesinto a rectangular grid pattern

Limitations of remap

• fails on 3–sided faces

• fails on faces that do not have rectangular shapes

• may fail on faces with too many edges

• multiple drive surfaces must be in grid formation


C


Swarf developable surface:

• Developable surfaces are special kinds of ruled surfaces when the surfacenormal vectors on any given rule line are the same (ruled surface withouttwisting)

• Only developable surfaces can be milled by swarfing without undercut orovercut

Planar milling

• Blank - the region to be included

• Part - the region that can not be violated

• Check - the additional region that can not be violated

• Trim - as a final step, the region to be trimmed away

(1) check inside

(2) blank inside

(3) trim outside

(4) part inside

Boolean logic

Boundary Drive

• Drive boundary - similar to "blank" if no part containment, otherwiseit is like "part"

• Part containment - similar to "blank"

Area Milling Drive

• Cut area - similar to "blank"

• Trim - behaves slightly different from planar milling

Stock

Part offset and part stock


C


What WherePart Offset Offset of part as the

permanent definition ofthe final shape of theproduct

Geometry Group

Part Stock Leftover materialon part by a givenoperation

Operation

• Part stock is defined on "top" of part offset

(1) part stock ofroughing

(2) part

(3) part stock ofsemi-finish

(4) part offset


C


Safe clearance and part stock offset

What WherePart Stock Offset Difference between the

part stock from theprevious operation andthe part stock of thecurrent operation

Operation

Safe Clearance The additional safetyzone for collisionchecking

Operation

• Safe clearance is defined on "top" of part stock offset

(1) safe clearance

(2) part

(3) part stock

(4) part offset

(5) part stockoffset

• Part stock offset is used in multiple pass, engage/retract and collisionchecking

• Safe clearance is used in engage/retract and collision checking

Gouge / Collision

Definitions:

Rapid moves Feed movesCutting part of toolassembly

Collision Gouge

Non-cutting part of toolassembly

Collision Collision

• Usually gouge check against part offset + part stock


C


• Usually collision check against part offset + part stock + part stock offset+ safe clearance

(1) collision

(2) gouge

Usage:

Collision check Gouge checkTool Path Generation No Yes on PartDrive Path Generation No Optional on DriveEngage/Retract No Optional on PartTransfer Moves Optional on Part Optional on PartCut RegionComputation

(Cut Area)

Optional (holder) onPart/Check

Yes on Part

Check Geometry No Optional on CheckGouge Check

(Operation Navigator)

No (No Part Stock)


C


Noncut moves

Azimuth / Latitude:

(1) latitude

(2) azimuth

(3) part normal

(4) cut vector

(5) engage/retract vector

• Begin with cut vector, rotate it toward the part normal degrees

• Then rotate around the part normal degrees (counter clockwise)

End / Intermediate traverse:

(1) retract

(2) departure

(3) int traverse

(4) end traverse

(5) approach

(6) engage

• There is only one End Traverse in the sequence, but there may be zero ormultiple Int Traverse

• The Start and End positions of the End Traverse move are determined byother moves in the sequence


C

Index

A

advanced surface contouring topicsboolean logic . . . . . . . . . . . . . . . . . C-7drive surface . . . . . . . . . . . . . . . . . C-5

remap of . . . . . . . . . . . . . . . . C-5swarf developable . . . . . . . . . . C-7

gouge/collision . . . . . . . . . . . . . . . C-9noncut moves . . . . . . . . . . . . . . . C-11planar milling . . . . . . . . . . . . . . . C-7projection . . . . . . . . . . . . . . . . . . . C-1

material side . . . . . . . . . . . . . C-3steep surface . . . . . . . . . . . . . C-2

stock . . . . . . . . . . . . . . . . . . . . . . C-7tool axis . . . . . . . . . . . . . . . . . . . . C-3

lead/tilt . . . . . . . . . . . . . . . . . C-3

C

Cavity MillCut Levels . . . . . . . . . . . . . . . . . . 2-2Cut Patterns

Cut Pattern . . . . . . . . . . . . . . 2-6Cavity Milling

cut region start points . . . . . . . . . 2-18Course Overview

Class Standards . . . . . . . . . . . . . . . 9Course Description . . . . . . . . . . . . . 7Intended Audience . . . . . . . . . . . . . 7Objectives . . . . . . . . . . . . . . . . . . . . 8Prerequisites . . . . . . . . . . . . . . . . . 7Student and Workbook parts . . . . . 13System Privileges . . . . . . . . . . . . . 13Workbook overview . . . . . . . . . . . . 12

Cut Area GeometryZ-Level Milling . . . . . . . . . . . . . . . 3-3

Cut Levels . . . . . . . . . . . . . . . . . . . . 2-2Cut Patterns . . . . . . . . . . . . . . . . . . 2-6

F

Fixed Contourdrive geometry . . . . . . . . . . . . . . . 4-2drive methods

flow cut . . . . . . . . . . . 4-3, 4-6–4-7radial cut . . . . . . . . . . . . . . . . 4-3tool path . . . . . . . . . . . . . . . . 4-3User Function . . . . . . . . . . . . 4-3

drive points . . . . . . . . . . . . . . . . . 4-2operation types . . . . . . . . . . . . 4-4–4-5

contour_area . . . . . . . . . . . . . 4-4contour_surface_area . . . . . . . 4-4fixed_contour . . . . . . . . . . . . . 4-4

terminology . . . . . . . . . . . . . . . . . 4-2check geometry . . . . . . . . . . . 4-2drive geometry . . . . . . . . . . . . 4-2drive method . . . . . . . . . . . . . 4-2drive points . . . . . . . . . . . . . . 4-2part geometry . . . . . . . . . . . . 4-2projection vector . . . . . . . . . . . 4-2

use of . . . . . . . . . . . . . . . . . . . . . . 4-2

G

Geometry TypesZ-Level Milling . . . . . . . . . . . . . . . 3-3

M

Multi-axismulti-axis

positioning . . . . . . . . . . . . . . . 5-3rotary axis . . . . . . . . . . . . . . 5-10tool axis . . . . . . . . . . . . . . . . . 5-3

P

Part Geometry

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide Index-1

Index

Check GeometryZ-Level Milling . . . . . . . . . . . 3-3

Projection Vectorsdefinition of . . . . . . . . . . . . . . . . . A-1specification of . . . . . . . . . . . . . . . A-2

as used in variable contour . . . A-3as used ins surface area

drive . . . . . . . . . . . . . . . . . A-3fixed . . . . . . . . . . . . . . . . . . . A-2

table of methods . . . . . . . . . . . . . . A-5

SSequential Milling

Check surface . . . . . . . . . . . . 7-4, 7-11creating operation . . . . . . . . . . . 7-27dialog . . . . . . . . . . . . . . . . . . . . . . 7-5Drive surface . . . . . . . . . . . . . . . . 7-4engage motion dialog . . . . . . . . . . 7-7loops . . . . . . . . . . . . . . . . . . . . . 8-17multiple check surface . . . . . . . . 7-12nested loops . . . . . . . . . . . . . . . . 8-17overview . . . . . . . . . . . . . . . . . . . . 7-3Part surface . . . . . . . . . . . . . . . . . 7-4point to point motion dialog . . . . . 7-9reference point . . . . . . . . . . . . . . 7-11replace geometry globally . . . . . . 8-30retract motion dialog . . . . . . . . . 7-10stopping position

Ds-Cs Tangency . . . . . . . . . . 7-11far side . . . . . . . . . . . . . . . . 7-11near side . . . . . . . . . . . . . . . 7-11on . . . . . . . . . . . . . . . . . . . . 7-11Ps-Cs Tangency . . . . . . . . . . 7-11

suboperations . . . . . . . . . . . . . . . . 7-6continuous path motion

commands . . . . . . . . . . . . . 7-6continuous path motion

dialog . . . . . . . . . . . . . . . . 7-8engage . . . . . . . . . . . . . . . . . . 7-6point to point motion

commands . . . . . . . . . . . . . 7-6terminology . . . . . . . . . . . . . . . . . 7-4tool axis control . . . . . . . . . . . . . . 8-3

at angle to Ps or Ds . . . . . . . . 8-5fan . . . . . . . . . . . . . . . . . . . . . 8-5normal to Ps or Ds . . . . . . . . . 8-4

parallel to Ps or DS . . . . . . . . 8-4tangent to Ps or Ds . . . . . . . . 8-5thru fixed point . . . . . . . . . . . 8-7

TTrim Geometry

Steep AngleZ-Level Milling . . . . . . . . 3-3, 3-8

VVariable Contour

drive geometry . . . . . . . . . . . . . . . 9-3drive methods

boundary . . . . . . . . . . . . . . . . 9-7curve/point . . . . . . . . . . . . . . . 9-7radial cut . . . . . . . . . . . . . . . 9-11spiral . . . . . . . . . . . . . . . . . . . 9-7surface area . . . . . . . . . . . . . . 9-8tool path . . . . . . . . . . . . . . . . 9-9User Function . . . . . . . . . . . 9-11

drive pointsdrive geometry . . . . . . . . . . . . 9-3

terminology . . . . . . . . . . . . . . . . . 9-5check geometry . . . . . . . . . . . 9-5drive geometry . . . . . . . . . . . . 9-5drive method . . . . . . . . . . . . . 9-5drive points . . . . . . . . . . . . . . 9-5part geometry . . . . . . . . . . . . 9-5projection vector . . . . . . . . . . . 9-5

tool axisdual 4-axis . . . . . . . . . . . . . . 9-25interpolated . . . . . . . . . . . . . 9-36normal . . . . . . . . . . . . . . . . . 9-22relative . . . . . . . . . . . . . . . . 9-23swarf drive . . . . . . . . . . . . . . 9-29

tool path accuracy . . . . . . . . . . . . . 9-3Variable Contour and Sequential Mill

comparison . . . . . . . . . . . . . . . . . 9-46part, drive, check surfaces . . 9-46

general considerations . . . . . . . . 9-46

WWAVE Geometry Linker

Assemblies and Wave . . . . . . . . . . 1-9At Timestamp . . . . . . . . . . . . 1-3, 1-6

Index-2 Multi-Axis Techniques — Student Guide ©UGS Corp., All Rights Reserved mt11050_g NX 5

Index

Blank Original . . . . . . . . . . . . . . . 1-3Create Non-Associative . . . . . . . . . 1-3definition of . . . . . . . . . . . . . . . . . 1-2deleting parent geometry . . . . . . . 1-8editing links . . . . . . . . . . . . . . . . . 1-5Extracted feature . . . . . . . . . . . . . 1-6linking procedure . . . . . . . . . . . . 1-13Links

Break Links . . . . . . . . . . . . . . 1-6broken . . . . . . . . . . . . . . . . . . 1-7deleting of . . . . . . . . . . . . . . . 1-9newly broken . . . . . . . . . . . . . 1-7

simplify . . . . . . . . . . . . . . . . . . . 1-16Simplify Body . . . . . . . . . . . 1-17

ZZ Level Five Axis

overview . . . . . . . . . . . . . . . . . . . . 6-3Tool Axis . . . . . . . . . . . . . . . . . . . 6-4

Z-Level MillingCheck Geometry . . . . . . . . . . . . . . 3-3Cut Area Geometry . . . . . . . . . . . . 3-3Geometry Types . . . . . . . . . . . . . . 3-3Part Geometry . . . . . . . . . . . . . . . 3-3Steep Angle . . . . . . . . . . . . . . . . . 3-8Trim Geometry . . . . . . . . . . . . . . . 3-3Types . . . . . . . . . . . . . . . . . . . . . . 3-2

©UGS Corp., All Rights Reserved Multi-Axis Techniques — Student Guide Index-3

This page left blank intentionally.

LEARNING

ADVANTAGE

UGS Education Services offers a blend of training solutions for all of our product lifecycle management products. Our Online Store “Learning Advantage” was developed to provide our customers with “just in time”training for the latest in application developments. Here are some of the Learning Advantages:

• Customers have direct access • Self-paced course layout • Online Assessments • Just in time training for the latest release

To learn more about the “Learning Advantage” visit our website http://training.ugs.com or email us at training @ugs.com

http://training.ugs.com/


STUDENT PROFILE

In order to stay in tune with our customers we ask for some background information. This information will be kept confidential and will not be shared with anyone outside of Education Services.

Please “Print”…

Your Name U.S. citizen Yes No Course Title/Dates / thru Hotel/motel you are staying at during your training Planned departure time on last day of class Employer Location Your title and job responsibilities / Industry: Auto Aero Consumer products Machining Tooling Medical Other Types of products/parts/data that you work with Reason for training Please verify/add to this list of training for Unigraphics, I-deas, Imageware, Teamcenter Mfg., Teamcenter Eng. (I-Man), Teamcenter Enterprise (Metaphase), or Dimensional Mgmt./Visualization. Medium means Instructor-lead (IL), On-line (OL), or Self-paced (SP) Software From Whom When Course Name Medium

Other CAD/CAM/CAE /PDM software you have used Please “check”! your ability/knowledge in the following…

Subject CAD modeling CAD assemblies CAD drafting CAM CAE PDM – data management PDM – system management

None

Novice

Intermediate

Advanced

Platform (operating system) Thank you for your participation and we hope your training experience will be an outstanding one.


Multi Axis Techniques 301 Course Agenda Day One • Course Overview • Lesson 1. WAVE Geometry Linker in Manufacturing • Lesson 2. Advanced Cavity Milling Topics Afternoon • Lesson 3 Z-Level Milling • Lesson 4. MILL_AREA Geometry Parent Groups • Workbook Drilling the Top Flange Day Two • Lesson 5. Fixed Contour Operation Types Afternoon • Lesson 6. Introduction to Four and Five Axis Machining • Lesson 7. Five Axis Z Level • Lesson 8. Sequential Mill Basics • Workbook Sequential Mill - Cutting the Manifold Flange Day Three • Lesson 9 Sequential Mill Advanced • Lesson 10. Variable Contour Basics Afternoon • Lesson 11. Variable Contour Advanced • Workbook Variable Contour - Cutting the Manifold Flange • Workbook Variable Contour – Additional Activities


Accelerators

The following Accelerators can be listed from within an NX session by choosing Information→Custom Menubar→Accelerators.

Function Accelerator File→New... Ctrl+N File→Open... Ctrl+O File→Save Ctrl+S File→Save As... Ctrl+Shift+A File→Plot... Ctrl+P File→Execute→Grip... Ctrl+G File→Execute→Debug Grip... Ctrl+Shift+G File→Execute→NX Open... Ctrl+U Edit→Undo Ctrl+Z Edit→Cut Ctrl+X Edit→Copy Ctrl+C Edit-Paste Ctrl+V Edit→Delete... Ctrl+D or Delete Edit→Selection→Top Selection Priority - Feature F Edit→Selection→Top Selection Priority - Face G Edit→Selection→Top Selection Priority - Body B Edit→Selection→Top Selection Priority - Edge E Edit→Selection→Top Selection Priority - Component C Edit→Selection-Select All Ctrl+A Edit→Show and Hide→Show and Hide...(by type) Ctrl+W Edit→Show and Hide→Hide Ctrl+B Edit→Show and Hide→Invert Shown and Hidden Ctrl+Shift+B Edit→Show and Hide→Show... Ctrl+Shift+K Edit→Show and Hide→Show All Ctrl+Shift+U Edit→Transform... Ctrl+T Edit→Object Display... Ctrl+J View→Operation→Zoom... Ctrl+Shift+Z View→Operation→Rotate... Ctrl+R View→Operation→Section... Ctrl+H View→Layout→New... Ctrl+Shift+N View→Layout→Open... Ctrl+Shift+O View→Layout→Fit All Views Ctrl+Shift+F View→Layout→Fit Ctrl+F View→Visualization→High Quality Image... Ctrl+Shift+H View→Information Window F4 Hide or show the current dialog box F3 View→Reset Orientation Ctrl+F8 Insert→Sketch... S Insert→Design Feature→Extrude... X

Insert→Design Feature→Revolve... R Insert→Trim→Trimmed Sheet... T Insert→Sweep→Variational Sweep... V Format→Layer Settings... Ctrl+L Format→Visible in View... Ctrl+Shift+V Format→WCS→Display W Tools→Expression... Ctrl+E Tools→Journal→Play... Alt+F8 Tools→Journal→Edit Alt+F11 Tools→Macro→Start Record... Ctrl+Shift+R Tools→Macro→Playback... Ctrl+Shift+P Tools→Macro→Step... Ctrl+Shift+S Information→Object... Ctrl+I Analysis→Curve→Refresh Curvature Graphs Ctrl+Shift+C Preferences→Object... Ctrl+Shift+J Preferences→Selection... Ctrl+Shift+T Start→Modeling... M or Ctrl+M Start→All Applications→Shape Studio... Ctrl+Alt+S Start→Drafting... Ctrl+Shift+D Start→Manufacturing... Ctrl+Alt+M Start→NX Sheet Metal... Ctrl+Alt+N Start→Assemblies A Start→Gateway... Ctrl+W Help→On Context... F1 Refresh F5 Fit Ctrl+F Zoom F6 Rotate F7 Orient View-Trimetric Home Orient View-Isometric End Orient View-Top Ctrl+Alt+T Orient View-Front Ctrl+Alt+F Orient View-Right Ctrl+Alt+R Orient View-Left Ctrl+Alt+L Snap View F8

Evaluation – Delivery

NX 5 Multi Axis Techniques, Course #MT11050 Dates thru

Please share your opinion in all of the following sections with a “check” in the appropriate box:

SOM

EW

HA

T

DIS

AG

RE

E

SOM

EW

HA

T

AG

RE

E

STR

ON

GL

Y

DIS

AG

RE

E

DIS

AG

RE

E

Instructor:

AG

RE

E

STR

ON

GL

Y

AG

RE

E

If there were 2 instructors, please evaluate the 2nd instructor with “X’s”

Instructor:

1. …clearly explained the course objectives

2. …was knowledgeable about the subject

3. …answered my questions appropriately

4. … encouraged questions in class

5. …was well spoken and a good communicator

6. …was well prepared to deliver the course

7. …made good use of the training time 8. …conducted themselves professionally 9. …used examples relevant to the course and audience 10. …provided enough time to complete the exercises

11. …used review and summary to emphasize important information 12. …did all they could to help the class meet the course objectives

Comments on overall impression of instructor(s):

Overall impression of instructor(s) Poor Excellent Suggestions for improvement of course delivery:

What you liked best about the course delivery:

Class Logistics: 1. The training facilities were comfortable, clean, and provided a good learning

environment 2. The computer equipment was reliable 3. The software performed properly 4. The overhead projection unit was clear and working properly 5. The registration and confirmation process was efficient

Hotels: (We try to leverage this information to better accommodate our customers)

1. Name of the hotel Best hotel I’ve stayed at

2. Was this hotel recommended during your registration process? YES NO

3. Problem? (brief description)

SEE BACK

Evaluation - Courseware

NX 5 Multi Axis Techniques, Course #MT11050 :

SOM

EW

HA

T

STR

ON

GL

Y

DIS

AG

RE

E

DIS

AG

RE

E

DIS

AG

RE

E

SOM

EW

HA

T

AG

RE

E

AG

RE

E

STR

ON

GL

Y

AG

RE

E

Please share your opinion for all of the following sections with a “check” in the appropriate box

Material:

1. The training material supported the course and lesson objectives 2. The training material contained all topics needed to complete the projects 3. The training material provided clear and descriptive directions 4. The training material was easy to read and understand

5. The course flowed in a logical and meaningful manner 6. How appropriate was the length of the course relative to the material? Too short Too long Just right

Comments on Course and Material:

Overall impression of course Poor Excellent

Student:

1. I met the prerequisites for the class (I had the skills I needed) 2. My objectives were consistent with the course objectives 3. I will be able to use the skills I have learned on my job 4. My expectations for this course were met 5. I am confident that with practice I will become proficient

Name (optional): Location/room

Please “check” this box if you would like your comments featured in our training publications. (Your name is required at the bottom of this form)

Please “check” this box if you would like to receive more information on our other courses and services. (Your name is required at the bottom of this form)

Thank you for your business. We hope to continue to provide your training

and personal development for the future.

Date post:	14-Jul-2016
Category:	Documents
Upload:	andreeaoana45
View:	10 times
Download:	4 times

mat_mt11050_g

Documents