multi-axis techniques student guide february 2006 mt11050 — nx 4

Multi-Axis Techniques

Student GuideFebruary 2006MT11050 — NX 4

Publication Numbermt11050_g NX 4

Manual History

ManualRevision

UnigraphicsVersion

PublicationDate

Version 16 August 2000Version 17.1.1 February 2001Version 18.0 November 2001Unigraphics NX November 2002Unigraphics NX 2 January 2004NX 3 May 2005NX 4 February 2006

This edition obsoletes all previous editions.

Proprietary & Restricted Rights Notice

This software and related documentation are proprietary to UGS Corp.

© 2006 UGS Corp. All Rights Reserved.

All trademarks belong to their respective holders.

©2006 UGS CorporationAll Rights Reserved.Produced in the United States of America.

2 Multi-Axis Techniques — Student Guide mt11050_g NX 4

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 . . . . . . . . . . . . . . 1-4Editing Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Broken Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Newly Broken Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Deleting Parent Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9Deleting Linked Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Activity: Creating an Assembly for WAVE . . . . . . . . . . . . . . . . . 1-11Linking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Activity: Creating WAVE Geometry . . . . . . . . . . . . . . . . . . . . . . 1-17Simplify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19Simplify Body Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20Activity: Using Simplify Body . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21Activity: Other Modeling Techniques . . . . . . . . . . . . . . . . . . . . . 1-23

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29

Advanced Cavity Milling Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cut Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Activity: Using Cut Levels Parameters . . . . . . . . . . . . . . . . . . . . 2-4

Cut Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Activity: Zig-Zag Cut Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

In-Process work piece for Cavity Milling . . . . . . . . . . . . . . . . . . . . . 2-16

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

Contents

Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18Activity: Using the Level Based In-process Workpiece (IPW) . . . 2-19Activity: Using the 3D In-Process Work Piece (IPW) . . . . . . . . . 2-25Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-32Activity: Using a Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . 2-35Cavity Milling Stock Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39Activity: Using the Blank Distance Option . . . . . . . . . . . . . . . . . 2-40

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16Z-Level Cutting Between Levels (aka Gap Machining) . . . . . . . . . . . 3-21Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30

MILL_AREA Geometry Parent Groups . . . . . . . . . . . . . . . . . . . . . . . 4-1

MILL_AREA Geometry Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Activity: MILL_AREA Geometry Parent Groups . . . . . . . . . . . . . 4-4Trim Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Activity: Using Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Fixed Contour Operation Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fixed Contour Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2More on Flow Cut Drive Methods . . . . . . . . . . . . . . . . . . . . . . . 5-12Activity: Creating Fixed Contour Operations . . . . . . . . . . . . . . . 5-17Non-Cutting Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32Activity: Using Non-Cutting Moves . . . . . . . . . . . . . . . . . . . . . . 5-35

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

Introduction to Four and Five Axis Machining . . . . . . . . . . . . . . . . 6-1

Multi-Axis Machining Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Activity: Operations at Other Than 0,0,1 Tool Axis . . . . . . . . . . . 6-3

Defining the Center of Rotation for a Rotary Axis . . . . . . . . . . . . . . 6-16Activity: Main and Local MCS in Multi-Axis Applications . . . . . 6-18Activity: Main and Local MCS in Multi-Axis Applications . . . . . 6-27

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

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

Contents

Sequential Mill Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Sequential Milling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Sequential Milling Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3Defining the Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11Multiple Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12Activity: Basic Sequential Milling Techniques . . . . . . . . . . . . . . 7-13More on Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37Activity: Sequential Milling of a Multi-Surfaced Floor . . . . . . . . 7-38

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Sequential Mill Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Tool Axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Activity: Sequential Mill Five-Axis Fan Motion . . . . . . . . . . . . . . 8-7Standard and Nested Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19Activity: Sequential Mill – Using Loops . . . . . . . . . . . . . . . . . . . 8-23Activity: Removing Excess Stock from a Closed Wall . . . . . . . . . 8-27Activity: Using Looping to Remove Excess Stock . . . . . . . . . . . . 8-34Additional Sequential Mill Options . . . . . . . . . . . . . . . . . . . . . . 8-36

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42

Variable Contour – Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2Terminology used in Variable Contour . . . . . . . . . . . . . . . . . . . . . 9-4Variable Contour vs Fixed Contour . . . . . . . . . . . . . . . . . . . . . . . 9-5Drive Methods for Variable Contouring . . . . . . . . . . . . . . . . . . . . 9-6Activity: Overview of Variable Contour Options . . . . . . . . . . . . . 9-18Tool Axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21Activity: Point and Line Tool Axis Types . . . . . . . . . . . . . . . . . . 9-25

Activity: Normal to Part and Relative to Part . . . . . . . . . . . . . . . . . 9-32Activity: Using Special Tool Axis and non Part Geometry . . . . . . 9-37Activity: Swarf Drive Tool Axis . . . . . . . . . . . . . . . . . . . . . . . . . 9-45Activity: Using the Interpolated Tool Axis . . . . . . . . . . . . . . . . . 9-61

A Comparison of Variable Contour vs. Sequential Milling . . . . . . . . 9-68Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71

Variable Contour – Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Advanced Variable Contour Machining . . . . . . . . . . . . . . . . . . . . . . 10-2Activity: Examining the Part and Part Objects . . . . . . . . . . . . . . 10-3

Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12Activity: Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . 10-13Geometry Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21Automatic Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22Activity: Floor selection and Automatic Wall . . . . . . . . . . . . . . . . . 10-23Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27Activity: Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28


Contents

Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32Activity: Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . 10-33Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41Activity: Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . . . . . . . . 10-48Activity: Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . 10-49Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55

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 with Basic Design or the CAST equivalent. Any additionalexperience in creating multi-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 workingin the 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 Corporation, 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 an Assemblies license.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 Corporation, All Rights Reserved mt11050_g NX 4

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


Editing Links

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

When this dialog 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 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.

When editing links and selecting new parent geometry, it may beeasier to temporarily work in an exploded view to distinguish betweenthe existing 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).


1


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 dialog orthe Edit during Update dialog.

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


1


Deleting 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


Deleting 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.


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Activity: Creating 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: Open the seed part, seedpart_in, and save it with a new name.

If necessary, start NX.

Use File→Open.


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Navigate to your parts folder and open the file seedpart_in .

Choose File→Save As ***_mixer_mfg where *** representsyour initials.

Step 2: Add the existing designed part as an assembly component.

Your first objective will be to add the existing mixer housing as thefirst component of the mixer_mfg assembly. All assembly linkswill be on layer 11.

If necessary, from the main menu, choose Start→Assemblies.

Change the Work Layer to 11.

From the main menu, choose Assemblies→Components→AddExisting.

In the Select Part dialog, select the Choose Part File button.

Select mixer_body, then choose OK.

In the Add Existing Part dialog, change the component nameto mixer. It can be typed in upper or lower case.

If necessary, while still in the Add Existing Part dialog, chooseSOLID from the Reference Set pull-down menu.

The Add Existing Part dialog is still displayed.

Verify that the Positioning pull-down menu is set to Absolute.


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Choose OK in the Add Existing Part dialog.

The Point Constructor dialog is displayed.

Choose the Reset button in the Point Constructor dialog, thenchoose OK.

The mixer body part is now a component of ***_mixer_mfg.

Cancel the Select Part dialog.

Step 3: Examine the current assembly structure.

Display the Assembly Navigator by choosing the AssemblyNavigator tab in the resource bar.

Clicking once on the tab temporarily displays theAssembly Navigator by sliding it to the left over thegraphics display.

Double-clicking on the tab displays the AssemblyNavigator in a separate window which can then bemoved 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 anygeometry.

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

Step 4: Create an empty component, then apply the seed part preferences.

Choose Assemblies→Components→Create New from themenu bar.

Choose OK

In the File Name field, of the Select Part Name dialog, type in***_mixer_casting, then choose OK.

The Create New Component dialog is displayed.


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In the Component Name field, type CASTING, then choose OK.

A new component, named CASTING, is displayed in theComponent Name column of the Assembly Navigator.The name of the part file is ***_mixer_casting. You mayneed to display the Component Name column by selectingMB3,Columns→Component Name.

Next, apply the layer and color standards from the seed partfile. In NX, all operations apply to the work part, which iscurrently ***_mixer_mfg. To apply the seed part defaults, theCASTING component should be the work part. For clarity, wewill also make it the displayed part.

In the Assembly Navigator, highlight the CASTING component,***_mixer_casting, and using MB3 choose Make Displayed Partfrom the pop-up menu.

To illustrate the lack of user-defined defaults, chooseFormat→Layer Settings.

Notice the category field is blank.

Choose Cancel in the Layer Settings dialog.

Choose File→Import →Part.

If necessary, in the Import Part dialog, uncheck Create NamedGroup, then choose OK.

Browse to the seedpart_in.prt, and double-click on it.


Choose OK in the Point Constructor dialog. Since no geometryis being imported, position is not relevant.

Also, there is no interaction on the screen.

Choose Cancel in the Point Constructor dialog.

Choose Format→Layer Settings.

Notice the several different layer categories defined.

Choose Cancel in the Layer Settings dialog.

Step 5: Make the top-level part the displayed part, and save the workcreated thus far.

In the Assembly Navigator, highlight ***_mixer_casting, andusing MB3, choose Display Parent→ ***_mixer_mfg.


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In the Assembly Navigator, highlight ***_mixer_mfg, and usingMB3, choose Make Work Part.

Choose the Save icon on the toolbar.

When you save an assembly, all modified componentsbelow the work part are saved as well.


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Linking Procedure

You use the Assemblies→WAVE Geometry Linker dialog to create associatedobjects between part files. The linker allows you to copy geometry downwardinto component parts, upward into higher level assemblies, or sidewaysbetween components within an assembly. As you build your assembly youwill 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.

• Set the Work Layer to the layer you want to contain the linked copies.

• Choose Insert → Associative Copy →WAVE Geometry Linker.

• Use the linker dialog to filter the type of object(s). You may select severalobjects of different types.

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


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Activity: Creating 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.

Highlight the component ***_mixer_casting in the AssemblyNavigator, and make it the Work Part by using MB3, andselecting Make Work Part.

The mixer body, in the graphics window, fades to green. This isa visual clue that geometry is no longer in the current modelinghierarchy.

The work layer is where linked geometry will be created.

Choose Format→Layer Settings.

Make Layer 1 the work layer.

Choose OK in the Layer Settings dialog.

Step 2: Select the Role Essentials with full menus and create a LinkedBody. The simplify option does not appear on the Essentials role.

Select the Roles tab and drag the Essentials with full menusicon 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.

Choose the BODY icon in the WAVE Geometry Linkerdialog.

Select the mixer body.

Choose OK.


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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 theAssembly Navigator useMB3 over the ***_mixer_castingcomponent, and choose Make Displayed Part.

In the graphics window, use MB3→Replace View→TFR-TRIfrom the pull-down menu.

Choose the Shaded icon from the main menu bar.

Choose Edit→Object Display.

Select the linked body and choose OK(green check mark) .

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

Change the Color to Yellow.

Choose OK in the Edit Object Display dialog.

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, usingMB3 on the ***_mixer_castingcomponent, choose Display Parent→***_mixer_mfg.

In the Assembly Navigator, using MB3 on ***_mixer_mfg,choose Make Work Part.

Choose the Save icon on the toolbar.


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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.


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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.


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Activity: Using 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.

In the Assembly Navigator, use MB3 on the ***_mixer_castingcomponent and choose Make Displayed Part.

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

Choose Start→Modeling.

Choose Insert→Direct Modeling→Simplify.

The Simplify Body dialog is displayed.

The cue line reads Select retained faces.


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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 Lless Than field and press theReturn key.

Choose Apply and then press OK in the Simplify Body dialog.

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 by choosing OK.


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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.

If necessary, in the Assembly Navigator, using MB3 on the***_mixer_casting component, choose Make Displayed Part.

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

Choose Start→Modeling.

Choose Insert→Design Feature→Extrude.

The Extrude Widget is displayed.

On the Selection Intent toolbar change the type filter from Anyto Face Edges.


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


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Choose the Unite icon from the Boolean pull-down menu.

Under Limits, End, change from Value to Until Extended.


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Select the outlet face, then choose OK on the Extrude dialog.

The O-ring groove has been removed from the outlet face.

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, key in 0.250 for the offset value.

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


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Choose OK.

The modeling changes are complete. It will be difficult tovisualize those changes in shaded mode, without a furtherdisplay change to the casting.

Step 4: Change the translucency of the casting.

To make it easier to visually distinguish between the originaldesigned part and the casting, you will make the casting modeltranslucent.

If necessary, use the Shaded icon to 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,choose Preferences→Visualization Performance, andturn off Disable Translucency, located on the GeneralSettings tab under 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.


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Find and depress the Assembly Navigator button to activatethe Assembly Navigator.

Use MB3 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 machinedfaces. All drilled holes have been removed, as well as the ringgroove.

This is only one potential method for creating a simulatedcasting body. Other methods and techniques could also havebeen used. However, this method is fully associated to theoriginal, so that if the original body changes, the casting bodywill update also.

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

Choose File→Close →Save All and Close.


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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.


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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


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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 ofstock that remains.


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The Cut Levels dialog is located under the Cut Levels button in the CavityMill dialog.

The Cut Levels dialog serves two primary functions:

• Create and 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.


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Activity: Using 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 bar andexpand the BASE_MALE_DIE parent group.

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


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Step 3: Use Verify to examine the operation.

You will use the Verify option to replay an existing operation.

To speed up the Dynamic Replay mode, make the imagesmaller. In the graphics window, choose MB3 → ZoomIn/Out and zoom the object out. This option is unavailablewhen the Tool path Visualization dialog is active.

Highlight the CAVITY_MILL operation, using MB3, chooseToolpath → Verify.

In the Tool path Visualization dialog, choose the 2D Dynamicproperty page (tab).

As shown, choose the Play icon.

This operation, in the current state, machines too low on thepart.

You will perform the steps necessary to correct this deficiency.

Choose Cancel in the Tool path Visualization dialog.

Step 4: Edit the Bottom of Range #1.

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


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Double-click on the CAVITY_MILL operation.

Generate the operation.

At this level, the part and blank geometry are identical, thetrace generated for the part and blank geometry are the same;therefore no geometry is available for machining. You will nowalter the cut levels to eliminate the warning message.

Choose OK to the Warning message.

Choose Cut Levels from the CAVITY_MILL dialog.

At the very top of the dialog, 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 foreach new range. The Single (3) button defines the cut rangebased on part and blank geometry.

Examining the status line, you will find that there are currently15 Cut Levels within one range in this operation.


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In the Cut Levels dialog, choose the Edit current range icon.

Choosing a face will modify the bottom of Range #1.


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Select the face of the part as shown.

The status line shows 13 cut levels and the range depthchanges to 3.25.

Choose OK on the Cut Levels dialog.


The operation successfully generates without warningmessages.

Save the part file.


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Cut PatternsThe Cut Method (1) determines the cut pattern used for cutting.


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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.


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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.


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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 enter 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.

Double-click on the CAVITY_MILL operation.

From the CAVITY_MILL dialog, choose the Zig-Zag Cut Method.


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Step 3: Generate the operation.

Choose the Generate icon to generate the operation.

The tool path is generated.

Step 4: Change the Cutting options.

Choose the Cutting button from the CAVITY_MILL dialog.

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

Key -45.0 in the Degrees field of the Cut Parameters dialog.


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Choose the Display Cut Direction button.

An arrow indicates the applied Cut Angle.

Choose OK on the Cut Parameters dialog.



Use 3D Dynamic verification to analyze the results.

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

Cancel the Tool path Visualization dialog.

Change the Cut Method to Zig with Contour.


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

This time the tool path is more efficient in the method ofcleaning up the corners.

Save the part.


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In-Process work piece for Cavity MillingTo make the various Cavity Milling operations as efficient as possible, youmust determine what has been machined in each operation. Variables suchas cutting tool lengths and diameters, draft angles and undercuts, fixture andtool clearances, will affect the amount of material that each operation mayleave. The material that remains after each operation is executed is referredto as the In-Process work piece or IPW.

Generally speaking, the remaining material (IPW) can be used for input intoa subsequent operation which may be used for additional roughing. The endresult is a semi-finished part that has most of the rough material or stockcompletely removed.

To use the IPW, certain conditions must be adhered to. Tool path generationmust be done sequentially, from the first operation to the last, within a certaingeometry group. The tool path must be successfully generated and acceptedin all previous operations in the sequence before the IPW can be used forthe next operation of the sequence.

Two methods for creating the In-Process work piece are available. Theoptions available are 3D IPW and Level Based IPW.


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Level Based IPW

Level-Based IPW uses the 2D cut regions from the previous Cavity Millingand/or ZLevel operations to identify and machine rest material. Theseprevious operations are referred to as reference operations. Level-Based IPWis limited to Cavity Milling or ZLevel milling operations with the same toolaxis as the previous operation. The rest milling and reference operationsmust belong to the same geometry group


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Use 3D

Use 3D uses a 3D internal definition to represent the remaining material.All milling operations can produce a 3D IPW. Use 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. If you must use 3DIPW for cavity milling operations.


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Activity: Using the Level Based In-process Workpiece (IPW)

In this activity, you will machine the part using three different cutter sizes.You will activate the use of the Level Based IPW and generate the operation.You will edit subsequent operations, each using smaller tools utilizing theLevel Based IPW.

Step 1: Open the part level_based_mfg and enter the Manufacturingapplication.

From the menu bar, select File.

Choose Open.

Select the file level_based_mfg, then choose OK.


Step 2: Activate the Operation Navigator.

Choose the Operation Navigator tab from the resource bar.


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

Choose the Geometry View button from the OperationNavigator tool bar, then expand the MCS_MILL , WORKPIECE, and MILL_AREA parent groups.

Step 4: Edit the operation CVM1and use the Level Based IPW.

Double-click the CVM1 operation in the Operation Navigator.

Choose Cutting from the CAVITY_MILL dialog.

Choose the Containment tab from the Cut Parameters dialog.


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Select Use Level Based for the In-process Workpiece.

Choose OK to accept the Cut Parameters.

Choose Generate to generate the tool path.

A warning Message appears “The preference to enable LevelBased IPW is not turned on” appears.

Choose NO to turn the preference on and continue.

Choose OK to accept the operation.



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Choose OK to accept the operation




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

This time the tool path is more efficient in the method ofcleaning up the corners.


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Close the part file.


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Activity: Using the 3D In-Process Work Piece (IPW)

In this activity, you will machine the core block for an ATM key pad usingthree different cutter sizes. You will define the BLANK in the MILL_GEOMparent group, activate the use of the 3D IPW and generate the operation. Youwill then use the subsequent IPW as the blank for the next operation and thenuse the IPW created from that operation to finish the keypad.

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


Choose Open.

Select the file ipw, then choose OK.





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

Choose the Geometry View button from the OperationNavigator tool bar, then expand the MCS_MILL andWORKPIECE parent groups.

Step 4: Edit the operations and use the IPW.



Choose the Containment tab from the Cut Parameters dialog.


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Select Use 3D for the In Process Workpiece.



The first Cavity Milling tool path is displayed. You will wantto display the amount of stock that remains that becomes theblank for the next operation.


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Choose the Display Resulting IPW icon.

The resultant IPW is displayed.

This IPW will be used as the Blank for the next operation,CVM2.

The initial IPW was defined as the Blank in the WORKPIECEgeometry parent group. You generated the operation, usingthe initial IPW, and set options needed to create the IPW for asubsequent operation. You will use this IPW as the Blank forthe operation, CVM2.


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Choose OK to accept the previous operation.






The second Cavity Milling tool path is displayed. You will nowdisplay the IPW to show the remaining material.


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Choose the Display Output IPW icon.

The resultant IPW is displayed.

This IPW will be used as the Blank for the next operation.

You will use the current IPW for the final Cavity Millingoperation.

Choose OK to accept the previous operation.



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Pre-Drill Engage and Cut Region Start Points

Pre-Drill Engage and Cut Region Start Points are found in the Points/ControlGeometry section of the Cavity Milling dialog. These two options providecontrol over the cutting start point within single and multiple regions ofCavity Milling. They also determine the direction that the tool moves towardsthe cavity or core walls.

Pre-Drill Engage Points

Cavity Milling determines the tool path start point.

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.


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To use this option, specify a pre-drilled engage point and an optional depthvalue. If you are going to specify a depth value, it must be done prior tospecifying the start point.

There are three methods available for specifying pre-drilled engage points:

• Point/Arc - by using existing points or arcs. The arcs are associative to thegeometry. They must be explicit or sketch curves.

• Cursor - by using the cursor position.

• Generic Point - by using the option on the generic point dialog.

The depth value for a start cut point is optional. If you do not specify a value,the pre-drilled engage point is used at every cut level.

As shown , cut level 1 uses the pre-drilled engage point that falls within thespecified depth. Cut levels 2 and 3 do not use the specified pre-drilled engagepoint since the cut levels are not within the specified depth. The processorwill use the internally defined cut start point to cut the remaining cut levels(2 and 3).

All specified depths are measured from the top plane.


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You can define Pre-drilled points using either the Engage/Retractdialog or the Pre-drill Start Points option located under the ControlGeometry button. The Engage/Retract Pre-drill points and settingsoverride the points defined under the Control Geometry Option. Ifyou specify multiple Pre-drill points you can optimize the order inwhich they are drilled by customizing the Engage/Retract optionswhich are available.

Cut Region Start Points

Cut Region Start Points allows you to specify cut start points for each regionin a multi-region cavity. When you use circular engages, this option can avoidengages into pocket corners by using the Automatic or User Defined methodof engagement.

The Cut Region Start Points defaults are as follows:

Automatic establishes the Cut Region Start Point at the "flattest" convexcorner of the cut region. If there are no convex corners, the midpoint of thelongest boundary segment of the cut region is used. This option assures thatthe tool will step over or engage the part at a location which is least likely tocause the tool to become buried in the material.

Standard establishes the Cut Region Start Point as close as possible to thestart point of the boundary region. The shape of the boundary, cut type,and position of islands and pockets will influence how closely the processorpositions the Cut Region Start Point to the Boundary Start Point. Moving theBoundary Start Point affects the location of the Cut Region Start Point.


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Activity: Using a Pre-Drill Engage Point

In this activity, you will edit the current operation to use a Pre-drilled EngagePoint to start your tool path. The Pre-drill Engage Point is a hole that hasbeen previously drilled.

Step 1: Open the part form_mold_mfg and choose the manufacturingapplication.


Choose Open.

Select the file form_mold_mfg, then choose OK.



Choose the Operation navigator tab from the resource bar.

Step 3: Edit an existing operation.

Double-click on the CM_ROUGH operation in the OperationNavigator.

The Cavity Milling dialog is displayed. You will now define apoint that represents a hole which has been previously drilled.This will be the engage point for the tool that is used to starteach cut level.

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


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Choose Points in the Control Geometry section.

The Control Geometry dialog is displayed. Notice that thereare two sections to this dialog, Pre-Drill Engage and CutRegion Start Points.


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Choose Edit in the Pre-Drill Engage Points section.

The Pre-Drill Engage Points dialog is displayed.

You can use the Depth parameter when you want a particularPre-Drill Engage Point to be used only for certain cut levels.If you do not specify a depth parameter, the point will be usedat all cut levels. If you use the parameter it must be definedbefore specifying the point.

For this activity, you will not specify a depth parameter. Thisparticular Pre-Drill Engage Point will be used at all cut levels.

Choose Generic Point.


Key in the following values: XC=5 YC=2.5 ZC=0


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Choose OK.

The point just created is displayed (this point is at the bottomof the part, if your display setting is solid, set to wire frameto see the point).

Choose OK until you return to the Cavity Milling dialog.

Step 5: Generate the tool path.

Choose the Generate icon to create the tool path.

Notice that all levels start at the Pre-Drill Engage Point inthe center of the part, then move to the start point which isdetermined by the processor.


Save your Part.


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Cavity Milling Stock Options

Stock options for Cavity Milling are found on the Cut Parameters dialog.This dialog is activated by selecting the Cutting button found on the CavityMill 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 trimboundary.

-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.


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Activity: Using the 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 enter 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 Start → Manufacturing .

The Operation Navigator is displayed.


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Step 2: Create an operation utilizing Blank Distance as a part offset.As shown below, select the Create Operation icon from theCreate toolbar.

The Create Operation dialog is displayed.

Select the Cavity Milling icon.

Set the following:

• Program: ROUGH_WITHOUT_CASTING

• Use Geometry: WORKPIECE

• Use Tool: EM-.375-.06

• Use Method: MILL_FINISH

On the Create Operation dialog, name the operationCM_.20_BLANKDISTANCE.

Choose OK.

The CAVITY_MILLING dialog is displayed.

Step 3: Verify the Part Geometry selection.

Under the Geometry label, select the Part icon.

Choose Display.

Note that the Part geometry is displayed.

Under the Geometry label, select the Blank icon.

Note that no Blank geometry has been selected.

Step 4: Specify Operation settings.Set the Cut Method to Follow Part.

Set Depth Per Cut to .125.

Choose Cutting.

The Cut Parameters dialog is displayed.


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Change the Cut Order to Depth First.

Change the Blank Distance to .20.

Choose OK.

The CAVITY_MILL dialog is displayed.


Choose the Generate icon to generate the tool path.

Choose OK after viewing each Cut Level.


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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.250" stock overall.

Choose OK to accept the tool path.

Save the part file.


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Cut Parameters - Trim by

Trim by enables the Blank geometry to be recognized on core parts whenthe Blank geometry has not been explicitly defined. The Trim by methodprovides a Silhouette option to clean up the material which surrounds thePart geometry. It is available only when Tolerant Machining is toggled to on.

This option positions the tool to the outer most edge periphery (silhouette) ofthe part geometry and then offsets it outside by the tool radius. The silhouettecan be consider as a shadow of the part projected along the tool axis.

When using Trim by Silhouette, the processor uses the traces at the bottom ofthe defined part geometry as trim shapes. These shapes are then projectedalong the tool axis to each cut level and are used to generate machinableregions as trim shapes.

Cut Parameters - Tolerant Machining

The Tolerant Machining ON option is the preferred method for Cavity Millingoperations. Tolerant Machining will find all machinable regions withoutgouging the part.

Tolerant Machining algorithms digitize a model on a rectangular grid that isdetermined by the defined cutting tolerance and the tool size. In most parts,the grid size range between 1-2 millimeters (.04 - .08").

When you specify a Blank distance that is an offset from the Part, thetolerance used to trace the Blank is larger than the tolerance used to trace


2


the Part. This is due to dimensions of Blank geometry not being as accurateas those of the Part geometry. When you specify Blank geometry that is closeto the size of Part geometry, the Blank and Part traces will overlap and resultin an undesirable cut region(s). In this case it would be better to cut a profilepass along the Part without specifying the Blank. The resultant tool path willbe along the Part geometry.

When the processor encounters geometry that contains gaps or that is notperfectly matched, it will move the tool using an approximation within thespecified tolerances.

The processing time is longer when Tolerant Machining is on. TolerantMachining SHOULD ALWAYS be turned on.

Cut Parameters - Undercut Handling

Undercut Handling is used with geometry features containing undercuts. Itis applied only to non-tolerant machining.

If Tolerant Machining is turned on, Undercut Handling is automaticallyturned off.

When using the Undercut Handling option Horizontal Clearance (specifiedunder the Engage/Retract Method) applies to the shank of the tool (theportion above the flutes) unless the Horizontal Clearance is greater than thetool radius. In this case the tool radius is used.


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As the tool progresses deeper through the various cut levels, HorizontalClearance will keep the shank from contacting the part geometry whichforms the undercut.

In the following example the Horizontal Clearance uses the default of .100.The tool radius is .120. The tool will be offset from the undercut face by .100.

Part, Blank, Check Geometry - Topology

Topology provides options for surface analysis that allow checking formaterial side inconsistency, gaps and missing and duplicate surfaces.

This option is available when you are editing geometry and aids in thecorrection of model geometry errors that occur when models from other CADsystems are converted into NX models or from within a model created usingNX.

The topology processor inspects the model for missing, duplicated andnon-tangent faces which can create multiple shells and an erratic tool path.

It is suggested that the Topology option be used only if tool pathgeneration fails.

The following are common causes of tool path generation failures.

• Duplicate faces

• Missing fillets and faces


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• Smaller than tolerance faces (usually fillets)

The following is a summary of the options on the Topology dialog:

Tolerances - Distance is the tolerance used for connecting faces and curves.The distance value represents the maximum value that two objects can beapart and still be considered connected. Angle is the tolerance used fordetermining the type of each edge (convex, concave or tangent). The Anglevalue represents the maximum angle that the normals of two adjacent facesor curves can vary at an edge to determine if the edge is convex, concave ortangent.

Rebuild Topology - After editing tolerances or material side, you can chooseRebuild Topology to create the shell. Surfaces are considered adjacent if thegaps are less than the tolerance specified and one or more shells are created.Model geometry is not modified.

Material Side- allows you to change the material side of any object that isused to define the cutting operation. Material Side is represented by a vectorarrow that points away from the material.


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Unify All - allows Material Side to be located on the same side for all objects.

Reverse All - allows Material Side to be reversed for all objects.

Inspect or Edit Shell - allows the inspection of the classification of edge typesand Material Side for individual objects.

Faces - allows the inspection of Material Side defined for each face. Faces canbe set to undefined, same or opposite.

• Undefined allows you to highlight all faces where the Material Side isnot defined

• Same allows you to highlight all of the faces where the Material Side isthe same as that of the majority of faces

• Opposite allows you to highlight all of the faces where the Material Sideis different than that of the majority of faces

Edges - allows the review of the classification of various edges. Edges canbe set to the following:

• Undefined allows the highlight of any edge which is not classified by thesystem

• Non-manifold allows the highlight of any unresolved edge where morethan two faces meet along the same portion of the edge

• Exterior allows the highlight of all of the outside edges that define thecutting region

• Interior allows the highlight of all of the inside edges that define thecutting region

• Inconsistent allows the highlight of edges where the adjacent faces havematerial sides on opposite sides

• Complex allows the highlight of edges that are neither completelytangent, concave or convex

• Tangent allows the highlight of all edges that are classified as beingtangent

• Concave allows the highlight of all edges that are classified as beingconcave

• Convex allows the highlight of all edges that are classified as being convex

Display Material Side - this option results in the display of the Material Sideindicator whenever one of the face options is chosen.


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The Material Side indicator is a vector that points towards the material tobe removed which is away from the Material Side.

Refresh Before Display - the system will refresh the screen every time youchoose one of the Face or Edge options.

Arrow Buttons - allows you to cycle through the different shells as you inspectand edit the topology.


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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


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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.


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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:

• ZLEVEL_FOLLOW_CAVITY - uses the Follow Part Cut Method;ideal for "cavity" type parts

• ZLEVEL_FOLLOW_CORE - uses the Follow Part Cut Method; idealfor "core" type parts

• 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_PROFILE_STEEP - uses the Profile Cut Method with theSteep Angle set to 65 degrees

• ZLEVEL_CORNER - Z-Level milling that uses an existing referencetool; 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.


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Z-Level Milling

1. Part

2. Check

3. Cut Area

4. Trim

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

Geometry

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

after cutting

• Check geometry consists of bodies and faces which represent clamps or

obstructions that are not to be machined

• Cut Area geometry represents the areas on the Part to be machined; it

can be some or all of the part

• Trim geometry consists of closed boundaries which indicate wherematerial will 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.


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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 Area Milling Drive Method.


Open the part base_mfg_3.

Enter the Manufacturing application.


Change the view of the Operation Navigator to the GeometryView.

The MCS_MILL Parent Group is displayed in the OperationNavigator.

Expand the MCS_MILL and WORKPIECE Geometry ParentGroups.

The ROUGHING_1 operation is listed in the OperationNavigator.

Step 2: Create a Z-Level operation.

Choose the Create Operation icon on the Manufacturing Createtool bar.

Make sure the Type is set to mill_contour.


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Z-Level Milling

Choose the ZLEVEL_PROFILE icon.

Set the Program to BASE_MALE_DIE.

Set Use Geometry to WORKPIECE.

Set Use Tool to EM_1.25_.25.

Set Use Method to MILL_FINISH.

Name the operation zlevel_finish.

Choose OK.

The ZLEVEL_PROFILE dialog is displayed.

Step 3: Change the Depth of Cut.

You will change the depth of cut.

For ease of viewing turn model shading off.

Next to the Global Depth Per Cut label, enter 0.100.

You will now change the cut levels. You will stop cuttingmaterial at the top of the bottom face. The default is thebottom face.


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Z-Level Milling

Choose the Cut Levels button.

The Cut Levels dialog is displayed.

Select the Down Arrow button.

Index to the 4th range and select the delete icon.

Choose OK.


Choose the Generate icon and generate the tool path.


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Z-Level Milling

Choose OK in the Display Parameters dialog to continuegenerating the tool path.


Step 5: Verify the Program that you have created.

Use Toolpath Verification to examine the tool path results.



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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.


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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 form_mold_mfg.




The MCS_MILL Parent Group is displayed in the OperationNavigator.


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Z-Level Milling


The CM_ROUGH operation is listed in the Operation Navigator.

Step 2: Create the ZLEVEL_PROFILE_STEEP operation.

Select the Create Operation icon from the Create toolbar.


Select the ZLEVEL_PROFILE_STEEP icon.

Set the following:

• Program: INTERIOR

• Use Geometry: WORKPIECE

• Use Tool: EM-.750-.06

• Use Method: MILL_FINISH


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Z-Level Milling

Choose OK.

The ZLEVEL_PROFILE_STEEP dialog is displayed.

Under the Geometry label, select the Part icon and chooseDisplay.

The Part geometry is displayed. Note that the Part geometrywas specified in the Parent Group named WORKPIECE.

Under the Geometry label, select the Cut Area icon and noticethat only the Select button is available.

Since the Cut Area was not specified, by default, the entirepart will be used for cutting.

Also note the Steep Angle and the other default option settings.


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Z-Level Milling


Choose the Generate icon and generate the tool path.

Choose OK to save the operation.

Notice the areas cut by the tool path. Remember that the SteepAngle was set to 65 degrees.

Do not save the part, you will be using it in the 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.

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.


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Z-Level Milling


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Z-Level Milling

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.

Control Geometry

Control Geometry allows the specification of Control Points to determinewhere the tool engages the part and the floor plane.


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Z-Level Milling

Trim by

Trim by is used to prevent the tool from rolling around corners.

The Silhouette option uses the outline of the part geometry, as viewed downthe tool axis, to generate a trace. The tool is positioned along the silhouette ofthe part geometry. The trace is then offset to the outside by the tool radiusdistance. The silhouette can be thought of as the shadow of the part projectedalong the tool axis.

When using Trim by Silhouette, the traces at the bottom of the part geometryare used as trim shapes. These shapes will be projected along the tool axis toeach cut level and will be used in the process of generating the machinableregions as trim shapes.

Remove Edge Traces

Edge tracing (edge roll) is usually an undesirable condition that can occurwhen the Drive Path extends beyond the edge of the part geometry. Thetool rolls over the edge of the part geometry potentially gouging the part.The Remove Edge Traces option allows the control of whether or not edgetracing occurs.


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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 Geometry ParentGroup (MILL_AREA) that contains the geometry necessary for machining.The tool path will cut only within the area that has been specified.

Step 1: Create the Geometry Parent Group.

Continue using form_mold_mfg.

Select the Create Geometry icon from the Create tool bar.

The Create Geometry dialog is displayed (make sure Type ismill_contour).

In the Create Geometry dialog select the Mill_Area icon.

If necessary, select the WORKPIECE as the Parent Group.

Enter ZLEVEL_AREA as the Name.


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Z-Level Milling

Choose OK.

The MILL_AREA dialog is displayed.

Choose the Cut Area icon.

Choose Select.

The Cut Area dialog is displayed.


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Z-Level Milling

Select the interior island geometry as shown.

Make sure that when selecting with a rectangle,selection criteria should be inside only.

Choose OK, twice to return to the Create Geometry dialog.

Note that you do not need to specify Blank Geometry.

To briefly review —– you have created a Geometry ParentGroup, named ZLEVEL_AREA which contains the geometryof the island. This Parent Group will be used in theZLEVEL_PROFILE operation.

You will now create the operation.

Step 2: Create the ZLEVEL_PROFILE Operation.

Choose the Create Operation icon.

Select the ZLEVEL_PROFILE icon.

Set the following:

Program: INTERIOR

Use Geometry: ZLEVEL_AREA

Use Tool: EM-.750-.06


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Z-Level Milling

Use Method: MILL_FINISH

Choose OK.


Under the Geometry label, select the Part icon and chooseDisplay.

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

Under the Geometry label, select the Cut Area icon and chooseDisplay.

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.

Change Cut Order to Depth First.



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Z-Level Milling



Do not Save the part file.


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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.

Gap Machining minimizes excessive tool wear and breakage caused by theremoval of large amounts of scallop stock left from previous operations.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. To further enhance the


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Z-Level Milling

control of the scallop height in these areas, you can also specify the stepoverdistance. Since each cut level range can have a different depth of cut, if youspecify Use Depth of Cut, then the range it lies in determines the stepoverfor that gap region. If a gap region spans several ranges that do not have cutlevels defined, the gap region will use the minimum depth of cut of the ranges.

Max Cut Traverse option

Max Cut Traverse defines the longest distance that the cutting tool feedsalong the part when not cutting. When connecting cutting areas, if the totaldistance is less than the Max Cut Traverse parameter, the tool will feed alongthe part. If the distance is larger then the current transfer method is used toretract, traverse, and engage to the next location. This value is a length or apercent of the tool diameter.

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

1. After each Z-level cut is completed, the tool begins to cut the level below it

2. When cutting the lower level, gaps between the lower level and theprevious level above it are determined

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

4. Gap level at the lower level is cut based on Max Cut Traverse parameter;if Max Cut Traverse is exceeded, a traverse move to the next level takesplaces; if the move to the next level is within the Max Cut Traversedistance, the tool makes a direct on-part move to the next level withouttraversing

• Level-to-level connections violating a gap region are removed and replacedwith a traversal move

• Engage and retract moves are kept to a minimum along the tool axis

• Connections are made from the Z-Level cut to the gap area; after cuttingthe gap area, the tool returns to the lower level


3

Z-Level Milling

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


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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.

ChooseStart → Manufacturing.

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


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Z-Level Milling

Step 2: Replay an existing Z-Level operation.

Double-click on the ZLEVEL_PROFILE operation for editingpurposes.



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Z-Level Milling

Choose the Replay button.

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.You will now turn on the Cut Between Levels (Gap Machining)option to completely finish machine the part in one completeoperation.


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Z-Level Milling

Choose the Cutting button.

The Cut Parameters dialog is displayed.

Choose the Connections to tab.

Turn On the Cut Between Levels option.


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Z-Level Milling

Set the Stepover to Constant.

Change the Distance to 0.15.

ChooseOK.


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Z-Level Milling



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


Do not Save the part file.


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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 MILL_AREA GeometryParent Groups

Purpose

This lesson introduces you to the MILL_AREA Geometry Parent Groups,which are used in limiting cut areas.

Objective


• Create and use MILL_AREA Geometry Parent Groups.

• Create and modify Trim Boundaries.

• Recognize the type of geometry MILL_AREA Parent Groups use.

MILL_AREA Geometry Overview

Occasionally, when machining large or complex parts, it is desirable to limitthe area that an operation machines. The MILL_AREA Geometry ParentGroup is designed for that purpose.

The MILL_AREA Geometry Parent Group allows the user to select a smallportion of a part to machine. This area is based on the faces of the part whichyou select. This group of faces to machine is called a Cut Area.

The area to machine can be further limited by use of a Trim Boundary.

Below is the MILL_AREA Geometry Parent Group dialog.


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MILL_AREA Geometry Parent Groups

• Part Geometry - is typically specified in the WORKPIECEGeometry Parent Group and represent the material to be cut

• Check Geometry - represents clamps, vises, locator pins, and otheritems that are not cut

• Cut Area - represents the specific geometry to be machined

• Wall Geometry - represents walls or sides of a part

• Trim Boundary - allows you to define trim boundaries that limitthe cutting area


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Cut Area

When choosing the Cut Area icon, the Cut Area dialog is displayed.

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.


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Activity: MILL_AREA Geometry Parent Groups

This activity will demonstrate how to create and use a MILL_AREA geometryParent Group in an operation. You will Replay and examine the results ofan existing operation. You will then create a MILL_AREA geometry ParentGroup consisting of faces and will modify the inheritance of the operation touse the MILL_AREA parent.

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.


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Step 2: Replay the current operation.

Highlight the FC_FINISH_RIBS operation, use MB3 and selectReplay.

This Fixed Contour operation machines the entire part. This isnot the desired result.

In the next steps, you will create a MILL_AREA geometryParent Group to limit the machining to just the two ribsprotruding from the part.


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Refresh the graphics screen.

There are at least three ways to refresh the screen:

1. MB3 → Refresh

2. Press the F5 button

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

Step 3: Create the MILL_AREA Geometry Parent Group.

Choose the Create Geometry icon.

If necessary, change the Type to mill_contour.

Choose the Subtype MILL_AREA.

Change the Parent Group to WORKPIECE.

In the Name field, enter two_ribs.

Choose OK.

The MILL_AREA dialog is displayed.

Step 4: Define the Cut Area geometry.

Choose the Cut Area icon.


4


Choose the Select button.


4


Choose the faces of the ribs, as shown.

When finished selecting the faces, choose OK.

Choose OK again to accept the dialog.


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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.

Currently, the Geometry View of the Operation Navigator looksas follows:

Using MB1, click and drag the FC_FINISH_RIBS operationso that it resides under the TWO_RIBS Parent Group, thenrelease MB1.


4


Highlight the FC_FINISH_RIBS operation, using MB3, selectGenerate from the pop-up menu.

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


4



Save the part file.


4


Trim Boundary

A Trim Boundary is the same as any other boundary except that any tool paththat falls within the area described by the boundary will be trimmed away.

When you choose the Trim Boundary icon, the standard boundary dialogis displayed.


4


Activity: Using 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 operation.


4


Choose the TRIM icon, and then choose Select.

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

Choose the Point Boundary icon.

Change the Point Method to Cursor Location.


4


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

Choose OK to return to the main dialog.



4


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

Any tool path that falls within the Trim boundary is removed.

Save the part file.


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SummaryThe MILL_AREA geometry group allows flexibility in determining exactareas for cutting purposes. The use of this geometry group and TrimBoundaries gives you the ability of isolating specific areas of geometry used inthe machining process.

In this lesson you:

• Created MILL_AREA geometry to machine specific areas.


5

Lesson

5 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

• Use Non-cutting moves in Fixed Contour operations

• Create Parent 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


5

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 output is created by internal processing which moves the toolfrom the drive point along the projection vector until contact is made with thepart geometry. The position may coincide with the projected drive point or, ifother part geometry prevents the tool from reaching the projected drive point,a new output point is generated and the unusable drive point is ignored.

Fixed Contour operations use a fixed tool axis for finishing contouredgeometry and can effectively clean up ridges and scallops left by other toolpaths.


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Fixed Contour is the better choice for finish machining for several otherreasons:

• In addition to Part geometry, Drive geometry can control tool movement

• Numerous Drive Methods are available for specialized machining

• Uncut areas left after semi-finishing or finishing passes can be easilyremoved

Fixed Contour Tool Path Accuracy

Fixed Contour provides several options that help insure the accuracy of thetool path. Included are:

• Check Geometry to stop tool movement

• Gouge Checking to prevent gouging of the part

• Collision Checking to prevent unintended tool contact with other geometry

• Various tolerance options

Fixed 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 as shown in the following illustration.

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 onto thepart geometry.


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drive method - method of defining drive points required to create a tool path.Some drive methods allow the creation of a string of drive points along a curvewhile others allow the creation of an array of drive points within an area.

projection vector - used to describe how the drive points project to the partsurface and which side of the part surface the tool contacts. The selecteddrive 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.


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

Area Milling drive method

The Area Milling drive method allows you to specify a cut area for tool pathgeneration. This drive method is similar to the Boundary drive method, butdoes not require drive geometry.

Cut Area(s) may be defined by selecting surface regions, sheet bodies, orfaces. Unlike the Surface Area drive method, the cut area geometry does nothave to be selected in an orderly grid of rows and columns.

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.

The Area Milling drive method is generally the preferred Fixed Contour drivemethod for creating tool paths.

Surface drive method

The Surface Area drive method allows you to create an array of drive pointsthat lie on a grid of drive surface. This drive method is useful in machiningvery complex surfaces. It provides additional control of both the tool axis andthe projection vector.

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. The drive surfaces do not have to be planar, but must be in an orderlygrid of rows and columns. Adjacent surfaces must share a common edgeand may not contain gaps that exceed the Chaining Tolerance defined underPreferences (Preferences → Selection → Chaining Tolerance). Trimmedsurfaces can be used to define drive surfaces as long as the trimmed surfacehas four sides. Each side of the trimmed surface can be a single edge curve orcomprised of multiple tangent edge curves that can be considered a singlecurve.

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.Drive points are generated along the existing tool path and then projectedon to the selected part surface(s) to create the new tool path that follows thesurface contours. The direction in which the drive points are projected on tothe part surfaces is determined by the projection vector.


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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. Thetool path is optimized for maximum part contact to minimize non-cuttingmoves.

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. These are optional, highlyspecialized custom routines developed for specific complex applications.

Parent Groups associated with Fixed Contour operations

There are three different Geometry parent groups available for use in FixedContour operations. They are:


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• The MILL_GEOM parent group which allows part, blank and checkgeometry.


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


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• The MILL_AREA parent group allows part and check but not blankgeometry. It also allows for the specification of Cut Areas ,Wall and Trimgeometry.

The parent group, MILL_AREA, which you used in Cavity Milling operations,is also used in Fixed Contour operations. It allows you to include or excludeareas to be machined in cut areas that you specify. These specific areasmay have been previously roughed by Cavity Milling or finished by PlanarMill operations.

Fixed Contour also provides several template operations that use the parentgroup, MILL_AREA. These operations also have the Area Milling drivemethod specified allowing you to quickly create finishing operations forcontoured parts.

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


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The following diagram can be used as an aid in the determination of theoperation type needed for various types of geometry:

Fixed Contour Operation types

The most commonly used 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.

• CONTOUR_SURFACE_AREA - Uses Surface Area drive method.Ideal for complex part surfaces where tool axis control is critical.

• FLOWCUT_REF_TOOL - Uses the Flow Cut drive method. FlowCut RTO (reference tool) will machine certain geometry types by level andprovide you with the options to cut the two sides alternatively with arounded or standard turn at each end, and side by side with the optionfrom the steep side to non-steep side. This operation type takes intoaccount the previous tool diameter used for roughing (you must specify


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this). This results in cutting parts with a more constant cutting load anda shorter distance of non-cutting moves.

• 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. Useful increation of addendum profile cuts for stamping dies.


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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.


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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. Surface regions, sheet bodies, facetedbodies and or faces can be used as the cut area. Concave valleys are analyzedwithin the 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 can be used to further constrain cut regions. MaterialInside or Outside determines the area of the cut region to be omitted. Trimboundaries are always Closed, always use an on condition, and are projectedto the Part geometry along the tool axis vector. More than one Trim Boundarymay be defined. Trim Stock may be specified to define the distance the tool ispositioned from the Trim Boundary.

Flow Cut Reference Tool Drive Method

Flow Cut Reference Tool drive method produces multiple cutting passes oneither side of the center flow cut by allowing you to specify a reference tooldiameter to define the total width of the area to be machined and a StepoverDistance to define the interior passes.


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This method is useful for cleanup machining after roughing out an areawith a large tool. This method also uses the Cut Type, Stepover Distance,Sequencing, Reference Tool Diameter, Overlap Distance, and SteepContainment options.


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Flow Cut Reference Tool Options

Maximum Concavity allows you to determine where Flow Cuts are createdbased on the Angle of Concavity. Cutting moves are created only where theAngle of Concavity is less than or equal to the specified Maximum Concavityangle. The value you enter must be positive and less than or equal to 179.0degrees. When the Angle of Concavity exceeds the specified MaximumConcavity angle, the tool will retract and traverse.

Minimum Cut Length allows you to eliminate short tool path segments thatmay occur in isolated areas of the part. Cutting moves shorter than this valueare ignored. This option is useful in eliminating very short cutting movesthat occur at the intersection of fillets.

Hookup Distance allows you to eliminate unwanted gaps in the tool path byconnecting disjointed cutting motions that exceed the specified MaximumConcavity angle. These unwanted motions occur where the tool retracts fromthe part surface and are caused by gaps between surfaces or variations inthe Angle of Concavity that exceed the specified Maximum Concavity angle.The value you enter determines the distance the tool will span to connectthe end points of cutting moves. The two ends will be connected by linearlyextending the two paths.

Cut Type (Zig-Zag and Zig) allows you to define how the cutter moves fromone cut pass to the next.

Stepover Distance allows you to specify the distance between successivepasses.

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

Inside-Out results in the cut starting at the center of the Flow Cutpass and moving toward one of the outside passes. The tool then movesback to the center cut and works its way toward the opposite side. You maystart the sequencing by choosing either side of the center of the Flow Cut.

Outside-In results in the cut starting at one of the outside passesand moving to the center of the Flow Cut pass. The tool then picks upthe outside cut on the opposite side and works its way to the center cutagain. You may start the sequencing by choosing either side of the centerof the Flow Cut.

Steep Last results in the cut moving from non-steep side to thesteep side.


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Steep First results in the cut moving from the outside pass onthe steep side to the outside pass on the non-steep side. The Steep Firstsequence is available for Zig, Zig-Zag, and Zig-Zag with Lifts patterns.

Inside-Out Alternate always cuts a Flow Cut valley from the middleFlow Cut pass. The cut starts at the center pass, moves to an inside passand then to the inside pass on the opposite side. The cut then moves tothe pass in the next pair on the first side and then to the pass in the samepair on the second side. If one side has more offset passes then the otherside, all the extra passes on that side are machined after machining thepasses which are paired on both sides. Inside-Out Alternate sequence canbe generated with a Zig, Zig-Zag, or Zig-Zag with Lifts pattern.

Outside-In Alternate always machines a Flow Cut valley frompasses in an outside pair to inside pair, and then to the middle Flow Cutpass when necessary. The cut starts at one outside pass and moves to theother outside pass on the opposite side. The cut then moves to the passin the next pair on the first side and to the pass in the same pair on thesecond side. After finishing the passes in the inside pair, the cut willmove to the middle Flow Cut pass, if required. If one side has more offsetpasses then the other side, all the extra passes on that side are machinedbefore machining the passes in pairs on both sides. Outside-In Alternatesequences can be generated in a Zig, Zig-Zag, or Zig-Zag with Lifts pattern.

Reference Tool Diameter enables you to specify the width of the finishing cutregion based on the diameter of the previous roughing (reference) tool. Thetool diameter specified must be larger than the current tool.

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. As in Area Milling drive method, Steep Containment allows therestriction of the cut area based on the steepness of the tool path. Steepnessis defined by specifying a Steep Angle and a Steep or Non-Steep option. Cutdirection is defined by specifying a Steep Cut or Non-Steep Cut Direction.You can also choose to machine flow cuts on both sides alternatively with arounded or standard turn at each end, or machine side by side from the steepside to non-steep side.


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Activity: Creating 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 the Manufacturing application and display the OperationNavigator.

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, using MB3, chooseREPLAY.

Note that a number of .250 steps were left in the material asa result of the specified Cut Level. Also, .050 Floor and SideStock were specified in the operation.


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Refresh the display.

You will create a Fixed Contour operation to semi-finishmachine the part.

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


If necessary, change the Type to mill_contour.

In the Create Operation dialog, set:

• Program to MALE_COVER

• Use Geometry to WORKPIECE

• Use Tool to BALLMILL-1.00

• Use Method to MILL_ROUGH

Choose the CONTOUR_AREA icon.

Enter the Name as rough_fc.


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Choose OK.

The Contour Area dialog is displayed.

Under the Geometry label, choose Display for the Part andCheck geometry.

You will use most of the default settings of the Area MillingMethod to create a roughing tool path.

Under the Drive Method label, choose Area Milling.

The Area Milling Method dialog is displayed.


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Set the following options:

• Pattern to Parallel Lines

• Cut Type to Zig Zag

• Cut Angle to Automatic

• Stepover to Tool Diameter

• Percent to 25

Choose OK.


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Generate the tool path and expect warning messages.

Choose OK to all warning messages.


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Choose the List icon to list the tool path.

Note that the listing contains many warnings of Interferencebetween the cutter and the Check geometry.

You will see messages similar to the one shown below.

Close the listing window.


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




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In the Create Operation dialog, set the following:




• Use Method to MILL_FINISH

Enter the Name as finish_fc.

Choose OK.

The CONTOUR_AREA dialog is displayed.

Under the Geometry label, choose Display for the Part andCheck geometry.

Note that the part geometry as well as the check geometryrepresenting pins, bolts and the surface plate are displayed.

Under the Drive Method label, choose Area Milling.

The Area Milling Method dialog is displayed.


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• Pattern to Follow Periphery

• Tool motion to Outward

• Stepover to Constant

• Distance to .030

Choose OK.

The next action will prevent the Warning message fromappearing.


Choose the Clearances tab.


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Change the When Gouging option to Retract.

Choose OK.


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Generate the tool path.

Your tool path should look similar to the above. Note thatWarnings were not generated and the tool path follows thecontour of the part.


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.


Choose the FLOWCUT_REF_TOOL icon.

In the Create Operation dialog, set:





Enter the Name as flow_fc.


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Choose OK.

The FLOWCUT_REF_TOOL dialog is displayed.

Under the Geometry label, Display the Part and Checkgeometry.

Note that on the dialog 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.


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Enter 1.00 in the Ref. Tool Diameter value field.

Step 7: Generating the tool path.


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Choose the Generate icon.

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

Choose OK.

Step 8: Create a finish Planar Milling Profile pass.

You have finish machined the core part except for the taperedouter edge. The geometry is planar and requires a finish cut;therefore, you will use a Planar Milling operation to generate thetool path. The MILL_BND geometry parent group, which containsthe geometry needed for the profile pass, has already been createdfor you.


Choose mill_planar as the Type.

Choose the PLANAR_PROFILE icon.


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Set the following:


• Use Geometry to MILL_BND

• Use Tool to DRAFTED_ENDMILL


Enter the Name as finish_pm.

Choose OK.

The PLANAR_PROFILE dialog is displayed.

Choose the Display button.

This Parent Group (MILL_BND) contains the outer edge Partboundary and the part Floor.

• Remember, this is a Planar Milling operation, which usesboundary geometry

• You normally use a MILL_BND Parent Group for PlanarMilling operations


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If necessary, set the Cut Depth to Floor Only for a single depthof cut.

The other default PLANAR_PROFILE settings will be used todemonstrate this operation.


Note that the tool cuts the outer boundary and forms thetapered wall joining the part to the plate.


Save the part file.


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Non-Cutting Moves

Fixed Contour operations uses Non-Cutting Moves for control of the toolwhen not physically cutting metal.


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There are five individual cases when the tool is not physically cutting metal.They are:

• Initial Case - At the beginning of the operation, controls how the toolmoves from it’s present position to cutting metal

• Final Case - At the end of the operation, controls how the tool moves fromit’s last cutting move to a safe position above the work piece

• Check Case - When the encountering check geometry, determines howthe tool retracts from the work piece and moves to a new cutting position

• Reposition Case - controls how the tool retracts and re-engages the workpiece when there are gaps in the part geometry

• Local Case - When the tool has to leave the part surface to complete thestep over for the next pass, this determines what action will be taken

The Case is specified at the top of the Non-Cutting Moves dialog.

Each Case has up to five moves that can be specified. The Moves are:

• Retract Move - controls how the tool disengages from the work piece

• Departure Move - Once the tool has retracted, controls how the tool movesto a safe clearance area

• Traverse - move from the current position to a safe area above the nextengage position

• Approach Move - controls movement into position for engage motion

• Engage Move - controls how the tool engages into the work piece

To avoid having you manually set all moves for all cases, the Default case wascreated. This case has all the moves that the other cases have. Each movehas been pre-defined for the most common machining situation. Additionally,all other cases have been assigned to use the Default case.


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To use Non-Cutting Moves:

• Create a Fixed Contour operation

• Set all Cutting Parameters necessary (Drive Method, stepover, etc.)

• Generate the operation

• Examine the default Non-Cutting moves

• If necessary, edit the Non-Cutting moves and change only the affectedmoves


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Activity: Using Non-Cutting Moves

This activity teaches you how to use the various Non-Cutting Moves options.

Step 1: Continue using the part file.

Continue using the ***_male_cover_mfg_3 part.


The Type should be set to mill_contour.


Set:



• Use Tool to ENDMILL-2.00-.125

• Use Method to MILL_ROUGH


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Enter the Name as non_cutting_fc.

Choose OK.

Step 2: Generate the default tool path.

The CONTOUR_AREA dialog is displayed. The Drive Method isArea Milling.

Also note, the geometry that you specified is WORKPIECE, whichis a MILL_GEOM Parent Group for contour geometry.

Under the Geometry label, Display the Part, and Checkgeometry to verify the geometry selections.

For easier visualization, set the Tool Display to Off.


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Choose the Cutting button and then select the Clearances tab.

If necessary, change the When Gouging parameter to Skip.

Choose OK on the Cut Parameters dialog.

Choose the Edit Parameters icon then change the Pattern toFollow Periphery.

Change the Inward radio button to Outward.

Choose OK.


Note the Non-Cutting move to the Automatic Clearance Plane.The move is represented as the dashed vertical line.


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Step 3: Specify Non-Cutting Moves.

On the CONTOUR_FOLLOW dialog, choose the Non-Cuttingoption.

Note that the Case is set to Default.

Also Note:

• The Engage icon is highlighted by default

• The Engage Status is Manual

• The movement is Linear


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Choose the Approach icon.

A default Automatic Clearance plane is created at a safedistance above the highest area of the Part and Check geometry.

Next you will change the default setting from AutomaticClearance to Clearance.

Choose Clearance from the Approach Status pull-down menu.

Choose the Departure icon.

Again, a default Automatic Clearance plane is created at asafe distance above the highest area of the Part and Checkgeometry.

You will now change the default setting from AutomaticClearance to Clearance.

Choose Clearance from the Approach Status menu.

Choose OK.

Generate and review the tool path to verify that the clearanceplane moves are correct.

Note that the tool path engages the part in a linear motion. Thepreferred method of engagement is a circular ramping motion.

Step 4: Change the Engage move.

Choose the Non-Cutting button.

You are still setting options for the Default case.


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Choose the Engage icon.

The Engage Status should be Manual by default.

Change Movement to Arc Tangent to Approach.

Change Radius Type to Radius.

Enter .375 for the Radius.

The Retract Status setting will be set to Use Engage bydefault. This can be verified by choosing the Retract icon.

Choose OK and return to the CONTOUR_AREA dialog.


Step 5: Change other Non-Cutting options.

On your own, explore the various Non-Cutting options, changevarious ones and generate tool paths to see the effects.

Save and close the part file.


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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.

• Created non-cutting moves to control cutter movements to and from thepart during the machining process.


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Lesson

6 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.


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Introduction to Four and Five Axis Machining

Multi-Axis Machining ConceptsThe majority of what NC/CNC programmers term as "multi-axis" can actuallybe considered planar or fixed axis machining. The spindle axis, on somemachines, is not normal to the Z direction of the machine tool and the actualmachining does not force a change in any motion of the rotary axis. This caseconsiders using 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

• Most, if not all, NX multi-axis operations work with a tool axis otherthan + Zc 0,0,1

• 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.

The following activity requires you to generate a tool path at other than anormal tool axis of (0,0,1).


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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.

Choose Start→Manufacturing.


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The Operation Navigator and the part are displayed.

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.

Choose the Create Operation icon from the toolbar.

If necessary, set the Type to mill_planar.

Choose FACE_MILLING as the operation type.

Choose the following Parent objects:

Program: FIXED_AXIS

Geometry: NORMAL_FACE

Tool: EM-1.00-0

Method: MILL_FINISH

Note that the geometry parent contains a boundary thatdescribes the top face of the part. The floor plane is set to thetop face.

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

Since this operation is used for finishing, no machining stockwill be left by the Method parent object.

Key in top_face as the name of the operation.

Choose OK.

The FACE_MILLING dialog is displayed.


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Change the Cut Method to Follow Periphery and the StepoverPercent to 50.

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

The generated tool path is displayed.


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.


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Highlight the FIXED_AXIS program object.

Choose the Verify Toolpath icon from the toolbar.

Choose the 2D Dynamic tab from the Tool Path Visualizationdialog.


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Choose the Play button from the bottom of the dialog.

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.

Choose Cancel from the Tool Path Visualization dialog.

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.


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Highlight the TOP_FACE operation and choose MB3→Copy.

Choose MB3→Paste.

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

Change the name of the new operation by highlighting theTOP_FACE_COPY operation, choosing MB3→Rename, thentyping ANGLE_FACE_1.

You will now change the geometry parent object.

Double-click on the ANGLE_FACE_1 operation.


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Choose the Groups property page.

Choose the Geometry radio button at the top of the dialog,then choose Reselect.

The Reselect Geometry dialog is displayed.


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Choose ANGLE_FACE_1 from the pull-down list.

Choose OK.

Choose the Main property page from the FACE_MILLINGdialog.

Choose Generate.

Choose OK on the Display Parameters dialog.

The Operation Parameter Error dialog is displayed.

This dialog is informing you that the operation type,FACE_MILLING, will not work unless the tool axis is setnormal to the floor axis. You will now redefine the tool axisnormal to the floor.

Choose OK from the Operation Parameter Error dialog.


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Choose the Machine button located on the FACE_MILLINGdialog.

The Machine Control dialog is displayed.

As described earlier, there is always a defined tool axis. In thisparticular case, the tool axis is the same as the Z of the MCS(the definition of "+ZM Axis"). You will now change the tool axisto one that is normal to the floor plane of the ANGLE_FACE_1geometry parent object.

Choose the Tool Axis pull-down arrow.


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Choose Specify Vector from the list.

The Vector Constructor dialog is displayed.

From the Vector Constructor dialog, choose the Face Normalicon.

Note that Face Normal means to set the vector perpendicularto the face.


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Select the angled face as shown in the following figure.

Hint: You may need to blank the stock component to select theproper face, by using the Assembly Navigator.

Choose OK until the FACE_MILLING dialog is displayed.



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 ANGLE_FACE_1 operation.

Choose MB3→ Copy.

Choose MB3→Paste.

Change the name of the new operation to ANGLE_FACE_2.

Edit the operation by doubling-clicking on ANGLE_FACE_2.

Choose the Groups property page.


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Choose the Geometry radio button at the top of the dialog,then choose Reselect.The Reselect Geometry dialog is displayed.

Choose ANGLE_FACE_2, as the geometry parent, from thepull-down list.

Choose OK.

Choose the Machine button located on the FACE_MILLINGdialog.

The Machine Control dialog is displayed.

Select the Tool Axis pull-down arrow.

Choose Specify Vector.The Vector Constructor dialog is displayed.

From the Vector Constructor dialog, choose the Face Normalicon.

Select the angled face as shown in the following figure.

Choose OK until the FACE_MILLING dialog is displayed.

Choose Generate.


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Choose OK on the Display Parameters dialog.

Choose OK on the FACE_MILLING dialog to save theoperation.


Use Verification to verify the tool path.

Close the part file without saving.


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Defining 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.

Placing 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


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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.


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Activity: Main and Local MCS in Multi-Axis Applications

In this activity, you will use the Main and Local MCS, which is used by thepost processor for formatting output used at the machine tool. The part filehas the main and local MCS already created for you. The Main MCS is setwhere the machine zero would be. When you list the tool paths, the output isbased on the Local MCS. When you post the program, the output of the toolpaths, 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.


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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 eachindividual one.


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Double-click on the MCS_MAIN group object.

The MCS dialog is displayed.

Select the green More Options arrow to see the CoordinateSystem Purpose options.

Note that the Coordinate System Purpose selected is Main.


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Choose OK.

Double-click on the MCS_000 group object.


Choose the green More Options if necessary arrow to see thecoordinate system purpose options.


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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.


Choose the green More Options 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.

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.


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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.

Choose the Postprocess icon.

The Postprocess dialog is displayed.

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.


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

The posted output is displayed.

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

Cancel the Postprocess dialog.

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.


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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.



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

Choose OK.


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If necessary, choose OK to overwrite Output File dialog.


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.



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Activity: Main and Local MCS in Multi-Axis Applications

In this activity, you will use the Main and Local MCS, which is used by thepost processor for formatting output used at the machine tool. The part filehas the main and local MCS already created for you. The Main MCS is setwhere the machine zero would be, the same as if you were using an ORIGINstatement to govern the output. When you list the tool paths, all have thesame X, Y, and Z values since they are based on the Local MCS. When youpost the program, the output of the three tool paths, with their respective X,Y, and Z values, are based 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.


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

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.


Choose the More Options arrow.

Note that the Coordinate System Purpose selected is Main.

Choose OK.





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

Choose OK.





Choose OK.





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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.


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

Choose OK.



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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.

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

Change to the Geometry view of the Operation Navigator.


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Highlight the MCS_000 parent group, key in 1 for the FixtureOffset and 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.

Highlight the TT1346-AA parent group.



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

Choose OK.




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If necessary, choose OK to overwrite Output File dialog.



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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.



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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.


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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


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Sequential Mill Basics

Sequential Milling OverviewSequential Milling operations are an alternative to Fixed or Variable Contouroperations used for finishing 3, 4, and 5-axis parts. You normally use Fixedand Variable Contour operations to finish cut areas using area tool motion.Sequential Milling operations are used to finish cut part edges using lineartool motion. You can area machine using Sequential Mill, however, the areais usually limited to an offset from a single drive surface or a single partsurface (or both).

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


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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.

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

Note that when a wall is tangent to a corner radius and the tool will contactthat tangency, you must choose this option. Otherwise, you must choose theNear Side, Far Side or On condition.

-


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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.


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The Sequential Mill dialog -

Allows you to:

• add stock to all drive and partsurfaces

• specify a Minimum Clearancevalue to be used in Engage andRetract suboperations

• add Corner Control

• specify Path Generation whichdetermines whether the tool pathis output for each suboperation

• Multi-axis output

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.


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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

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

The Engage Motion

The Engage Motion suboperation defines where the tool initially contacts thepart. This is usually the first suboperation dialog which you will encounter.


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(1) Insert or modify suboperations

(2) toggles between 4 types ofsuboperations

(3) list of suboperations

(4) replay, list or delete highlightedsuboperation

(5) change engage feed rate

(6) relative tool position (required)

(7) specify geometry (required)

(8) specify tool axis

(9) display tool at current location

The Continuous Path Motion dialog

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


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• 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.

(1) specify tool direction

(2) must be specified

(3) number of check surfaces


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The Point To Point Motion dialog

The Point to Point dialog 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 when creatingSequential Mill operations.

(1) specify special traverse feed rate

(2) defines the way the tool will moveto the next location


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The Retract Motion dialog

The Retract Motion dialog enables you to create a non-cutting move from thepart to the avoidance geometry or to a defined retract point. It is similar tothe Engage Motion dialog.

(1) type of retract move

(2) feed rate control for feed ratemove


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Defining the Check Surfaces

When you are creating a Continuous Path Motion suboperation, you mustdefine 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.

(1) type of geometry used for Checksurface

(2) add stock or define the toolposition with respect to Checkgeometry

(3) action to take after suboperation

(4) navigating through multipleCheck surface dialogs


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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.


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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.

This part is programmed in the context of an assembly. Thetop-level component, box_mfg contains all of the manufacturingdata. The box_stock file contains a WAVE-linked representationof the raw material and the box file contains the part that is tobe machined.

The raw material file, box_stock, has been hidden from thedisplay.

Rename the part to ***_box_mfg.


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


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Step 2: Create a Sequential Milling operation.

Choose the Create Operation icon


If necessary, change the Type to mill_multi-axis.

Choose Sequential_Mill as the subtype.


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Set the Parent objects as shown and name the operation SM_1:

Choose OK.

The Sequential Mill dialog is displayed.

This dialog allows the input of basic global parameters thatare active throughout the operation (unless changed in ansuboperation).


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Choose the Display Options button.

The Display Options dialog is displayed.

Change the Tool Display to 3-D and the Path Display Speedto 9.

Choose OK.


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Choose the Default Feed Rates button.

The Feeds and Speeds dialog is displayed.


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Choose the Reset from Table button.

Based on the tool material, part material and number of cutterflutes, the feeds and speeds will be recalculated and reset.

Choose OK until you return to the Sequential Mill dialog.

The global parameters are now set.

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

Normally, for any operation, choosing OK from the maindialog would save the operation, which would be subsequentlydisplayed in the Operation Navigator. In Sequential Milling,however, choosing OK from the main dialog results in thesuboperation dialog being displayed. This is where the actualprogramming process takes place.

Choose OK from the Sequential Mill dialog.

The Engage Motion suboperation dialog is displayed. Bydefault, the suboperation dialog 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.


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Change the motion from Engage to Pt to Pt.

The dialog changes to match Point to Point motion.

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

Change the Motion Method to Point, Tool Axis.


Change the Offset from None to Rectangular.

Note that using a Rectangular Offset allows an X, Y and Zdelta offset from the point chosen.


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Choose the corner of the ledge, as shown.

The Point Constructor dialog has changed to allow the inputof delta values from the point selected.

Key in the following values:

Delta XC 1.00

Delta YC -1.00

Delta ZC 1.00

Choose OK.


You will accept the default tool axis vector of 0,0,1 which is thesame as the Z coordinate of the WCS.

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.


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Choose OK.

You will now define the Engage component.

Change to an Engage suboperation.

The Engage Motion dialog is displayed.

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

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

Choose the Geometry button from the Engage Motion dialog.

The Engage Geometry dialog is displayed.

The defaults are set to Drive geometry, the Type is Face andthe Stopping Position is Near Side.

You will now select the Drive geometry.


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Select the face as shown.

The geometry selection on the dialog advances to Part geometry.

You will now select the Part geometry.


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Select the bottom of the pocket as the Part geometry.

The geometry selection on the dialog advances to Checkgeometry.


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

As soon as the last geometry is selected, the dialog reverts tothe Engage Motion suboperation.

You will now specify the Engage motion.


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Choose the Engage Method button from the Engage Motiondialog.

The Engage Method dialog is displayed.

Change the Method to Vector Only.



I=-1.000

J= 1.000

K=-1.000

Choose OK.


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

Change the Clearance Move to None.


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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. In this case the direction is correct. Ifthe arrow was pointed in another direction, it would have beennecessary to change direction by using the Direction option.


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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 is displayed.

You are now ready to select the first (in this case, the only)Check surface. As soon as the surface is selected, the dialogadvances to Check Surface No. 2. It is important to specify anychanges to the dialog before the surface is selected.

Note that the current Drive surface is tangent to the nextsurface that the tool will drive to. A stopping position of NearSide is incorrect. You will change the stopping position to DriveSurface/Check Surface Tangency.


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Change the Stopping Position to Ds-Cs Tangency.


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Select the Blend face as shown.

There will not be a second Check surface to select.

Choose OK in the Check Surface dialog.

Choose OK in the Continuous Path Motion dialog.

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.


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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.


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

Change the Stopping Position to Far Side.


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Select the surface as shown below.



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

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


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Change the suboperation to Retract.

The Retract Motion dialog is displayed.

Choose the Retract Method button.

The Retract Method dialog is displayed.

Change the Method from None to Vector Only.



I= 1.000

J= -1.000

K= 1.000


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Choose OK.

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

Choose OK.

Choose OK in the suboperation dialog.

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, use MB3→Refresh.


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Choose Redisplay Tool Path from the End Operation dialog.

The tool path is displayed.

Choose OK from the End Operation dialog.

Save and Close the part file.


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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 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. If the Check surface istangent to the present Part surface and PS-CS Tangency is chosen, the frontedge of the cutting tool will be positioned to prevent gouging of the tool intothe Check surface. This may cause the tool to be Out of Position to the newPart surface at the beginning of the next move. To compensate for this action,it may become necessary to drive the tool on to the Check surface, eventhough a tangency condition exists.

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).

When selecting either Drive or Part surface from the Continuous Path Motiondialog, you have the options of Other Surface, Previous ds, Previous ps andPrevious cs.


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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.


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.


If necessary change the Type to mill_multi_axis.

Choose the SEQUENTIAL_MILL icon.


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On the Create Operation dialog, set:

Program:MULTI-FLOOR-PROG

Use Geometry: WORKPIECE

Use Tool:EM_.75_.125

Use Method:MILL_FINISH

Enter the operation name fin-poc-walls into the Name field.

Choose OK.


On the Sequential Mill dialog, verify that the Multiaxis Outputcheck box is OFF.




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

Choose OK and continue to the Engage Motion dialog.

Step 3: Specify an Engage motion.

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

Choose the Engage Method button.


Change the Method to Vector Only.


Key in the -1.000 value for I.

Choose OK.


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Choose OK to return to the Engage Motion dialog.

Under the Reference Point label, specify a Position Point at:X=11, Y=6.5, Z=2.

Choose OK in the Point Constructor dialog.

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

(1) Drive Surface

(2) Part Surface

(3) Check Surface (add .250 stock)


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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.

Choose 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.

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.


Change the Check Stock to 0.

Change the Check surface Stopping Position to Ps-CsTangency.


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Specify a new Check surface as shown.

Return to the Continuous Path Motion dialog and choose OK.

The tool moves to the new position.

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


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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.


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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.


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

Specify the Check surface Stopping Position as Near Side.


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

Specify the Check surface Stopping Position as Ps-CsTangency .


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Specify a new Check surface.



Note the status of the Drive and Part surfaces changed.

Specify the Check surface Stopping Position as Ps-CsTangency.


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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.


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Change Cont. Path to Retract.

The Retract Motion dialog is displayed.

Change the Retract Method to Vector Only and then +XC Axis.

Change the Distance to .200.


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Return to the Retract Motion dialog and choose OK.

The tool retracts to the Clearance Plane.

Choose End Operation and then OK to save the operation.

The entire tool path is displayed.



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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.


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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.


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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 (orDS) Normal

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

• An angle - at angle to PS (or DS)


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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 angledto the Part or Drive surfaces

• fan between surfaces

• pivot from a point


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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.

(1) Drive Surface ruling

(2) Ring height

(3) Part Surface


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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.

(1) Final Tool Axis

(2) Check Surface

(3) Check Surfacecontact point

(4) Part Surface

(5) 5–Axis Fanning


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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 dialog todefine the point.

(1) User defined pivot point

(2) Check Surface

(3) Drive Surface

(4) Part Surface


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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.


Choose the Operation Navigator tab from the toolbar.

Highlight the SIDE_1 program object, then use MB3, chooseTool Path, and then Verify.

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


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Choose 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.

Choose OK on the Tool Path Visualization dialog.

Step 2: Create the Sequential Mill Operation.

Choose the Create Operation icon from the ManufacturingCreate toolbar.



Choose Sequential_Mill as the subtype.

Set the Parent objects as follows:

Program: FINISH_1Use Geometry: PART_AND_BLANKUse Tool: EM-.5–.130–CARBIDEUse Method: MILL_FINISHName: SM_FINISH_WALLS_POCKET_1

Choose OK.



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

You will now set the tool display options, which will make the tooleasier to visualize.




Choose OK twice.


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.


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Change the Motion Method from Undefined to Point, Tool Axis.


Key in the following values for the Base Point:

XC -5.00

YC 0.00

ZC 2.00

Choose OK.


You will accept the default tool axis vector of 0,0,1 which is thesame as the Z coordinate of the WCS.

Choose OK to accept the tool axis default.


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Choose OK to accept the first suboperation.

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

Step 4: Create the Engage Motion.

A best practice is to establish a cutting tool along a straight wallas well as to feed into the wall away from a corner to eliminate toolchatter. You will engage the wall as shown.

You will now define the Engage component.


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Change to an Engage suboperation.


Choose the Engage Method button.



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I= 0.000

J= –1.000

K= –.500

Choose OK.


Choose OK.


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Choose the 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.

Choose the Three Points option from the Plane dialog.


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Select the three control points as shown. Note that in thefollowing views, the part has been rotated 180 degrees tofacilitate looking at the wall being created. The stock andcheck geometry have been removed from the view for purposesof clarity.

As the last point is selected, the geometry selection advancesto Part geometry.

Change the Type back to Face.

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


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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.

Change the Tool Axis from 3-axis to 5-axis.

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

Choose OK in the Five Axis Options dialog.

Choose OK to create the Engage suboperation.

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

Step 5: Create the first Continuous Path Motion.


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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, choose the CheckSurfaces button.

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

Select the corner fillet surface as shown.

Choose OK in the Check Surfaces dialog.


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


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 past the temporary plane made up of controlpoints on the edges of the surfaces. This should prevent anyscallops from being left 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.


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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.

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


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The Loop Control dialog follows:

(1) starts and ends the loopingroutines that cut toward the drivesurface

(2) starts and ends the loopingroutines that cut toward the partsurface

(3) specifies the inner and outerloops when both start on the samesuboperation

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).


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Choose Options→Loop Control→Start/End and change to Start. Thisestablishes the beginning of the Loop.

You can also 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 in thegraphics window.

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


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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.

(1) Drive Surface Start/Endparameter

(2) Part Surface Start/End parameter

(3) Nesting Status option

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


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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.


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Double-click on the FINWALLS operation.

Note that the Multiaxis Output option is selected.

Choose OK.

The Point to Point Motion dialog is displayed.

Choose OK.


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

Choose Options.

The Other Options dialog is displayed.


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Choose 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.

Choose OK three times to return to the Continuous PathMotion dialog.

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


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Choose OK twice to return to the Continuous Path Motiondialog.

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, choose the Options button, thenthe Loop Control button to check the loop status. They areset to End.

Step 3: Start the looping process.

Choose OK three times until the Loop Debug Options dialogis displayed.

On the Loop Debug Options dialog, choose 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.


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Activity: Removing 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.

Highlight the SM_FINISH_WALLS_POCKET_1 operation thatyou previously created, then use MB3, Copy.

Highlight the PM_FINISH_BOSSES operation, then use MB3,Paste.

Use MB3, 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 on the SM_SEMI_FINISH_WALLS_POCKET_1operation.


Change the Global Stock on Drive Surfaces to .030.

Change the Global Stock on Part Surfaces to .030.

Choose OK on the Sequential Milling dialog.


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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 and choosethe 4 cpm suboperation.


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Choose the Delete button and confirm the choice in the messagedialog.

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

The dialog should look as follows:

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.


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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.

Choose OK on the Check Surfaces dialog.


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Choose 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.


Select the wall as shown below.


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Choose OK on the Check Surfaces dialog.

Choose 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.


Change the Type to Temporary Plane.

Choose the Three Points method.

In the Point Constructor dialog, choose the Control Point icon.

Select the three edges in the area as shown below.


Choose OK to accept the suboperation.

Change the motion type to Retract.

Choose the Retract Method button.



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Key in the following values to create the vector:

I = 0.0

J = –1.0

K = 1.0

Choose OK in the Vector Constructor dialog.

Key in 1.0 in the Distance field.

Choose OK in the Retract Method dialog.

Choose OK to accept the suboperation.

The suboperation, 6 Ret, is created.

Choose End Operation.

Choose OK in the End Operation dialog.

Save the part file.


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Activity: Using 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.

Choose OK in the Sequential Mill dialog.

Choose OK in the Point to Point Motion dialog to advance tosuboperation 2.

In the Engage Motion dialog, choose the Options button.


The Loop Control dialog is displayed.

Change the Ds loop parameters Start/end from None to Start.


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

Choose OK.

Choose OK on the Other Options dialog.

Choose OK on the Engage Motion dialog.

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

Choose Options.


Change the Ds loop parameters from Contin to End.

Choose OK on the Loop Control dialog.

Choose OK on the Other Options dialog.

Sequential Milling is now ready to create the additional looppasses.

Choose OK on the Loop Debug Options dialog.

When satisfied with the additional passes, choose EndOperation on the Point to Point Motion dialog.

Choose OK in the End Operation dialog.

Visually examine the output using Visualization.

Save and close the part.


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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.

Path Generation and Multiaxis Output

You can turn Path Generation on or off from the Sequential Mill dialog. Whenthis option is toggled on, the tool path segment is graphically displayed aseach suboperation is accepted. When it is off, the tool path segment is notcalculated or displayed.

Multiaxis Output is an option. This outputs the I, J, and K components ofthe tool axis vector with each output point. This option must be active if 4 or5-axis tool positioning is used. The default is ON (box is checked).

Replace Geometry Globally

Replace Geometry Globally, replaces faces, curves and temporary planes byother faces, curves and temporary planes throughout the operation.


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This option is located on the Sequential Mill dialog.


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Other Options

Use the Other Options dialog to set custom tolerances, limit the step distanceand number of output points, set tool path and tool display options, use ofCorner Control, and to specify looping routines for a specific suboperation.

A summary of the options on the Other Options dialog follows:

Custom Surface Tolerances specifies special Intol and Outtolvalues forthe current suboperation. This option is only active in the Engage andContinuous Path Motion dialog.

Custom Tool Axis Tolerance specifies a special tool axis tolerance forthe current suboperation. This option is only active in the Engage andContinuous Path Motion dialog.

Custom Corner Control specifies the cutter feed rate, slowdowns, andfillet radius at corners. By toggling the Custom Corner Control button


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and selecting the Edit Parameters action button, you bring up the Cornerand Feed rate Control dialog. This option is available for Continuous Pathsuboperations only.

Maximum Step specifies the maximum length of individual tool moves in thesuboperation. If you change the default value of ten inches, the new valuebecomes the default value for the current and subsequent suboperations. Ifyou are editing a suboperation, changing the Maximum Step does not affectsubsequent suboperations. You must specify a positive value. This option isavailable for Continuous Path suboperations only.

Maximum Points specifies the maximum number of points generated in asuboperation. If you change the default value of 400, the new value becomesthe default value for the current and subsequent suboperations. If youare editing a suboperation, changing the Maximum Points does not affectsubsequent suboperations.

Output CL Points temporarily suspends the output of points to the CL sourcefile. By suspending the output of CL points, you can move the tool in severalsuboperations that are not included in the tool path. When you finallyposition the tool to the correct geometry, activate this option and the tool pathcontinues (this is similar to APT’s CUT/DNTCUT).

Automatic Redefinition establishes a check plane at the last valid toollocation when the processor is unable to complete the tool path for asuboperation. You can continue programming from the new check plane.

Automatic Reposition is useful if the tool is not within tolerance to the Driveor Part surface at the start of a suboperation.

Display Option sets tool, pattern, and tool path display options for the currentsuboperation. This is the same Display Options dialog used in OperationParameters.

Loop Control specifies a looping routine for area clean-up of Drive or Partgeometry, or both.

Most Sequential Milling processor errors are caused by the tool being outof tolerance to the geometry.


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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 when thetool can move to more than one location or if the tool is not close to thesurface

• 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 when the tool is onor 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 MaximumStep (on the Other Options dialog)

• when using a Fan tool axis, reduce the Maximum Step (on the OtherOptions dialog)

• 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

• if you 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


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• 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


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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.


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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


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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


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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 as shown by the following illustration.

(1) Drive points

(2) Projection vector

(3) extension of partgeometry

(4) Part geometry

(5) Valid

(6) Invalid


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Terminology used in Variable Contour

• Part Geometry - is geometry selected to cut

• Check Geometry - is used to stop tool movement

• Drive Geometry - is used to generate drive points

• Drive Points - are 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.


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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.


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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. The drive geometry isprojected on to the part surface(s) where the tool path is created. The curvesmay be open, closed, contiguous, non-contiguous, planar or non-planar.

When points define the drive geometry, the cutter moves along the tool pathfrom one point to the next in the order in which they were specified. The samepoint may be used more than once, provided it is not defined consecutively inthe sequence. A closed drive path can be created by defining the same pointas the first and last point in the sequence.

The Curve/Point Drive Method dialog allows you to specify the distancebetween drive points and the projected location of drive points. You can alsouse the Display Drive Point option to view the location of the drive pointsbefore generating the tool path.

(1) Used to select and edit drivegeometry

(2) Controls the distance betweendrive points

(3) determines the method ofprojection onto the part

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 size ofthe part surfaces while Loops must correspond to exterior part surface edges.Cut regions are defined by Boundaries, Loops, or a combination of both.


generic

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The Boundary Drive Method allows you to use a permanent boundary, partcurves or faces to generate drive points.

(1) Boundary

(2) Tool axis

(3) Projection vectorDrive points aregenerated withinthe boundary andare then projectedlinearly onto the partgeometry according tothe specified projectionvector.

The Boundary Drive Method is preferred to the Surface Area Drive Method.You can quickly create a boundary and tool path without the surface designrequirements of the Surface Area Drive Method.

This method does not allow as many choices of tool axis options that areavailable in the Surface Area Drive Method and is better suited for roughingoperations. The Surface Area Method is better suited for finishing operations.

Each boundary member is assigned an On, Tanto, or Contact tool position(unique to Variable Contour Boundary Drive Method). The Contact toolposition can be used when specifying boundaries using curves and edges.

The boundary members graphically represent the associated tool positionsas illustrated below:

(1) tanto condition (2) on condition (3) contact condition


generic

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generic

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Options associated with the boundary drive method follows:

Pattern option enables you to define the shape of the tool path. Some patternscut the entire region, while others cut just around the perimeter of theregion. Some patterns follow the shape of the cut region, while others areindependent of it.

The selected Pattern determines which other options are available. If youselect Parallel Lines as the cut pattern, the Cut Type, Cut Angle, and Degreesoptions become available. If you select Follow Pocket, only the Inward andOutward options are available.

Parallel Lines creates a cut pattern defined by a series of parallel passes. Youare required to specify a Cut Type of Zig-Zag, Zig, Zig With Contour, or Zigwith Stepover and a specific Cut Angle.


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Radial Lines creates linear cut patterns extending from a user-specified orsystem calculated optimum center point. You are required to specify a CutType, a Pattern Center, and pocketing method as Inward or Outward. Youmay also specify an angular stepover, which is unique to this type. TheStepover distance for this cut pattern is measured along the arc length at theboundary point farthest away from the center.

(1) point furthest away from center

(2) stepover distance measured alongarc length

Concentric Arcs creates progressively larger or progressively smaller circularcut patterns from a user-specified or system calculated optimum center point.You are required to specify a Cut Type, a pattern center, and a pocketingmethod as Inward or Outward. In areas such as corners that the full circularpattern cannot extend into, concentric arcs are created and connected by thespecified Cut Type before the cutter moves to the next corner to continuecutting.

(1) stepover

Cut Type defines how the cutter moves from one cut pass to the next.The options are used in combination with Parallel Lines, Radial Lines, orConcentric Arcs cut patterns. When used in combination with the ParallelLines pattern, Zig-Zag, Zig and Zig with Contour work in the same way astheir counterparts in Planar and Cavity Milling.

Pattern Center allows interactive or automatic definition of the center pointof Concentric Arcs and Radial Lines cut patterns.


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Cut Angle determines the angle of rotation for the Parallel Lines CutPatterns. This option is available if the Cut Angle is set to Specify. Enter thedegrees of rotation for the Parallel Lines Cut Pattern.

Outward and Inward allow you to specify a pocketing method that determineswhether to cut from the inside out or the outside in of a Follow Pocket,Concentric Arcs, or Radial Lines cut type.

Stepover specifies the distances between successive cut passes.

Constant specifies a fixed stepover distance between successive cut passes.When used with the Radial Lines cut type, the constant distance is measuredalong the arc length at the boundary point farthest away from the center.

Scallop determines the stepover distance based on the scallop height youenter.

Tool Diameter defines the stepover in terms of a percentage of the effectivetool diameter.

Variable allows you to vary the stepover distance within a specified minimumand maximum value. The required input values differ depending on theselected cut type.

Angular defines a constant stepover by keying in an angle. This option isused only in combination with the Radial Cut pattern.

Additional Passes specifies an additional number of passes that allows thetool to step toward the boundary in successive concentric cuts for Profile andStandard cutting patterns.

More Drive Parameters displays a dialog containing the following options:

Options displays a dialog that enables you to create start pointsautomatically or interactively and to specify how cut regions will bedisplayed when the Display button is selected.

Display generates a temporary screen display of the cut regions for visualreference. The display is generated using the parameters specified underCut Region Display options.

Display Drive Path displays the Drive Path used to generate the tool path.The path is created as a temporary element projected onto the WCS alongthe tool axis and is for visual reference only.

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.


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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.

(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

If you do not specify a center point, the system uses the (0,0,0) of the AbsoluteCoordinate System. If the Center Point is not on the part geometry, it followsthe defined projection vector to the part geometry. The direction of the spiral(clockwise vs. counterclockwise) is controlled by the Climb or Conventionalcut direction.

The following parameters pertain to Spiral Drive method:

Stepover allows you to specify the distances between successive cut passesand are a smooth constant transition outward; does not require an abruptchange of direction.

(1) stepover

Constant allows you to specify a fixed distance between successive cutpasses. Key in the desired distance between subsequent cut passes.

Tool Diameter allows you to define the Stepover in terms of a percentageof the effective tool diameter.


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Maximum Spiral Radius allows you to limit the area to be machined byspecifying a Maximum Radius. This constraint reduces processing timeby limiting the number of drive points created. The radius is measured inthe plane normal to the Projection Vector.

(1) maximum spiralradius

(2) part surface

If the specified radius is contained within the part geometry, the center ofthe tool positions to the radius before retracting. If the specified radiusexceeds the part geometry, the tool continues to cut until it can no longerposition to the part geometry. The tool then retracts and engages.

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.


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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 Surface Area Drive method is much more accurate than the BoundaryDrive method for complex parts and is useful for finishing types of operations.

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.

(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

The following parameters pertain to Surface Area Drive method:

Select allows you to select the Drive Geometry. Note that you can usepart geometry as drive geometry.

Surface Stock offsets drive points along surface normals a specifieddistance.

Tool Position determines the tool contact points on the drive geometry aseither On or Tanto.

Cut Direction is the tool path direction and the quadrant where the firstcut will begin. It is specified by selecting one of the vector arrows whichappear in pairs at each of the surface corners.

Flip Material reverses the direction of the Material Side Vector whichdetermines the side of the surface the tool contacts when machiningdirectly the drive geometry. When machining part geometry, theProjection vector determines the Material Side.


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Cut Area defines how much of the total drive geometry area to utilizeby specifying surface percentages or diagonal points and to display theboundary of the cut area.

Surface % specifies the drive geometry area to cut by using positive ornegative percentage values for the beginning and end of first and lastpass, and the first and last Stepover.

Diagonal Points uses the cursor to indicate two diagonal points definingthe area.

Pattern defines the shape of the tool path as Follow Pocket or ParallelLines.

Cut Type in combination with the Parallel Lines pattern defines cuttermovement from one cut pass to the next. The types are: Zig-Zag, Zig-Zagwith Lifts and Zig.

Cut Step controls the distance between drive points created along thedrive curve. For complex parts, the closer the drive points, the moreaccurate the tool path. You can control the cut step by specifying aTolerance or by specifying a Number of points.

Stepover controls the distance between successive cut passes. Stepoverchoices are:

Scallop, (for Parallel Lines pattern) which requires you to enter theHeight of the scallop and the Horizontal and Vertical Limit to restrictthe distance the tool moves in a direction normal to the ProjectionVector. This option avoids leaving wide ridges on near vertical surfacesby limiting the horizontal distance of the Stepover.

Number, which requires you to enter the First and Second Directionsof cutting (for Follow Pocket) or the Number of Steps (for ParallelLines). These are used to generate drive points.

When Gouging indicates the processor action when gouging is detected.The actions are: None; issue a Warning in the tool path output; Skip theoutput point; or Retract and avoid the gouge.

Cutting Parameters affect each of the Drive Methods. The correspondingCutting Parameters dialog follows:

The Part Stock option defines an envelope of material surroundingthe part geometry which remains on the part after machining. Thestock specified applies to those part entities which do not have CustomStock specified (under Custom Data in the Part geometry dialog).


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The Check Stock option is an envelope of material surrounding theCheck geometry, which the tool will not gouge.

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

When you select Tool Path as the drive method, you must specify an existingCLSF to be used to generate drive points.


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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

The tool will Zig or Zig-Zag along the boundary in the direction of theboundary indicators. This can be changed by selecting Reverse Boundary.The following Radial Cut Drive Method options are available:

Select displays the Permanent Boundary or Temporary Boundary dialogallowing you to define the area to be cut. The Permanent Boundary dialogis only displayed if permanent boundaries currently exist. If multipleboundaries are defined, a lift is applied, allowing the tool to traverse fromone boundary to the next.

Bandwidth defines the total width of the machined area measured in theplane of the boundary. The bandwidth is the sum of the Material Side andOpposite Side offset values.

The Material Side is the right side of the boundary as you look in thedirection of the boundary indicators. The Opposite Side is the left side.The sum of the Material Side and Opposite Side cannot equal zero.

(1) looking in the directionof boundary indicators

(2) bandwidth

(3) material side

(4) opposite side

Cut Type enables you to define how the cutter moves from one cut pass tothe next. The following options are available:


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(1) Zig-Zag

(2) Zig

Stepover specifies the distances between successive drive paths.

Each Stepover methods require you to enter a corresponding Distancevalue.

Follow Boundary and Reverse Boundary allow you to determine thedirection the tool travels along the boundary.

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.


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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 is displayed.

Step 3: View the Variable Contour dialog options.

You will review the option settings on the Variable Contour dialog,then you will note the option settings on the Surface Area DriveMethod dialog. These options are required to create the tool path.


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Choose the Groups tab and, if necessary, choose the Geometryradio button, then choose Display.

The geometry Parent Group, WORKPIECE, is displayed. Thisis the Part geometry.

Refresh the graphics window and select the Main tab.

Under the Geometry label, note that the Part icon is alreadyselected. Choose Display.

The geometry Parent Group named WORKPIECE is displayedsince it was selected as the part geometry.

Choose the Check icon.

Note that no previous Check geometry was selected.

Under the Drive Method label, view the Drive Methods thatare available.

Note that the Area Milling, Flow Cut and Text Drive Methodsare not available and are grayed out.

On the Variable Contour dialog, under the Tool Axis label, notethe various tool axes which are available.

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 is displayed.

Under the Drive Geometry label, choose Display.

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.

Under the Projection Vector label, choose Specify Vector.

The Projection Vector is I=0, J=0, K=-1 and is displayedpointing downward.

The Drive Points will be projected to the top of the partgeometry, which are also their current location.

Choose Cancel.


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Choose Display Drive Path.

The temporary Drive Points are displayed (which are used tocreate contact points.

Choose 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.




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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:


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Drive methodToolAxis Curve/

Point

Spiral Bndry SurfaceArea

Tool Path Radial

AwayFrompoint

X X X X X X

TowardPoint X X X X X XAwayFromLine

X X X X X X

TowardLine X X X X X XRelativetoVector

X X X X X X

4–axisNorm.To Part

X X X X X X

4–axisRel. ToPart

X X X X X X

Dual4–Axison Part

X X X X X X

Interpolate X XSwarfDrive XNormalTo Drive XRelativeTo Drive X4–axisNorm.To Drive

X

4–axisRel. ToDrive

X

Dual4–Axison Drive

X

Sameas DrivePath

X


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Point and Line Tool Axes

The following tool axis types use focal points and can produce 5-axismovements:

Away From Point

Towards Point


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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.


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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.


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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.


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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.



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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.


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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.


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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


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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


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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.


Under the Tool Axis area of the dialog, choose Relative to Partas the tool axis.

You are prompted to change the Lead and Tilt angles. Use thedefaults of 0°

Choose OK.


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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.


Under the Tool Axis label, choose Relative to Part.

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.


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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.


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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.


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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.


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Activity: Using 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.

Choose the Assembly Navigator tab from the toolbar.

The Assembly Navigator and the part model are displayed.

Note that the assembly consists of a mounting plate, compoundrotary table, numerous bolts and the hub cover core part.

Step 3: Examine various operations.

Choose the Operation Navigator tab from the toolbar.



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If necessary, change to the Program Order view of theOperation Navigator.

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.


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.


If necessary, set the Type to mill_multi_axis.

Choose the VARIABLE_CONTOUR icon.

Set the Parent Groups as follows:

Program: HUB-FINISH


Use Tool: BALL_MILL-.75


Name: vc_flute_fin

Choose OK.

The Variable_Contour dialog is displayed.

Change the Drive Method from Boundary to Surface Area.


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Choose OK on the Drive Method Information dialog.

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.

Choose the Select button and select the outside face of thecylinder 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.


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Choose the Cut Direction button.

Cut direction vectors are displayed.

Choose the vector as shown (1).


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Choose Surface % from the Cut Area pull-down menu.

Note the system highlight at the top and bottom of the cylinder.

Refresh the screen.

Set the start and end values as shown:

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.

Change the Tool Axis from Normal to Part to Relative to Drive.


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Set the Tilt angle to 45.

Choose OK.

Set the Projection Vector to Toward Line.

The Line Definition dialog is displayed.

Choose the Point and Vector button.

Choose OK on the Point Constructor dialog (accept thedefaults).


Choose the ZC Axis icon

Choose OK twice.

The Variable_contour dialog is displayed.



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Notice the last pass make an erratic move next to the clearancehole near the bottom of the part.

To avoid this move, you will need to select Check (2) geometry.

Choose the Check geometry icon from the Variable_contourdialog.


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Choose the Select button and then choose the small disc arealocated near the bottom of the part.

You will now set the parameters used in collision detection.

Choose OK.


Select the Clearances tab.

Select Skip from the When Gouging pull-down menu.

Set the Check Safe Clearance parameter to .01

Choose OK.

Choose Generate and review the tool path.



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Activity: Swarf Drive Tool Axis

In this activity, you will create an operation to finish the walls of a taperedwalled part using the Swarf Drive Tool Axis. The part will be modified inorder to start the tool path at the center of one of the walls, which preventsthe cutter from engaging the interior corner of the part.

Step 1: Open a part file and rename it for the current activity.

Open the part file tub_ftg_mfg_asmb.

Rename the part to ***_tub_ftg_mfg_asmb.

To prevent engaging and then gouging an interior corner of thepart, you will engage the part from the middle of one of the longsides of the part. You must first subdivide one of the taperedside walls by creating a curve (in this case a line) before youcan subdivide the face.

Step 2: Enter the Assemblies application and create a WAVE Linked bodyused for dividing the faces.

You will first change the work layer to the layer used formanufacturing data and will then create the WAVE linked body.

Verify that Assemblies is turned on.

Set the work layer to 151.

Choose Insert→Associative Copy→Wave Geometry Linkerfrom the main menu bar.

The WAVE Geometry Linker dialog is displayed.


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Select the Body icon.

Select the solid body that is the part.

Choose OK.

A linked body has been added to layer 151 which is associativeto the engineering model (tub_fitting) that appears in theAssembly Navigator. This linked body can now be modified,whereas the engineering model (tub_fitting) can not.

Step 3: Turn off the display of the component and change the color of thelinked body.

Using the Assembly Navigator, turn off the display of thecomponent by clicking the check mark in front of the tub_fittingcomponent (the check mark will turn from red to gray).

Change the color of the linked body by choosing Edit→ObjectDisplay from the main menu bar.


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Select the linked body and OK the selection.

The Edit Object Display dialog is displayed.

Select the check box for Apply to all faces.

Change the color to one that is not the same as the engineeringpart.

Choose OK.

Step 4: Enter the Modeling application, create a datum plane and curvefor subdividing and subdivide the tapered sidewall face.

Enter the Modeling application.

Choose Insert→Datum/Point→Datum Plane from the menu bar.

Select the end face and key in the value –6.0 (Hint: use Offsetas a constraint).

Choose OK.

Choose Insert→Curve from Bodies→Intersect from the menubar.

The Intersect Curve dialog is displayed.


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Choose the First Set icon from the dialog and then select thecontoured face.


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Choose the Second Set icon from the dialog, then select thedatum plane.

Choose OK.

You created a line that will be used to subdivide the face. ADatum Plane was used to create the curve to allow movementof the line easily. You will now move the Datum Plane to itsproper layer and then subdivide the face.

Choose Format→Move to Layer and select the datum plane.

Choose OK.

In the Layer Move dialog, set the Destination Layer to 61.


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Choose OK.

Choose Insert→Trim→Divide Face from the menu bar.

Change the face selection filter to Single face.

Select the face to subdivide.

Choose OK from the Selection Confirmation dialog.

The curve Subdivide Face dialog is displayed.

Choose Blank dividing objects.

You must select the curve you are going to use to subdividethe face.


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Select the newly created line.

Choose OK.

The face is divided into two faces.

Choose Cancel.

From the menu bar, choose Preferences→Selection.

Set the Chaining tolerance to .001.

Choose OK.

You will now create the tool path to cut the part.

Step 5: Change to the Manufacturing application.


Choose mill_multi-axis as the CAM Session Configuration.

Choose mill_multi-axis as the CAM Setup.

This will initialize the part with multi-axis parameters.

Choose Initialize.

Step 6: Create an end mill needed to machine the part.

Choose the Create Tool icon.


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Choose the Mill tool icon.

Name the tool EM-.75-.06.

Choose OK.

In the Milling Tool-5 Parameters dialog, enter a diameter of.75 and a lower radius of .06.

Choose OK.

Step 7: Edit the MCS in the Operation Navigator and set the ClearancePlane 1.000 above the top face of the part.

Double-click the MCS group object in the Geometry view ofthe Operation Navigator.

The MILL_ORIENT dialog is displayed.

Check the Clearance box and choose the Specify button.

The Plane Constructor dialog is displayed.

Set the clearance plane as being 1.000 above the uppermosttop face of the part.

Step 8: Specify the Part Geometry.

You will now select the floor of the part as the Part Geometry.

Choose the Create Geometry icon.

Set the Operation Navigator to the Geometry View.

Choose the Mill_Geom icon.

Choose WORKPIECE as the Parent Group.

Name the geometry Parent Group PART_FLOOR.

Note that the Type is mill_multi_axis.

Choose OK.

In the MILL_GEOM dialog, under the Geometry label, choosethe Part icon.

Choose Select.The Part Geometry dialog is displayed.


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The Selection Options should be set to Geometry.

Change the Filter Methods to Faces.

Select the floor of the part.

Choose Accept from the Selection Confirmation dialog.

Choose OK until you return to the Create Geometry dialog.

Verify that the Parent Group, PART_FLOOR was created inthe Operation Navigator.

Step 9: Create the Variable Contour operation using the Surface AreaDrive Method.


Choose the Variable Contour icon.


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Set the following:

Program: Program

Use Geometry: PART_FLOOR

Use Tool: EM-.75-06


Name: fin-poc-walls

Choose OK.


Step 10: Define an Engage and Retract move using the Non-cutting Movesoption.

Choose Non-cutting from the Machining Parameters area.

The Non-cutting Moves dialog is displayed.

You will now define an Approach move for the Default Case.

You can also define different Approach moves for the Initial,Final Check, Local, and Reposition moves.

Choose the Approach icon.

The options available have changed to reflect the Approachmove options.

Next to the Status label, change None to Clearance.

The Clearance geometry is assigned to the default Approachmove. The Non-cutting Moves dialog is displayed again.

You will now specify a Departure move for the Default case.

Choose the Departure icon.

Next to the Status label, change None to Clearance.

You will now define an Engage move for the Initial case.

Choose the Engage icon.

Next to the Status label, change None‘ to Manual.


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Under the Movement label, change Linear to Arc: NormalTool axis.

Change the Radius Type to Radius.

Key in .500 into the Radius value field.

Step 11: Set the Display options.

Choose the Edit Display icon in the Tool Path section of thedialog.



Tool Display = 3D

Frequency = 5

Path Display Speed = 8

Choose OK.


You have specified how to drive the bottom of the tool. Youmust specify how to drive the side of the tool. This is done bychoosing a Drive Method from the available types.

Step 12: Define the Drive Method.


If necessary, accept the warning message.


Step 13: Select the Drive Geometry.

Choose Select from the Drive Geometry area.

The Drive Geometry dialog is displayed.


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Select all the interior faces, beginning at (1) and ending at (9),in a counterclockwise direction.

Choose OK from the Drive Geometry dialog when the faceselection is complete.

If the material side and direction indicator appears as follows:

Choose Flip Material from the Surface Drive Method dialog(perform this action only if the indicators appears as above).

Step 14: Define the drive direction.

You must now define the direction of the cut.


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Choose Cut Direction from the Surface Drive Method dialog.

Cut direction arrows are displayed. You will select the directionarrow that points in the direction that you will want to cut.

Choose the lower left arrow (1).

Step 15: Set the Number of Passes.

Next to Stepover, set the option to Number.

In the Number of Steps field, enter 0.

Zero indicates that only one pass will be made.

Step 16: Define the Gouge Action.

Next to the When Gouging label, change None to Skip.

The Skip option will move the tool to the next non-gougingpoint if gouging is detected.

Step 17: Define the Tool Axis.

Under the Tool Axis label, change Normal to Part to SwarfDrive.

Remember, Swarf Drive enables you to define a tool axis thatfollows the swarf rulings of the drive geometry with the sideof the tool.

Notice that several vector indicators appear. They are relativeto the first drive geometry you selected. The vector you selectdefines the swarf ruling direction that the tool axis will follow.The vector should point towards the tool holder.

Select the arrow pointing up.

Step 18: Define the Projection Vector.

The Projection Vector determines the direction that the drivepoints are projected upon the part geometry.


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Under Projection Vector, change Specify Vector to Tool Axis.

The Surface Area Drive Method parameters are now complete.

Choose OK.


Step 19: Create the tool path.

Choose the Generate button.

The tool path is generated and the option menu is displayed.

The tool engages and retracts along the defined radius of thenon-cutting move.

The side of the tool maintains wall contact throughout the cut.

Notice that the tool appears as to be gouging the part. It is not.The tool is longer than the surface it is cutting which makes itappear to be violating the geometry.

(1) retract

(2) engage

Choose OK from the option menu.



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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, smootherdrive 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 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.


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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.

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. Selecting Back accepts all of the defined vectors andreturns you to the Interpolated Tool Axis dialog.

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.


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Activity: Using 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.



Choose the Variable Contour icon.

In the Create Operation dialog, set the following:

Program: PROGRAM-AXIS-LIMITS


Use Tool: BALL_MILL-1.0


Name: interpolate


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Choose OK.


Under the Machining Parameters label, select Non-Cutting.

Specify the Approach and Departure motions to ClearancePlane.

Step 3: Define the Drive Geometry.



Step 4: Specify a Drive Method.

Under the Drive Geometry label, choose Select.


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Choose the surfaces as shown.

Choose OK.

Choose the Cut Direction button.


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Choose the Cut Direction arrow as shown.

Change the Cut Type to Zig.

Change the Cut Step to Tolerances.

Under the Stepover label, change the Number of Steps to 4.

Change the Tool Axis to Interpolate.

The Interpolated Tool Axis dialog is displayed.

The default vector arrows show the current tool axis vectordirection.


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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.



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Choose OK to return to the Variable Contour dialog.

Under the Tool Path label, choose the Edit Display icon andchange the Tool Display to Axis.

Choose OK to return to the Variable Contour dialog.


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.


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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.


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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."


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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


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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


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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.


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Lesson

10 Variable Contour – Advanced

Purpose

This lesson will introduce advanced concepts in conjunction with VariableContour operations.

Objective


• create associative drive surfaces used to control the tool axis

• use Associative Datum planes to create surfaces and geometric objectsused for creation of start points and initial tool axis


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Variable Contour – Advanced

Advanced Variable Contour MachiningThe activity which follows will take you through some of the steps that allowgreater control of the tool axis and avoids chaining tolerance errors that occurwhen drive surfaces edges do not match precisely.

Surfaces will be extracted from the solid body by use of the WAVE GeometryLinker with timestamp applied. The use of the timestamp will prevent newgeometry, which is created after the timestamp, from being used by theWAVE Linked surfaces.

Associative Datum planes are created for use in creating the initial startpoint and tool axis as well as for the creation of various geometric elementsthat will be required for tool control.

All surfaces which have not been intersected by parallel datum planes willbe selected as part surfaces. The tool axis will be set to swarf drive and theprojection vector will be the tool axis.


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Activity: Examining the Part and Part Objects

The part in this activity can represent any type of five-axis work that could beperformed on an aircraft structural assembly, the inside of a mold or someother type of part that requires five-axis machining. You will be required tosemi-finish and finish the walls with two different diameter cutters. Assumethat the part has already been roughed.


Open the part file vc_nc_assy.

There are two existing sample operations that you will examineand then create like operations. First you will examine thevarious parts which comprise the assembly.


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Step 2: Examine the assembly.

If necessary, enter the Manufacturing application.


The Assembly Navigator and the part model are displayed.

Make the vc_solidbody component the Displayed Part.

Note the cut out areas on top of the walls.

Make the vc_assy the Work Part.

Step 3: Examine layers in the assembly.

Choose Format→Layer Settings from the menu bar.


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Check the Show Object Count and Show Category Namesboxes.

Note the change in the Layer/Status/Count/Category area ofthe dialog.

You will now examine the layers.

Make all layers Invisible.

Make layer 15 Selectable.

Choose OK.

Now examine the WAVE Linked surfaces.

Note that the cut outs were not passed to the WAVE Linkedgeometry due to the use and placement of the timestamp.


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The view now shows the part with the Associative Datumplanes that are used to create the necessary intersection curves.


The view now shows the part with the Associative Curves thatare used to create the necessary ruled surface.


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The view now shows the part with the Associative Ruledsurface that is used to create the Drive surfaces.


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Make layer 15 Invisible.

The single vertical plane was used to split the WAVE Linkedsurface prior to the creation of the Intersection Curves. Thiscan be at any angle to establish the initial tool axis.

Dismiss the Layer Settings dialog by choosing Cancel.

Step 4: Enter the Manufacturing application and review the existingoperations.

You will review the operations by examining their settings.


Choose the Operation Navigator tab from the menu bar.


Expand the MCS and WORKPIECE Parent group objects.

Double-click on the operation VC_RGH_POC_1.50_WO_CS.

The Variable_Contour dialog is displayed.


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Display the Part geometry and then the Check geometry.

Notice that the Select button appears when you choose theCheck geometry icon. There is no Check geometry availablefor display.

Replay the operation and zoom in at the corner of the part.

Notice the cutter violates the drive surfaces.

Double-click on the operation VC_RGH_POC_1.50_W_CS.


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Display the Part geometry, then the Check geometry.

Notice that the side walls of the part have been selected asCheck surfaces.


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Replay the operation and zoom in at the corner of the part.

Notice the cutter does not violate the walls.

Replay the operation VC_FIN_POC_1.00.

Examine the operation parameters and the surfaces used.

Notice that this operation does not need Check surfaces.

Step 5: Create new operations.

Create operations to semi-finish and finish the pocket, usingthe previous operations as a guide only. Do not copy them.



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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.


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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.




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Choose the CONTOUR_PROFILE icon.

Set the group objects as shown:

The CONTOUR_PROFILE dialog is displayed.

Choose OK.

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.


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Under the Geometry area of the dialog, choose the Floor (1)icon and then Select (2).


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Choose the bottom of the pocket as shown.

Choose OK.


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Choose the Wall icon (1) from the Geometry area of theCONTOUR_PROFILE dialog.

Choose Display (2).

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.

Choose the Cutting button from the CONTOUR_PROFILEdialog.

The Cutting Parameters dialog is displayed.


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Select the Multiple Passes tab.

Turn on the Wall (1) option.

Key in 0.1 for the Wall Stock Offset (2).

Set the Step Method to Passes (3).

Set the Number of Passes to 3 (4).

Choose OK (5).

You have set the cutting parameters to remove .100 stock inthree equally spaced passes.

Step 4: Generate the operation and examine the tool path.

Choose the Generate button from the CONTOUR_PROFILEdialog.


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Examine the tool path.

(1) Tool path prior to stock removal; (2) tool path after stockremoval


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If time permits, create a second Contour Profile operation tomachine the walls of the next pocket.



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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.


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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.


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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.







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Set the group objects as shown and select OK.


Step 3: Specify the Floor Geometry.

Under the Geometry area of the dialog, choose the Floor (1)icon and then Select (2).


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Choose the bottom of the pocket as shown.

Choose OK.


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Choose the Wall icon (1) from the Geometry area of theCONTOUR_PROFILE dialog.

Choose Display (2).

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.


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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.


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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.

Step 1: Continue to use the existing part file.

The part file mfg_wedge should be open.






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Step 3: Turn off the Automatic Wall option.

Turn off Automatic Wall.

Step 4: Specify the Wall Geometry.


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Under the Geometry area of the dialog, choose the Wall iconand then Select .

Choose all of the walls on the outside of the part.

Choose OK.

Select Follow BottomWall on the CONTOUR_PROFILE dialog.


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The operation will detect the bottom of the walls to use for floorgeometry. The path could also be offset from the Bottom Wall.




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.

Set the Tool Position Offset to .250 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.


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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.


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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.








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10




Choose OK.


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Select Automatic Auxiliary Floor on the CONTOUR_PROFILEdialog.

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 bottomof the wall. The path could also be offset from the AutomaticAuxiliary Floor.




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.


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In the graphics screen click and drag the cone head to specifyan offset of -.3 and select the Green Check Mark to accept it.

Step 7: You will now select multiple floor passes.

Choose Cutting→ Multiple Passes and select Floor.

Set the Floor Stock Offset to 2.00, the Step Method to Passesand the Number of Passes to 4.

Choose OK to return to the CONTOUR_PROFILE dialog.

Choose Generate.


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Choose OK to accept the operation and tool path.

You will also add multiple Wall passes to the operation.


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Step 8: Choose Cutting→ Multiple Passes and select Walls.

Set the Wall Stock Offset to .100, the Step Method to Passes andthe Number of Passes to 2.


Choose Generate.


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Step 9: Move the operation to the Unused Items group on the OperationNavigator.



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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.


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Activity: Auxiliary FloorYou will create a new operation using the Auxiliary Floor option.








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Step 3: Make the layer containing the auxiliary floor selectable.

Select Format→ Layer Settings , highlight layer 52 and chooseSelectable.

Choose OK.





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Under the Geometry area of the dialog, choose the Wall iconand then Select.


Choose OK.


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Select Auxiliary Floor on the CONTOUR_PROFILE dialog andthen choose Select.

You will select the sheet body as the Auxiliary Floor.

Step 6: Generate the operation and examine the tool path




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The tool path follows the Auxiliary Floor geometry while using thewall geometry to guide the tool axis.


Choose Cutting→ Multiple Passes, and select Floor.



Choose Generate.


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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.



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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.


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Activity: Auxiliary Floor and Automatic Auxiliary FloorYou will create a new operation using the Auxiliary Floor and AutomaticAuxiliary Floor.

.








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10




Choose OK.


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Select Auxiliary Floor on the CONTOUR_PROFILE dialog andthen choose Select.

You will select the sheet body as the Auxiliary Floor.

Step 5: You will also turn on the Automatic Auxiliary Floor option.

Choose Automatic Auxiliary Floor.

Step 6: Generate the operation and examine the tool path


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The tool path follows the Auxiliary Floor and the AutomaticAuxiliary floor geometry while using the wall geometry to guidethe tool axis.


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Choose Cutting→ Multiple Passes and select Floor.



Choose Generate.



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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.


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 DriveMethods.

©UGS Corporation, 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 Corporation, All Rights Reserved mt11050_g NX 4

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 Corporation, All Rights Reserved mt11050_g NX 4

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


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 Corporation, All Rights Reserved Multi-Axis Techniques — Student Guide B-1

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 Corporation, All Rights Reserved Multi-Axis Techniques — Student Guide C-1

C

Advanced Surface Contouring

Projection and Steep Surface:

• ∆X = ∆d/sin ∆d/

∆X becomes large if is very small (steep surface)

• The source of ∆d is the chordal deviation of the drive path

(1) drivepath

(2) drivepoint

(3) ∆d

(4) ∆x

(5)

C-2 Multi-Axis Techniques — Student Guide ©UGS Corporation, All Rights Reserved mt11050_g NX 4

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


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-3Approach Move

Non_Cutting Moves . . . . . . . . . . 5-33

C

CaseFixed Contour . . . . . . . . . . . . . . 5-33

Cavity MillCut Levels . . . . . . . . . . . . . . . . . . 2-2Cut Patterns

Cut Pattern . . . . . . . . . . . . . . 2-9In-Process work piece . . . . . . . . . 2-16

Cavity Millingcut parameters

tolerant machining . . . . . . . . 2-44trim by . . . . . . . . . . . . . . . . 2-44undercut handling . . . . . . . . 2-45

cut region start points . . . . . 2-32, 2-34pre-drill engage . . . . . . . . . . . . . 2-32topology . . . . . . . . . . . . . . . . . . . 2-46

Check CaseNon_Cutting Moves . . . . . . . . . . 5-33

Course Overview

Class Standards . . . . . . . . . . . . . . . 9Course Description . . . . . . . . . . . . . 7Intended Audience . . . . . . . . . . . . . 7Objectives . . . . . . . . . . . . . . . . . . . . 8Prerequisites . . . . . . . . . . . . . . . . . 7Student and Workbook parts . . . . . 13System Privileges . . . . . . . . . . . . . 13Workbook overview . . . . . . . . . . . . 12

Cut AreaMILL_AREA . . . . . . . . . . . . . . . . 4-3

Cut Area GeometryZ-Level Milling . . . . . . . . . . . . . . . 3-3

Cut Levels . . . . . . . . . . . . . . . . . . . . 2-2Cut Patterns . . . . . . . . . . . . . . . . . . 2-9

D

Departure MoveNon_Cutting Moves . . . . . . . . . . 5-33

E

Engage MoveNon_Cutting Moves . . . . . . . . . . 5-33

F

Final CaseNon_Cutting Moves . . . . . . . . . . 5-33

Fixed ContourCase . . . . . . . . . . . . . . . . . . . . . . 5-33drive geometry . . . . . . . . . . . . . . . 5-2drive methods

area milling . . . . . . . . . . . . . . 5-5flow cut . . . . . . . . . . . . . . . . . 5-6,

5-12–5-13, 5-15–5-16radial cut . . . . . . . . . . . . . . . . 5-6surface . . . . . . . . . . . . . . . . . . 5-5tool path . . . . . . . . . . . . . . . . 5-5

©UGS Corporation, All Rights Reserved Multi-Axis Techniques — Student Guide Index-1

Index

User Function . . . . . . . . . . . . 5-6drive points . . . . . . . . . . . . . . . . . 5-2Non_Cutting Moves . . . . . . . . . . 5-32operation types . . . . . . . . . . 5-10–5-11

contour_area . . . . . . . . . . . . 5-10contour_surface_area . . . . . . 5-10fixed_contour . . . . . . . . . . . . 5-10flowcut_ref_tool . . . . . . . . . . 5-10

Overview . . . . . . . . . . . . . . . . . . . 5-2parent groups . . . . . . . . . . . . . . . . 5-6

MILL_AREA . . . . . . . . . . . . . 5-9MILL_BND . . . . . . . . . . . . . . 5-8MILL_GEOM . . . . . . . . . . . . . 5-7

terminology . . . . . . . . . . . . . . . . . 5-3check geometry . . . . . . . . . . . 5-3drive geometry . . . . . . . . . . . . 5-3drive method . . . . . . . . . . . . . 5-4drive points . . . . . . . . . . . . . . 5-3part geometry . . . . . . . . . . . . 5-3projection vector . . . . . . . . . . . 5-4

use of . . . . . . . . . . . . . . . . . . . . . . 5-2

GGeneral Milling Enhancements

In-Process Workpiece for fixed axismilling applicationshow to use . . . . . . . . . . . . . . 2-16

Geometry Parent GroupsMILL_AREA . . . . . . . . . . . . . . . . 4-1

Geometry TypesZ-Level Milling . . . . . . . . . . . . . . . 3-3

IInitial Case


LLocal Case


MMILL_AREA . . . . . . . . . . . . . . . . . . 4-1

Cut Area . . . . . . . . . . . . . . . . . . . 4-3Trim Boundary . . . . . . . . . . . . . . 4-12

Multi-axis

multi-axispositioning . . . . . . . . . . . . . . . 6-2rotary axis . . . . . . . . . . . . . . 6-16tool axis . . . . . . . . . . . . . . . . . 6-2

NNon_Cutting Moves

Approach Move . . . . . . . . . . . . . . 5-33Check Case . . . . . . . . . . . . . . . . . 5-33Departure Move . . . . . . . . . . . . . 5-33Engage Move . . . . . . . . . . . . . . . 5-33Final Case . . . . . . . . . . . . . . . . . 5-33Fixed Contour . . . . . . . . . . . . . . 5-32Initial Case . . . . . . . . . . . . . . . . 5-33Local Case . . . . . . . . . . . . . . . . . 5-33Reposition Case . . . . . . . . . . . . . 5-33Retract Move . . . . . . . . . . . . . . . 5-33Traverse . . . . . . . . . . . . . . . . . . . 5-33

PPart Geometry

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

RReposition Case

Non_Cutting Moves . . . . . . . . . . 5-33Retract Move


SSequential Milling

Check surface . . . . . . . . . . . . 7-3, 7-11creating operation . . . . . . . . . . . 7-37dialog . . . . . . . . . . . . . . . . . . . . . . 7-5Drive surface . . . . . . . . . . . . . . . . 7-3engage motion dialog . . . . . . . . . . 7-6

Index-2 Multi-Axis Techniques — Student Guide ©UGS Corporation, All Rights Reserved mt11050_g NX 4

Index

loops . . . . . . . . . . . . . . . . . . . . . 8-19multiaxis output . . . . . . . . . . . . . 8-36multiple check surface . . . . . . . . 7-12nested loops . . . . . . . . . . . . 8-19, 8-22other options . . . . . . . . . . . . . . . 8-38overview . . . . . . . . . . . . . . . . . . . . 7-2Part surface . . . . . . . . . . . . . . . . . 7-3path generation . . . . . . . . . . . . . 8-36point to point motion dialog . . . . . 7-9reference point . . . . . . . . . . . . . . . 7-3replace geometry globally . . . . . . 8-36retract motion dialog . . . . . . . . . 7-10stopping position

Ds-Cs Tangency . . . . . . . . . . . 7-3far side . . . . . . . . . . . . . . . . . 7-3near side . . . . . . . . . . . . . . . . 7-3on . . . . . . . . . . . . . . . . . . . . . 7-3Ps-Cs Tangency . . . . . . . . . . . 7-3

suboperations . . . . . . . . . . . . . . . . 7-5continuous path motion

commands . . . . . . . . . . . . . 7-6continuous path motion

dialog . . . . . . . . . . . . . . . . 7-7engage . . . . . . . . . . . . . . . . . . 7-6point to point motion

commands . . . . . . . . . . . . . 7-6terminology . . . . . . . . . . . . . . . . . 7-3tool axis control . . . . . . . . . . . . . . 8-2

at angle to Ps or Ds . . . . . . . . 8-5fan . . . . . . . . . . . . . . . . . . . . . 8-5normal to Ps or Ds . . . . . . . . . 8-4parallel to Ps or DS . . . . . . . . 8-4tangent to Ps or Ds . . . . . . . . 8-5thru fixed point . . . . . . . . . . . 8-6

TTraverse

Non_Cutting Moves . . . . . . . . . . 5-33Trim Boundary

MILL_AREA . . . . . . . . . . . . . . . 4-12Trim Geometry

Steep AngleZ-Level Milling . . . . . . . . 3-3, 3-8

V

Variable Contour . . . . . . . . . . . . . . 10-2drive geometry . . . . . . . . . . . . . . . 9-2drive methods

boundary . . . . . . . . . . . . . . . . 9-6curve/point . . . . . . . . . . . . . . . 9-6radial cut . . . . . . . . . . . . . . . 9-16spiral . . . . . . . . . . . . . . . . . . 9-10surface area . . . . . . . . . . . . . 9-12tool path . . . . . . . . . . . . . . . 9-15User Function . . . . . . . . . . . 9-17

drive pointsdrive geometry . . . . . . . . . . . . 9-2

terminology . . . . . . . . . . . . . . . . . 9-4check geometry . . . . . . . . . . . 9-4drive geometry . . . . . . . . . . . . 9-4drive method . . . . . . . . . . . . . 9-4drive points . . . . . . . . . . . . . . 9-4part geometry . . . . . . . . . . . . 9-4projection vector . . . . . . . . . . . 9-4

tool axisdual 4-axis . . . . . . . . . . . . . . 9-31interpolated . . . . . . . . . . . . . 9-59normal . . . . . . . . . . . . . . . . . 9-28relative . . . . . . . . . . . . . . . . 9-29swarf drive . . . . . . . . . . . . . . 9-35

tool path accuracy . . . . . . . . . . . . . 9-2used for . . . . . . . . . . . . . . . . . . . 10-2

Variable Contour and Sequential Millcomparison . . . . . . . . . . . . . . . . . 9-68

part, drive, check surfaces . . 9-68general considerations . . . . . . . . 9-68

W

WAVE Geometry LinkerAssemblies and Wave . . . . . . . . . 1-10At Timestamp . . . . . . . . . . . . 1-3, 1-6Blank Original . . . . . . . . . . . . . . . 1-3Create Non-Associative . . . . . . . . . 1-3definition of . . . . . . . . . . . . . . . . . 1-2deleting parent geometry . . . . . . . 1-9editing links . . . . . . . . . . . . . . . . . 1-5Extracted feature . . . . . . . . . . . . . 1-6linking procedure . . . . . . . . . . . . 1-16

©UGS Corporation, All Rights Reserved Multi-Axis Techniques — Student Guide Index-3

Index

LinksBreak Links . . . . . . . . . . . . . . 1-6broken . . . . . . . . . . . . . . . . . . 1-7deleting of . . . . . . . . . . . . . . 1-10newly broken . . . . . . . . . . . . . 1-8

simplify . . . . . . . . . . . . . . . . . . . 1-19Simplify Body . . . . . . . . . . . 1-20

ZZ-Level Milling

Check Geometry . . . . . . . . . . . . . . 3-3Cut Area Geometry . . . . . . . . . . . . 3-3Geometry Types . . . . . . . . . . . . . . 3-3Part Geometry . . . . . . . . . . . . . . . 3-3Steep Angle . . . . . . . . . . . . . . . . . 3-8Trim Geometry . . . . . . . . . . . . . . . 3-3Types . . . . . . . . . . . . . . . . . . . . . . 3-2

Index-4 Multi-Axis Techniques — Student Guide ©UGS Corporation, All Rights Reserved mt11050_g NX 4

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Multi Axis Techniques- 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. Sequential Mill Basics • Workbook Sequential Mill - Cutting the Manifold Flange

Day Three • Lesson 8 Sequential Mill Advanced • Lesson 9. Variable Contour Basics

Afternoon • Lesson 10. 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→Blank→Blank... Ctrl+B Edit→Blank→Reverse Blank All Ctrl+Shift+B Edit→Blank→Unblank Selected... Ctrl+Shift+K Edit→Blank→Unblank All of Part 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→Visualization→High Quality Image... Ctrl+Shift+H View→Information Window F4 View→Current Dialog 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

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multi-axis techniques student guide february 2006 mt11050 — nx 4

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