NX Manufacturing Fundamentals Student Guide April 2007 MT11021 NX 5 Publication Number mt11021_s NX 5

Manual History Manual Revision Unigraphics Version Version 16.0 Version 17.0 Version 17.0 Version 18.0 Unigraph ics NX Unigraphics NX 2 NX 3 NX 4 NX 5 Publication Date March 1999 January 2001 June 2001 September 2001 September 2002 September 2003 November 2004 January 2006 April 2007 This edition obsoletes all previous editions. Proprietary and Restricted Rights Notices This software and related documentation are proprietary to UGS Corp. 200 7 UGS Corp. All Rights Reserved. All trademarks belong to their respective holde rs. 2 NX Manufacturing Fundamentals mt11021_s NX 5

Contents Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Intended Audience . . . . . . . . . . . . . . . Prerequisi tes . . . . . . . . . . . . . . . . . . . Objectives . . . . . . . . . . . . . . . . . . . . . Student responsibilities . . . . . . . . . . . Layer standards . . . . . . . . . . . . . . . . . Implementing a layer standard Seed Parts . . . . . . . . . . . . . . . . . . . . . How to use this manual . . . . . . . . . . . Lesson format . . . . . . . . . . . . . Activity format . . . . . . . . . . . . Learning tips . . . . . . . . . . . . . Workbook Overview . . . . . . . . . . . . . . Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 7 8 8 8 9 10 10 10 10 10 11 Basic CAM Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 The NC Programming Sequence . . . . . . . . . Manufacturing toolbar s . . . . . . . . . . . . . . . Create the Manufacturing assembly Creating the M anufacturing Setup . . . . . . . Create an Operation . . . . . . . . . . . . . . . . . . Specify additional Operation settings . . . . . The Operation Navigator . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . 1-4 . 1-6 . 1-7 . 1-8 1-10 1-11 1-12 1-13 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tools . . . . . . . . . . . . Carrier . . . . . . . . . . . Retrieve from Library Activity . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -2 2-4 2-6 2-8 2-9 Cavity Mill and Parent Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Creating the manufacturing assembly and parent groups Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity Mill ing overview . . . . . . . . . . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UGS Corp., All Rights Reserved . . . . . . . . . . . . . . . .

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Contents Modify Parent Groups . . . . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Choose the Blank and Part in the WORKPIECE Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Cavity Milling topics . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cut Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . In-Process Work Piece for Cavity Milling . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cavity Milling Stock options . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cutting Parameters Trim by . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 . 3-7 . 3-8 . 3-9 3-10 3-11 3-12 3-13 3-14 3-15 3-16 3-17 3-18 3-19 The Operation Navigator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 The Operation Navigator . . . . . . . . . . . . . . . . . . . Ac tivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Opera tion Navigator views . . . . . . . . . . . . . . Parent Groups, Operations and I nheritance . . . . . The Operation Navigator appearance and columns Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . 4-2 . 4-4 . 4-5 . 4-7 . 4-8 4-10 Coordinate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Coordinate Systems . . . . . . . . . . . . . . . . . Absolute Coordinate System . . . . . . . . . . . Work Coordinate System . . . . . . . . . . . . . Machine Coordinate System . . . . . . . . . . . Saved Coordinate Syste m . . . . . . . . . . . . . Summary of Coordinate Systems . . . . . . . Absolute Coordinate System . . . . . . . . . . . Work Coordinate System . . . . . . . . . . . . . Machine Coordinate System . . . . . . . . . . . Reference Coordinate S ystem . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Coordinate System information I,J,K Vectors . . . . . . . . . . . . . . . . . . . . . . . Rotary Vectors . . . . . . . . . . . . . . . . . . . . . Tool Axis versus ZC Axis . . . . . . . . . . . . . Orientation of the WCS t o MCS . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 . 5-3 . 5-4 . 5-5 . 5 -6 . 5-7 . 5-8 . 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 Visualization (ISV) . . . . . . . . . . . . . . . 6-1 Tool Path . . . . . . . . . . . . . . . . 4 NX Manufacturing Fundamentals . . . . . . . . . . . . . . . . . . . . . . . . Visualization . . . . . . . . . . . . . . . . . . . . . 6-2 UGS Corp., All Rights Reserved mt11021_s NX 5

Contents Replay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D Dynamic Tool Path d isplay . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Tool Path display options Edit Display Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6-4 6-5 6-6 6-7 6-8 6-9 Planar Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Planar Milling . . . . . . . . . . . . . . . . Boundari es . . . . . . . . . . . . . . . . . . Part boundaries . . . . . . . . . . . . . . . Blank boundaries . . . . . . . . . . . . . . Check boundaries . . . . . . . . . . . . . . Trim boundaries . . . . . . . . . . . . . . . Multi-level Cutting . . . . . . . . . . . . . Depth of cut . . . . . . . . . . . . . . . . . . Acti vity . . . . . . . . . . . . . . . . . . . . . MILL_BND geometry Parent groups A ctivity . . . . . . . . . . . . . . . . . . . . . Introduction to Pro ling . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Face Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Face Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Face Milling Area geometry . . . . . . . . . . . . . . . . . . . Face Milling geometry . . . . . . . . . . . . . . . . . . . . . . . Cut A rea and Face Geometry . . . . . . . . . . . . . . . . . . Cut Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Passes . . . . . . . . . . . . . . . . . . . . . . . . . . . Blank Distance, Depth per Cut, Final Floor Stock . . . Boundary Construction from a Face and its Chamfers Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Face Milling and surrounding geometry . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machining multiple faces in one Operat ion . . . . . . . . Cutting parameters, Region Sequencing . . . . . . . . . . Ac tivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Face Milling Blank Overhang . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wall Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . 8-3 . 8-4 . 8-5 . 8-6 . 8-7 . 8-8 . 8-9 8-10 8-11 8-12 8-13 8-14 8-15 8-16 8-18 8-19 8-20 8-21 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5

Contents Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Creating Drilling Operations . . . . Drilling Cycle s . . . . . . . . . . . . . . . Cycle Parameter Sets . . . . . . . . . . Minimum Clearance . . . . . . . . . . . Creating Drilling Tools . . . . . . . . . The D rill Geometry Parent Groups Activities . . . . . . . . . . . . . . . . . . . Dep th Offset . . . . . . . . . . . . . . . . Optimizing the Tool Path . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 . 9-3 . 9-4 . 9-5 . 9-6 . 9-7 . 9-8 . 9-9 9-10 9-11 9-12 Text Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Text Engraving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4 Summ ary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5 Tool Path Information Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1 Output CLSF . . . . . . . . . . . . . . . . . . . . Post Processing . . . . . . . . . . . . . . . . . . NX POST Execute . . . . . . . . . . . . . . . . Manufacturing Output Manager (MOM) Post Processing Us ing NX POST . . . . . . NX POST Builder . . . . . . . . . . . . . . . . . Activi ty . . . . . . . . . . . . . . . . . . . . . . . . Shop Documentation . . . . . . . . . . . . . . Shop Documentation dialogs . . . . . . . . . Activity . . . . . . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2 . 11-4 . 11-5 . 11-8 . 11-9 11-10 11-12 11-13 11-14 11-15 11-16 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1 6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Course Overview The NMFcourse teaches the use of the NX Manufacturing application for creating 21 /2 and 3axis tool paths. Intended Audience This course is designed for Manufacturing Engineers, Process Planners and NC/CNC Programmers that have the basic knowledge of NC/CNC manual programming of 3axis positioning and contouring equipment. Prerequisites This is a basic NX manufacturing class that requires you to have basic computer knowledge and experience as an NC/CNC programmer. Objectives After successfully completing this course, you should be able to perform the fol lowing activities in NX: Create Manufacturing assemblies Understand the Master M odel concept Create parent group objects that supply information to operations U tilize options and parameters that are common to various operation types Create drilling, milling and subsequent tool paths UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7

Student responsibilities Student responsibilities Be on time. Be considerate of the needs of other students. Listen attentively an d take notes. Ask questions. Practice what you learn. Have fun! Layer standards Parts used in this course were created using layer categories the same as or ver y similar to those found in the Model template parts. Layers provide an advanced alternative to display management (Show and Hide) to organize data. Layer categ ories in the Model template parts Layers 110 1120 2140 4160 6180 91255 Category SOLIDS SHEETS SKETCHES CURVES DATUMS No category assigned Description Solid bodies She et bodies All external sketches Non-sketch curves Planes, axes, coordinate syste ms Implementing a layer standard You may implement or enforce layer standards using some of the methods below: Cr eate NX Open programs to create a standard part organization and verify it upon release. Use a macro to create layer categories: ToolsMacroPlayback. Your administ rator can enforce company standards by providing suitable templates. In this cou rse you may use a layer organization method you anticipate using in your work. 8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Course Overview

Seed Parts Seed parts are an effective tool for establishing defaults or any settings that are part dependent (saved with the part le). This may include non-geometric data such as: Sketch preferences Commonly used expressions Layer categories User-de ne views and layouts Part attributes Various machining attributes Once a seed part is established, it should be write-protected to avoid accidental modi cation. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9

How to use this manual How to use this manual The following guidelines describe how you can get the most bene t from your use of the course guide and the accompanying HTML activities. Lesson format The general format for lesson content is: Instructor presentation One or more ac tivities Workbook project Projects allow you to test your new skills without det ailed instruction. Consult your instructor for additional information. Summary Activity format Activities have the following format: Step 1: This is an example of a step. Numb ered steps specify the actions you will perform. Action bullets detail how to co mplete the step. Always read the Cue and Status information while working throug h activities and as you perform your regular duties. As you gain skills you may need only to read the step text to complete the step. Learning tips Ask questions. Con rm important facts by restating them in your own words. It is i mportant to use your Student Guide in the sequence it is written. Workbook Overview The workbook contains a project that requires you to apply the knowledge that yo u learned in the class and in the student activities. The projects do not contai n detailed instructions as do the student activities. 10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Course Overview It is the intent of this project to allow you to apply the skills taught in this course. However, the time constraint of this course is also a factor, at any po int when progress is not being made, enlist the help of your instructor. Classroom System Information Your instructor will provide you with the following items for working in the cla ssroom: Student Login: User name: Password: Work Directory: Parts Directory: Instructor: Date: UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11

Lesson 1 1 Basic CAM Fundamentals Purpose This lesson introduces several concepts that you will need to understand and apply in order to effectively use the Manufacturing application of NX. Appl ying these concepts, prior to creating operations, will save you considerable ti me in the creation of your program. Objectives Upon completion of this lesson, y ou will be able to: Know the six steps of the NC Programming Sequence Recognize and identify the ve different Manufacturing toolbars Understand the NX Manufactur ing Process Select the CAM Express Role and create the Manufacturing Setup Recog nize and identify the differences in creating program, tool, geometry and method parent group objects Recognize and identify the usage differences in operations Understand the meaning of generating a tool path Recognize and use the Operatio n Navigator UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-1

Basic CAM Fundamentals 1 The NC Programming Sequence The normal sequence of steps, in the NC Programming Sequence of the NX Manufactu ring Application, is to perform the following: Create the Manufacturing Setup creates a manufacturing assembly and adds other data related to your type of par t. Establish the Parent Group objects - minimizes the selection of objects for r epeated use and establishes the concept of inheritance, where parameters can be passed down to other objects. Create the operation(s) - allows you to assign spe ci c parameters and methods that affect how the tool path is created. Verify the t ool paths created - minimizes errors by visualization of the tool path. Post Pro cess the tool paths - formats the data for your particular machine tool/controll er combination. Create Shop Documentation - minimizes the effort that shop perso nnel uses to set up and process the individual job. This sequence is shown in the following Manufacturing Process ow chart. 1-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals 1 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-3

Basic CAM Fundamentals 1 Manufacturing toolbars Five toolbars exist for the Manufacturing application. They are: Manufacturing C reate - allows the creation of operations and groups (program, tool, geometry an d method) in your NC program. The four group creation dialogs allows for the cre ation of groups that de ne parameters shared among operations. The position of any group may be changed by cutting and pasting above, below, or inside of any othe r group in the Operation Navigator. Manufacturing Operations - allows the selection of functions related to the gene ration and veri cation of tool paths as well as post processing and the creation o f shop documentation. Manufacturing Objects - allows for editing, cutting, copying, pasting, deletion and displaying of an object. Manufacturing Workpiece - allows for displaying and saving of a 2D and 3D work p iece object. 1-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals Operation Navigator - the Operation Navigator is a graphical user interface (GUI ) that enables you to manage operations and operation parameters for the current part. The Operation Navigator allows you to specify groups of parameters that a re shared among operations. The Operation Navigator allows you to view objects i n the Program Order, Machine Tool, Geometry or Method view, using a tree structu re to illustrate the relationships between groups and operations. Parameters may be passed down or inherited from group to group and from group to operation bas ed on the positional relationships in the Operation Navigator. 1 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-5

Basic CAM Fundamentals 1 Create the Manufacturing assembly In Manufacturing, Assemblies pertain to the Master Model conceptThis concept pro tects the design criteria from corruption by other users. When you create a Manu facturing Assembly and add a component, such as a xture plate or clamping device, application speci c data can be generated in a separate part le that will referenc e the master geometry. This prevents the duplication of model geometry and allow s for the concurrent use of the Master Model. 1-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals Creating the Manufacturing Setup When using CAM Express templates, the Manufacturing Setup creates a master model assembly where the setup part is the top level assembly. This allows the Progra ms, Tools, Geometry and Machining Method groups to be created in a separate le th an the master model. This is normally the parent of the Manufacturing Assembly. The Manufacturing Setup also includes Manufacturing Templates that are most like ly to be used on a speci c part type. Setup Templates include the following for in ch and metric parts; 1 DieMold Express Turning Express Machinery Express Multi Axis Express These templates create some basic parent groups for you. These include: A Progra m group. A tool Carrier and 30 Pockets An MCS parent group with an empty Geometr y group. Method groups The templates also load creation templates for the four parent groups. The templ ates will match the part type that you selected when you created the Setup UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-7

Basic CAM Fundamentals 1 Create an Operation Before you create an operation, you may assign the: Program Geometry Tool and Me thod Parent Group to the operation. First you select the operation type (Subtype ), then the various Parent Group objects and then nally the Name of the operation . Note that if you select the Subtype after the Name, the Name is changed to the default of the Subtype 1-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals selected. Once you have made the selection, you choose OK to the dialog box and then the various operation or Subtype dialogs will be displayed. 1 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-9

Basic CAM Fundamentals 1 Specify additional Operation settings Additional settings are available in the operation dialogs. These include settin gs such as; Cut Pattern Tool Stepover Depth Per Cut Non Cutting Moves Generating the tool path After you specify all the operation settings, you Gener ate the tool path. Generating the tool path results in use of the speci ed setting s and options for tool path calculation. Veri cation, Post Processing, and creatin g Shop Documentation After you are satis ed with the operations and the tool paths that you create, you may use other Manufacturing application features to visual ly inspect the data. You can post process all of the tool paths so that the data is in the standard format used by NC/CNC machine tool controllers. Finally, you can create the Shop Documentation that describes the data to shop personnel. 1-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals The Operation Navigator The Operation Navigator is a graphical user interface that allows you to manage operations and their parameters in the current part. It allows you to specify gr oups of parameters that are shared among operations and uses a tree structure to illustrate the relationships between groups and operations. Parameters are pass ed or inherited from group to group and from group to operation based on the pos itional relationships in the Operation Navigator. The Operation Navigator is fou nd on the Resource bar and is a primary tool used in the creation and/or modi cati on of operations. 1 Manufacturing application capabilities The Manufacturing Application has extensi ve capabilities allowing you to generate very simple to extremely complex tool p aths. You will be introduced to: The CAM User Interface Creation of Parent Group s and use of the Operation Navigator Speci c Drilling, Planar Milling, and Cavity Milling operation types The processes you will use to create milling/drilling op erations Tool path generation procedures Visualization, Post Processing, and Sho p Documentation procedures UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-11

Basic CAM Fundamentals 1 Activity In the Basic CAM Fundamentals section, do the activity: Creating the Manufacturi ng Setup 1-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Basic CAM Fundamentals Summary This lesson is an introduction to basic CAM concepts. In this lesson, you learne d: The six steps of the NC Programming Sequence The functionality of the ve diffe rent Manufacturing toolbars The NX Manufacturing Process To recognize and select the proper CAM Setup that determines the types of operations that are made avai lable to you To recognize and identify the differences in the various Manufactur ing Create options To recognize the Operation Navigator 1 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 1-13

Lesson 2 Tools Purpose Cutting tools perform the material removal process that is crucial to ma chining. This lesson will teach you how to create and use tools. Objectives Upon completion of this lesson, you will be able to: Understand the concept of carri ers, pockets and tools Create carriers, pockets and tools Assign tool numbers 2 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 2-1

Tools Tools Cutting tools are grouped according to the type of machining that they perform. For example, drilling tools are listed in the drill type, but not in the mill_pl anar or mill_contour type. The following chart shows the types and associated to ols. Some cutting tools are available in more than one group. Type mill_planar, mill_contour, mill_multi_axis mill_planar, mill_contour, mill_ multi_axis mill_planar, mill_contour, mill_multi_axis mill_planar mill_planar, m ill_contour, mill_multi_axis mill_planar, mill_contour, mill_multi_axis mill_pla nar drill drill drill drill drill drill drill mill_contour mill_contour mill_pla nar Button Description milling tool Usage general milling purposes, available in 5, 7 and 10 parameter con gurations applicable for ball-end mill applications. Av ailable in tapered or str. ute con g. slab milling applications cutting under overh anging ledges surface contouring applications thread milling applications spot d rilling holes drilling holes boring holes for accuracy ream holes to tolerance s ize counter bored holes counter sunk holes tapped holes spot faced holes represe nts 7 parameter tool de nition represents 10parameter tool de nition represents spec ial user de ned milling form cutters represents machine carousel which holds cutti ng tools represents the pocket that cutting tools are stored in 2 ball mill face mill t-cutter barrel cutter thread mill spot drill drill boring bar reamer counter bore tool counter sinking tool tap spot facing tool 7parameter tool 10para meter tool user de ned milling tool all carrier all pocket 2-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tools all all retrieve from library head retrieve a tool from the cutting tool library represents a tool mounting head Some objects are not actual cutting tools that are listed as part of the Create Tool dialog box. The items are associated with cutting tools and are available w ith every group object (carrier, pocket, head and retrieve from library). 2 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 2-3

Tools Carrier A carrier represents the tool carousel on the machine tool and can hold a number of tools. The basic purpose of a carrier is to mimic the tool carousel of the m achine tool. Use the following steps to create a carrier: 1. Click Create Tool 2 . Click Carrier 3. Choose OK. 4. If desired, the carrier can be given a name. 5. Choose OK to create the carrier. Pocket Once a carrier has been created, pocket s are placed in the carrier. A pocket represents the individual holding position on the carousel or tool changing device. The purpose of the pocket is to hold i ndividual tools. A pocket can be assigned a number, which can then be inherited by the tool that resides in that pocket. The pocket number will then become the tool number when the NC program is post processed. Note the Carrier/Pocket/Tool relationship in the diagram that follows: . or choose Insert Tool. 2 Use the following steps to create a pocket: 1. Click Create Tool 2. Click MCT_Po cket 2-4 NX Manufacturing Fundamentals or choose Insert Tool. . UGS Corp., All Rights Reserved mt11021_s NX 5

Tools 3. Verify that the Parent group is Carrier. 4. Choose OK. 5. Enter the number of the pocket. 6. Choose OK to create the pocket. 2 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 2-5

Tools Retrieve from Library NX CAM is delivered with a library of commonly used cutting tools. This saves yo u the time of creating each tool individually. Mechanisms for insertion into the tool library are provided for those tools that are not part of the standard lib rary Cutting Tools Cutting tools for modern metal working machines come in many different styles and varieties. Most of these tools are supported in NX and are grouped according to the type of machining that they perform. Cutting Tool Param eters Since each type of cutting tool is different, numerous parameters are avai lable for their de nition. Numerous parameters, such as diameter, length and numbe r of utes are common. Other parameters are unique to each type of tool, such as t he point angle of a drilling tool. The Holder Tab In addition to specifying the various parameters of the cutting tool, you may also de ne the parameters of the t ool holder by selection of the Holder tab on the tool de nition dialog. 2 The holder is built in a series of steps from the end of the tool upward. For ea ch step, the Diameter, Length, Taper Angle and Corner Radius may be speci ed. Usua lly, the rst step is smaller than the last step. 2-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tools 2 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 2-7

Tools Activity In the Tools section, do the activity: Tool Creation 2 2-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tools Summary Cutting tools are crucial to ef cient machining of simple to complex parts. The ab ility to de ne and use numerous types of cutting tools are critical to the manufac turing process. NX allows this exibility through the use of carriers, pockets and tools. In this lesson you: Learned about the de nition and use of carriers, pocke ts and tools Learned the de nition and use of holders Created carriers, tools and holders and assigned pockets 2 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 2-9

Lesson 3 Cavity Mill and Parent Groups Purpose This lesson introduces the fundamentals of Cavity Mill operations. Cavit y Mill is used in roughing operations involving planar and contoured geometry. Y ou will also create some of the tools required and incorporate their use through the Tool Parent Group object and use the Operation Navigator to observe the met hod in which operations inherit information. Objectives Upon completion of this lesson, you will be able to: Understand the use of Cavity Mill Create and modify various Parent Group objects in Cavity Mill operations Apply the use of Cavity Mill operations to rough geometry from an un nished to semi- nished condition Create and use Tool objects 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-1

Cavity Mill and Parent Groups Creating the manufacturing assembly and parent groups Creating parent groups before creating the cutting operations can save time and simplify the following operations. The parent groups de ne the Programs, Tools, Ge ometry and Methods to be used in the operations. The parameters speci ed in the pa rent groups is inherited by the cutting operations. The manufacturing assembly a nd machining environment will also be selected. The following outlines the proce dure 3 Create the Manufacturing Assembly Select the Manufacturing Environment Specify t he parent groups Create the cutting operations 3-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Creating the manu facturing assembly and parent groups 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-3

Cavity Mill and Parent Groups Cavity Milling overview Cavity Milling is designed for volume removal of material. It works best when us ed to remove excess amounts of material from blank stock to produce a near-net s hape part. Cavity Milling works with planar and/or contoured geometry and uses a xed tool axis.. Stock removal is done in levels. At each new level the tool path follows the part contours at that level. Cavity Milling can be used on sheet bo dies, wire frame, and solid bodies. Solid bodies are easiest to use 3 How Cavity Milling creates Tool Paths In order to ef ciently use Cavity Mill, it i s important to understand the process that Cavity Milling uses to create tool pa ths. The process is: Select or de ne Blank (or stock) material Select Part geometr y Top and bottom of the selected geometry is automatically set as the highest an d lowest level of cutting Based on the de ned Cut Levels, a plane(s) is created th at is perpendicular to the tool axis At each Cut Level, a cut pattern is created to remove material from that level Plane symbols are used to display the Cut Ranges (the larger symbols) and Levels (the smaller symbols). 3-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Create a Cavity M illing operation 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-5

Cavity Mill and Parent Groups Modify Parent Groups The Operation Navigator Geometry View Cavity Milling operations (all operations) obtain or inherit some types of information from objects that exist outside the operation that is being created. The ROUGHING_1 operation that you created is s hown in the Geometry View, of the Operation Navigator, below. 3 The operation, ROUGHING_1, obtains the PART and BLANK geometry from the Geometry Parent Group WORKPIECE. Above the WORKPIECE Geometry Parent Group, lies the MCS _MILL Parent Group. This Geometry Parent Group contains information about the lo cation and orientation of the Machine Coordinate System and the Clearance Plane. By following the hierarchy, of the parent groups and operations, you see that t he MCS_MILL parent is passing information to the WORKPIECE parent. The WORKPIECE parent then passes this information, plus any information that it contains, to the ROUGHING_1 operation. By this method, the ROUGHING_1 operation inherits the geometry information as well as other parameters needed to create a tool path. T he Operation Navigator Machine Tool View If the Operation Navigator were changed to the Machine Tool view, geometry objects would no longer display. Instead, to ols that exist in the part would be displayed. Once again, the Operation Navigator displays the ROUGHING_1 operation. However, this time, it displays the operation as it pertains to the cutting tool that is being used. Through the principle of inheritance, information about the tool, in cluding offset register and tool number, are passed to the operation. In the nex t activity, you will create a new tool. Then you will change the existing operat ion to use that new tool. 3-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Modify the Machin e Tool Parent Group 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-7

Cavity Mill and Parent Groups Choose the Blank and Part in the WORKPIECE De ning the Part, Blank, and Check geometry in the Geometry Parent Group will allo w any operations that are located under it to inherit the geometry object. 3 3-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Parent Groups in an Operation 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-9

Cavity Mill and Parent Groups Additional Cavity Milling topics Advanced Cavity Milling Topics include: Cut Levels Cut Patterns In-Process Work Piece for Cavity Milling 3 Cavity Milling Stock Options Cut Levels Cavity Milling cuts geometry in planes o r levels. The advantage to this approach is that tool paths remain relatively sh ort, due to minimum tool path movement, which is performed in layers. The disadv antage is that when machining geometry that is close to horizontal more stock ma y remain than desired. The closer the geometry approaches horizontal, the more s tock that remains. Through the use of Cut Level parameters, you can reduce the a mount of stock that remains. The Cut Levels dialog box is located under the Cut Levels button in the Cavity Mill dialog box. The Cut Levels dialog box has two p rimary functions: Create and modify Ranges Modify Cut Levels within Ranges To reduce the amount of additional stock, a new range can be added. The Depth pe r Cut in that Range only is modi ed. In the next activity, you will use various Cu t Level parameters. 3-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Cut Level paramet ers 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-11

Cavity Mill and Parent Groups Cut Patterns The Cut Pattern determines the cut pattern used for cutting. Cut Patterns Zig-Za g machines in a series of parallel straight line passes. Climb or conventional c ut directions are not maintained since the cut direction changes from one pass t o the next. Zig always cuts in one direction. The tool retracts at the end of ea ch cut, then positions to the start of the next cut. Zig with Contour also machi nes with cuts going in one direction. However, contouring of the boundary is add ed between passes, before and after the cut motion. The tool then retracts and r e-engages at the start of the contouring move for the next cut. Follow Periphery offsets the tool from the outermost edge that is de ned by Part or Blank geometry . Internal islands and cavities will require Island Cleanup or a clean up Pro le p ass. Follow Part creates concentric offsets from all speci ed Part geometry. The o utermost edge and all interior islands and cavities are used to compute the tool path. Climb (or Conventional) cutting is maintained. Trochoidial cut pattern us es small loops along a path (resembles a stretched-out spring). This is a useful cut pattern in high speed machining applications when constant volume removal n eeds to be maintained. Pro le follows a boundary using the side of the tool. For t his method, the tool follows the direction of the boundary. 3 3-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Zig-Zag Cut Patte rn 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-13

Cavity Mill and Parent Groups In-Process Work Piece for Cavity Milling To make the various Cavity Milling operations as ef cient as possible, you must de termine what has been machined in each operation. The material that remains afte r each operation is executed is referred to as the In-Process work piece or IPW. To use the IPW, certain conditions must be adhered to. Tool path generation mus t be done sequentially, from the rst operation to the last, within a certain geom etry group. The tool path must be successfully generated and accepted in all pre vious operations in the sequence before the IPW can be used for the next operati on of the sequence. 3 3-14 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: In-Process Work P iece (IPW) 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-15

Cavity Mill and Parent Groups Cavity Milling Stock options Stock options for Cavity Milling are found on the Cut Parameters dialog box. Thi s dialog box is activated by selecting the Cutting button found on the Cavity Mi ll operation dialogs. Some of the stock options are as follows: -Part Side Stock adds stock to the individual walls of the part. 3 -Part Floor Stock adds stock to the oor. -Check Stock is the distance that the to ol will stay away from the check geometry. -Trim Stock is the distance that the tool will stay away from the trim boundary. -Blank Stock is stock applied to Bla nk geometry. -Blank Distance applies to Part geometry. This is an offset distanc e which can be used for a casting or forging. 3-16 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Activity In the Cavity Mill and Parent Groups section, do the activity: Blank Distance op tion 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-17

Cavity Mill and Parent Groups Cutting Parameters Trim by Trim by enables the Blank geometry to be recognized on core parts when the Blank geometry has not been explicitly de ned. The Trim by method provides a Silhouette option to clean up the material which surrounds the Part geometry. 3 This option positions the tool to the outer most edge periphery (silhouette) of the part geometry and then offsets it outside by the tool radius. The silhouette can be consider as a shadow of the part projected along the tool axis. When usi ng Trim by Silhouette, the processor uses the traces at the bottom of the de ned p art geometry as trim shapes. These shapes are then projected along the tool axis to each cut level and are used to generate machinable regions as trim shapes. 3-18 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Cavity Mill and Parent Groups Summary Cavity Milling is used to remove large amounts of material in roughing operation s. You can use Cavity Milling on planar or contoured geometry. Material removal is performed in levels using a xed tool axis. In this lesson you: Learned how to create a Cavity Milling operation Learned how information passes from Parent Gro up objects to operations through the concept of inheritance Modi ed Parent Group o bjects Changed inheritance by moving operations in the Operation Navigator Used the In Process Workpiece for accurate removal of material using different size c utting tools 3 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 3-19

Lesson 4

The Operation Navigator Purpose This lesson introduces you to the basic use and functionality of the Ope ration Navigator. Objectives Upon completion of this lesson, you will be able to : Customize types of data displayed in the Operation Navigator Cut, paste, dr and drop data in the Operation Navigator Recognize the Operation Navigator symbo ls Rename an operation Manipulate the screen placement of the Operation Navigato r Drag and drop multiple objects Activate the Operation Navigator from the resou rce bar Perform functions by right-clicking 4 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 4-1

The Operation Navigator The Operation Navigator The Operation Navigator is selected from the resource bar after you have initial ly entered the Manufacturing application. The resource bar contains numerous opt ions designated by tabs with icons, based on preferences that you select and the application which is activated. Double-clicking the Operation Navigator tab all ows the Operation Navigator to break away from the resource bar. The Operation N avigator can then be docked wherever you may choose to drag and drop it. When yo u close the Operation Navigator window, it will return to the resource bar. 4 Objects The objects (Parent Groups) that you create are displayed in the Operati on Navigator in one of four different views: Program Order View Machine Tool Vie w Geometry View Machining Method View Each view displays classes or groups (Commonly referred to as Parent Groups) of information that is relevant to that particular view. For example, an end mill u sed for milling would fall within the Machine Tool view, since a machine tool us es the cutting tool. Check geometry would fall within the Geometry view since th e check geometry is used when machining the part. The Operation Navigator also a llows you to: drag and drop objects cut and paste objects delete objects edit ob jects rename objects edit object parameters Display of the Operation Navigator is also controlled by the Operation Navigator toolbar which is located on the Manufacturing menu bar. 4-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

The Operation Navigator Choosing any of the icons that represent the various Operation Navigator views w ill determine the view that is displayed. 4 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 4-3

The Operation Navigator Activity In the The Operation Navigator section, do the activity: Operation Navigator 4 4-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

The Operation Navigator The Operation Navigator views When creating new cutting operations you will choose the appropriate parent grou ps. This will allow you to use the same programs, tools, geometry and methods fo r multiple operations. It will also allow you to change the parents for multiple operations without editing each operation individually. The parent groups inclu de the following: Program Machine Tool Geometry Machining Method 4 These . The SF or longs . parent groups are separated into the four views of the Operation Navigator Program Order view is used to sequence the operations for output to the CL post processor. It also shows which program parent group each operation be to. This is the only view in which the order of the operations is relevant

The Machine Tool view arranges operations by cutting tools and can organize cutt ing tools by the type of tool. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 4-5

The Operation Navigator 4 The Geometry view shows the MCS and machining geometry that operations and or ge ometry Parent Groups will use. The Machining Method view allows the organization of operations under machining disciplines that share common parameter values such as rough, semi- nish, and nish. 4-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

The Operation Navigator Parent Groups, Operations and Inheritance As mentioned previously, objects (commonly referred to as Parent Groups) and ope rations that you create are displayed in the Operation Navigator in one of four different views. The Operation Navigator uses a tree structure to show the relat ionship between the various Parent Groups and operations. Parent Groups may cont ain other Parent Groups and or operations. Information can be passed down (or in herited) to lower members contained within the group. This information might be a physical cutting tool, part or check geometry, MCS, tolerance or stock values. Any change you make to the Tool, Geometry or Method Parent Group, changes that setting in the operations or other Parent Group contained within that particular group. For example, if you change a Method Parent Group cut feed rate, all oper ations contained in that Parent Group will have their cut feed rate changed. If you were to cut an operation from within a Parent Group and paste it under anoth er Parent Group (in that same view) the operation will inherit the values of the new Parent Group. Most parameter or objects that can be inherited can be modi ed so that they are not inherited. In the example that follows of the Geometry View , the Parent Groups are: 4 Unused Items - Default Geometry group name, sometimes used as a place holder. MC S_MILL - Parent Group containing the MCS. This MCS will be common to all group o bjects contained within MCS_MILL. WORKPIECE- Parent Group containing the work pi ece geometry. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 4-7

The Operation Navigator The Operation Navigator appearance and columns Status Icons in columns The Operation Navigator can display both icons and text, icons, or just text in the columns that are displayed. 4 The Name column In the Name column, operations are preceded by a status symbol w hich represents Complete, Regenerate, or Repost. The icons and their representat ion are: Complete indicates the tool path has been generated and output has been created (post processed or CLS output). The path has not changed since the outp ut was generated. Regenerateindicates the tool path has not been generated or th e tool path is out of date. In the Operation Navigator, use Rightclick Objects Upd ate List to display an Information window to see what has changed and is causing the tool path to be regenerated. Repost indicates the tool path has never been output or the tool path has changed since it was last output. In the Operation N avigator, use Rightclick Objects Update List to display an Information window to see what has changed and is causing the repost status. This information window d isplays the prompt Need to Post. Click Output CLSFon the toolbar to repost and u pdate the status. The Toolchange column Displayed only in the Program View. The icons displayed are based on the type of the tool used. If a drill tool is being used, the button for a drill tool is displayed. The Tool Number column Displays actual tool number which is passed on to the post processor. 4-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

The Operation Navigator The Carrier Number column Displays Carrier number. The Pocket Number column Disp lays Pocket number. The Path column Represents the status of the tool path. The status can be: Generated indicates that the tool path has been created. It may o r may not contain actual tool movement. None indicates the tool path has either been deleted or not generated. Imported indicates that the tool path is a Cutter Location Source File (Tools CLSF Import). It can be replayed, post processed or edited with the graphical tool path editor (Rightclick Tool path Edit). Edited i ndicates the tool path has been changed with the graphical tool path editor (Rig htclick Tool path Edit). Suspect indicates that questionable geometry was encount ered when the tool path was generated. The path may or may not be valid and need s to be examined by using either Rightclick Object Display or Rightclick Object Inf ormation which will show diagnostics with a description of the condition encount ered. Transformedindicates the tool path is from a transformed operation (Rightcl ick Object Transform). The In-Process Workpiece (IPW) column The IPW column indi cates that an In-Process Workpiece has been saved by use of the Visualize Dynami c Material Removal option. The icons displayed are: Generated indicates the IPW has been generated and is current. None indicates that an IPW does not exist. Ou t of Date indicates the IPW is not current. It is updated if the next operation uses the IPW or if the operation is generated by the Dynamic Visualize option. T his button will appear in the IPW column for all the operations below the operat ion that is out of date. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 4-9 4

The Operation Navigator Summary In this lesson you: Became familiar with the functionality and views of the Oper ation Navigator. Selectively changed the data displayed in columns on the Operat ion Navigator. Used the cut, paste, drag and drop functions of the Operation Nav igator. Moved an operation in the Operation Navigator to use a different tool an d inherit its values. 4 4-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Lesson 5 Coordinate Systems Purpose This lesson will explain the different coordinate systems that are used in the Manufacturing application, including the purpose and function of each one . Objectives Upon completion of this lesson, you will be able to: Understand the use and functionality of the various coordinate systems. Create and move the Ma chine Coordinate System (MCS). 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-1

Coordinate Systems Coordinate Systems A coordinate system can be viewed as a marker in 3-D model space to which other objects are referenced. There are ve coordinate systems that Manufacturing uses. They are: Absolute Coordinate System Work Coordinate System Machine Coordinate S ystem Reference Coordinate System Saved Coordinate System 5 5-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Absolute Coordinate System The Absolute Coordinate System is xed in model space, and cannot be moved.This co ordinate system is invisible to the user. It is most useful as a reference for l arge assemblies. Frequently, users will design large scale machines composed of many different components. It is easy to nd their relative position to being abso lute since the components are located in reference to one another. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-3

Coordinate Systems Work Coordinate System The Work Coordinate System (WCS) has several modeling and some manufacturing fun ctions as well. The WCS is a moveable coordinate system, which increases its use fulness. Not only can the WCS be moved in model space, but its orientation can c hange as well. The WCS is a visible coordinate system, and is represented as the following: Notice that each leg of the WCS is followed by a "C". This is a visual indicatio n that it is the WCS. The WCS is used in creating geometry. Most important to ma nufacturing users, it is also used when establishing I,J,K vectors. I,J,K vector s are used to establish the tool axis, cut direction and geometric entities. 5 5-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Machine Coordinate System The Machine Coordinate System (MCS), like the WCS, is also a moveable coordinate system. Notice that the MCS has an M at the end of each leg to distinguish it f rom the WCS. Also, the legs of the MCS are longer than the WCS. In the following gure, both the WCS and MCS are shown together, to emphasize this difference. The MCS references the NC/CNC program origin or simply 0,0,0, since the location of the MCS is the zero reference point for all tool path output. If the MCS mov es, so does the zero point of all tool paths that use it. Another important func tion of the MCS is contained in the Z-axis. The default tool axis is the same as the Z-axis of the MCS. It is important to remember that if a tool axis is estab lished using I,J,K vectors, that tool axis is actually based on the orientation of the WCS. If the default tool axis is used, it is based upon the orientation o f the MCS. The MCS is only visible when in the Manufacturing application. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-5

Coordinate Systems Saved Coordinate System An additional coordinate system that you sometimes refer to is known as the Save d Coordinate System. The Saved Coordinate System is a marker, or place holder, t o designate a position in model space. You can move the WCS or the MCS to this s aved location. The following is an example of a Saved Coordinate System: 5 5-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Summary of Coordinate Systems 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-7

Coordinate Systems Absolute Coordinate System Fixed in model space Cannot be displayed unless assigned to WCS or MCS User may save coordinate system to mark location Useful as a reference in large assemblie s 5 5-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Work Coordinate System Referred to as the WCS Displayed in graphics area with C after each leg Moveable and changeable Used heavily in modeling I,J,K Vectors are based on orientation of WCS 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-9

Coordinate Systems Machine Coordinate System Referred to as the MCS Displayed in graphics area with M after each leg Moveable and changeable Zero (0,0,0) location for tool path output Default tool axis, Zaxis is referenced by this coordinate system 5 5-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Reference Coordinate System Referred to as the RCS Eliminates re-speci cation of parameters by allowing the re trieval and mapping of stored parameters 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-11

Coordinate Systems Activity In the Coordinate Systems section, do the activity: Changing the MCS Position 5 5-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Additional Coordinate System information The following additional information pertains to coordinate systems. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-13

Coordinate Systems I,J,K Vectors A vector can be thought of as a line between two points, has magnitude and direc tion. The rst point of the vector is always assumed to be 0,0,0. The second point is the one you de ne. A temporary line between these two points is created to est ablish a vector. The letters I,J,K correspond (parallel) to the X,Y,Z axes of th e Work Coordinate System. I - relates to - X J - relates to - Y K - relates to Z When a value is given for each axis, the second point is computed creating the v ector.: 5 5-14 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Rotary Vectors When programming, it is not uncommon for some machine tools to support 4 and 5-a xis movement. There are rules for naming the rotary axes on machine tools. These rotary axes are given the letter designation A, B, or C. The letter A designate s a rotary axis about the linear X. To determine positive rotation, form your ha nd into a thumb's-up gesture (right hand rule), and point your thumb in the positi ve X direction. Your curled ngers show positive A axis rotation. The letter B des ignates a rotary axis about the linear Y. To determine positive rotation, form y our hand into a thumb's-up gesture and point your thumb in the positive Y directio n. Your curled ngers show positive B axis rotation. The letter C designates a rot ary axis about the linear Z. To determine positive rotation, form your hand into a thumb's-up gesture and point your thumb in the positive Z direction. Your curle d ngers show positive C axis rotation. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-15

Coordinate Systems Tool Axis versus ZC Axis It is commonly assumed that 3-axis machining can only be performed with the tool axis at the same orientation as the machine tool's Z-axis. This assumption is inc orrect. On 4-axis machining centers, it is possible to perform 3-axis milling wi th the rotary axis at a different orientation than the MCS Z-axis. 5 5-16 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Orientation of the WCS to MCS Orient WCS to MCS allows the WCS to position and orient to the operation or grou p object when either is edited. This is a toggle button found in the Manufacturi ng Preferences dialog box. When editing milling, drilling or hole making operati ons, Orient WCS to MCS will place the WCS at the active MCS. The active MCS for any single operation will be the MCS de ned in the parent Mill Orient Geometry Gro up of the operation being edited. The next activity will demonstrate a simple wa y to perform 3-axis milling with the tool axis at a different angle than the MCS Z-axis. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-17

Coordinate Systems Activity In the Coordinate Systems section, do the activity: Changing the Tool Axis 5 5-18 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Coordinate Systems Summary The ease of manipulation of the Machine Coordinate System affords the exibility o f performing various types of machining operations. The following functionality is used in de ning coordinate systems and vectors that control machine tool output : When de ning vectors, the values are entered with respect to the WCS. Machine to ol output coordinate output is controlled by the MCS. The default tool axis is t he same as the MCS Z-axis. 5 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 5-19

Lesson 6 Visualization (ISV) Purpose This lesson introduces you to the Visualization options that are part of the Integrated Simulation Veri cation (ISV) module. Visualization allows you to v erify tool paths with options allowing the display of material removal, control of tool display, IPW creation and collision checking. Objectives Upon completion of this lesson, you will be able to: Use Visualization to inspect single and mu ltiple tool paths Display the tool as it removes material in one or more tool pa ths Change Tool Path display options 6 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 6-1

Visualization (ISV) Tool Path Visualization Tool Path Visualization provides graphical tool path display for all machining o perations. Visualization also includes detecting unacceptable conditions such as gouging. There are three methods of Veri cation: Replay - displays the tool or to ol assembly, positioning to each point within the tool path, allowing for gouge checking 3D Dynamic - displays the tool as it moves along the tool path(s), show ing the path(s) with the material removed 2D Dynamic - processes faster than 3D but doesn't allow for part rotation during replay. The 3D Dynamic veri cation method requires that you de ne the Blank in the WORKPIECE Parent Group object. You can access the Tool Path Visualization dialog box by c hoosing: The Toolpath Verify button toolbar from the Manufacturing Operations 6 Toolpath Verify, from the Operation Navigator Tools Operation Navigator Toolpath Ver ify, from the menu bar. Toolpath Verify button within an operation 6-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Visualization (ISV) Replay You also have the option to select a single tool path or a series of tool paths for veri cation purposes. Replay is designed to provide a quick method of viewing the tool path by displaying the cutter location at each GOTO point. This is the quickest method of veri cation. The Replay options allow you to: Replay all tool p aths Replay by current cut level Replay a speci ed number of tool motions Replay d isplaying warnings and collisions (gouges) 6 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 6-3

Visualization (ISV) Activity In the Visualization (ISV) section, do the activity: Replay Veri cation 6 6-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Visualization (ISV) 3D Dynamic Tool Path display 3D Dynamic displays the cutter as it follows a tool path and removes material. Y ou can also use the 3D Dynamic option to generate a faceted model from the In-Pr ocess Work piece (IPW). If material is encountered at RAPID moves, these areas a re highlighted in red as a warning. If you are using multiple tools, each tool w ill display in a different color. 3D Dynamic Material generates a 3D display. Ro tate, Zoom and Pan options are available. 6 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 6-5

Visualization (ISV) Activity In the Visualization (ISV) section, do the activity: 3D Dynamic removal 6 6-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Visualization (ISV) Setting Tool Path display options Edit Display The tool path display options are used to control the display of the cutting too l and the tool path. You can de ne the setting in the Method Parent Group or withi n an operation. Within the Method Parent Group, the settings will apply to all o perations that are located below it (inherited). Within the operation, the setti ngs apply to just that operation. Individual operation display settings override settings from the Parent Group. To edit the tool path display options within an operation, you use the Edit Display button. The Process Display Parameters Exam ine the tool path Display Options. Display Cut Regions Pause After Display Refer sh Before Display Suppress Tool Path Display Displays the cut area before proces sing the path. Pauses after the cut region and/or the cutter path is displayed. The screen is refreshed before the next cut. The path is not displayed You can toggle the options on and off as needed. For example, you may want to se e the Cut Regions as you start to develop the tool path. Later, when you may onl y need to look at the cutter path, the cut region display can be turned off. 6 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 6-7

Visualization (ISV) Activity In the Visualization (ISV) section, do the activity: Edit Display options 6 6-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Visualization (ISV) Summary In this lesson, you learned how to verify operations and tool paths using the Re play and 3D Dynamic options of the ISV module. In this lesson you: Replayed sing le and multiple operations Used the 3D Dynamic Replay option to examine material removal in an operation Replayed operations step by step for visualization purp oses Used the Edit Display features to change the tool display in an operation 6 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 6-9

Lesson 7 Planar Milling Purpose This lesson introduces you to the interaction and usage of Planar Millin g. You use Planar Milling for roughing and nishing operations using boundary geom etry. Objectives Upon completion of this lesson, you will be able to: Create Pla nar Mill operations Create Part and Blank boundaries in a MILL_BND Parent Group Create Planar Milling tool paths that cut multiple levels Utilize Pro le cut patte rn 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-1

Planar Milling Planar Milling Planar Milling allows you to de ne an area to be machined where the geometry is ap plicable for 3-axis milling while the Z-axis remains xed. For example, a part hav ing a pocket to be machined, where the walls are perpendicular to the oor, would be typical of Planar Milling. Planar Milling guidelines: Planar Milling can be u sed to rough and/or nish Planar Milling uses a xed tool axis. Planar Milling multi ple levels can be done only when the boundary and oor planes are parallel. Planar Milling does not use solid geometry to determine cut regions; instead it uses b oundaries. Planar Milling can perform single and multi-level cutting 7 7-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Boundaries Planar Milling is controlled by boundaries. The tool will cut inside or outside of the boundary depending upon whether you are cutting pockets or islands. Bound aries are created by selecting a face or a series of edges, curves, or points to de ne a pro le. Boundaries can be created: in a MILL_BND geometry Parent Group with in an operation The MILL_BND geometry Parent Group method is preferred when a boundary is used b y several Planar Milling operations. This allows you to de ne geometry once that c an be used in several operations. 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-3

Planar Milling Part boundaries Part boundaries are used to de ne the part geometry. 7 7-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Blank boundaries Blank boundaries are used to de ne the material within which the part is located. This boundary type is very useful for parts that have protruding features that a re above the overall topology of the part. For example, if a boss is located on the top of the part and you need to machine all the material around it, you will need to de ne the area for machining by selecting a Blank boundary. As shown in the gure above, the Blank boundary de nes the excess stock to remove. T he tool will enter from outside the Blank boundary and remove material until it encounters the part boundary. 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-5

Planar Milling Check boundaries Check Boundaries are used to identify areas you do not want the tool to violate. An example of check geometry would be clamps, xture components or speci c areas of a part that does not get cut. 7 7-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Trim boundaries Trim boundaries are used to control speci c areas for cutting/non cutting purposes . When creating boundaries you can select planar faces, edges, curves and points . 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-7

Planar Milling Multi-level Cutting To successfully perform multi-level cutting in Planar Milling, some rules need t o be followed. These rules pertain to best practices for boundary creation, and setting the depth per pass. They are: Planar Milling ignores all boundaries unti l the tool is below the level of that boundary; each boundary needs to be at the top of the geometry that it represents The part can contain an unlimited number of boundaries You can cut sides and tops of islands You can specify the depths of cut or the maximum and minimum cut depths If you have islands within the pock et, cut levels are created at the top of these islands; if a level cannot be gen erated at the top of an island and remains within the cut depth constraint, you can specify an optional pass to cut the top face of the islands 7 7-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Depth of cut You de ne the cut levels for your multi-level tool path using the Depth of Cut Par ameters dialog box which is activated by the Cut Depths button from the main PLA NAR_MILLING (or like type operation) dialog box. When there are islands in the p art, and the maximum and minimum depths of cut are de ned, the tops of the islands will be one of the cut depths. This is subject to the number of islands de ned an d the speci ed maximum and minimum cut depths. Use the Top Off Islands option to e nsure that they are cut even if the Minimum depth value bypasses an island top. There are ve types of Cut Levels available under the Type label: User De ned - You can set the Maximum, Minimum, Initial, and Last depths of cut Floor Only - Gener ates a single cut level at the Floor plane Floor & Island Tops - Generates one c ut level at the Floor plane and then generates a cleanup cut at the top of each island Levels at Island Tops - Generates a cut level at the top of each island F ixed Depth - Generates cut levels at a constant depth, using the Maximum eld 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-9

Planar Milling Activity In the Planar Milling section, do the activity: Select a Boundary within an Oper ation 7 7-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling MILL_BND geometry Parent groups When an area of a part is machined using many different operations, it may be de sirable to create Geometry Parent Groups. vThis allows you to select geometry on ce that can be used in many different operations. MILL_BND is one type of Geomet ry Parent Group that is used in Planar Milling operations that allows you to de ne boundary geometry once and reuse it numerous times. Creating MILL_BND Parent Gr oups To create a Geometry Parent Group, click Create Geometry from the main menu bar. Choose the MILL_BND .

MILL_BND Geometry Parent can be used by the following operation types: PLANAR LL PLANAR_PROFILE ROUGH_FOLLOW ROUGH_ZIGZAG ROUGH_ZIG CLEANUP_CORNERS FINISH_WAL LS FINISH_FLOORS 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-11

Planar Milling Activity In the Planar Milling section, do the activity: Geometry Parent Groups 7 7-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Introduction to Pro ling This portion of the lesson introduces Pro ling. Follow Periphery, Follow Part, and Zig-Zag are designed for milling areas. Generally, they use closed boundaries. Pro ling typically uses an open boundary. Pro le follows a boundary using the side of the tool. For this method, the tool fo llows the direction of the boundary. The following activity will demonstrate the creation of an open boundary followed by the creation of an operation using the Pro le cut method. 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-13

Planar Milling Activity In the Planar Milling section, do the activity: Pro le Cut Pattern 7 7-14 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Planar Milling Summary Planar Milling operations offer diverse methods of roughing and nishing planar or 2D geometry. The exibility of these operations allows for roughing, semi- nishing and nishing, using a multitude of options to achieve the desired results. In this lesson you: De ned boundary geometry inside of an operation Created an operation to rough and nish a pocket Selected and used boundary geometry in a MILL_BND Geom etry Parent Group Edited a MILL_BND Geometry Parent Group Created a Planar Milli ng operation to remove material in multiple cuts Edited boundary members and dat a within an operation 7 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 7-15

Lesson 8 Face Milling Purpose This lesson is an introduction to Face Milling which is used in cutting one or more planar faces. Objectives Upon completion of this lesson, you will be able to: Create Face Milling operations Cut single and multiple faces Avoid cut ting open areas on a face Use various Cut Methods in face milling operations 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-1

Face Milling Face Milling Face Milling is designed to help you quickly and easily create milling tool path s for planar faces. It uses Cut Area or Boundary geometry to de ne the limits of t he machining area. Face Milling requires the selection of a face or faces. The f aces must be both planar and perpendicular to the tool axis. The tool axis is de n ed by the MCS as a Z-axis vector. Since Face Milling removes material in planar levels with respect to the tool axis, the normal of a face boundary plane must b e perpendicular with the tool axis. If not, the face will be ignored during tool path generation. Face Milling requires geometry, a cutting tool and various parameters to generat e a tool path. For each selected cut area or boundary to be cut, traces are crea ted from geometry, regions are identi ed and then cut without gouging the part. Ge ometry used in Face Milling Face Milling requires Part and Face geometry. 8 The cut area for FACE_MILL_AREA operations is determined by selecting solid face s. The cut area for FACE_MILL operations is created using boundaries. 8-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Face Milling Area geometry Part Geometry Part Geometry is selected using bodies that represent the nished pa rt. Cut Area Cut Area geometry is used to contain the tool path. Cut Area will n ot place limitations on types of faces allowed. Tool paths are generated for fac es that are at and normal to the tool axis. Cut Area faces are a subset of Part g eometry. You can select the entire part as Cut Area geometry and all of the at fa ces normal to the tool axis will be used. Wall geometry Wall geometry is based o n Cut Area faces. For each face/ oor in the Cut Area, walls will start with faces that are adjacent to the oor and form a concave angle or curve up relative to the material side of the oor. The walls will continue upward, including faces that a re tangent, concave, or slightly convex. Check Body Check bodies can be selected as areas to avoid while machining, clamps and other holding devices are typicall y selected as check bodies. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-3

Face Milling Face Milling geometry Face Mill geometry varies slightly from Face Mill Area geometry. Face Mill geome try operations use the following geometry types; Part Geometry You can select bo dies that represent the nished part. Face Boundary geometry consists of closed bo undaries with inside material indicating the areas to be cut. A face boundary ca n be created by selecting one or more of the following Planar faces Curves and/o r edges When a face boundary is created from a face, the body associated to the selected face boundary is automatically used as part geometry to avoid any gouging of th e part. A face boundary created from curves, edges or points does not have this association. All members of a face boundary have tanto tool positions. At least one face boundary must be selected to generate a tool path. The normal of a face boundary plane must be parallel with the tool axis. Check Body Check bodies can be selected as areas to avoid while machining, clamps and other holding devices are typically selected as check bodies. Check Boundary Check boundaries are sim ilar to check bodies except that they are generated from faces, edges or curves. 8 8-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Cut Area and Face Geometry You can use Cut Area, or Face Geometry (blank boundaries) to de ne the blank conta inment for a Face Milling operation. Cut Area is the preferred method. Some of t he differences between using Face Geometry and Cut Area include the following: C ut Area Wall geometry is allowed Non-planar geometry is ignored Geometry faces m ust be a subset of the part geometry Always ignores holes, chamfers will be off Face Geoemtry Wall geometry is not allowed Non-planar geometry is not allowed Ge ometry can be created from faces, curves, edges or points You specify Ignore Hol es and Ignore Chamfer options 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-5

Face Milling Cut Pattern Cut Pattern determines the tool path pattern used to machine cut regions. The fo llowing cut patterns are available; Zig-Zag, Zig, and Zig with Contour produce v ariations of parallel linear cutting moves. Follow Periphery produces a sequence of concentric cutting passes that progress inward or outward. Follow Part creat es a cut pattern by forming an equal number of offsets from all speci ed Part geom etry. Follow Part offsets from Blank geometry only when there is no de ned Part ge ometry to offset from. Trochoidal cut pattern feature is used when you need to l imit excess step over to prevent tool breakage when the tool is fully embedded i nto a cut and when you want to avoid cutting excess material. Most cut patterns generate embedded regions between islands and parts during the engage as well as in narrow areas. The use of Trochoidal Cut pattern eliminates this problem by c reating a trochoidal cut offset from the part. The tool path cuts along the part , and then uses a smooth follow pattern to cut the regions inward. Trochoidal cu tting can be described as a method of milling where the cutter moves in a circul ar looping pattern while the center of the circle moves along a path. This is si milar in appearance to a stretched-out spring. 8 (1) Stepover (2) Path Width Pro le produces a single cutting pass that follows the cut region contour. Pro le is designed to nish the walls of a part. Mixed allows you to select different cut m ethods at each region to ensure the most ef cient machining for various regions of the part. If you decide that the predetermined automatic cut patterns are not e f cient, you can choose to use Manual Cut Pattern and create your own or select Om it for no cutting at all. UGS Corp., All Rights Reserved mt11021_s NX 5 8-6 NX Manufacturing Fundamentals

Face Milling Additional Passes Additional Passes are available only when using a Pro le cut method. It allows the removal of material in multiple passes. Additional Passes represents the number of passes in addition to the single pass along the boundary. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-7

Face Milling Blank Distance, Depth per Cut, Final Floor Stock Blank Distance de nes the total thickness of material to be removed and is measure d above the plane of the selected face geometry along the tool axis. Blank Dista nce is used with Final Floor Stock and de nes the thickness of material that is le ft uncut above the face geometry. The total thickness of material to be removed is the distance between the Blank Distance and the Final Floor Stock. Depth Per Cut equally subdivides the total thickness of material to be removed into numero us levels. 8 8-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Boundary Construction from a Face and its Chamfers Ignore Chamfers determines whether or not adjacent chamfers, llets, and rounds wi ll be recognized when creating boundaries from selected faces. When Ignore Chamf ers is toggled off, boundaries are created on the edges of the selected faces. W hen toggled on, boundaries are created to include chamfers, llets, and rounds adj acent to selected faces. If other objects are to inherit these boundaries, you would use Blank boundaries in a MILL_BND Geometry Parent Group. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-9

Face Milling Activity In the Face Milling section, do the activity: Face Milling Basics 8 8-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Face Milling and surrounding geometry You can machine faces inside of a part. The Face Mill option will determine whic h faces to cut or avoid without gouging other geometry. The following activity w ill show some of the strengths of Face Milling's ability to determine the use of s urrounding geometry. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-11

Face Milling Activity In the Face Milling section, do the activity: Face Milling Interior Geometry 8 8-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Machining multiple faces in one Operation In some cases it may be advantageous to machine several faces in a single operat ion and to specify a separate cut pattern for each face. This can be accomplishe d by using the Mixed cut pattern. Here are the steps required for using this opt ion: Create a new Face Milling operation Select the Faces to be machined Set the Cut Method to Mixed Generate the tool paths 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-13

Face Milling Cutting parameters, Region Sequencing The Cutting Parameter, Region Sequencing, uses four methods of automatically and manually specifying the order in which cut regions are machined. The four metho ds are: Standard allows the processor to determine the order in which cut region s are machined. The order in which cut regions are machined can be arbitrary and inef cient when using this option. Optimize Follow Start Points and Follow Predri ll Points orders the machining of cut regions based on the order in which Cut Re gion Start Points or Pre-Drill Engage Points were speci ed. The following activity will guide you through the process of machining multiple faces in one operation . 8 8-14 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Activity In the Face Milling section, do the activity: Face Milling Utilize Mixed Cut Pat tern 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-15

Face Milling Face Milling Blank Overhang Blank Overhang allows you to control the distance that the cutting tool will tra vel beyond the edge of a face. Blank Overhang is the distance from the leading edge of the cutter to the edge o f the face that is being cut. 8 Setting the Blank Overhang parameter to a value smaller than the cutter diameter minimizes tool motion. 8-16 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Blank Overhang is not the same as Blank Stock. There is a distinct difference be tween the two parameters. Blank Stock applies additional stock to a nished face w hile Blank Overhang is the distance that the leading edge of the cutter extends beyond the edge of the face. Use of these parameters, either individually or in combination, can greatly mini mize the amount of time that is spent cutting air. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-17

Face Milling Activity In the Face Milling section, do the activity: Face Milling Utilize Blank Overhan g 8 8-18 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling Wall Geometry Wall Stock and Wall Geometry in Face Milling Area Operations. Use Wall Stock and Wall Geometry to override the global Part Stock for walls related to the machin ed faces on a Part Body. With Wall Stock and Wall Geometry in Face Milling opera tions, you can select faces on the Part body (other than the faces being machine d) as Wall Geometry and apply a unique Wall Stock to those faces in place of Par t Stock. Walls can be de ned automatically or selected manually. Automatic Wall de tection allows Face Milling operations to recognize and apply wall stock to face s that are adjacent to selected Cut Area faces. The following illustrates how au tomatic walls are selected. For more information please see the technical docume ntation. Automatic Wall Limitations: Automatic Wall detection will not apply if Face Geom etry (blank boundaries) is used to de ne blank containment. In cases where the wal l faces extend below the Cut Area oor face(s), Automatic Wall may select more wal l faces than is appropriate. In these cases you will need to select the wall geo metry manually. 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-19

Face Milling Activity In the Face Milling section, do the activity: Wall Geometry and Wall stock 8 8-20 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Face Milling

Summary This lesson was an introduction to Face Milling. Face Milling's exibility and ease of creating speci c operations for milling faces of a part affords you increased p roductivity and ef ciencies in the machining of your parts. In this lesson you: C t single and multiple faces Used the Traverse option to move the tool quickly ov er void areas of a face Used the ignore holes option to minimize the time cuttin g air Used different cut patterns when cutting multiple faces on the part Used t he Blank Overhang option to minimize cutter travel Used the Run-Off and various helical engagement options to maximize tool life by controlling engagement into the part 8 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 8-21

Lesson 9

Drilling Purpose Drill Operation types are used to create tool paths for drilling, tappin g, boring, counter boring and reaming operations. Numerous parameters are used t o control depths and features that are associated with various types of holes. A ssociated with drilling operations are drill geometry parent groups which contai n the geometry necessary to create various drilling type operations. Objectives Upon completion of this lesson, you will be able to: Create Drill Geometry Pa t Groups Specify drill geometry Specify and edit drill geometry from within an o peration Optimize drilling tool paths Create cycles and cycle parameter sets Cre ate drilling tools Create operations for Spot Drilling, Drilling, and Reaming Us e various options to control drilling operations 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-1

Drilling Creating Drilling Operations The process of creating a drilling operation, select the following; Operation Ty pe Operation Subtype Program Tool Geometry Machining Method After the selections are made the operation is created and generated. 9 9-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Drilling

Drilling Cycles A cycle describes the machine tool movements necessary to perform point to point machining functions, such as drilling, tapping or boring. Through post processi ng, cycle statements are normally output as canned cycle codes. However, some ma chines do not have canned cycles. In those cases, only GOTO points are output. C ycle Characteristics Types The cycle type of No Cycle, Peck Drill, and Break Chi p do not output CYCLE/ commands in the tool path; the motion is simulated with G OTO points Standard Cycle options will output a CYCLE/ command at each of the sp eci ed CL (Cutter Location) points `Drill', `Drill Deep' and `Drill, Break Chip' output canne cycles and are the equivalent of `No Cycle', `Peck Drill' and `Break Chip' which output sim ulated motion generate code for all the tool motions in a CYCLE/ operation to be executed by the machine tool, or generate GOTO/ command statements to de ne each of the tool motions and machine functions which simulate the desired cycle After you choose one of the cycle options other than No Cycle, Peck Drill and Br eak Chip, you must specify how many parameter sets you intend to de ne for that cy cle operation. 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-3

Drilling Cycle Parameter Sets Cycle Parameter Sets are machining parameters such as depth, feed rate, dwell ti mes and cutting increments. If all the point to point positions in a tool path h ave the same cycle parameter values, you will use one Cycle Parameter Set. If yo u want to vary any of the cycle parameter values, for example the depth (when no t using model depth) , you will create a Cycle Parameter Set for each hole or gr oup of holes with different depths. You can have up to ve parameter sets per cycl e. The following is a summary of the different cycle parameter options: CAM - is a number that speci es a preset CAM stop position for tool depth for machine tool s with no programmable Z axis Csink Diameter - is the diameter of a countersunk hole Depth - is the depth of cut Dwell - is the delay of tool at the depth of cu t Entrance Diameter -is the outside diameter of an existing hole that is to be e nlarged by a countersink operation Feedrate - is the cutting feed rate Increment - is the dimensional value of one of a series of regular consecutive cuts to pr ogressive depths used in Peck and Break Chip drilling operations Option- is used to activate machining characteristics that are unique to a particular machine a nd is usually post processor dependent (this function includes the word OPTION i n the CYCLE/ statement) RTRCTO - is the cycle retract distance Step Values - is the dimensional value of one of a series of regular consecutive cuts to progress ive depths used in Standard - Drill, Deep and Standard - Drill, Brkchp operation s 9 9-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Drilling Minimum Clearance The Minimum Clearance distance determines how the tool is positioned before ente ring the material. If a Clearance Plane has not been set, the tool will position to the next hole at the rapid feed rate directly to the speci ed Minimum Clearanc e distance above the part surface. If a Clearance Plane is speci ed, the tool will move at the rapid feed rate from the Clearance Plane to the speci ed Minimum Clea rance. 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-5

Drilling Creating Drilling Tools The Setup that you specify becomes the Type shown in the Create dialog box. Sele ct the Drill Type on the Create Tool dialog to create drilling tools The Subtype determines the drilling tool to be created.. 9 9-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Drilling The Drill Geometry Parent Groups Geometry Parent Groups contain the geometry that is used in an operation(s). The Geometry Parent Groups that are used for Drill operation types are: MCS The MCS is used to de ne the origin for subsequent tool path data based on the Machine Coordinate system. WORKPIECE The WORKPIECE is typically used to assign Part and Blank material. It is also used in tool path veri cation. DRILL_GEOM The DRILL_GEOM geometry parent is used to de ne hole geometry used in d rilling operations. 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-7

Drilling Activities In the Drilling section, do the activities: Create Drill Geometry Parent Groups Create a Spot Drilling Operation Create a Drilling Operation Create a Reaming Op eration 9 9-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Drilling Depth Offset The Depth Offset options are used in conjunction with the depth you set in the C ycle Parameter Sets. Depth Offset options are: Blind Hole - De nes the amount of m aterial that will remain above the bottom of a blind hole using the tip of the t ool Thru Hole - De nes the distance that the drill will move past the break out of a thru hole 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-9

Drilling Optimizing the Tool Path In some cases the tool path that is generated may not be the most ef cient tool pa th in terms of motion. Optimize allows you to rearrange the tool moves into a mo re ef cient order. To summarize the Optimize dialog box: Shortest Path - arranges the points in the order required to minimize total machining time Horizontal Ban ds and Vertical Bands -are used for con ning the tool path; these bands are used f or other machining constraints, such as clamp locations, machine travel limits, table size, etc. Repaint Points -repaints all the points after each optimization if toggled to Yes Shortest Path options To summarize Optimization Parameters dialog box: Level Sta ndard or Advanced - Refers to the process of analysis that you want to use in de termining the shortest tool path; advanced increases machine time ef ciency at a m aximum Based On - Distance is the only option for a xed axis tool path; variable axis tool paths can take the tool axis into account when determining machining e f ciency Start Point - controls the start point of the tool path End Point - contr ols the end point of the tool path Start Tool Axis - is for variable axis tool p aths only and controls the tool axis at the beginning of the cutting motion End Tool Axis - is for variable axis tool paths only and controls the tool axis at t he end of the cutting motion Optimize - initiates the optimization process 9 9-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Drilling Activity In the Drilling section, do the activity: Optimize a Tool Path 9 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 9-11

Drilling Summary Drilling operation types allows for tool path creation for various types of hole s. Numerous options which are available to you allow the control of depths, type of cycles generated and quality of the hole that is being created. In this less on, you learned how to: Create DRILL_GEOM Parent Groups Retrieve tools from the standard tool library Optimization functionality Create the necessary tools used for spot drill, drilling, and reaming operations Specify the options to de ne Cyc le Parameter sets Set the tool depth and de ned the tool offset to prevent the too l from gouging the bottom of a blind hole Set the Minimum Clearance Distance for tool positioning 9 9-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Lesson 10 Text Engraving Purpose This lesson will show you how to generate tool paths for Text Engraving on planar and contour surfaces. Objectives Upon completion of this lesson, you w ill be able to: Create drafting notes to be engraved Create tool paths for plana r text from drafting notes Create tool paths for contour text from drafting note s 10 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 10-1

Text Engraving Text Engraving There are numerous occasions that you may want to engrave part information or id enti cation on to a planar or contoured surface.Text Engraving allows you to gener ate a tool path that engraves text from drafting notes using Planar Milling or F ixed Axis Surface Contouring operation types. Use this operation type when engra ving text (drafting notes) onto a part. The tool will make one pass following th e strokes of the font of the text object in an on condition. To use this feature you must select an existing drafting annotation or create th e desired text selecting Insert Annotation from the main menu bar. You can then select the note for cutting in either Planar Milling or Surface Contouring. Ente r the text string that you wish to engrave in the text box. Create your text wit hout a leader. Insert the text onto your part by clicking the left mouse button on the desired area. To create a group of text, click Create Geometry, select mi ll_planar (1) as the Type (or mill_contour for contoured text), and then click M ILL_TEXT (2). Notes pertaining to text creation: Several fonts use multiple strokes to ll in so lid areas on a character. If a cutter with a very small tip diameter is used for these fonts, the areas between the strokes may not be cut. UGS Corp., All Rights Reserved mt11021_s NX 5 10 10-2 NX Manufacturing Fundamentals

Text Engraving If you set the text depth/part stock so that the tool cuts below the part surfac e, gouge checking reports the moves as gouges. Check and Trim Boundaries are ign ored in tool path generation. Create text in a plane parallel to the oor plane. F or tool path creation, the text is project along the tool axis to the oor plane. For contour text creation that use ball tools. Do not use a depth greater than t he radius of the ball tool. In Surface Contouring, tool paths are not reliable i f the negative oor stock (part stock - text depth) exceeds the lower radius of th e tool. A warning is generated when such conditions occur. The default tool axis is the +ZM axis. 10 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 10-3

Text Engraving Activities In the Text Engraving section, do the activities: Planar and Contour Text Engrav ing Create a Contour Text operation Create a Planar Text operation 10 10-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Text Engraving Summary This lesson introduced you to Text Engraving operations In this lesson you: Crea ted drafting notes. Engraved a text string using Contour Text operation types. E ngraved a text string using Planar Mill Text operation types. 10 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 10-5

10

Lesson 11 11 Tool Path Information Output Purpose This lesson introduces several ways that tool path data can be output as data and text. You will learn how to use NX POST to post process your program. Once you successfully post the program you can then create the shop documentatio n that can be used on the shop oor. Objectives Upon completion of this lesson, yo u will be able to: Output a CLSF Post process with NX POST Create Shop Documenta tion UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-1

Tool Path Information Output 11 Output CLSF Cutter Location Source Files, also referred to as CLSF, are output formats that can be used for input into numerous post processing systems, including legacy GP M and other 3rd party systems. Output CLSF - is used to create a CLSF. Types of output are: CLSF_STANDARD - standard APT (Automatic Programmed Tools) type outpu t, with GOTO and post processors statements CLSF_COMPRESSED - outputs only the S TART and END-OF-PATH statements CLSF_ADVANCED - automatically generates Spindle and Load Tool commands based on operation data CLSF_BCL - represents Binary Code d Language which is a speci c controller language developed in conjunction with th e US Navy CLSF_ISO - represents a cutter location source le based on ISO standard s CLSF_IDEAS_MILL - represents an IDEAS compatible cutter location source le for milling CLSF_IDEAS_TURN - represents an IDEAS compatible cutter location source l e for turning 11-2 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output 11 If you have legacy data that you need to post using the GPM, you would use the C LSF_Standard format. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-3

Tool Path Information Output 11 Post Processing Tool paths consist of GOTO points and other information that controls the moveme nt of a tool with respect to the part. This unmodi ed tool path usually needs to b e speci cally formatted for a particular machine tool/controller combination. Diff erences are based on character formats, tool change requirements, type of machin e, number of controlled axis of motion, etc. The tool path must be formatted to match the unique characteristics of the machine tool/controller combination. The procedure of modifying this generic tool path to a form that can be understood and used by the machine tool controller is called post processing. Two elements are required for post processing. They are: Tool path - A NX internal tool path Post processor - this is a program that reads, converts and reformats tool path information for a particular machine tool/controller combination 11-4 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output NX POST Execute NX provides a post processor, NX POST, which utilizes NX tool path data as input and outputs machine controller readable NC/CNC code. NX POST is customized thro ugh the use of user created Event Handler and De nition les. These les, in conjuncti on with NX POST, are used to generate output for the simplest to the very comple x of machine tool/controller combinations. The NX POST processor is highly scala ble and can be used to generate output for simple milling machines and lathes to ultra complex multi-axis (4+ axis) machining and production centers (a producti on center is considered to be a milling/turning type machine). The exibility of N X POST is achieved through the scripting language Tcl and the use of the NX conc ept of De nition les. The following owchart illustrates the steps required to proces s (post process) tool path data in an acceptable format for a machine tool/contr oller using the NX POST post processor. 11 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-5

Tool Path Information Output 11 11-6 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output The NX POST execute module consists of the following components: Event Generator - sends Events to NX POST when you post process; an Event is a collection of da ta which is processed by NX POST, creating data which causes a speci c action(s) b y the machine tool/controller Event Handler - is a le containing a speci c set of i nstructions, written in the Tcl scripting language, dictating how each event typ e is to be processed De nition le- is a le containing speci c information about machin e tool/controller format Output le- is a le generated by NX POST, passed to the ma chine tool/controller, that executes speci c instructions 11 The Event Generator, Event Handler, and the De nition le are interdependent and tog ether convert the internal tool path into a set of instructions that can be read and executed by the speci c machine tool/controller combination. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-7

Tool Path Information Output 11 Manufacturing Output Manager (MOM) The Manufacturing Output Manager, commonly referred to as MOM, is a utility prog ram used by NX POST for generating output based upon data that is stored within the internal tool path. Functionally, NX POST uses the Manufacturing Output Mana ger to start, add data and specify functions to the interpreter, and to load Eve nt Handlers and De nition les. 11-8 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output Post Processing Using NX POST The NX POST post processor is activated by selecting Post Process from the Manuf acturing Operations toolbar. 11 Post processors are added to the Post Process dialog box by modifying the templa te_post.dat le located in the /mach/resource/postprocessor directory. This le spec i es the location of the De nition and Event handler les used for your particular pos t processor. Output File Name allows you to specify where you want the posted ou tput to go. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-9

Tool Path Information Output 11

NX POST Builder The NX POST mechanism, as mentioned earlier, uses Tcl (Tool Command Language) sc ripts and numerous les to post process information. These les are used to extract information from the part le, process this information according to de ned rules, f ormat the information for output and then output the data to a le which is later used by the machine control for machining a part. These les may be customized and require the knowledge of the Tcl scripting language. To ease the process of cre ating these les and knowing Tcl, the NX POST Builder was developed. NX POST Build er provides an interactive graphical User Interface for building post processors . The design intent of the NX POST Builder is to create all the necessary les nee ded for post processing without the knowledge of le structure or Tcl. The NX POST Builder is very exible and allows for the de nition of various types of output blo cks and word addresses. Sequence of output in the NC output le is very easy to co ntrol for blocks involving the start of program, start of operation, end of oper ation, end of program, tool changes and canned cycles. NX POST Builder currently con gures post processors for the following: 3-axis milling machines 4-axis mi ng machines with a rotary table or a rotary head 5-axis milling machines with du al rotary heads or dual rotary tables 5-axis milling machines with rotary head a nd rotary table 2 and 4 axis lathes Mill-Turn centers (lathes with a live millin g spindle) 2 and 4 axis Wire EDM machines The following owchart illustrates the process of building a post processor using the NX POST Builder. 11-10 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output 11 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-11

Tool Path Information Output 11 Activity In the Tool Path Information Output section, do the activity: Post Processing wi th NX POST 11-12 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output Shop Documentation Shop Documentation allows you to generate customized information in the form of reports that can aid in the manufacturing processes of creating a part. This inf ormation includes data concerning: tools and material control geometry machining parameters post commands tool parameters tool path information 11 Output can be either ASCII text or HTML format. Generic templates are provided o r customized templates can be created and used to create very detailed output th at can be incorporated into the manufacturing environment. UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-13

Tool Path Information Output 11 Shop Documentation dialogs Shop Documentation is activated by clicking Shop Documentation from the Manufact uring Operations toolbar. The Shop Documentation dialog box lists the Available Templates which are used t o format the output. These customized templates create various formatted output in both ASCII text and HTML for: operation and tool list operation list by metho d tool list by program advanced operation list web page listings You can add your own custom templates to the dialog box by modifying the shop_do c.dat le located in the /mach/resource/shop_doc directory. This le speci es the loca tion of the template and event handler les used for your shop documentation. 11-14 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Tool Path Information Output Activity In the Tool Path Information Output section, do the activity: Create Shop Docume ntation 11 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals 11-15

Tool Path Information Output 11 Summary The exibility of the post processing and shop documentation options that are avai lable allows you to post process data and generate customized shop documentation for your speci c needs. In this lesson you: Used the NX POST post processor to cr eate output for a 3-axis milling machine Created Shop Documentation for providin g information for set-ups and manufacturing processes in both ASCII text and HTM L formats 11-16 NX Manufacturing Fundamentals UGS Corp., All Rights Reserved mt11021_s NX 5

Index A Absolute Coordinate System . . . . . . 5-3 B Blank Boundaries . . . . . . . . . . . . . . 7-5 Boundaries in Planar Mill . . . . . . . . . . . . . . . . 7-3 C Cavity Mill Blank Geometry . . . . . . . . . . Cut Levels . . . . . . . . . . . . . . Cut Patterns Cut Pattern . . . . . . . . . . How to create a tool path . . . In-Process work piece . . . . . . Overview . . . . . . . . . . . . . . . Part Geometry . . . . . . . . . . . Cavity Milling cut parameters trim by . . . . . . . . . . . . . Check Boundaries . . . . . . . . . . CLSF Advanced . . . . . . . . . . . . CLSF Compressed . . . . . . . . . . CLSF Standard . . . . . . . . . . . . Coordinate System Absolute Coordinate System . I, J, K Vectors . . . . . . . . . . . . Machine Coordinate System . Rotary Vectors . . . . . . . . . . . Sav ed Coordinate System . . . Work Coordinate System . . . Creating a MILL_BND Pare nt Group . . . . . . . . . . . . . . . . . . Cut Levels . . . . . . . . . . . . . . . . Cut Method Face Mill . . . . . . . . . . . . . . . . . . . 3-8 . . . 3-1 0 . . . . . . . . . . . . . . . 3-12 . 3-4 3-14 . 3-4 . 3-8 Cut Patterns . . . . . . . . . . . . . . . . . 3-12 Cycle Parameter Sets . . . . . . . . . . . . 9-4 D De nition le . . . . . . . . . . . Depth of Cut in Planar Mi ll . . . . . . . . . DRILL_GEOM . . . . . . . . . . Drilling Cycle Parameter Set s . . . Cycle Types . . . . . . . . . . Cycles . . . . . . . . . . . . . . Depth Offset . . . . . . . . . . Geometry Parent Groups Minimum Clearance . . . . Opt imizing . . . . . . . . . . . Tool Types . . . . . . . . . . . Dynamic Tool Path Visualization . . E . . . . . . 11-7 . . . . . . . 7-9 . . . . . . . 9-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 9-3 9-3 9-9 9-7 9-5 9-10 . 9-6 . . . . . . . . . . . . . 6-5 . . . . . . . . . . . . . 3-18 7-67-7 . . 11-2 . . 11-2 . . 11-2 . . . . . . . . . . . . . 5-3 5-14 . 5 -5 5-15 . 5-6 . 5-4 Edit Display Tool Path Display Options . . . . . . . 6-7 Event Generator . . . . . . . . . . . . . . 11-7 Event Handler . . . . . . . . . . . . . . . . 11-7 F F ace Geometry . . . . . . . . . . . . . . Face Mill . . . . . . . . . . . . . . . . . . Additional Passes . . . . . . . . . . blank overhang . . . . . . . . . . . . difference with blank stock Cut Method . . . . . . . . . . . . . . Face Geom etry . . . . . . . . . . . . Multiple Faces . . . . . . . . . . . . Part Geometr y . . . . . . . . . . . . Stock Parameters . . . . . . . . . . NX Manufacturing Fundamentals . . . 7-11 . . . 3-10 . . . . 8-6 . . . 8-2 8-38-4 . . . 8-7 . . 8-16 . . 8-17 . . . 8-6 . . . 8-4 . . 8-13 . . . 8 -4 . . . 8-8 Index-1 UGS Corp., All Rights Reserved

Index G General Milling Enhancements In-Process Workpiece for xed axis milling applicat ions how to use . . . . . . . . . . . . . . 3-14 Geometry Parent Groups DRILL_GE OM . . . . . . . . . . . . . . . 9-7 Drilling . . . . . . . . . . . . . . . . . . . . 9-7 MCS . . . . . . . . . . . . . . . . . . . . . . . 9-7 WORKPIECE . . . . . . . . . . . . . . . . 9-7 Geometry View . . . . . . . . . . . . . . . . 4-6 I I, J, K Vectors . . . . . . . . . . . . . . . . 5-14 L language Tcl . . . . . . . . . . . . . . . . . . . . . . 11-10 M Machine Coordinate System . . . . Mach ine Tool View . . . . . . . . . . . Manufacturing Output Manager Method Views . . . . . . . . . . . . . . MILL_BND Parent Group . . . . . Creating . . . . . . . . . . . . . . . . . MOM Post processing . . . . . . . . . . . . Multi-Level Cut ting in Planar Mill . . . . . . . . . . . . . N NX Post Builder . . NX POST Buil der Flow Chart . . . . NX POST Execute Flow Chart . . . . Post processing . O Op eration Navigator . . . . . . . . 1-11, 4-2 Columns . . . . . . . . . . . . . . . . . . . . 4-8 Index-2 NX Manufacturing Fundamentals Geometry View . . . . . Machine Tool View . . Method Views . . . . . . Program O rder Views resource bar . . . . . . . Tool View . . . . . . . . . Views . . . . . . . . . . . . Optimizing Tool Paths . . . . . . . . Output CLSF . . . . . . . . CLSF Advanced . . . . CLSF BCL . . . . . . . . CLSF Compressed . . CLSF Ideas . . . . . . . CLSF ISO . . . . . . . . . CLSF Standard . . . . Output File . . . . . . . . . P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6, 4-6 . . . 4-5 . . . 4-6 . . . 4-5 . . 1-11 . . . 3-6 . . . 4-5 . . . . . . . . . . . . . . . . . . 9-10 11-2 11-2 11-2 11-2 11-2 11-2 11-2 11-7 . . . . . . . . . . . . . 5-5 . 4-5 11-8 . 4-6 7-11 7-11 . . 11-8 . . . 7-8 . . . . . . . . . . . . 11-10 . . . . . . . . . . . . 11-10 . . . . . . . . . . . . . 11-5 . . . . . . . . . . . . . 11-5 Parent Groups . . . . . . . . . . Geometry Parent Group . Inheritance . . . . . . . . . . . MILL_BND . . . . . . . . . . Operations . . . . . . . . . . . WORKPI ECE . . . . . . . . . Part Boundaries . . . . . . . . . Part Geometry . . . . . . . . . . Planar Mill . . . . . . . . . . . . Blank Boundaries . . . . . . Bound aries . . . . . . . . . . . Check Boundaries . . . . . . Depth of Cut . . . . . . . . . . Multi-Level Cutting . . . . Part Boundaries . . . . . . . Pro le Cut Met hod . . . . . Post processing . . . . . . . . . de nition of . . . . . . . . . . M

OM . . . . . . . . . . . . . . . NX Post Builder . . . . . . . NX POST Execute . . . . . Post processor NX Post Execute . . . . . . . Process Display Parameters Tool Path Display Options Program Order Views . . . . UGS Corp., All Rights Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 . . 3-8 . . 4-7 . 7-11 . . 4-7 . . 3-8 . . 7-4 8-38-4 . . . 7-2 . . . 7-5 . . . 7-3 7-67-7 . . . 7-9 . . . 7-8 . . . 7-4 . . 7-13 . . 11-4 . . 11-4 . . 11 -8 . 11-10 . . 11-5 . . . . . . . . . . . . . 11-5 . . . . . . . 6-7 . . . . . . . 4-5 mt11021_s NX 5

Index R Replay Tool Path Visualization . . . . . . . . . 6-3 Rotary Vectors . . . . . . . . . . . . . . . . 5-15 S Saved Coordinate System . . . . . . . . . 5-6 Shop Documentation . . . . . . . . . . 11-13 T Tcl Post processing . . . . . . . . . . Tool Axis . . . . . . . . . . . . . . . . Tool Path Display Options Edit Displ ay . . . . . . . . . . . . Process Display Parameters Tool Path Visualization Dynamic . . . . . . . . . . . . . . . . . . . . 6-5 Replay . . . . . . . . . . . . . . . . . . . . . 6-3 Tools Drilling . . . . . . . . . . . . . . . . . . . . 9-6 V Vectors I, J, K Vectors . . . . . . . . . . . . . . . 5-14 Rotary Vectors . . . . . . . . . . . . . . 5-15 W . . . 11-10 . . . . 5-16 . . . . . 6-7 . . . . . 6-7 Work Coordinate System . . . . . . . . . 5-4 WORKPIECE . . . . . . . . . . . . . . . . . 9-7 Z ZC Axis . . . . . . . . . . . . . . . . . . . . . 5-16 UGS Corp., All Rights Reserved NX Manufacturing Fundamentals Index-3

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UGS Education Services offers a blend of training solutions for all of our produ ct lifecycle management products. Our Online Store Learning Advantage was develope d to provide our customers with just in time training for the latest in applicati on developments. Here are some of the Learning Advantages: Customers have direct access Self-paced course layout Online Assessments Just in time training for th e latest release L E A R N I N G A D V A N T A G E To learn more about the Learning Advantage visit our website http://training.ugs.c om or email us at training @ugs.com

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STUDENT PROFILE In order to stay in tune with our customers we ask for some background informati on. This information will be kept confidential and will not be shared with anyon e outside of Education Services. Please Print Your Name Course Title/Dates Hotel/motel you are staying at during your training Planned departure time on la st day of class U.S. citizen / thru Yes No Employer Your title and job responsibilities Industry: Auto Aero Consumer produc ts / Location Machining Tooling Medical Other Types of products/parts/data that you work with Reason for training Please verify/add to this list of training for Unigraphics, I-deas, Imageware, T eamcenter Mfg., Teamcenter Eng. (I-Man), Teamcenter Enterprise (Metaphase), or D imensional Mgmt./Visualization. Medium means Instructor-lead (IL), On-line (OL), or Self-paced (SP) Software From Whom When Course Name Medium Other CAD/CAM/CAE /PDM software you have used Please check! your ability/knowledge in the following Subject CAD modeling CAD assemblies CAD drafting CAM CAE PDM data management PDM system management None Novice Intermediate Advanced

 Platform (operating system) Thank you for your participation and we hope your training experience will be an outstanding one.

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NX Manufacturing Fundamentals Agenda Wednesday Morning Lesson 1. Lesson 2. Lesson 3. Afternoon Lesson 3. Lesson 4. Le sson 5. Cavity Mill and Parent Groups (continued) Operation Navigator Coordinate Systems Basic CAM Fundamentals Tools Cavity Mill and Parent Groups Thursday Morning Lesson 6. Visualization Workbook Project: Setting the Machining Environm ent, Set the MCS, Part, Blank, Check Geometry and Mill Method, Create a Cavity M illing Operation, Visualize and Verify Lesson 7. Planar Milling Afternoon Lesson 7. Lesson 8. Planar Milling (continued) Face Milling Friday Morning Workbook Section 9 Assembly Completion Lesson 9. Drilling Lesson 10. Tex t Engraving Lesson 11. Tool Path Information Output Afternoon Workbook Project: Face Milling, Drilling, Post Processing and Shop Documentation

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Accelerators The following Accelerators can be listed from within an NX session by choosing I nformation Custom Menubar Accelerators. Function File New... File Open... File S ave File Save As... File Plot... File Execute Grip... File Execute Debug Grip... File Execute NX Open... Edit Undo Edit Cut Edit Copy Edit-Paste Edit Delete... Edit Selection Top Selection Priority - Feature Edit Selection Top Selection Pri ority - Face Edit Selection Top Selection Priority - Body Edit Selection Top Sel ection Priority - Edge Edit Selection Top Selection Priority - Component Edit Se lection-Select All Edit Show and Hide Show and Hide...(by type) Edit Show and Hi de Hide Edit Show and Hide Invert Shown and Hidden Edit Show and Hide Show... Ed it Show and Hide Show All Edit Transform... Edit Object Display... View Operatio n Zoom... View Operation Rotate... View Operation Section... View Layout New... View Layout Open... View Layout Fit All Views View Layout Fit View Visualization High Quality Image... View Information Window Hide or show the current dialog b ox View Reset Orientation Insert Sketch... Insert Design Feature Extrude... Acce lerator Ctrl+N Ctrl+O Ctrl+S Ctrl+Shift+A Ctrl+P Ctrl+G Ctrl+Shift+G Ctrl+U Ctrl +Z Ctrl+X Ctrl+C Ctrl+V Ctrl+D or Delete F G B E C Ctrl+A Ctrl+W Ctrl+B Ctrl+Shi ft+B Ctrl+Shift+K Ctrl+Shift+U Ctrl+T Ctrl+J Ctrl+Shift+Z Ctrl+R Ctrl+H Ctrl+Shi ft+N Ctrl+Shift+O Ctrl+Shift+F Ctrl+F Ctrl+Shift+H F4 F3 Ctrl+F8 S X

Insert Design Feature Revolve... Insert Trim Trimmed Sheet... Insert Sweep Varia tional Sweep... Format Layer Settings... Format Visible in View... Format WCS Di splay Tools Expression... Tools Journal Play... Tools Journal Edit Tools Macro S tart Record... Tools Macro Playback... Tools Macro Step... Information Object... Analysis Curve Refresh Curvature Graphs Preferences Object... Preferences Selec tion... Start Modeling... Start All Applications Shape Studio... Start Drafting. .. Start Manufacturing... Start NX Sheet Metal... Start Assemblies Start Gateway ... Help On Context... Refresh Fit Zoom Rotate Orient View-Trimetric Orient View -Isometric Orient View-Top Orient View-Front Orient View-Right Orient View-Left Snap View R T V Ctrl+L Ctrl+Shift+V W Ctrl+E Alt+F8 Alt+F11 Ctrl+Shift+R Ctrl+Shift+P Ctrl +Shift+S Ctrl+I Ctrl+Shift+C Ctrl+Shift+J Ctrl+Shift+T M or Ctrl+M Ctrl+Alt+S Ct rl+Shift+D Ctrl+Alt+M Ctrl+Alt+N A Ctrl+W F1 F5 Ctrl+F F6 F7 Home End Ctrl+Alt+T Ctrl+Alt+F Ctrl+Alt+R Ctrl+Alt+L F8

Evaluation Delivery NX 5 NMF, Course #MT11021 Dates thru SOMEWHAT DISAGREE SOMEWHAT AGREE STRONGLY DISAGREE STRONGLY AGREE Please share y our opinion in all of the following sections with a check in the appropriate box: If there were 2 instructors, please evaluate the 2nd instructor with X's Instructor: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. clearly explained the course objectives was knowledgeable about the subject answered my questions appropriately encouraged q uestions in class was well spoken and a good communicator was well prepared to del iver the course made good use of the training time conducted themselves profession ally used examples relevant to the course and audience provided enough time to com plete the exercises used review and summary to emphasize important information did all they could to help the class meet the course objectives T Comments on overall impression of instructor(s): Overall impression of instructor(s) Suggestions for improvement of course delive ry: Poor Excellent What you liked best about the course delivery: Class Logistics: 1. The training facilities were comfortable, clean, and provided a good learning environment 2. The computer equipment was reliable 3. The software performed pr operly 4. The overhead projection unit was clear and working properly 5. The reg istration and confirmation process was efficient Hotels: (We try to leverage thi s information to better accommodate our customers) 1. Name of the hotel Best hot el I've stayed at YES NO 2. Was this hotel recommended during your registration process? 3. Problem? (bri ef description) SEE BACK AGREE Instructor: R DISAGREE

Evaluation - Courseware NX 5 NMF, Course #MT11021 : SOMEWHAT DISAGREE SOMEWHAT AGREE STRONGLY DISAGREE STRONGLY AGREE DISAGREE Please share your opinion for all of the following sections with a check in the ap propriate box Material: 1. 2. 3. 4. 5. The training material supported the course and lesson objectives The training material contained all topics needed to complete the projects The t raining material provided clear and descriptive directions The training material was easy to read and understand The course flowed in a logical and meaningful m anner Too short Too long Just right 6. How appropriate was the length of the course relative to the material? Commen ts on Course and Material: Overall impression of course Poor AGREE Excellent Student: 1. 2. 3. 4. 5. I met the prerequisites for the class (I had the skills I needed) My objectives were consistent with the course objectives I will be able to use the skills I have learned on my job My expectations for this course were met I a m confident that with practice I will become proficient Name (optional): Location/room Please check this box if you would like your comments featured in our training pub lications. (Your name is required at the bottom of this form) Please check this bo x if you would like to receive more information on our other courses and service s. (Your name is required at the bottom of this form) Thank you for your business. We hope to continue to provide your training and pe rsonal development for the future.