Escolar Documentos
Profissional Documentos
Cultura Documentos
Student Guide
May 2007
MT11050 NX 5
Publication Number
mt11050_g NX 5
Proprietary and restricted rights notice
Course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Course description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Student responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Class standard for NX parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Class part naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seed part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to use this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Workbook overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Classroom system information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Student and workbook parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Activity: Level Based In-process Workpiece (IPW) . . . . . . . . . . . 2-14
Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-18
Activity: Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Cavity Milling stock options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Activity: Blank Distance option . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Contents
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Course overview
Course description
The Multi-Axis Machining course teaches the use of the Manufacturing
application for creating 4 and 5-axis milling tool paths. You will learn about
the Variable Contour and Sequential Mill operation types that are designed
for multi-axis machining. You will also learn about the tool axes that are
available within Variable Contour and Sequential Mill operations.
Intended audience
This course is intended for Manufacturing Engineers, NC/CNC programmers
and anyone with the desire to learn how to create four and five axis tool paths.
Prerequisites
The required prerequisites for the course are NX Manufacturing
Fundamentals or the CAST equivalent. Any additional experience in creating
multi-axis tool paths is an asset in taking this course.
Objectives
After successfully completing this course, you will be able to perform the
following activities in NX:
choose between Variable Contour and Sequential Mill operation types
choose the best type of tool axis for creating various multi-axis tool paths
Student responsibilities
Be on time.
Participate in class.
8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Course overview
Where the student is requested to save a part file for later use, the initials
of the students given name, middle name, and surname replace the course
identifier "***" in the new file name with the remainder of the file name
matching the original. These files should reside in the students personal
directory.
There are standard layer assignments and category names in each of the
part files. They are as follows:
Layers 1-100, Model Geometry (Category: MODEL)
Layers 1-14, Solid Geometry (Category: SOLIDS)
Layers 15-20, Linked Objects (Category: LINKED OBJECTS)
Layers 21-40, Sketch Geometry (Category: SKETCHES)
Layers 41-60, Curve Geometry (Category: CURVES)
Layers 61-80, Reference Geometry (Category: DATUMS)
Layers 81-100, Sheet Bodies (Category: SHEETS)
Layers 101 - 120, Drafting Objects (Category: DRAFT)
Layers 101 - 110, Drawing Borders (Category: FORMATS)
Layers 121 - 130, Mechanism Tools (Category: MECH)
Layers 131 - 150, Finite Element Meshes and Engr. Tools (Category: CAE)
Layers 151 - 180, Manufacturing (Category: MFG)
Layers 181 - 190, Quality Tools (Category: QA)
Colors
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Course overview
Seed part
Seed parts are an effective tool for establishing customer defaults or any
settings that are part dependent (saved with the part file). This may include
non-geometric data such as:
sketch preferences
layer categories
part attributes
Activity
Summary
While working through lesson activities, you will experience a higher degree
of comprehension if you read the Cue and Status lines.
At the start of each class day you will be expected to log onto your terminal
and start NX, being ready to follow the instructors curriculum. At the end of
the days class you should always exit NX and log off the terminal.
Workbook overview
The workbook contains a project that requires you to apply the knowledge
that you learned in the class and in the Student Activities. The projects do
not contain detailed instructions as do the Student Activities.
The intent of the projects is to allow you to apply the skills taught in this
course. At any point when you are not making progress, ask your instructor
for help.
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Course overview
Student Login:
User name:
Password:
Work Directory:
Parts Directory:
Instructor:
Date:
The parts for this class are stored in the class Parts directory. There are two
directories located in the Parts directory, the Student_parts and workbook.
The Student_parts directory contains the parts that you will use when
working on activities in the Student Manual.
The workbook directory contains the parts that you will use when working
on the project within the workbook.
System privileges
You do not have the system privilege to modify any of the part files. If you
attempt to do so, you will get a message saying that the file is Read Only.
However, this does not restrict you from working with these files.
Purpose
In this lesson, you will learn different methods available for creating
machining geometry, using the WAVE (What If Alternative Value
Engineering) Geometry Linker, that is associated to the designers original
geometry.
Objective
Build a simulated casting solid body using the Wave Geometry Linker.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 1-1
WAVE Geometry Linker in Manufacturing
1
The WAVE Geometry Linker
The WAVE Geometry Linker is used to associatively copy geometry from a
component part in an assembly into the work part. The resulting linked
geometry is associated to the parent geometry. Modifying the parent geometry
will cause the linked geometry in the other parts to update.
The WAVE Geometry Linker is available with a Manufacturing Bundle
license. It does not require a NX WAVE license.
Different types of objects can be selected for linking, including points, curves,
sketches, datums, faces, and bodies. The linked geometry can be used for
creating and positioning new features in the work part.
The Wave Geometry linker is accessed by choosing InsertAssociative
CopyWAVE Geometry Linker from the menu bar.
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WAVE Geometry Linker in Manufacturing
1
The At Timestamp option lets you specify where the linked object is placed
in the feature list. When turned off, any new features added altering the
parent geometry will be reflected in the linked geometry. When turned on,
new features added after the link was created will not be affected.
Blank Original lets you blank the original geometry so that the linked
geometry in the work part will be easier to work with while the assembly
is displayed.
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WAVE Geometry Linker in Manufacturing
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Geometry types used by the Geometry Linker
Curves/Strings
Sketches
Datums
Faces
Regions of Faces
When selecting geometry to copy, you should consider how permanent the
geometry will be. If you copy as little geometry as possible to do the job,
performance will be improved but updates will be less robust when the parent
geometry is altered.
For example, if you copy individual curves to another part, the link may not
update correctly if one of the curves is deleted. Conversely, if you copy an
entire sketch, curves may be removed or added and the link will update.
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WAVE Geometry Linker in Manufacturing
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Edit links
When this dialog box is displayed, the cursor is active in the graphic window
allowing new parent geometry selection for the link being edited. The new
parent geometry must be the same type as the old geometry (curve, datum,
solid body, etc.)
Parent indicates the parent geometry type. If the feature was linked, but
the link has been broken, the parent is shown as a Broken Link.
Part shows the name of the part where the parent geometry is located. If
the parent geometry is located in the current work part, the part name
given is Work Part.
The dialog box information updates when you select new parent
geometry, which you can do at any time.
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WAVE Geometry Linker in Manufacturing
1
At Timestamp allows you to specify the timestamp at which the linked
feature is placed. If toggled on, the list box will display the features in the
parent part. One of these features may be selected from the list to specify
a new timestamp location for the linked feature being edited. If toggled
off, all features in the parent part will be reflected in the linked feature.
Break Link lets you break the association between the linked feature and
its parent. This means that the linked feature will no longer update if its
parent changes. You can later define a new parent by selecting geometry
with the cursor.
Depending on the geometry type of the feature being edited, other options
may appear on the dialog box.
When editing links and selecting new parent geometry, it may be easier
to temporarily work in an exploded view to distinguish between the
existing linked geometry and the new parent geometry.
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WAVE Geometry Linker in Manufacturing
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Broken links
The path from the linked geometry to the parent part is broken. This can
occur if the component part containing the parent geometry is deleted
or substituted.
If the parent is removed from the start part reference set that defines
the linked part.
If you deliberately break the link (e.g., using Edit Feature or the Break
option on the WAVE Geometry Navigator dialog box).
When a link breaks for an indirect reason (i.e., any reason except the last one
listed above), the link is identified as newly broken until you accept it. You
can accept newly broken links from the WAVE Geometry Navigator dialog
box or the Edit during Update dialog box.
After a link is accepted, its status is changed to broken until a new parent is
defined.
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WAVE Geometry Linker in Manufacturing
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Delete parent geometry
The Information option provides details about the links that will be
broken in an Information window.
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WAVE Geometry Linker in Manufacturing
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Delete linked geometry
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WAVE Geometry Linker in Manufacturing
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Activity: Create an assembly for WAVE
In this activity, you will create an assembly structure for later use with the
WAVE Geometry Linker. Remember that WAVE only works in the context
of an assembly.
This activity uses a hypothetical company that has been awarded a contract
to machine a mixer housing.
The customer has supplied a NX solid model of the designed part. Since
high-production quantities are needed, the customer has decided to make the
part as an aluminum casting. This will reduce significantly, the amount of
time spent machining. Unfortunately, the customer has not supplied a solid
model of the casting which we will need to create. Using WAVE, you will
create a simulated casting model that is associated with the original geometry.
For the casting body, it will be necessary to remove the seven drilled holes,
and add .250" machining stock on the inlet, outlet and mixer tube faces. Also
note that the ring groove will not exist on the casting body.
All machined faces have 1/4" of added stock. Once the modeling changes
are made, you will drill all holes and machine the ring groove into the
mixer outlet face, since the casting process was not accurate enough for the
tolerances required.
Step 1: Create a new part.
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WAVE Geometry Linker in Manufacturing
1
Click the Model tab. Expand the Units list and select Inches.
In the New File Name group, in the Name input box, replace
the default name with ***_mixer_mfg , where *** represents
your initials. Ensure Folder is set to your home folder.
Saving parts to your home is standard practice for this class.
Parts that you create must be saved in a folder to which you
have read and write permissions.
Click OK.
Step 2: The Add Component dialog box appears. This will allow you to
add the part we are going to work on.
Click OK.
There are currently two parts in this assembly. The top level
control part is ***_mixer_mfg, while mixer_body is the single
component. Currently, only the component contains any geometry.
The next step will be to create a new component that will contain
the WAVE casting body.
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WAVE Geometry Linker in Manufacturing
1
Choose AssembliesComponentsCreate New from the
menu bar.
In the File Name group, in the Name input box, replace the
default name with ***_mixer_casting.
Click OK.
Click OK.
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WAVE Geometry Linker in Manufacturing
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Link procedure
Change Work Part to the part that is to receive the linked copies.
Use the linker dialog box to filter the type of object(s). You may select
several objects of different types.
Choose Apply to make copies and remain in the Selection dialog box, or
OK to copy objects and exit the dialog box.
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WAVE Geometry Linker in Manufacturing
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Activity: Create WAVE geometry
In this activity, you will practice using the geometry linker. You will create
a WAVE linked copy of the mixer body, then perform modifications to that
copy to simulate a casting.
Step 1: Prepare the assembly.
If necessary, open the ***_mixer_mfg assembly part and then
the Assembly Navigator.
The mixer body changes to the color Dark Faded Green. This is
a visual clue that geometry is no longer in the current modeling
hierarchy.
Step 2: Select the System Defaults Role tab and drag the Essentials with
full menus icon to the graphics screen.
Choose InsertAssociative CopyWave Geometry Linker.
Click OK.
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WAVE Geometry Linker in Manufacturing
1
Choose EditObject Display.
Step 4: Make the top-level part the displayed part, then save the work
in progress.
At this point no physical difference exists between the mixer body
and the mixer casting. They do have a visual difference. In the next
activity, you will perform modeling changes to the mixer casting.
Click Save .
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WAVE Geometry Linker in Manufacturing
1
Simplify
Simplify is a powerful modeling tool that can be used to satisfy a wide range
of needs in developing models that are associative, but somewhat different.
Simplify provides a method of removing faces. This process must be able to
extend surrounding faces to "heal the wound" where the faces have been
removed.
Uses of Simplify:
Remove "machined" features for preparing an as cast part from a body
that is not appropriately constructed for link At Timestamp, or from a
body whose features are not accessible.
Remove details such as holes and blends for finite element analysis.
In casting tooling work, core and pattern preparation in parts where the
regions were not modeled separately. Simplify can often be used both
to remove interior faces, for patterns, and to remove exterior faces, for
cores (if the system cannot heal wounds left by core removal, the pattern
designer must extract regions and sew core-print faces to obtain a core
body).
Preparing a body for export to a supplier who need only be concerned with
the exterior envelope. Interior faces are removed using simplify, then the
simplified part is linked into a new part for export to the supplier. The
linked part has no "knowledge" of interior features in the original, but it
can still be updated by the owning company if the parent body changes.
1-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
WAVE Geometry Linker in Manufacturing
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Simplify Body procedure
You will use the Simplify Body function to remove holes from your mixer
casting body.
To simplify geometry:
Choose as a retained face, one that will not be simplified away.
Set the size for the Hole Dia Less Than parameter.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 1-17
WAVE Geometry Linker in Manufacturing
1
Activity: Simplify Body
In this activity, you will practice using Simplify Body as a tool to reduce the
complexity of a linked solid body.
Step 1: Make the CASTING component the work and displayed part.
If necessary, open your ***_mixer_mfg assembly part and then
open the Assembly Navigator.
Step 2: Perform a Simplify Body operation on the seven bolt holes on the
outlet face and mixer tubes.
Choose StartModeling if required.
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WAVE Geometry Linker in Manufacturing
1
Select any face on the body that will not be removed when the
holes are removed.
Specify .500 in the Hole Dia Less Than field and press the
return key.
Click Save .
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WAVE Geometry Linker in Manufacturing
1
Activity: Other modeling techniques
Previously Simplify Body was used to remove unwanted geometry from the
Linked casting body. Now, you will explore other ways to modify a linked
body. The first option explored is Extrude.
Step 1: Make the CASTING component the work and displayed part.
If necessary, open your ***_mixer_mfg assembly part and then
open the Assembly Navigator.
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WAVE Geometry Linker in Manufacturing
1
Choose the bottom face of the ring groove, as shown below.
In the Limits group, set End to Until Extended and select the
outlet face.
In the Offset Faces dialog box, type 0.250 for the Offset value.
Select the inlet and outlet faces, and the two mixer tube faces.
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WAVE Geometry Linker in Manufacturing
1
Choose OK.
Step 5: Make ***_mixer_mfg the work part, and compare the two solid
bodies.
To fully realize the extent of the changes made, you will display
both the original and the linked body together.
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WAVE Geometry Linker in Manufacturing
1
Open the Assembly Navigator.
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WAVE Geometry Linker in Manufacturing
1
Summary
The WAVE Geometry Linker provides an efficient method to associatively
copy geometry used for machining from a component part in an assembly into
a work part. The machining geometry is modifiable for manufacturing needs
but does not change the original design intent.
In this lesson you:
Used Assemblies to enable "Best Practices" for modeling in manufacturing.
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Lesson
Purpose
This lesson teaches you how to use additional Cavity Milling options to create
tool paths. You will also use Geometry Parent Groups to machine Cavity
Milling geometry.
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-1
Advanced Cavity Milling topics
Cut Levels
Cavity Milling cuts geometry in planes or levels.
The advantage to this approach is that tool paths remain relatively short, due
2 to minimum tool path movement, which is performed in layers.
The disadvantage is that when machining geometry that is close to horizontal
more stock may remain than desired. See the diagram below.
The closer the geometry approaches horizontal, the more stock that remains.
Through the use of Cut Level parameters, you can reduce the amount of stock
that remains by reducing the depth of cut in these near level areas.
Use Cut Levels in the Cavity Mill dialog box to access the Cut Levels
dialog box.
The Cut Levels dialog box serves these primary functions:
Create, delete or modify Ranges
To reduce the amount of additional stock, a new range can be added. The
Depth per Cut in that Range only is modified.
In the next activity, you will use various Cut Level parameters.
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Advanced Cavity Milling topics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-3
Advanced Cavity Milling topics
A warning message states that the Tool cannot fit into level 14.
At this level, the part and blank geometry are identical, the trace
generated for the part and blank geometry are the same; therefore
no geometry is available for machining. You will now alter the cut
2 levels to eliminate the warning message.
Large and small plane symbols appear. The large plane represents
the Range, and the small planes are the Levels within the Range.
Some Ranges do not have any additional levels.
2-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced Cavity Milling topics
At the very top of the dialog box, there are three buttons for
defining ranges. The Auto Generate (1) button defines ranges
that will align with planar horizontal faces. The User Defined (2)
button defines ranges by selection of the bottom plane for each
new range. The Single (3) button defines the cut range based on 2
part and blank geometry.
The color changes for the active planes, and the Range number and
Level numbers change to Range 2, Levels 2-7.
This is where we want to stop machining at, but there is one more
Range left.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-5
Advanced Cavity Milling topics
Cut patterns
In the Path Settings Group, Cut Pattern determines the pattern the cutter
will use when machining the part.
2 The Cut Patterns are as follows:
Zig always cuts in one direction. The tool retracts at the end of each
cut, then positions to the start of the next cut.
Zig with Contour also machines with cuts going in one direction.
However, contouring of the boundary is added between passes, before and
after the cut motion. The tool then retracts and re-engages at the start of
the contouring move for the next cut.
Follow Periphery offsets the tool from the outermost edge that is
defined by Part or Blank geometry. Internal islands and cavities will require
Island Cleanup or a clean up Profile pass.
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Advanced Cavity Milling topics
Follow Part creates concentric offsets from all specified Part geometry.
The outermost edge and all interior islands and cavities are used to compute
the tool path. Climb (or Conventional) cutting is maintained.
2
Profile follows a boundary using the side of the tool. For this method,
the tool follows the direction of the boundary.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-7
Advanced Cavity Milling topics
In this activity, you will use the Zig-Zag cut pattern to cut the part.
Step 1: Open the part file and start the Manufacturing application.
2
Continue using the part from the previous activity,
***_base_mfg_2.
In the Cavity Mill dialog box, in the Path Settings group, select
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Advanced Cavity Milling topics
Click Generate .
2
The tool path is generated.
In the Path Setting group in the Cavity Mill dialog box, click
Cutting Parameters .
Click the Strategy tab, then type 45.0 in the Degrees field.
You may need to refresh the screen in order to see the Cut
Direction Arrow.
Click Verify .
The Zig-Zag cut pattern does not have a stepover on every pass,
resulting in a less than desirable tool path.
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Advanced Cavity Milling topics
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Advanced Cavity Milling topics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-11
Advanced Cavity Milling topics
Level Based IPW uses the 2D cut regions from the previous Cavity Milling
and/or Z-Level operation to identify and machine the remaining (Rest)
2 material.
Must be Cavity Mill or Z-Level operations.
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Advanced Cavity Milling topics
Use 3D
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-13
Advanced Cavity Milling topics
In this activity, you will machine the part using three different cutter sizes.
You will start with a cavity mill operation and activate the use of the Level
2 Based IPW by using the REST_MILLING operation type and generate the
multiple operations.
You will make three operations, all using the same WORKPIECE and
MILL_AREA. Planning ahead when programming will lead you to make and
use Geometry groups
Step 1: Open level_based_mfg and start the Manufacturing application.
Rename the part ***_level_based_mfg using the File Save
As option on the menu bar.
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Advanced Cavity Milling topics
In this case, Cavity Mill will use only the MILL_AREA to contain
the tool to inside of the pockets, rather than the entire part.
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Advanced Cavity Milling topics
Click Generate .
The Information Window appears because the tool cannot fit into
some of the areas of the part, namely the square corners.
Click Generate .
Again the Tool Path generate message comes up and states that
warning have been generated. Click Cancel this time, as we know
that there are square corners in our model which cannot be cut.
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Advanced Cavity Milling topics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-17
Advanced Cavity Milling topics
Pre-Drill Engage and Cut Region Start Points are used in the following:
Operation
2 Where Found
Non Cutting Moves Start/Drill
Cavity Mill
Points
Non Cutting Moves Start/Drill
Corner Rough
Points
Non Cutting Moves Start/Drill
Rest Milling
Points
Non Cutting Moves Start/Drill
Z-Level Processors
Points
Non Cutting Moves Start/Drill
Profile 3D
Points
Non Cutting Moves Start/Drill
Face Milling Processors
Points
Non Cutting Moves Start/Drill
Planar Mill Processors
Points
Plunge Mill Points in Path Settings
Region Start Points allows you to specify cut start points for each region in
a multi-region cavity. When you use circular engages, this option can avoid
engages into pocket corners by selecting either Mid Point or Corner in the
Default Region Start pull down.
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Advanced Cavity Milling topics
The Cavity Mill dialog box is displayed. You will now define a point
that represents a hole which has been previously drilled.
Click the Start/Drill Points tab and expand the Pre-Drill Points
group.
Expand the List and verify that a value of 5.2500, 2.5000, and
3.1250 is present.
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Advanced Cavity Milling topics
Expand the List and verify that a value of 4.4575, 2.5000, and
.2000 is present.
In the Closed Area group, select Plunge for the Engage Type.
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Advanced Cavity Milling topics
Notice that all levels start at the Pre-Drill Engage Point in the
2
center of the part, then move to the start point which is determined
by the processor.
Click Verify .
Click Play .
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Advanced Cavity Milling topics
Stock options for Cavity Milling are found on the Cut Parameters dialog box.
This dialog box is activated by selecting the Cutting button found on the
2 Cavity Mill operation dialogs.
2-22 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced Cavity Milling topics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-23
Advanced Cavity Milling topics
Click OK.
Click OK.
2-24 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced Cavity Milling topics
Click OK.
2
The tool path cuts all of the core geometry.
Notice that the tool path follows the part contour since you used
the Blank Distance option rather than selecting other geometry
(such as a solid block) to represent the Blank shape.
In this case, you specified that the Blank was near-net-shape with
.200" stock overall.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 2-25
Advanced Cavity Milling topics
Summary
The Cavity Milling module provides efficient and robust capabilities
of removing large amounts of stock, primarily in cavity and core type
2 applications.
The following functions are available in Cavity Milling:
Use of the In-Process work piece for accurate removal of material using
different size cutting tools
2-26 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Lesson
3 Z-Level Milling
Purpose 3
This lesson is an introduction to the Z-Level operation type, which is useful
when profiling steep areas. You can also isolate specific areas that you want
to cut or avoid cutting within a Z-Level operation.
Objective
Understand the meaning and use of steep and non-steep areas of geometry.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-1
Z-Level Milling
Z-Level Milling
Z-Level Milling is designed to profile bodies or faces at multiple depths. It
will cut steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face) or the entire part.
The following Z-Level operation types are available:
Part geometry and Cut Area geometry can be specified to limit the area to
be cut. If cut area geometry is not defined, then the entire part is used as
the cut area.
3-2 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
Many of the option settings found in Z-Level Milling are the same as in other
operation types. A description of some of these options are as follows:
Geometry
Part geometry consists of bodies and faces which represents the Part after
cutting
During tool path generation, the geometry is traced, steep areas and trace
shapes are determined, cut areas are identified and a tool path is generated
for all cut depths specified.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-3
Z-Level Milling
In this activity, you will generate tool paths using Z-Level Milling. Z-Level
is designed to profile an entire part or steep areas that were previously left
by the roughing operations.
Step 1: Open the part file and enter the Manufacturing application.
Open the part base_mfg_3.
3-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
In the Path Settings group, set Global Depth per Cut to 0.100.
You will now change the cut levels. You will stop cutting material
at the top of the bottom face. The default is the bottom face of
the part.
The Cut Levels dialog box is displayed, and plane symbols appear
on our part which represent Ranges and Levels.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-5
Z-Level Milling
Select the Downward icon and observe the Range change and
the highlighted area move down on the model.
Choose OK.
3-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-7
Z-Level Milling
Steep Angle
The steepness of the part at any given area is defined by the angle between
the tool axis and the normal of the face. The steep area is the area where the
steepness of the part is greater than the specified Steep Angle. When the
Steep Angle is toggled on, areas of the part with a steepness greater than or
equal to the specified Steep Angle are cut. When the Steep Angle is toggled
off, the part, as defined by the part geometry and any limiting cut area
geometry, is cut.
3
3-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-9
Z-Level Milling
Tool: EM-.500-.06
Geometry: MILL_AREA
Method: MILL_FINISH
Click OK.
3-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
The system prepares a display of what our stock looks like after
the two operations, but we do not need to watch the step by step
material removal.
Notice the areas cut by the tool paths. Many of the
areas near the blends were not machined so that another
operation with a more appropriate tool radius could be used.
Remember that the Steep Angle was set to 65 degrees and
may need to be changed.
Save the part file, but do not close as you will be using it in
the next activity.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-11
Z-Level Milling
Depth Per Cut allows the specification of the maximum depth per cut in
a range. Cut depths are calculated that are equal and do not exceed the
specified Depth Per Cut value.
Cut Order
3-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
3
Select Create Geometry from the Manufacturing Create
tool bar.
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-13
Z-Level Milling
Make sure that the system you are using has the Preference
Selection Multi-Selection set to Rectangle for the Mouse
Gesture, and Inside for the Selection rule.
Click OK.
Operation .
3-14 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-15
Z-Level Milling
3-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
Stepover option
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-17
Z-Level Milling
Max Cut Traverse defines the longest distance that the cutting tool feeds
along the part when not cutting.
Z-Level and gap tool paths are sequenced and ordered as follows:
Z-Level tool path is machined from the top-down and uses the same
3 connection methods as it would without the Cut Between Levels option
When a gap is discovered, the gap is cut, cutting continues until another
gap is found or the cut is complete at that level.
Z-Level Gap machining is activated from the Cut Parameters dialog box by
selecting the Connections tab and selection of Cut Between Levels. Modify the
parameters on that dialog box as needed.
Additional information on Z-Level Gap Machining can be found in the
on-line documentation from within the NX Help pull down.
3-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
Click Replay .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-19
Z-Level Milling
The tool path is displayed. Note the non-steep areas and the
numerous engage retracts that occur.
ChooseOK.
3-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Z-Level Milling
The non-steep areas are now machined as well as the steep areas
of the part.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 3-21
Z-Level Milling
Summary
This lesson was an introduction to Z-Level milling, which is used when
profiling steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face). This operation
type is useful in minimizing the amount of scallop or cusps that remains
on the part.
In this lesson you:
3-22 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Lesson
Purpose
This lesson will show you how to create a Fixed Contour operation using
several of the options and concepts that are unique to Fixed Contour
machining. You will also review the steps necessary to create various Parent
Groups that will aid you in the selection of geometry and cutting tools. Fixed
Contour operations are generally used for creation of tool paths used to finish 4
the contoured areas of a part.
Objective
Choose the most appropriate drive method for a Fixed Contour operation
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-1
Fixed Contour operation types
Drive Points - are generated from the drive geometry and projected onto
the part geometry.
Projection Vector - used to describe how the drive points project to the
part surface and which side of the part surface the tool contacts. The
selected drive method determines which projection vectors are available.
The projection vector does not need to coincide with the tool axis
vector.
4-2 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-3
Fixed Contour operation types
The MILL_GEOM group which allows part, blank and check geometry.
The MILL_BND group which also allows part, blank, check and trim
and floor boundary geometry.
The MILL_AREA group allows part and check but not blank geometry. It
also allows for the specification of Cut Areas ,Wall and Trim geometry.
4-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-5
Fixed Contour operation types
The Flow Cut drive method allows the specification of Climb, Conventional,
or Mixed cut directions for single pass operations.
The Climb and Conventional options allow the climb or conventional method
for all cutting passes in the operation. If a steep side can be determined, the
steep side is used to calculate the Climb or Conventional cut direction. If a
steep side cannot be determined, the cut direction is determined internally.
The Mixed option allows for the internal calculation of the cut direction.
4-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Flow Cut drive method using Cut Area and Trim Boundary Geometry
The Flow Cut drive method allows Cut Area geometry to be defined the same
way as the Area Milling drive method. Concave valleys are analyzed within
the cut area as well as concave valleys formed by the cut area and part
geometry. Valleys formed by the cut area and check geometry are excluded.
Trim boundaries:
Are defined as an On condition
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-7
Fixed Contour operation types
Outside In Alternate cuts a Flow Cut valley from outside towards the middle
Reference Tool Diameter lets you specify the diameter of the tool from the
previous operation on this part of the part.
Overlap Distance enables you to extend the width of the area defined by the
Reference Tool Diameter along the tangent surfaces.
Steep enables the use of steepness to control the cut regions and their cut
directions.
Much additional information on Flow Cut can be found in the Help
Documentation NX5 Help Library Manufacturing Manufacturing
Milling Fixed and Variable Contour Fixed Only Flow Cut Drive
Methods and then choose the area of interest.
4-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Save As ***_male_cover_mfg_3 .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-9
Fixed Contour operation types
4 Operation .
Tool to BALLMILL-1.00
Geometry to WORKPIECE
Method to MILL_SEMI_FINISH
Choose OK.
4-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Percent to 25
Click OK.
4
Generate the tool path.
Operation .
Tool to BALLMILL-1.00
Geometry to WORKPIECE
Method to MILL_FINISH
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-11
Fixed Contour operation types
Stepover to Scallop
Height to .002
Choose OK.
4
Generate the tool path.
4-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Operation .
Tool to BALLMILL-0.500
4
Geometry to WORKPIECE
Method to MILL_FINISH
Click OK.
Leave the Overlap distance set to .03. The amount of overlap with
the previous operation may change due to size of cutters and your
company preferences.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-13
Fixed Contour operation types
Click Generate .
Note that the area being cut is in reference to the 1.000 Reference
Tool diameter.
Choose OK.
4-14 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Cut Area
In the previous activity, we attacked the entire part with our operations for
semi-finish and finishing. Now we are going to break our part down into
smaller pieces. This may be due to machine time consideration or other shop
driven reasons.
If an area of our part requires numerous machining operation on any given
area, then a separate Geometry Group should be made under the Create
Geometry group. We are going to create our Cut Area as a Geometry Group.
We will break our part down to an even smaller machining area by using a
Trim Boundary in the next activity.
Only faces and sheet bodies can be selected for Cut Area geometry. The
Features option allows surface regions (groups of faces or sheet bodies) for
selection purposes. 4
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-15
Fixed Contour operation types
This activity will demonstrate how to create and use a MILL_AREA geometry
group in an operation. You will Replay and examine the results of an existing
operation. You will then create a MILL_AREA geometry group consisting of
faces and will modify the inheritance of the operation to use the MILL_AREA
parent.
Step 1: Open the part file, rename it, and enter the Manufacturing
application.
Open the part male_cover_mfg_2.
4-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
4
This Fixed Contour operation machines the entire part. This is not
the desired result.
In the next steps, you will create a MILL_AREA geometry group to
limit the machining to just the two ribs protruding from the part.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-17
Fixed Contour operation types
Click OK.
4-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
The tool path is generated and cuts the faces selected in the
MILL_AREA group.
Save the part file, but do not close, as we will use it in the
next activity.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-19
Fixed Contour operation types
Trim Boundary
A Trim Boundary is like any other boundary except it can control the tool
path and prevent the generation either inside or outside of the boundary.
A Trim Boundary can be part of the Mill Area Geometry group, or as an
addition to the operation. Does the area in question require multiple
machining will determine where it should be placed.
4-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Click TRIM .
Only four points are needed, as the boundary processor will close
the shape for you.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-21
Fixed Contour operation types
Any tool path that falls within the Trim boundary is removed. This
is because our Trim Side was set to Inside.
4-22 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Fixed Contour operation types
Summary
This lesson introduced you to Fixed Contour operations that gives you the
ability to machine complex contour geometry with numerous options.
In this lesson you:
Created Area Milling and Flow Cut operations.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 4-23
4
Lesson
Purpose
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-1
5
Introduction to four and five axis machining
Fixed-Axis machining with a tool axis other than (0,0,1) involves setting
the tool axis to the proper orientation
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-3
Introduction to four and five axis machining
In this activity, you will machine the top and two angled areas of a sleeve
collar used in a yoke mechanism. All necessary Parent objects have been
created and the part has been previously roughed. The operations which you
will create will finish mill the top and two angled faces of the part.
Step 1: Open an existing part file and enter the Manufacturing application.
Open the part file, collar_mfg_setup_1.
Choose StartManufacturing.
5-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
Program FIXED_AXIS
Tool EM-1.00-0
Geometry TOP
Method MILL_FINISH
Click OK.
The FACE_MILLING_AREA dialog box is displayed.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-5
Introduction to four and five axis machining
Click Play .
5 Two operations will be replayed. The first operation is used
for roughing, the second is the finish operation that you just
created.
Click Cancel.
5-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
Choose OK.
Choose Generate.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-7
Introduction to four and five axis machining
Right-click Copy.
Right-clickPaste.
5-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
Click Generate.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-9
Introduction to four and five axis machining
Disadvantages:
Output in created program does not match output or dimensions on part
print
Fixture Offset
CSYS rotation
5-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
The default setting is Fixture Offset. The designated option setting is then
passed to the post processor, along with the Main and Local coordinate system
to output the appropriate fixture offset values (G54...G59). The post processor
needs to be modified for this action to occur.
Advantages:
Output in the program matches the part print
Disadvantages:
Programmer needs to understand the complexities associated with use of
the Main and Local coordinate system and the options provided
Machine tool post processor must be set up to obtain the correct output
The following activity will address using a Main and Local MCS. 5
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-11
Introduction to four and five axis machining
In this activity, you will use the Main and Local MCS. The the main and local
MCS have been created for you. The Main MCS is set at the machine zero.
When you list the tool paths, the output is based on the Local MCS. When
you post the program, the output of the tool paths, with their respective X,
Y, and Z values, are based upon the Main MCS.
Step 1: Open the part file and enter the Manufacturing application.
Open the part file t_stone_mfg_assm.
5-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-13
Introduction to four and five axis machining
Choose OK.
You will now list the tool paths for the existing operations that use
the Local MCS and observe that the X, Y and Z values are output
from the Local MCS.
Highlight the FM_002 operation, replay and list the tool path.
You will now post process the operations and note that the X, Y
and Z values are based on the MAIN MCS.
Step 4: Post process the existing operations and examine the output.
Change to the Program Order view in the Operation Navigator.
Choose OK.
5-14 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
5
Notice the values for the X, Y and Z axes.
Step 5: You will now modify the local MCS so the output is from the local
MCS.
Change to the Geometry view of the Operation Navigator.
Edit the MCS_000 parent group and change the Special Output
to Fixture Offset.
Choose OK.
Choose OK.
Click Postprocess .
The Postprocess dialog box is displayed.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-15
Introduction to four and five axis machining
Choose OK.
Notice the values for the X, Y and Z axes and compare with the
previously posted output. The tool path is now output from the
local MCS.
5-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
In this activity, you will use the Main and Local MCS.. The main and local
MCS have been created for you. The Main MCS is set at the machine zero
would be. When you list the tool paths, all have the same X, Y, and Z values
since they are based on the Local MCS. When you post process the program,
the output of the three tool paths, with their respective X, Y, and Z values, are
based upon the Main MCS.
Step 1: Open the part file and enter the Manufacturing application.
Open the part file mcs_local_main.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-17
Introduction to four and five axis machining
5-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
Choose OK.
Choose OK.
You will now list the tool paths for the existing operations that
use the Local MCS and observe that the X, Y and Z values are
the same for each one.
Step 4: Post process the existing operations and examine the output.
Change to the Program Order view in the Operation Navigator.
Click Postprocess .
Choose OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-19
Introduction to four and five axis machining
Step 5: Modify the Local MCS by adding fixture offsets and re-posting
the operations.
Change to the Geometry view of the Operation Navigator.
Edit the MCS_000 parent group, type 1 for the Fixture Offset
and change the Special Output to Fixture Offset.
Repeat the above step action item for MCS_90 and MCS_180
parent groups, using 2 as the fixture offset for the MCS_90
parent group and 3 as the fixture offset for the MCS_180
parent group.
Choose OK.
5-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Introduction to four and five axis machining
Click Postprocess .
The Postprocess dialog box is displayed.
Choose OK.
Notice the values for the X, Y and Z axes and compare with the
previously posted output. Also note the G54, G55 and G56 that is
used for fixture offsets.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 5-21
Introduction to four and five axis machining
Summary
The majority of "multi-axis" machining can actually be considered to be
planar or fixed axis in nature. The spindle axis, on some machines, is not
normal to the Z direction of the machine tool and the actual machining does
not force a change in rotation of the rotary axis. Designation of tool axis and
MCS is crucial to perform this type of work.
In this lesson you:
Performed planar type machining at a tool axis other than (0,0,1).
5-22 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Lesson
Purpose
The Z Level Five Axis operations allow you to create Z level operations with
the addition of four and five axis options. These operations can then be
utilized for roughing and finishing multi axis and deep wall parts.
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-1
6
Five Axis Z Level
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-3
Five Axis Z Level
Toward Point
Toward Curve
Tilt Angle
6-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
This tool path was generated using an Maximum Wall Height of 1.00. The tool
rests on the part surface but the tool holder interferes with the part geometry.
The same operation generated with a Maximum Wall Height of 2.00. Notice
that the tool leans over so the first diameter of the holder doesnt collide
with the part. The Part Safe Clearance is the clearance distance for the
holder. The large diameter still collides because the Maximum Wall Height
still needs to be adjusted. 6
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-5
Five Axis Z Level
The same operation generated with an Maximum Wall Height of 3.00. Notice
that the tool tilts so the large diameter of the holder doesnt collide with
the part.
Setting the Maximum Wall Height smaller can keep the tool from tilting
excessively when your cuts arent going to cause interference.
6-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Click ZLEVEL_5AXIS .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-7
Five Axis Z Level
Click OK.
The Z Level 5 Axis dialog box is displayed.
Click Generate .
Orient your view to the left view and observe the tool axis. The
tool axis is tilted far enough to clear the entire tool holder.
Step 4: Verify the tool path and examine the tool axis.
6 Click Verify .
Click Play .
Click OK.
The tool axis tilts away from the part so that the entire tool holder clears
the part geometry.
Click OK to return to the operation.
6-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Click ZLEVEL_5AXIS .
Click OK. 6
The Z Level 5 Axis dialog box is displayed.
Click OK.
This tool path is set shallower to demonstrate the new tool axis.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-9
Five Axis Z Level
Step 4: Verify the tool path and examine the tool axis.
Click Verify .
Click Play .
The tool axis tilts away from the part so that only the first step of the tool
holder clears the part geometry. If the path was cut to the depth in the
previous operation the tool holder would collide with the part geometry.
Click OK to return to the operation.
6-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
In the previous activities you used an Away from part tool axis tilt and an
automatic angle. The following activities will examine some other tool axis
tilt options. These options include Away from part, Away from point, Toward
point, Away from curve and Toward curve. All of the tool axis tilt options
allow an Automatic or a Specified angle.
Away from part Tilts away from the part geometry at an angle relative
to the MCS Z axis.
Away from point Tilts away from the specified point at an angle to
the MCS Z axis.
Toward point Tilts toward the specified point at an angle to the MCS Z
axis.
Away from curve Tilts away from the curve or curves at an angle to
the MCS Z axis.
Toward curve Tilts toward the curve or curves at an angle to the MCS
Z axis.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-11
Five Axis Z Level
In this activity, you will machine the outside vertical walls of the part. The
Away from point tool axis tilt will be used.
Step 1: Continue using the ***_zl_multi_axis_2_setup_1.prt part and
create a new operation.
6-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Select the arc at the top of the part to select the arc center.
Click Generate .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-13
Five Axis Z Level
Click Verify .
6 Click Play .
The tool axis is tilted 30 degrees from the ZM axis about the
point that was selected.
The tool axis is tilted away from the point along the curved portion
of the part but also continues to rotate along the linear section
of the part.
6-14 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
In this activity, you will machine the outside vertical walls of the part. The
Away from curve tool axis will be used. You will use a single curve to control
the tool axis. The tool axis will tilt away from the curve at the specified angle.
Step 1: Continue using the***_zl_multi_axis_2_setup_1 part and create a
new operation.
Click ZLEVEL_5AXIS .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-15
Five Axis Z Level
Click OK.
You will select the line to control the tool axis tilt.
Choose Away from curve(s) from the Tool Axis Tilt list.
Click Generate .
6-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
The tool axis tilts away from the selected curve at the angle
specified from the ZM axis.
Click Verify .
6
Click Play .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-17
Five Axis Z Level
In this activity, you will machine the outside vertical walls of the part. The
Away from curve tool axis will be used. You will select multiple curves to
control the tool axis tilt.
Step 1: Continue using the***_zl_multi_axis_setup_1 part and create a
new operation.
Click ZLEVEL_5AXIS .
6-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Click Generate .
6
Right-click in the graphics screen and select OrientTop.
Click Verify .
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-19
Five Axis Z Level
Click Play .
The tool axis is tilted away from the arc along the cylindrical face
and away from the line along the planar face.
6-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-21
Five Axis Z Level
6
Click ZLEVEL_5AXIS .
6-22 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Click OK.
Click Generate .
Click Verify .
Click Play .
The tool axis is tilted 3 degrees from the ZM axis away from
the part geometry and the cut depths are constant.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-23
Five Axis Z Level
Click OK.
Click Generate .
Click Verify .
Click Play .
The tool axis is tilted 3 degrees from the ZM axis away from the
part geometry. The cut levels are closer together in the flatter
areas of the part.
6-24 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Five Axis Z Level
Summary
Z Level 5 Axis operations utilize tool axis tilt allowing shorter tools to be
used. The tool axis is applied using ball nose cutters to planar cut levels.
These cut levels are perpendicular to the Machine Coordinate System
You can now create 5 Axis Z Level operations and incorporate;
Several tool axis tilt options.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 6-25
6
Lesson
Purpose
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-1
7
Sequential Mill basics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-3
Sequential Mill basics
In the above illustration, the tool is in contact with the Part, Drive and Check
surfaces. The bottom of the tool follows the Part surface, the side of the tool
follows the Drive surface until the tool contacts the Check surface.
Several dialogs are used in Sequential milling. The operation starts with the
Sequential Mill dialog where you set global parameters and progresses to
suboperation dialogs that control each suboperation.
7-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
When you create a new Sequential Mill operation you first see the Sequential
Mill dialog where global operation parameters are set.
Specify a Minimum
Clearance value to be used
in Engage and Retract
suboperations
Multi-axis output
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-5
Sequential Mill basics
Suboperations
After you set the Sequential Mill operation options you can create a
suboperation to control tool motion.
Suboperations are individual tool motions. The four different types of
suboperations are Engage, Continuous Path, Point to Point and Retract
motion.
Normally, you will use these suboperations in sequential order.
Initially, specify an Engage move
7-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
The Engage Motion suboperation defines where the tool initially contacts
the part. This is usually the first suboperation dialog box which you will
encounter.
To create an Engage Motion suboperation you must
Specify the Engage Method
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-7
Sequential Mill basics
The cutter moves along the drive and part geometry until it reaches check
geometry.
7-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
The Point to Point motion enables you to create linear, non-cutting moves. It
is used to move the tool to another position where continuous path motions
can then continue. You may or may not need to use this dialog box when
creating Sequential Mill operations.
To create a Point to Point suboperation you must define the Motion Method
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-9
Sequential Mill basics
Retract Motion
The Retract Motion dialog box enables you to create a non-cutting move from
the part to the avoidance geometry or to a defined retract point. It is similar
to the Engage Motion.
To create a Retract Motion suboperation you must specify the Retract Method.
7-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
Far Side indicates that the tool will stop when it reaches the farthest side
of the specified part relative to the current tool position
On indicates that the tool will stop when its center axis reaches the edge
of the specified part relative to the current tool position
Ds-Cs Tangency and Ps-Cs Tangency indicates that the tool will stop when
it is at the position that the drive (or part) surface is tangent to the check
surface
-
You must initially specify a tool Reference Point position to determine the side
of the drive, part, and check geometry for tool placement. This establishes
direction only. 7
Once you specify the Reference Point, you can specify the tool starting
position as the Near Side, Far Side, or On the Drive, Part, or Check geometry.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-11
Sequential Mill basics
In a Continuous Path Motion command the cutter moves along the Drive and
Part Surface until it reaches a Check Surface.
If you specify more than one Check Surface (multiple check surfaces), motion
continues until the tool reaches the first of the possible stopping positions.
You can define up to five Check Surfaces for each Continuous Path Motion
suboperation. After you have defined the first Check Surface, you are
automatically prompted to define the next Check Surface.
The following activities will familiarize you with Sequential Mill operations.
7-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
7
Sequential Mill basics
In this activity, you will use basic interactions necessary to create Sequential
Milling operations. You will drive a tool around a simple part, create several
suboperations, and establish Drive, Part, and Check geometry used in the
various operations.
Step 1: Open and rename an existing part file and then enter the
Manufacturing application.
7-14 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
Click Sequential_Mill .
Choose OK.
The Sequential Mill dialog box is displayed.
This dialog box allows the input of basic global parameters
that are active throughout the operation (unless changed in
an suboperation).
Choose OK.
The global parameters are now set.
The Sequential Milling dialogs behave somewhat differently
than other operation dialogs that you are normally familiar
with.
Choosing OK from the main dialog box results in the
suboperation dialog box being displayed. This is where the 7
actual programming process takes place.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-15
Sequential Mill basics
Choose OK.
The Vector dialog box is displayed.
Click ZC Axis
7
Choose OK.
The Point to Point suboperation is complete. By choosing OK,
the suboperation will be placed in the sub-op list and you will
be ready to create the next suboperation.
Choose OK.
You will now define the Engage component.
7-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
Click Geometry.
The Engage Geometry dialog box is displayed.
You will now select the Drive geometry.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-17
Sequential Mill basics
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Sequential Mill basics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-19
Sequential Mill basics
J= 1.000
K=-1.000
Choose OK.
Choose OK twice.
The second suboperation, 2 Eng, is created. The tool side is now
positioned tangent to Drive and Check geometry and tangent
to the Part geometry with the bottom of the tool.
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Sequential Mill basics
The Drive Surf is set to the Previous ds (drive surface). The Part
Surf is set to the Previous ps (part surface). It will be necessary
to set the Check surface.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-21
Sequential Mill basics
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Sequential Mill basics
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-23
Sequential Mill basics
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Sequential Mill basics
J= -1.000
K= 1.000
Choose OK.
Choose OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-25
Sequential Mill basics
7-26 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
In the previous activity, you used the same Part surface for each Continuous
Path Motion suboperation. The suboperation ended after the tool moved
along the Drive surface to the Check surface. The Check surface then became
the Drive surface for the next suboperation and the Continuous Path Motion
dialog box anticipated this choice by selecting Previous Check Surface as the
Drive surface at the beginning of each Continuous Path Motion suboperation.
It is also possible to exchange the Part surface for the next Check surface.
One consideration that should be made when exchanging the Check surface
as the new Part surface is the Stopping Position..
In the following activity, the Drive and Part surfaces, as well as the Check
geometry will change throughout the operation as you generate the tool path.
You will see that the Check surface in a current suboperation can become the
Part surface, as well as the Drive surface, in the next suboperation. You will
also see that the processor is able to anticipate your choice for Drive and Part
surfaces in Continuous Path Motion suboperations, so that you only need to
specify the Check surface(s).
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-27
Sequential Mill basics
In this activity, you will machine a floor that is flat, sloped, and curved. The
part requires that you re-specify the part surface when the floor surface
changes.
Step 1: Open a new part, rename and begin a Sequential Mill operation.
Open the part file sq_3 and rename it to ***_sq_3.
Click SEQUENTIAL_MILL .
7-28 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
Click OK.
The Sequential Mill dialog box is displayed.
Click OK.
The global parameters are now set and you are ready to begin
the Sequential Milling process.
Click XC Axis
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-29
Sequential Mill basics
Click OK .
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Sequential Mill basics
Click the Geometry button and specify the Drive and Part
surfaces as shown.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-31
Sequential Mill basics
Click OK.
The tool moves from the Clearance plane to the position just
specified.
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Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-33
Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
Note that the Sequential Mill processor did not change the
status of the Drive or Part surfaces.
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Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
Note that the Sequential Mill processor expects that the next
Part surface will be the previous Part surface.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-35
Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
Note that the status of the Drive or Part surfaces did not
change.
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Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
Note the status of the Drive or Part surfaces did not change.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-37
Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
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Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-39
Sequential Mill basics
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
7-40 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill basics
Click XC Axis
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 7-41
Sequential Mill basics
Summary
Sequential Milling operations allow complete control of cutter movement and
are useful in the finish machining of complex, multi-axis geometry. The more
experienced programmer will use Sequential Milling techniques to simplify
the creation of complex tool paths.
The following functions are used in Sequential Milling applications:
Selecting of specific tool axis.
Specifying tool starting and stopping positions based on contact with Part,
Drive, and Check surfaces.
7-42 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Lesson
Purpose
Some of the more advanced features of Sequential Milling allow for multiple
passes and control of the tool axis. These options allow for increased flexibility
for roughing and finishing operations.
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-1
8
Sequential Mill advanced
Project Part Surface (or Drive Surface) Normal indicates that the tool axis is
calculated by rotating the surface normal by a lead or lag angle, projecting
the resulting vector onto a plane perpendicular to the specified Perpto Vector,
and then rotating it in that plane by a specified angle. This option causes the
Perpto Vector and the Next Cut Direction buttons to appear.
Tangent To PS (or DS) indicates that the side of the tool is tangent to the
designated surface while the tool axis remains perpendicular to the specified
Perpto Vector.
At Angle To Ps (or Ds) indicates the tool axis maintains a fixed angle with
the designated surface normal while remaining perpendicular to the specified
Perpto Vector.
5-axis allows the tool axis to :
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-3
Sequential Mill advanced
Normal To Ps (or Ds) causes the tool axis to remain perpendicular to the
specified surface. This generally involves keeping the center of the bottom
of the tool in contact with the surface. Optionally, you can offset the contact
point from the bottom center of the tool.
Parallel to Ps (or Ds) causes the side of the tool to be kept parallel to the
surface rulings at the contact point. A ring on the tool must be specified to
indicate where the side of the tool must touch the surface.
8-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
Tangent to Ps (or Ds) causes the side of the tool to be tangent to the specified
surface while the tool axis stays perpendicular to the current direction of
motion. You must specify a ring height.
At Angle to Ps (or Ds) causes the tool axis to maintain a fixed angle (Tilt) with
the surface normal and a fixed angle with the current direction of motion
(a Lead or Lag angle).
Fanning is an even distribution of tool axis change from the start to the stop
8
position. This can be useful, for example, when the tool is canted at either
or both positions.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-5
Sequential Mill advanced
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Sequential Mill advanced
Thru Fixed Point indicates that the tool axis always lies along the line joining
the tool end tip and a user-defined point. Use the Point Constructor dialog
box to define the point.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-7
Sequential Mill advanced
In this activity, you will create a Sequential Milling operation to finish the
walls of a pocket on an aircraft structural component.
Step 1: Open, rename and examine the part file.
Open the part file spar_mfg.
8-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
Click the Play Forward button from the bottom of the dialog.
The In-Process work piece of the part is represented. You will
begin machining the left most pocket in the part.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-9
Sequential Mill advanced
Click OK.
The Sequential Mill dialog is displayed.
Step 3: Set Tool Display options and create a Point to Point Motion.
Click Display Options.
The Display Options dialog is displayed.
Choose 3-D from the Tool Display list and change the Path
Display Speed to 9.
Click OK twice.
The Engage Motion dialog is displayed.
You will now establish the tool location and axis by using a
Point to Point suboperation.
Click ZC Axis .
8-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
J= 1.000
K= .500
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-11
Sequential Mill advanced
Click OK.
8-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
8
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-13
Sequential Mill advanced
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Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-15
Sequential Mill advanced
When you reach the original surface that you used for engaging
the part, drive a temporary plane selected like the original
temporary plane. This should prevent any scallops from being
8 left on the wall.
Retract the tool from the pocket and end the operation.
8-16 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
Standard loops
Loops are modified copies of an original tool path. They are copies of a portion
of a tool path that are repeated to remove extra stock.
Creating loops
The Loop option is located in any of the Motion dialogs (Engage, Retract,
Continuous Path, or Point to Point) under the Options Loop Control.
Before you begin the creation of a loop, the tool should be in the proper
position within the operation (where you want the tool to start repeating
from).
You can specify Loop Stock. This is the stock that is applied to the
geometry within the loop. It is removed as the looping routine progresses.
To end the loop, you should be in the desired position within the operation
and then stop the loop. Choose OptionsLoop ControlStart/End and
change to End.
The tool path is then recomputed by adding the loop Stock and moving
toward the part in a specified number of steps. The path will display in
the graphics window.
You can also create an operation without a loop. You can later edit the
operation and then add the loop.
Nested loops
A Drive surface and a Part surface loop within the same suboperation or a
later suboperation is considered a nested loop (one inside of another).
If the Ds loop and the Ps loop are started within the same suboperation, you
must determine whether you want the Ds loop or the Ps loop to be cut first. 8
The Nesting Status option defines this for you. This option is only available
after both the Ds and Ps Start/End Parameters are defined.
The next activity will familiarize you with some of the basic concepts of
looping within Sequential Mill.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-17
Sequential Mill advanced
In this activity, you will replay and examine Sequential Mill looping
operations.
The tool path makes several passes toward the part walls and
floors. You will now examine the loop settings.
8-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
Click OK.
The Point to Point Motion dialog is displayed.
Click OK.
The Engage Motion dialog is displayed.
Normally, you start the looping process from within this dialog.
Click Options.
The Other Options dialog is displayed.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-19
Sequential Mill advanced
8-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
In this activity, you will use the looping functionality of Sequential Mill to
remove the excess stock on a undercut wall. You will make a copy of the
previous operation that you created and modify that operation for doing
looping activities.
Double-click SM_SEMI_FINISH_WALLS_POCKET_1 .
The Sequential Mill dialog box is displayed.
Hold down the shift key, scroll back up in the dialog box and
choose the 4 cpm suboperation.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-21
Sequential Mill advanced
Click the Delete button and confirm the choice in the message
dialog box.
There should now be three suboperations remaining in the
suboperation list a Point to Point; an Engage, and a CPM.
Since this operation will leave stock on the wall and the tool
radius is nearly the size of the corner fillet, the corner fillet
radii will not be selected. When stock is added to the fillet,
it becomes impossible for the tool to reach its designated
tangency point.
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Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-23
Sequential Mill advanced
8-24 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-25
Sequential Mill advanced
J = 1.0
8
K = 1.0
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Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-27
Sequential Mill advanced
Key in 0.2 in the Initial stock field and .05 in the Increment
field.
Click OK.
Click Options.
8 Click Loop Control.
8-28 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-29
Sequential Mill advanced
The following are Sequential Mill options that you have not used in the
activities. You can review these options with your instructor or on your own.
8-30 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-31
Sequential Mill advanced
Engaging:
Use a reference point that is near the startup geometry
Use the Direction Move option on the Engage Geometry dialog box when
the tool can move to more than one location or if the tool is not close to
the surface
Remember that the Direction Move is applied first to the Drive, second to
the Part, and last to the one or more Check surfaces
Use Side Indication on the Engage Geometry dialog box when the tool
is on or overlaps a surface
You should imagine the tool moving initially after you specify the Drive
surface. Then, if you need to specify a direction for the Part surface, do so
from the imagined position. Then imagine the tool moving to the new position
if you need to specify a Direction Move for the Check surface.
Continuous Path:
If the Drive and Part surfaces are flat and long, reduce the Maximum Step
(on the Other Options dialog box)
When using a Fan tool axis, reduce the Maximum Step (on the Other
Options dialog box)
When using a Fan tool axis around curved geometry, limit the motion to
60 degrees
Looping:
Start a loop on an Engage or Point to Point Motion suboperation; starting
8 a loop on a Continuous Path Motion suboperation can cause the tool to be
out of tolerance
ifIyou do not want the tool retracting during the loop, be careful in ending
the loop on a Continuous Path Motion suboperation so that the loop ends
with the tool in the same position and orientation as at the start of the loop
8-32 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Sequential Mill advanced
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 8-33
Sequential Mill advanced
Summary
The more advanced features of Sequential Milling allow for multiple passes
and complete control of the tool axis. These options allow for increased
flexibility for roughing and finishing operations. Some of the more advanced
features are:
Looping control allowing for removal of excess stock.
8-34 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Lesson
Purpose
Objective
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-1
9
Variable Contour basics
Variable Contour provides several options that help insure the accuracy of
the tool path. Included are:
9
Check geometry to stop tool movement
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-3
Variable Contour basics
9-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
Drive Points - Generated from the Drive geometry and projected onto
part geometry
Projection Vector - Used to describe how the Drive Points project to the
Part Surface and which side of the Part Surface the tool contacts; the
selected drive method determines which Projection Vectors are available
The projection vector does not need to coincide with the tool axis
vector.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-5
Variable Contour basics
The primary difference between Fixed Contour and Variable Contour lies
with the various methods of tool axis control and the drive methods available.
9-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
Allows you to define drive geometry by specifying points and curves. Using
points, the drive path is created as linear segments between the points. Using
curves, drive points are generated along the curves.
The Boundary Drive Method allows you to define cut regions by specifying
Boundaries and Loops. Boundaries are not dependent on the shape and size
of the part surfaces while Loops correspond to exterior part surface edges.
Cut regions are defined by Boundaries, Loops, or a combination of both.
The boundary members graphically represent the associated tool positions
as illustrated below:
The Spiral Drive Method allows you to define drive points that spiral outward
from a specified center point. The drive points are created within the plane
normal to the projection vector and contain the center point. The drive points
are projected on to the part surfaces along the projection vector.
Spiral Drive Method stepovers are a smooth, constant transition outward.
This drive method maintains a constant cutting motion and is applicable to
high speed machining applications.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-7
Variable Contour basics
Surface Area Drive Method allows you to create an array of drive points that
lie on a grid of drive surfaces. This Drive Method is useful in machining very
complex surfaces. It provides additional control of both the Tool Axis and
the Projection vector.
To generate Drive Points from part geometry, select the surfaces as drive
geometry and do not select any part geometry. The drive points are then
generated on the drive geometry.
To generate Drive Points from other geometry, select the drive and part
geometry. The Drive Points are then generated on the drive geometry and are
projected onto the part geometry according to the Projection vector.
In either case, the tool axis can follow the drive geometry contour.
The Surface Area Drive method also provides an additional Projection Vector
option, Normal to Drive, which enables you to evenly distribute drive points
onto convex part geometries.
9
The limiting factor of the Surface Area Drive method is that surfaces must
be arranged in an orderly grid of rows and columns and adjacent surfaces
must share a common edge.
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Variable Contour basics
(1) columns
(2) rows
(3) common edge
(4) drive surface
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-9
Variable Contour basics
When you select Tool Path as the drive method, you must specify an existing
CLSF to be used to generate drive points.
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Variable Contour basics
The Radial Cut Drive Method allows you to generate drive paths
perpendicular and along a given boundary, using a specified Stepover
distance, Bandwidth and Cut Type. This method is useful in clean-up type
applications.
This method is a simple to use drive method to cut the undercut or overcut
walls of a part and is especially effective in machining multi-pocket type
parts. Selection of the bottom of the pocket, setting of various cut parameters,
and generation of the operation are the only steps required for use.
User Function Drive method creates tool paths from special drive methods
developed using User Function programming. These are optional, highly
specialized custom routines developed for specific applications.. Options
available are:
CAM Exit Name is the name of an operating system environment variable
which contains the path name of the shared library containing the User
Function Program.
Users Parameters access a user exit specifying parameters for the drive
path. The User Function program associates these parameters with the
calling operation, using the name of the operation as the link.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-11
Variable Contour basics
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Variable Contour basics
Under the Drive Method label, view the Drive Methods that
are available.
Expand Tool Axis and note the various tool axes which are
available.
Choose Cancel.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-13
Variable Contour basics
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Variable Contour basics
The Variable Contour Tool Axes can be grouped based on the geometry that
determines the tool axis.
The choice of tool axis depends upon the Drive Method you choose. For
instance, the Surface Area Drive Method allows you to specify many 4 and 5
axis tool positions that are not available by using any other Drive Method.
The table which follows shows the various drive methods with permissible
tool axis:
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-15
Variable Contour basics
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Variable Contour basics
Dual
4Axis
X X
on
Drive
Same
as
X
Drive
Path
The following tool axis types use focal points and can produce 5-axis
movements:
Towards Point
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-17
Variable Contour basics
The following tool axis types use focal lines and can produce 4-axis
movements:
Towards Line
9-18 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
In this activity, you will replay a series of Variable Contour operations that
use point and line geometry to control the tool axis.
Step 1: Open the part file and enter the Manufacturing application.
Open the part file vx_4.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-19
Variable Contour basics
The tool path is replayed using the tool axis option Away from
Line.
The tool path is replayed using the tool axis option Away from
Point.
Notice the amount of difference in tool tilt between the two
different methods. Proper placement of the focal point and line
can greatly reduce the amount of tool tilt resulting in reduced
risk of head or tool interference with clamps and or fixturing.
9-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
The tool path is replayed using the tool axis option Towards
Line.
The tool path is replayed using the tool axis option Towards
Point.
Notice the difference in the amount of tool tilt. The method
chosen, towards or away from a point or line, along with their
respective placement of the geometry being cut, gives you
precise control of the tilt of the tool.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-21
Variable Contour basics
Normal Tool Axis maintains a tool axis that is perpendicular to the part
geometry, drive geometry, or rotational axis (4-axis) at each contact point.
This is a preferred method of tool axis control when the contoured geometry
that is being machined does not change radically in shape and or direction.
(1) Normal
to part
geometry at
each drive
point
The following tool axis types use the Normal tool axis:
Normal To Part
The 4-axis type options allow you to apply a rotational angle to the tool axis.
This rotational angle effectively rotates the part about an axis as it would on
a machine tool with a single rotary table. The 4-axis orientation causes the
tool to move within planes which are normal to the defined rotational axis.
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Variable Contour basics
In the following example, the rotational angle causes the tool axis to lean
forward in relation to an otherwise normal tool axis.
Relative tool axis maintains a tool axis that is perpendicular to the part
geometry, drive geometry, or rotational axis (4-axis) at each contact point and
allows the application of Lead or Tilt angle to the tool axis.
You can apply Lead or Tilt to the following tool axis types:
Relative To Part
Relative to Vector
Dual 4-axis
Lead Angle defines the angle of the tool forward or backward along the tool
path. A positive Lead Angle leans the tool forward based on the direction of
the tool path. A negative Lead Angle (lag) leans the tool backwards based on
the direction of the tool path.
9
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-23
Variable Contour basics
Tilt Angle defines the angle of the tool, side to side. A positive value tilts the
tool to the right as you look in the direction of cut. A negative value tilts
the tool to the left.
You can specify a Minimum and Maximum angle of movement for the Lead
and Tilt of the tool axis.
Unlike a Lead angle, a 4-axis rotational angle always leans to the same side
of the normal axis and is independent of the direction of the tool movement.
The rotational angle causes the tool axis to lean to the right of the part
geometry normal axis in both zig and zag moves. The tool moves within
planes normal to the defined rotational axis.
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Variable Contour basics
Dual 4-Axis
Dual 4-Axis applies rotational, Lead and Tilt angle to the Zig and the Zag
moves independently.
You can specify a 4-axis rotation angle, a lead angle, and a tilt angle. The
4-axis rotation angle rotates the part about an axis as it would on a machine
tool with a single rotary table.
In Dual 4-Axis mode, these parameters may be defined separately for Zig
and Zag moves.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-25
Variable Contour basics
You will change the Tool Axis to Relative to Part and compare
the tool paths.
Expand Tool Axis and choose Relative to Part from the Axis
9 list.
You are prompted to change the Lead and Tilt angles. Use the
defaults of 0
Choose OK.
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Variable Contour basics
Compare this tool path to the previous one. Note that the tool
paths are nearly identical. Both tool paths are created using
the surface normal at each contact point.
Choose Cancel.
Expand Tool Axis and choose Relative to Part from the Axis
list.
Choose OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-27
Variable Contour basics
Choose Cancel.
Expand Tool Axis and choose Relative to Part from the Axis
list.
Choose OK.
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Variable Contour basics
Choose Cancel.
Swarf Drive tool axis maintains a tool axis that is parallel to the drive
geometry. The drive geometry guides the side of the tool while the part
geometry guides the end of the tool.
The Swarf Drive tool axis should be used only when the drive geometry
consists of ruled surfaces, since the drive geometry rulings define the swarf
ruling projection vector. 9
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Variable Contour basics
This projection vector can prevent the gouging of the drive geometry when
using a tapered tool as shown by the following:
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Variable Contour basics
The part in this activity has been partially machined. You are going to
continue to machine the core for a hub cover used on a four wheel drive
vehicle. To maximize the part finish, you will be using a short tool to prevent
cutter deflection.
There are two existing sample operations that you will examine
and then create like operations. First you will examine the
various parts which comprise the assembly.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-31
Variable Contour basics
Step 4: Create the operations to finish the fluted area of the part.
Choose the Create Operation icon.
Tool: BALL_MILL-.75
Geometry: WORKPIECE
Method: MILL_FINISH
Name: vc_flute_fin
Choose OK.
9-32 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
Choose OK.
You will now set the direction of cut and its cut area in relation
to the overall size of the outside face of the stock geometry.
You will also set the Cut Type. 9
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-33
Variable Contour basics
Choose OK.
Note the area that is now highlighted. The cutter will now be
limited to this area which encompasses the flutes.
Click OK.
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Variable Contour basics
Choose OK.
Choose OK twice.
The Variable_contour dialog box is displayed.
Step 5:
Generate the tool path.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-35
Variable Contour basics
drive geometry). Interpolate can also be used to adjust the tool axis to avoid
overhangs or other obstructions.
You can define as many vectors extending from specified positions on the
drive geometry as required to create smooth tool axis movements. The tool
axis, at any arbitrary point on the drive geometry, will be interpolated by the
user-specified vector. The more vectors specified, the more control you have
of the tool axis.
This option is available only when using the Curve/Point or Surface Area
drive method.
(1)
user-defined
controlling
vectors
(2) excessive
tool axis
change
(3) smoother
tool axis
movement
(4) drive
surfaces
(5) tool axis
normal to
drive surface
(6)
interpolated
tool axis
Specify as defines the vectors used to interpolate the tool axis. You can
define as many vectors as necessary to control the tool axis.
9-36 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
After you choose OK to accept the desired vector or angle, you can continue
defining data points and vectors until you choose Back in the Point
Constructor dialog box. Selecting Back accepts all of the defined vectors and
returns you to the Interpolated Tool Axis dialog box.
Data Point allows you to create, delete and modify vectors used to
interpolate the tool axis.
Add enables you to create new data points. First specify a data point
on the drive geometry and then a vector direction. After specifying the
data point, a vector normal to the drive geometry is displayed.
Remove enables you to delete data points. Use the Arrow Buttons
to highlight the desired data point or select the desired data point
directly from the screen and then choose Remove.
Edit enables you to modify the tool axis at an existing data point. It
does not allow you to move data points.
Display displays all currently defined data points for visual reference.
Cubic Spline interpolates the tool axis using a variable rate of change
between drive points; this method allows a smoother transition between
points
Interpolate displays drive tool axis vectors at each drive point (when Specify
as Vector is used) or drive points and interpolated lead and tilt angle values
(when Specify as Angle/PS or Angle/DS is used).
Reselect removes all defined data points.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-37
Variable Contour basics
In this activity, you will create an operation using an Interpolated Tool Axis.
The tool will start at the rear of the part with a tool axis that is normal and
will then cut to the front of the part, ending with a tool axis that is aligned
with the ZC axis. As the tool moves from the rear to the front, its orientation
changes incrementally along the tool path.
Step 1: Open a part file, rename and enter the Manufacturing application.
Open the part file interpolate_mfg_asmb and rename it to
***_interpolate_mfg_asmb.
9
Click Variable Contour .
9-38 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
Geometry: WORKPIECE
Tool: BALL_MILL-1.0
Method: MILL_FINISH
Name: interpolate
Choose OK.
The Variable Contour dialog box is displayed.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-39
Variable Contour basics
Choose OK.
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Variable Contour basics
Expand More.
Click OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-41
Variable Contour basics
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Variable Contour basics
Choose OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-43
Variable Contour basics
Expand Options.
Click Edit Display icon and change the Tool Display to Axis.
9
Notice that the tool starts cutting along the surface normal
vector at the rear of the part, gradually changing its axis to the
vectors specified at the front of the part, which is parallel to
the +ZC axis.
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Variable Contour basics
List the tool path and verify the start and finish tool axis.
By listing the tool path, you can see the tool axis position at the
first GOTO, is not parallel to the ZC axis. As the tool moves,
the tool axis position interpolates and becomes parallel to the
ZC axis at the last GOTO.
Choose OK.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-45
Variable Contour basics
Part geometry
Variable Contour does not always require that you specify Part geometry.
When you do not, Drive geometry is used as Part geometry.
Sequential Mill requires selection of Part geometry. The default selection is
the previous Part geometry.
Drive geometry
Drive geometry is used to create drive points that are projected to the Part
geometry. You may use geometry other than that contained within the model.
This "external" drive geometry can be points, curves, a boundary, etc. that
you select after you choose an appropriate Drive Method.
Drive geometry in Sequential Mill is used to control the side of the tool
without developing and projecting drive points. Typically, you select a part
wall that you want the side of the tool to contact as it follows the Part surface.
Check geometry
General considerations
9-46 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
The answer depends upon whether the part model has features that only
Variable Contour or Sequential Mill can resolve. If both processors are
capable, you should consider the following relative strength of each processor:
preferred method for area milling preferred method for linear milling
primary cutting with bottom of tool primary cutting with side of tool
numerous drive methods for tool single drive method
path containment
numerous cut patterns for specific no cut patterns other than looping or
applications nested loops
sheet body and surface region temporary plane geometry allowed
geometry allowed
constant tool axis can change tool axis during operation
edits apply to entire tool path edits apply to part of tool path
best at convex wall cuts best at overcut and undercut type
walls
easy to create operation numerous steps in operation creation
easy to create multiple depth paths N/A
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-47
Variable Contour basics
The following table compares tool axis usage in Variable Contour and
Sequential Mill operations:
9-48 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour basics
Summary
Variable Contour operations provide an efficient and robust capability to
machine complex geometry for multiple axes machining processes (4 plus
axis). Numerous types of tool axis control and drive methods, give the
NC/CNC programmer the ability to machine the simplest to the most complex
of parts. The following features are common to variable contour operations.
Complete tool axis control that allows for minimal tool and table rotations.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 9-49
9
Lesson
Purpose
Objective
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-1
10
Variable Contour advanced
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-3
Variable Contour advanced
10 Click CONTOUR_PROFILE .
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Variable Contour advanced
Click OK.
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-5
Variable Contour advanced
Click OK.
10
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Variable Contour advanced
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-7
Variable Contour advanced
Click OK .
You have set the cutting parameters to remove .100 stock in
three equally spaced passes.
10
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Variable Contour advanced
(1) Tool path prior to stock removal; (2) tool path after stock
removal
10
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Variable Contour advanced
10
10-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour advanced
Geometry selection
Creating a Contour Profile tool path requires Part geometry, Wall geometry
and Floor geometry. There are several options that can be used to define
the geometry. You can define the geometry by selecting the geometry or by
allowing parts of the geometry to be detected automatically.
Part Geometry
Use Part geometry to specify the complete set of geometry that represents the
finished part. In many cases, roughing and finishing operations are done on
sections of the finished part
Floor Geometry
The floor is the geometry that limits the location of the cutter when it is placed
against the wall. Floor geometry may be specified by selecting geometry from
your part, from another geometry or in some cases it can be defined for you.
Wall Geometry
Wall Geometry defines the area to be cut. The cutter is first placed
against the wall, and once a tool axis is established, the cutter
is then positioned against the floor. Wall geometry can also be
selected manually or in some cases it can be defined automatically.
The following activities will examine some of the possible geometry selection
methods and combinations.
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-11
Variable Contour advanced
Automatic Wall
When using the Automatic Wall selection you will select the part geometry
and the floor geometry and turn on the Automatic Wall option. The walls
will be detected for you.
10
10-12 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour advanced
Click CONTOUR_PROFILE .
Click OK
The CONTOUR_PROFILE dialog box is displayed.
Click OK.
10
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Variable Contour advanced
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-15
Variable Contour advanced
10
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Variable Contour advanced
Step 3: Edit the operation and add the tool axis settings.
Right-click the operation and choose Edit.
Click OK.
The tool path follows the bottom contour of the wall geometry
while tilting 10 degrees from the walls.
10
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Variable Contour advanced
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-19
Variable Contour advanced
Click CONTOUR_PROFILE .
10-20 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour advanced
Click OK.
The operation will detect the bottom of the walls to use for floor
geometry. The path could also be offset from the Bottom Wall.
The tool path follows the bottom contour of the wall geometry
while using the wall geometry to guide the tool axis.
The tool path cuts to the bottom of the selected walls. You will
edit the operation to apply a depth offset so the cutter cuts deeper
than the part geometry.
Step 7: Move the operation to the Unused Items group on the Operation
Navigator You will cut the same area of the part using slightly
different options.
Highlight the operation CONTOUR_PROFILE_1 and drag it
to the Unused Items group.
10
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Variable Contour advanced
10
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Variable Contour advanced
Click CONTOUR_PROFILE .
Click OK.
10 The CONTOUR_PROFILE dialog box is displayed.
10-24 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour advanced
Click OK.
The operation will detect the bottom of the part to use for floor
geometry. Use the Automatic Auxiliary Floor to define an infinite
plane that is perpendicular to the access vector at the bottom of the
wall. The path could also be offset from the Automatic Auxiliary
Floor.
The tool path follows a plane at the bottom of the geometry while
using the wall geometry to guide the tool axis.
In the graphics screen click and drag the cone head to specify
an offset of -.3 and select the Green Check Mark to accept it.
10
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Variable Contour advanced
Click Generate.
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-27
Variable Contour advanced
10
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Variable Contour advanced
Step 8: You will also add multiple Wall passes to the operation.
Click Generate.
Click Generate.
Step 9: Move the operation to the Unused Items group on the Operation
Navigator. 10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-29
Variable Contour advanced
10
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Variable Contour advanced
Auxiliary Floor
Auxiliary Floor allows you to select geometry that doesnt belong to the model
being cut to represent the floor geometry. In the following activity you will
use another face to simplify the tool motion for the cut.
10
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Variable Contour advanced
Click CONTOUR_PROFILE .
Click OK.
10-32 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Variable Contour advanced
Click OK.
Click OK.
The tool path follows the Auxiliary Floor geometry while using the
wall geometry to guide the tool axis.
10
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Variable Contour advanced
Click Generate.
10
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Variable Contour advanced
Step 8: Move the operation to the Unused Items group on the Operation
Navigator.
Highlight the operation CONTOUR_PROFILE_3 and drag it
to the Unused Items group.
10
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Variable Contour advanced
10
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Variable Contour advanced
Click CONTOUR_PROFILE .
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Variable Contour advanced
Click OK.
10
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide 10-39
Variable Contour advanced
Step 5: You will also turn on the Automatic Auxiliary Floor option.
Click Automatic Auxiliary Floor.
The tool path follows the Auxiliary Floor and the Automatic
Auxiliary floor geometry while using the wall geometry to guide
the tool axis.
10
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Variable Contour advanced
10
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Variable Contour advanced
Click Generate.
10
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Variable Contour advanced
Summary
Variable Contour operations provide an efficient and robust capability to
machine complex geometry for 4 and 5-axis machining centers. This lesson
familiarizes you with some the requirements that are necessary to make the
programming task simpler.
10
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10
A
Appendix
A Projection Vectors
The Projection Vector indicates the side of the part surface to be cut. It is also
used to project drive points from the drive to the part surface.
The following illustration shows a Projection Vector (defined as Away From
Line, i.e. the center line) indicating the side of the part surface to be cut. It
also shows a drive point projected, along the projection vector, from the drive
surface (P1) to the part surface (P2).
Note that, in this example, the drive point is projected in the opposite
direction of the Projection Vector arrowhead. The drive point is always
projected toward the part surface along the projection vector but without
regard to the Projection Vector arrowhead.
A Projection Vector is required for all Variable Contour Drive Methods.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide A-1
Projection Vectors
A
The following options allow you to define the Projection Vector:
Specify Vector fixed projection vectors
User Function
I, J, K define the vector by keying in values relative to the origin of the Work
Coordinate System.
Line End Points by defining two points, selecting an existing line, or defining
a point and a vector.
2 Points by using the point Constructor to specify two points. The first point
defines the tail of the vector; the second point defines the arrowhead of the
vector.
Tangent to Curve defines a vector tangent to a selected curve. Specify a
point on the curve, select an existing curve, and select one of two displayed
tangent vectors.
A-2 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Projection Vectors
A
Spherical Coordinates defines a fixed vector by keying in two angular values,
designated as Phi and Theta. Phi is the angle measured from +ZC and rotated
in the ZC-XC plane from ZC to XC. Theta is the rotation angle about the ZC
axis from XC to YC.
(1) Phi
(2) Theta
Tool Axis define a projection vector relative to the existing tool axis. When
using tool axis, the vector always points in the opposite direction of the tool
axis vector.
Away From Point creates a projection vector extending away from a specified
focal point toward the part surface. Useful in machining the inside spherical
(or sphere like) surfaces where the focal point is the center of the sphere.
Towards Point creates a projection vector extending from the part surface to
a specified focal point. Useful in machining the outside spherical (or sphere
like) surfaces where the focal point is the center of the sphere.
Away From Line creates a projection vector extending from a specified line to
the part surface.
Towards Line creates a projection vector extending from the part surface to
a specified line.
Normal to Drive define projection vectors relative to the drive surface normals.
Swarf Ruling allows you to define the projection vector parallel to the swarf
rulings of the drive surfaces when you use a swarf drive tool axis. It should be
used only when the drive surfaces are equivalent to ruled surfaces, since the
drive surface rulings define the swarf projection vector.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide A-3
Projection Vectors
A
The Swarf Ruling projection vector can prevent gouging the drive surface
when using a tapered tool as illustrated below:
The above figure compares the Swarf Ruling projection vector to the Tool Axis
projection vector (the Tool Axis projection vector is the reverse of the Tool Axis
Vector). Drive points are projected along the specified vector to determine the
tool position. When using the Tool Axis projection vector, drive points are
projected along the tool axis (at an angle to the drive surface), causing the tool
to gouge the drive surface. When using the Swarf Ruling projection vector,
drive points are projected along the drive surface swarf rulings causing the
tool to position tangent to the drive surface.
A-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Projection Vectors
A
The following is a summary table showing the types of projection methods
available for each tool axis. The x indicates that the Projection Method
is not available.
Tool Axis Projection Methods
Fixed Tool Toward Toward Norm Swarf
Vector Axis / Away / Away Drive Rule
Point Line
Away From Point X
Toward Point X
Away From Line X
Toward Line X
Relative To Vector X
Normal to Part X
Relative to Part X
4axis Normal to Part X
4axis Relative to Part X
Dual 4Axis on Part X
Interpolate X
Normal to Drive X
Swarf Drive
Relative to Drive
4axis Norm to Drive
4axis Rel to Drive
Dual 4Axis on Drive
Same as Drive Path X X
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide A-5
A
Appendix
(1) trim
(2) specify
cut
direction
by selecting
direction
arrows
Zig-Zag Surface tool paths are generated in parallel passes. The drive
points are generated on the surface to be machined. You can control the
number of input points by a chordal deviation (adjusting the step tolerance)
in the direction of cut. This is the allowable deviation from the surface.
Scallop height controls the distance between parallel passes according to the
maximum height of material (scallop) you specify to be left between passes.
This is affected by the cutter definition and the curvature of the surface.
Zig-Zag Surface also provides gouge check so that the system can check for
violation of the surface.
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide B-1
B
Appendix
Projection C
Mathematics of Projection:
Place tool end at drive point
If necessary, adjust the tool axis and repeat the above steps until the
tool axis is satisfied
Add more intermediate drive points to satisfy the Intol/Outol with the part
(1) drive
point
(2)
projection
vector
(3) tool
position
(4) part
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-1
Advanced surface contouring
(1) drive
path
C
(2) drive
point
(3) d
(4) x
(5)
C-2 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced surface contouring
In the case of Area Milling Drive (no projection vector), the tool axis vector
is used to decide Material Side
Tool axis
Definition of Lead/Tilt angles:
(1) lead
(2) tilt
(3) tool axis
vector
(4) reference
vector
(5) cut vector
(6) tool axis
Begin with cut vector, rotate it toward the Reference vector 90- degrees
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-3
Advanced surface contouring
C-4 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced surface contouring
Drive surface
Remap of drive surface:
Remap algorithm:
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-5
Advanced surface contouring
Limitations of remap
fails on 3sided faces
C-6 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced surface contouring
Planar milling
Blank - the region to be included
C
Part - the region that can not be violated
Boolean logic
Boundary Drive
Drive boundary - similar to "blank" if no part containment, otherwise
it is like "part"
Stock
Part offset and part stock
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-7
Advanced surface contouring
What Where
Part Offset Offset of part as the Geometry Group
permanent definition of
the final shape of the
product
Part Stock Leftover material Operation
on part by a given
operation
C Part stock is defined on "top" of part offset
C-8 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced surface contouring
What Where
Part Stock Offset Difference between the Operation
part stock from the
previous operation and
the part stock of the
current operation
Safe Clearance The additional safety Operation
zone for collision C
checking
Gouge / Collision
Definitions:
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-9
Advanced surface contouring
Usually collision check against part offset + part stock + part stock offset
+ safe clearance
C
(1) collision
(2) gouge
Usage:
C-10 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Advanced surface contouring
Noncut moves
Azimuth / Latitude:
(1) latitude
(2) azimuth
(3) part normal C
(4) cut vector
(5) engage/retract vector
Begin with cut vector, rotate it toward the part normal degrees
(1) retract
(2) departure
(3) int traverse
(4) end traverse
(5) approach
(6) engage
There is only one End Traverse in the sequence, but there may be zero or
multiple Int Traverse
The Start and End positions of the End Traverse move are determined by
other moves in the sequence
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide C-11
C
Index
A F
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide Index-1
Index
Index-2 Multi-Axis Techniques Student Guide UGS Corp., All Rights Reserved mt11050_g NX 5
Index
UGS Corp., All Rights Reserved Multi-Axis Techniques Student Guide Index-3
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Multi Axis Techniques 301 Course Agenda
Day One
Course Overview
Lesson 1. WAVE Geometry Linker in Manufacturing
Lesson 2. Advanced Cavity Milling Topics
Afternoon
Day Two
Afternoon
Day Three
Afternoon
Function Accelerator
FileNew... Ctrl+N
FileOpen... Ctrl+O
FileSave Ctrl+S
FileSave As... Ctrl+Shift+A
FilePlot... Ctrl+P
FileExecuteGrip... Ctrl+G
FileExecuteDebug Grip... Ctrl+Shift+G
FileExecuteNX Open... Ctrl+U
EditUndo Ctrl+Z
EditCut Ctrl+X
EditCopy Ctrl+C
Edit-Paste Ctrl+V
EditDelete... Ctrl+D or Delete
EditSelectionTop Selection Priority - Feature F
EditSelectionTop Selection Priority - Face G
EditSelectionTop Selection Priority - Body B
EditSelectionTop Selection Priority - Edge E
EditSelectionTop Selection Priority - Component C
EditSelection-Select All Ctrl+A
EditShow and HideShow and Hide...(by type) Ctrl+W
EditShow and HideHide Ctrl+B
EditShow and HideInvert Shown and Hidden Ctrl+Shift+B
EditShow and HideShow... Ctrl+Shift+K
EditShow and HideShow All Ctrl+Shift+U
EditTransform... Ctrl+T
EditObject Display... Ctrl+J
ViewOperationZoom... Ctrl+Shift+Z
ViewOperationRotate... Ctrl+R
ViewOperationSection... Ctrl+H
ViewLayoutNew... Ctrl+Shift+N
ViewLayoutOpen... Ctrl+Shift+O
ViewLayoutFit All Views Ctrl+Shift+F
ViewLayoutFit Ctrl+F
ViewVisualizationHigh Quality Image... Ctrl+Shift+H
ViewInformation Window F4
Hide or show the current dialog box F3
ViewReset Orientation Ctrl+F8
InsertSketch... S
InsertDesign FeatureExtrude... X
InsertDesign FeatureRevolve... R
InsertTrimTrimmed Sheet... T
InsertSweepVariational Sweep... V
FormatLayer Settings... Ctrl+L
FormatVisible in View... Ctrl+Shift+V
FormatWCSDisplay W
ToolsExpression... Ctrl+E
ToolsJournalPlay... Alt+F8
ToolsJournalEdit Alt+F11
ToolsMacroStart Record... Ctrl+Shift+R
ToolsMacroPlayback... Ctrl+Shift+P
ToolsMacroStep... Ctrl+Shift+S
InformationObject... Ctrl+I
AnalysisCurveRefresh Curvature Graphs Ctrl+Shift+C
PreferencesObject... Ctrl+Shift+J
PreferencesSelection... Ctrl+Shift+T
StartModeling... M or Ctrl+M
StartAll ApplicationsShape Studio... Ctrl+Alt+S
StartDrafting... Ctrl+Shift+D
StartManufacturing... Ctrl+Alt+M
StartNX Sheet Metal... Ctrl+Alt+N
StartAssemblies A
StartGateway... Ctrl+W
HelpOn Context... F1
Refresh F5
Fit Ctrl+F
Zoom F6
Rotate F7
Orient View-Trimetric Home
Orient View-Isometric End
Orient View-Top Ctrl+Alt+T
Orient View-Front Ctrl+Alt+F
Orient View-Right Ctrl+Alt+R
Orient View-Left Ctrl+Alt+L
Snap View F8
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