nx6_fixed axis techniques_student guide

Fixed Axis TechniquesStudent Guide

Sept 2008MT11065 – NX 6

Publication Numbermt11065_s NX 6

Proprietary and restricted rights notice

This software and related documentation are proprietary to Siemens ProductLifecycle Management Software Inc.

© 2008 Siemens Product Lifecycle Management Software Inc. All RightsReserved.

All trademarks belong to their respective holders.

2 Fixed Axis Techniques – Student Guide mt11065_s NX 6

Contents

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

Course description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Course objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Student responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Class standards for NX part files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Class part file naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Layers and categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Activity format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Workbook overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Classroom system information . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

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

The WAVE Geometry Linker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Geometry types used by the Geometry Linker . . . . . . . . . . . . . . . 1-3Edit links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Broken links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Delete parent geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Delete linked geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8Activity: Create an assembly for WAVE . . . . . . . . . . . . . . . . . . . . 1-9Link procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12Activity: Create WAVE geometry . . . . . . . . . . . . . . . . . . . . . . . . 1-13Delete Face procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15Activity: Delete Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16Activity: Other modeling techniques . . . . . . . . . . . . . . . . . . . . . 1-18

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22

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

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

Cut patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Activity: Zig-Zag cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

In-Process Work Piece for Cavity Milling . . . . . . . . . . . . . . . . . . . . . . . 2-13Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Activity: Level Based In-process Workpiece (IPW) . . . . . . . . . . . 2-16Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-21

Fixed Axis Techniques – Student Guide 3

Contents

Activity: Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . . . . . . . 2-22Cavity Milling stock options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25Activity: Blank Distance option . . . . . . . . . . . . . . . . . . . . . . . . . 2-26

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

Plunge Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Plunge milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Activity: Create a Plunge Milling operation . . . . . . . . . . . . . . . . . . . . . . 3-5Plunge Milling Step Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9Activity: Plunge Milling Step Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Steep Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Activity: ZLEVEL_PROFILE_STEEP Operations . . . . . . . . . . . . . . . . . . 4-8Activity: Z-Level Profile Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Z-Level Cutting Between Levels (aka Gap Machining) . . . . . . . . . . . . . 4-14Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Overview of the NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Activity: The NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Machining options that require change for High SpeedMachining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Activity: Create a High Speed Machining operation . . . . . . . . . . . 6-4Mixed Cut Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Activity: Mixed Cut Directions . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Trochoidal Cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Activity: Trochoidal cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Fixed Contour overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2Drive methods for Fixed Contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3Geometry groups associated with Fixed Contour operations . . . . . . . . . . 7-5Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6More on Flow Cut drive methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7Flow Cut drive method using Cut Area and Trim Boundary Geometry . . 7-8


Contents

Flow Cut Reference Tool Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9Activity: Create Fixed Contour operations . . . . . . . . . . . . . . . . . . . . . . 7-10Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15Activity: Mill Area geometry groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16Trim Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20Activity: Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2Flow and Cross curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3Activity: Create an Automatic Streamline operation . . . . . . . . . . 8-5Activity: Create a Manual Streamline operation . . . . . . . . . . . . 8-10

Activity: Add additional curves for more control . . . . . . . . . . . . . . . . . . 8-15Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20

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


Course overview

Course descriptionThe Fixed Axis Techniques course teaches the use of the NX Manufacturingapplication for creating 2–1/2 and 3–axis tool paths.

Course objectivesAfter successfully completing this course, you should be able to perform thefollowing activities in NX:

• Create group objects that supply information to operations

• Utilize options and parameters that are common to various operationtypes

• Create Associative Machining Geometry, Advanced Roughing operationsand Finishing operations.


Course overview

Intended audienceThis course is designed for Manufacturing Engineers, Process Planners andNC/CNC Programmers that have the basic knowledge of NC/CNC manualprogramming of 3-axis positioning and contouring equipment.

Prerequisites• Essentials for NX Designers or self-paced course equivalent

• Basic understanding of the Master Model concept

Working knowledge of the following:

• NX user interface

• Part file saving conventions

• Experience as an NC/CNC programmer

Student responsibilities• Be on time

• Participate in class

• Listen attentively and take notes

• Practice what you have learned

• Enjoy the class


Course overview

Class standards for NX part filesThe following standards will be used in this class. Standardization allowsusers to work with other parts while being able to predict the organizationof the part file. All work should be performed in accordance with thesestandards.

Class part file naming

This class utilizes the following file naming standard:

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

Currently up to 128 characters are valid for file names. A four characterextension (.prt) is automatically added to define the file type. Thismeans the maximum number of user defined characters for the filename is actually 124.

Layers and categories

Parts used in this course were creating using layer categories the same as orvery similar to those found in the Model template parts.

Layers provide an advanced alternative to display management (Show andHide) to organize data

Layers Categories Description1–10 SOLIDS solid bodies11–20 SHEETS sheet bodies21–40 SKETCHES all external sketches41–60 CURVES non-sketch curves61–80 DATUMS planes, axes, coordinate systems91–255 no category assigned

Activity format

Activities have the following format:


Course overview

Step 1: This is an example of a step. Steps specify what will beaccomplished.

This is an example of an action bullet.

Action bullets detail how to complete the step.

Workbook overviewThe workbook contains a project that requires you to apply the knowledgethat you learned in the class and in the student activities. The projects do notcontain detailed instructions as do the student activities.

It is the intent of this project to allow you to apply the skills taught in thiscourse. However, the time constraint of this course is also a factor, at anypoint when progress is not being made, enlist the help of your instructor.

Classroom system information

Your instructor will provide you with the following items for working in theclassroom:

Student Login:

User name:

Password:

Work Directory:

Parts Directory:

Instructor:

Date:


1Lesson

1 WAVE Geometry Linker inManufacturing

Purpose

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

Objective

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

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

• Make modifications to linked geometry.

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

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

Fixed Axis Techniques – Student Guide 1-1

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WAVE Geometry Linker in Manufacturing

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

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

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

The Wave Geometry linker is accessed by choosing Insert®AssociativeCopy®WAVE Geometry Linker from the menu bar, or from the WAVEGeometry Linker button on the Assemblies toolbar.

• The Fix at Current Timestamp determines weather or not features addedto parent body after linked body is created will propagate to liked body.When turned off, any new features added altering the parent geometrywill be reflected in the linked geometry. When turned on, new featuresadded after the link was created will not be affected.

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

• Associative determines weather or not linked body will update to reflectchanges in parent..

1-2 Fixed Axis Techniques – Student Guide mt11065_s NX 6

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Geometry types used by the Geometry Linker

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

• Composite Curve

• Point

• Datum

• Face

• Region of Faces

• Body

• Mirror Body

• Routing Object

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

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


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Edit links

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

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

• Parent indicates the parent geometry type, work part or other part.

• Wave Information shows the name of the part where the parent geometryis located, parent feature, and link status. If the parent geometry islocated in the current work part, the part name given is Work Part. If the


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feature was linked, but the link has been broken, the parent is shown asa Broken Link.

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

• The Fix at Current Timestamp determines weather or not features addedto parent body after linked body is created will propagate to liked body.When turned off, any new features added altering the parent geometrywill be reflected in the linked geometry. When turned on, new featuresadded after the link was created will not be affected.

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

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

• Reverse Direction reverses the normal of the face selected.

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

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


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Broken links

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

• The parent geometry is deleted.

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

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

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


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Delete parent geometry

To prevent unintentional deletion of the parents of linked geometry, a messagewill warn you if a delete operation would cause inter-part links to break.

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


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Delete linked geometry

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

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

Assemblies and WAVE

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


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Activity: Create an assembly for WAVE

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

Using WAVE, you will create a simulated casting model that is associatedwith the original geometry.

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

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

Step 1: Create a new part.

On the Standard toolbar, click New .

Notice that the dialog box has several tabbed pages.

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

On the Model page, select the Assembly template.

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

In the New File Name group, in the Name box, type***_mixer_mfg , where *** represents your initials. Make sureFolder is set to your “home” folder.


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

Click OK.

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

In the Part group, click Open .

Select mixer_body from the parts folder.

Click OK.

From the Positioning list select Absolute Origin.

Expand Settings.

Type mixer in the Name box.

From the Reference Set list select SOLID

Click OK.

Step 3: Examine the current assembly structure.

In the Resource bar, click the Assembly Navigator tab.

There are currently two parts in this assembly. The top level partis ***_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 containthe WAVE casting body.

Step 4: Create an empty component.

Choose Assemblies→Components→Create New Componentfrom the menu bar.

Expand the Units list and select Inches.

On the Model page, select the Model template.

In the File Name group, in the Name box, type***_mixer_casting.

Ensure Folder is set to your “home” folder.


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Click OK.

In the Create New Component dialog box expand the Settingsgroup and change the component name to casting.

Click OK.

A new component, named CASTING, is displayed in theComponent Name column of the Assembly Navigator. The nameof the part is ***_mixer_casting. To display the Component Namecolumn, right-click and choose Columns→Component Name.

Step 5: Save the assembly.

Click Save on the toolbar.

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


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Link procedure

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

To create linked geometry:

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

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

• Choose Insert® Associative Copy®WAVE Geometry Linker.

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

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


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Activity: Create WAVE geometry

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

Step 1: Prepare the assembly.

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

Choose Start→Modeling.

In the Assembly Navigator, right-click ***_mixer_casting andchoose Make Work Part.

The mixer body changes color. This is a visual clue that geometryis no longer in the current modeling hierarchy.

Step 2: Change the Role.

Select the Roles tab and click Essentials with full menus icon.

Step 3: Choose Insert→Associative Copy→Wave Geometry Linker.

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

Set Type to BODY in the WAVE Geometry Linker dialogbox.

Select the mixer body.

Click OK.

Step 4: Modify the display of the linked casting.

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

In the Assembly Navigator, right-click the ***_mixer_castingcomponent and choose Make Displayed Part.

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

Choose Edit→Object Display.


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Select the linked body and choose OK.

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

In the Basic group, change Color to Yellow.

Choose OK in the Edit Object Display dialog box.

Step 5: Make the top-level part the displayed part, then save the workin progress.

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

In the Assembly Navigator, right-click the ***_mixer_castingcomponent and choose Display Parent→***_mixer_mfg.

In the Assembly Navigator, right-click ***_mixer_mfg andchoose Make Work Part, if necessary.

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

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

Click the grey check mark in front of mixer_body and theoriginal model will appear.

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

Click Save .

Delete Face

Use the Delete Face command to delete faces. You can:

• Automatically heal the open area left in the model by the deleted faces, byextending adjacent faces.

• Preserve adjacent blends


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Delete Face procedure

You will use the Delete Face function to remove holes from your mixer castingbody.

To use Delete Face:

• Click Synchronous Modeling ®Delete Face on the DirectModeling toolbar.

• Click Select Face

• Click Apply or OK.

• The selected faces are deleted and the open area is healed


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Activity: Delete Face

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

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

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

Right-click the ***_mixer_casting component and choose MakeDisplayed Part.

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

Choose Start→Modeling if required.

Choose Insert→Synchronous Modeling→Delete Face.

The cue line reads: “Select faces to delete.”

Select the five holes on the mounting face. Select the cylindricalfaces of the holes.

Select the two cylindrical faces of the inlet tubes.


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Click OK in the Delete Face dialog box.

Click Save .


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Activity: Other modeling techniques

Previously Delete Face was used to remove unwanted geometry from theLinked casting body. Now, you will explore other ways to modify a linkedbody. The first option explored is Make Coplanar.

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

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

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

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

Choose Start→Modeling.

Choose Insert→Synchronous Modeling→Constrain→MakeCoplanar.

The Make Coplanar dialog box is displayed.

Select the bottom face of the ring groove, as shown below. Thisis the Motion Face.


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Select the Stationary Face, select the outlet

face.

Click OK.

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

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

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

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

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

Click OK.

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

Step 4: Change the translucency of the casting.

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


1


If necessary, turn on Shaded mode.

From the menu bar, choose Edit→Object Display.

Select the body and choose OK.

Slide the Translucency bar to 50% and choose OK.

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

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

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

Open the Assembly Navigator.

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

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

Examine the two models.

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


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

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

Choose File→Close →Save All and Close.


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

In this lesson you:

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

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

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


2

Lesson

2 Advanced Cavity Milling topics

Purpose

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

Objective


• Utilize advanced Cavity Milling options

• Create and modify Geometry parent groups for Cavity Milling

• Create and modify Cut Levels

• Utilize the In-Process Work Piece


2

Advanced Cavity Milling topics

Cut LevelsCavity Milling cuts geometry in planes or levels.

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

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

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

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

The Cut Levels dialog box serves these primary functions:

• Create, delete or modify Ranges

• Modify Cut Levels within Ranges

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

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


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Activity: Cut Levels parameters

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

Step 1: Open, rename the part, and start the Manufacturing application.

Open base_mfg_2_setup_1.

Choose Start→Manufacturing.

Step 2: Display the Operation Navigator.

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

In the Resource bar, click the Operation Navigator tab andexpand the BASE_MALE_DIE parent group.

Step 3: Generate the operation.

In the Operation Navigator, double-click CAVITY_MILL to editthe operation.

Click Generate .

Refresh or hit F5 to remove the path display.

Step 4: Edit the Bottom of Range #1.

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


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

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

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

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

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

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


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

click Delete Current Range and delete Range 5.

OK the Cut Levels dialog box.

Click Generate .

The path now stops at the desired level.

OK to the Cavity Mill dialog box.

Close the part.


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

The Cut Patterns are as follows:

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

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


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

Follow Periphery offsets the tool from the outermost edge that is definedby Part or Blank geometry. Internal islands and cavities will require IslandCleanup or a clean up Profile pass.

Follow Part


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creates concentric offsets from all specified Part geometry. The outermostedge and all interior islands and cavities are used to compute the tool path.Climb (or Conventional) cutting is maintained.

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


2


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


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Activity: Zig-Zag cut pattern

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

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

Open base_mfg_2_setup_1.

If necessary, choose Start →Manufacturing.

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

In the Operation Navigator, double-click the CAVITY_MILLoperation.

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

Zig-Zag for the Cut Pattern.


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Click Generate .

The tool path is generated.

Step 4: Change the Cutting options.

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

Cutting Parameters .

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

Click the Strategy tab.

In the Degrees box, type 45.

Click Display Cut Direction .

An arrow indicates the applied Cut Angle.

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

OK the Cutting Parameters dialog box.


Click Generate to generate the operation.

Click on the Assembly Navigator tab.

Expand the base_mfg_2 part.

Right click on the base_stock and select Hide.

Click Verify .

Use 3D Dynamic verification to analyze the results.

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

Cancel the Tool Path Visualization dialog box.

Change the Cut Pattern to Zig with Contour.


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Choose Generate to generate the operation.

Verify the tool path, using 3D Dynamic.

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

Close the part..


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

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

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

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

1. 3D IPW

2. Level Based IPW


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Level Based IPW

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

• Must be Cavity Mill or Z-Level operations.

• Must be under the same Geometry Group.

• Must have the same Tool Axis.


2


Use 3D

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


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Activity: Level Based In-process Workpiece (IPW)

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

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

Step 1: Open level_based_mfg_setup_2 and start the Manufacturingapplication.

Rename the part ***_level_based_mfg_setup_2 usingFile→Save As on the menu bar.

Step 2: Display the Operation Navigator.

Click the Operation Navigator tab in the Resource bar.


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

On the Operation Navigator toolbar, click Geometry View ,then expand the MCS_MILL andWORKPIECE parent groups.

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

Step 4: Create the first operation.

Click Create Operation .

Select mill_contour from the Type list.

Click CAVITY_MILL .


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Set the following location specifications:

Program PROGRAMTool EM-1.00Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

For Name type RM_ROUGH_1 and click OK.

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

Click Generate to generate the tool path.

Click OK to accept the path.

Step 5: Create the second operation.

On the Manufacturing Create toolbar, click Create Operation

.

Make sure Type is set to mill_contour and click CAVITY_MILL

.

Set the following location options:

Program PROGRAMTool EM-.75Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

Name the operation RM_ROUGH_2 and click OK.

Click Cutting Parameters .

Click the Containment tab.

From the In Process Workpiece list select Use Level Based.

Click OK.

Click Generate .

A Tool Path generate message is displayed.

Click OK.


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

Dismiss the Information Window, and click OK to accept thepath

Step 6: Create the third operation.


.

Click CAVITY_MILL .

Set the following location options:

Program PROGRAMTool EM-.5Geometry INSIDE_MILL_AREAMethod MILL_ROUGH

Name the operation RM_ROUGH_3 and click OK


Click the Containment tab.

From the In Process Workpiece list select Use Level Based.

Click OK.

Click Generate .

Click OK to accept the path.

Step 7: Verify the Tool Path.

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

From the operation navigator right-click PROGRAM and selectTool Path→Verify.

Select the 3D Dynamic tab.

Click Play.


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Close the part.


2


Pre-Drill Engage and Cut Region Start Points

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

Operation Where Found

Cavity Mill Non Cutting Moves – Start/DrillPoints

Corner Rough Non Cutting Moves – Start/DrillPoints

Rest Milling Non Cutting Moves – Start/DrillPoints

Z-Level Processors Non Cutting Moves – Start/DrillPoints

Profile 3D Non Cutting Moves – Start/DrillPoints

Face Milling Processors Non Cutting Moves – Start/DrillPoints

Planar Mill Processors Non Cutting Moves – Start/DrillPoints

Plunge Mill Points in Path Settings

Pre-Drill Engage Points

Operations normally determine where they start.

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

Region Start Points

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


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Activity: Pre-Drill Engage Point

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

Step 1: Open the form_mold_mfg_setup_3 part and start theManufacturing application.

Choose File→Open.

Select form_mold_mfg_setup_3, then click OK.

Choose Start → Manufacturing.

Step 2: Activate the Operation Navigator.In the Resource bar, click the Operation Navigator tab.


Step 3: Edit an existing operation.

Double-click the CAVITY_MILL operation.

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

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

In the Path Settings group, click Non Cutting Moves .

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

Verify the Selection Scope is set to Within Work Part andComponents.

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

Click OK in the Point dialog box.

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

Expand the Region Start Points group.


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

OK the Point dialog box.

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

Click the Engage tab.

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

Click OK in the Non-Cutting Moves dialog box.


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Step 5: Generate the tool path.

Click Generate to create the tool path.

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

Click Verify .

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

Click Play .

You may want to slow the animation speed down.

OK the Tool Path Visualization dialog box.

OK to accept the operation.

Close all pars without savingt.


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Cavity Milling stock options

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

Some of the stock options are as follows:

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

Part Floor Stock adds stock to the floor.

Blank Stock is stock applied to Blank geometry.

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

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

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


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Activity: Blank Distance option

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

Step 1: Open a new part, rename and start the Manufacturing application.

Open the horn_mfg_setup_1 part.


In the Resource bar, click the Operation Navigator tab.


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


.

The Create Operation dialog box is displayed.

Click CAVITY_MILL .


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Set the following:

Program ROUGH_WITHOUT_CASTINGTool EM-.375-.06Geometry WORKPIECEMethod MILL_FINISH

Name the operation CM_.20_BLANKDISTANCE.

Click OK.

The Cavity Mill dialog box is displayed.

Step 3: Verify the Part Geometry selection.

For Specify Part click Display .

Note that the Part geometry is displayed.

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

Step 4: Specify Operation settings.

In the Path Settings group, select Follow Part from the CutPattern list.

In the Global Depth per Cut type .125.


The Cut Parameters dialog box is displayed.

Click the Strategy tab if required.

In the Cutting group, select Depth First from the Cut Order list.

In the Blank group type .20 in the Blank Distance box.

Click OK.



Click Generate .

Click OK.


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The tool path cuts all of the core geometry.

Notice that the tool path follows the part contour since you usedthe Blank Distance option.

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

Click OK to accept the tool path.

Close the part.


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

The following functions are available in Cavity Milling:

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

• Cut levels to precisely control depths of cut

• Cut patterns to control direction and method of removing stock


3

Lesson

3 Plunge Milling

Purpose

In this lesson you will use Plunge Milling for roughing with multipleoperations. You will also utilize the 3D IPW to limit cut areas betweenoperations.

Objective


• Create Plunge Milling operations.

• Specify Pre-Drill Engage Points to safely enter the material.

• Utilize 3D IPW geometry used to limit the cut area.


3

Plunge Milling

Plunge millingPlunge Milling will provide for material removal using vertical motion, thestrongest cut direction of the machine tool and cutter.

Plunge milling cuts to the deepest part of the cut region and then stepsupward toward the shallower cut levels.

Pre-drilled Points are needed when non center cutting tools are used. You canspecify where the pre-drilled hole is located in the operation, then you createthe required operation to drill that hole.

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

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

2. Cursor by using the cursor position.

3. Generic Point by using the option on the generic point dialog box.

Plunge MillParameter

Description

Cut Method

Zig-Zag, Zig, Zig with Contour. Follow Periphery, and FollowPart are for roughing, Profile is for finishing. Follow Parthas specific enhancements for plunge roughing. Profile hasspecific enhancements for plunge finishing.


3

Plunge Milling

Parameter DescriptionMax CutWidth

Max Cut Width is the maximum width, looking down the toolaxis, that the tool can cut. This is usually supplied by thetool manufacturer, based on the size of the inserts. If this issmaller than the tool radius, then the bottom of the tool has anon-cutting portion in the center. This parameter determinesthe tool type for Plunge Milling operations. Max Cut Widthmaylimit the step over and step ahead to prevent the non-cuttingportion of the tool from plunging into solid material.

Set Max Cut Width to 50% or more for center cutting tools tomaximize the amount of cutting.

NX now assumes that this is a center cutting tool anddoesn’t check to see if there is a non-cutting portion ofthe tool that violates the in-process workpiece.

SetMax Cut Width to less than 50% for non-center cutting tools.

NX now assumes this is a non-center cutting tool, anduses Max Cut Width to determine if a non-cutting portionof the tool violates the in-process workpiece.

If it isn’t possible to cut a closed cavity without violatingthe Max Cut Width, the operation will output pre-drillpoints and a warning for you to add the required drillingoperation

In the figure below, A = tool insert, B= workpiece, C = MaxCut Width.


3

Plunge Milling

Stepover Stepover specifies the distance between adjacent cutpasses.

Step Ahead

Step ahead specifies the forward step from one plungeto the next. When necessary, the system reduces theappliedStep ahead to stay within the Max Cut Width value.

Step Ahead andStepover

For non-center cutting cases, either the step-overdistance or the step-ahead distance must be less thanthe specified Max Cut Width value. The software reducesthe applied Step ahead to stay within the Max CutWidth value.

Figure. Step Ahead (A) and Stepover (B)Plunge Levels Use Plunge Levels to define the plunge depth.


3

Plunge Milling

Activity: Create a Plunge Milling operationIn this activity, you will create a new Plunge Milling operation. The 3D IPWwill be activated. The 3D IPW will be used in the next activity limiting thetool path to the remaining material. Pre-Drill Engage Points will be added toallow take advantage of a hole that has been previously drilled in the part.

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

Open the plunge_mill_mfg_setup_1 part.

Choose Start→Manufacturing if necessary.

In the Resource bar, click the Operation Navigator tab.

Step 2: Create a new operation.

On the Manufacturing Create toolbar, click Create Operation.

The Create Operation dialog box displays.

From the Type list select mill_contour.

In the Operation Subtype group, click PLUNGE_MILLING .

In the Location group, set the following parameters:

Program PROGRAMTool EM-1.25Geometry MILL_AREAMethod MILL_ROUGH

Name the operation PLUNGE_1.25

Click OK.


3

Plunge Milling

Review the Geometry selection in the Plunge Milling dialog box.

Step 3: You will set a Pre Drilled Point as a safe starting position for thetool path.

In the Plunge Milling dialog box, in the Path Settings group,

click next to Points.

In the Pre-Drill Engage Points group click Edit

Click the Generic Point button and select the arc center of thehole in the part.

Click OK until you return to the Plunge Milling dialog box.

Step 4: Generate and Verify the operation.

Generate the tool path.

Click Verify on the Plunge Milling dialog box.

In the Tool Path Visualization dialog box, choose the 2DDynamic tab.

Click Play .

The operation removes the part material from the deepest pocketworking upward towards the top of the part.

Click OK in the Tool Path Visualization dialog box.


3

Plunge Milling

Click OK to save the operation.

Step 5: You will copy the previous operation, replace the tool with asmaller tool and use the 3D IPW from the original operation tomaximize tool motion.

Change the Operation Navigator to the Machine Tool View.

In the background of the navigator, right-click and chooseExpand All.

Right-click the PLUNGE_1.25 operation found under theEM-1.25 in the Operation Navigator and choose Copy.

Right-click EM–.75 and choose Paste Inside.

Right-click the new operation and choose Rename— changethe operation name to PLUNGE_.75.

Right-click the new operation and choose Edit.

You will now turn on 3D IPW option to avoid unnecessary toolmotion in the next tool path.

In the Plunge Milling dialog box, click Cutting Parameters .

Select the Containment tab and set In-process Workpiece toUse 3D.

Click OK.

Click Generate .

Notice that the tool only cut the areas that were not accessible tothe previous tool.

You will use the Verify option to replay the operation.

Click Verify .

In the Tool Path Visualization dialog box, choose the 3DDynamic property tab.

Click Play .

The operation removes the part material from the deepest pocketworking upward towards the top of the part.


3

Plunge Milling

Click OK in the Tool Path Visualization dialog box.

Click OK to save the operation.

Step 6: Close the part.


3

Plunge Milling

Plunge Milling Step UpIn this activity, you will change Plunge Milling Step Up. The Step up featureallows for improved material control on steep or shallow walls.

The Step Up option lets you control the distance between two or more cutlevels.


3

Plunge Milling

Activity: Plunge Milling Step Up1. Open base_2_setup_3 and start Manufacturing

2. Create a PLUNGE_MILLING operation.

Click Create Operation .

From the Type list, select mill_contour.

From the Operation Subtype list, select PLUNGE_MILLING .

Set the Location as follows;

Program 1234Tool EM-1_.125Geometry WORKPIECEMethod MILL_FINISH

Click OK.

3. Generate and Verify the tool path.

Click Generate.

The tool path utilizes the Step Up distance. The Step Up distance is 25%of the tool diameter.

4. Change the Step Up distance.

In the Step Up box type 50.

5. Generate and Verify the tool path.

Click Generate.

The tool path utilizes the Step Up distance. The Step Up distance is 50%of the tool diameter.


3

Plunge Milling

The Step Up is the minimum distance allowed. This is to eliminate plungecuts that remove small amounts of material.

Click OK.

6. Close the part.


3

Plunge Milling

SummaryThe Plunge Milling module provides efficient and robust capabilities ofremoving large amounts of stock using a plunge mill approach.

You examined the following in Plunge Milling:

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

• Added Pre-Drilled Engage points to safely enter the material.

• Used the Step Ahead and Max Cut Width parameters


4

Lesson

4 Z-Level Milling

Purpose

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

Objective


• Understand the uses of Z-Level milling.

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

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


4

Z-Level Milling

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

The following Z-Level operation types are available:

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

• ZLEVEL_PROFILE— Uses the Profile Cut Method without the SteepAngle being set

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

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

1. Create new Geometry

2. Select or Edit the Part Geometry

3. Select or Edit the Check Geometry

4. Select or Edit the Cut Area Geometry

5. Select or Edit the Trim Boundaries Geometry

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


4

Z-Level Milling

Geometry

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

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

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

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

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


4

Z-Level Milling

Activity: Z-Level Milling

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


Open the part base_mfg_3_setup_1.

Start the Manufacturing application if necessary.

Step 2: Activate the Operation Navigator.

In the Resource bar, click the Operation Navigator tab, andthen change to the Program Order View.

Expand the BASE_MALE_DIE group.

Step 3: Create a Z-Level operation.

Click Create Operation on the Manufacturing Create toolbar.

From the Type list select mill_contour.

In the Operation Subtype group, click ZLEVEL_PROFILE .

In the Location group set the following parameters:

Program BASE_MALE_DIETool EM_1.25_.25Geometry WORKPIECEMethod MILL_FINISH

Click OK.


4

Z-Level Milling

The Zlevel Profile dialog box is displayed.

Step 4: Change the Depth of Cut.

For ease of viewing turn model shading off.

In the Path Settings group, type 0.100 in the Global Depthper Cut box.

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

Click Cut Levels .

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

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

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

Choose OK.


4

Z-Level Milling



Step 6: Verify the Program that you have created.

Click Verify to examine the tool path results.

In the Tool Path Visualization dialog box, choose the 2DDynamic property tab.

Click Play .

Click OK twice to complete the operation.

Close the part.


4

Z-Level Milling

Steep AngleThe steepness of the part at any given area is defined by the angle betweenthe tool axis and the normal of the face. The steep area is the area where thesteepness of the part is greater than the specified Steep Angle. When theSteep Anglecheck box is selected, areas of the part with a steepness greaterthan or equal to the specified Steep Angle are cut. When Steep Angle checkbox is cleared, the part, as defined by the part geometry and any limiting cutarea geometry, is cut.


4

Z-Level Milling

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


Open the part cap_2_setup_1.

Start the Manufacturing application.

Step 2: Activate the Operation Navigator.

In the Resource bar, click the Operation Navigator tab, andthen change to Geometry View.

The MCS_MILL Parent Group is displayed in the OperationNavigator.

Expand the MCS_MILL and WORKPIECE Geometry ParentGroups.

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

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

Step 3: Create the ZLEVEL_PROFILE operation.


.

The Create Operation dialog box is displayed.


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Z-Level Milling

In the Operation Subtype group, select ZLEVEL_PROFILE

.

Set the following:

Program INTERIORTool EM_1.00_.25Geometry MILL_AREAMethod MILL_FINISH

Click OK.


Click Display next to Specify Part.

The entire part highlights, then refresh the graphics area.

Click Display next to Specify Cut Area.

Only the inside faces highlight.

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

In the Path Settings group, from the Steep Containment list,select Steep Only.

The Angle option defaults to 65 Degrees.

Set Global Depth per Cut to .05.


Click Generate and generate the tool path.

Choose OK to save the operation.

Step 6: Verify the tool path

With Program Order View on in the Operation Navigator,right-click INTERIOR program and choose Tool Path→Verify.

The Tool Path Visualization dialog box is displayed.

Click the 3D Dynamic tab.

Select Suppress Animation near the bottom of the dialog box.


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Z-Level Milling

Click Forward to Next Operation .

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

Notice the areas cut by the tool paths. Many of the areasnear the blends were not machined. A contour area operationmay be a better choice for finishing less steep areas.


Step 7: Set the Steep Parameter and Depth of Cut.

The Angle option appears and is defaulted to 65 Degree.

Right-click ZLEVEL_PROFILE and choose Edit.

Set Steep Angle to 45.




Step 9: Verify the tool path comparing the results with the initial path.

With Program Order View on in the Operation Navigator,right-click INTERIOR program and choose Tool Path→Verify.

The Tool Path Visualization dialog box is displayed.

Click the 3D Dynamic tab.

Select Suppress Animation near the bottom of the dialog box.



The tool path is adjusted to the new Steep Angle.

Close the part.


4

Z-Level Milling

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

Step 1: Create the Geometry Parent Group.

Open the steep_form_mfg_setup_1 part and startManufacturing.

Select Create Geometry from the Manufacturing Createtool bar.

The Create Geometry dialog box is displayed.

In the Geometry Subtype group, click Mill_Area .

If necessary, set the Geometry Location to WORKPIECE.

Enter ZLEVEL_AREA as the Name.

Click OK.

The Mill Area dialog box is displayed.

Click Specify Cut Area .

The Cut Area dialog box is displayed.


4

Z-Level Milling

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

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

Click OK.

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

Click OK.

You will now create the operation.

Step 2: Create the ZLEVEL_PROFILE Operation.

On the Manufacturing Workpiece toolbar, select Create

Operation .

In the Operation Subtype group, click ZLEVEL_PROFILE .

Set the following:

Program INTERIOR-PROGRAMTool EM-.500-.06Geometry ZLEVEL_AREA


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Z-Level Milling

Method MILL_FINISH

Click OK.

The ZLEVEL_PROFILE dialog box is displayed.

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

In the Geometry group, select Cut Area and choose Display

.

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

Change the Global Depth per Cut to .15.




Close the part.


4

Z-Level Milling

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

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

Stepover option

Stepover pertains to machining the gap areas.

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

Max Cut Traverse option

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

Sequencing of Gap and Z-Level tool paths

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


4

Z-Level Milling

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

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

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

Additional information on Z-Level Gap Machining can be found in theonline documentation from the NX Help menu.


4

Z-Level Milling

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


Open the part male_cover_mfg_setup_1.

Rename the part ***_male_cover_mfg_setup_1 usingFile→Save As on the menu bar.


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

Step 2: Replay an existing Z-Level operation.

Double-click the ZLEVEL_PROFILE operation for editingpurposes.


Click Replay .

Clear the Pause After Display and Refresh Before Displaycheck boxes and click OK.


4

Z-Level Milling

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

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


The Cut Parameters dialog box is displayed.

Click the Connections tab.

Select the Cut Between Levels check box..

Select Constant from the Stepover list.

In the Distance box, type 0.15.

ClickOK.



4

Z-Level Milling

Click Generate.

Clear the Pause After Display and Display Cut Regions checkboxes and click OK.

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


Close the part.


4

Z-Level Milling

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

In this lesson you:

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

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

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


5

Lesson

5 NC Assistant

Purpose

This lesson will familiarize you with the functionality of the NC Assistant.The NC Assistant is a very useful tool used to analyze corner and fillet radii,draft angles and cutting depths. Analyzing these features will aid you in thedetermination of the tool configuration needed to cut the part.

Objective


• Use the NC Assistant

• Determine cutter geometry based on information feedback from the NCAssistant


5

NC Assistant

Overview of the NC Assistant

The NC Assistant is only available inside of the Manufacturing applications,and assists you in analyzing the geometry and determining the proper tooling.

The Assistant is found in the main menu bar by choosing Analysis®NCAssistant and provides you the following four options:

1. Depths of floors and faces

2. Corner radii

3. Fillet radii

4. Draft angles

The information provided is color coded on the shaded model along with alisting giving data on the geometry being analyzed.

You select the geometry to be analyzed by selecting individual faces or byrectangular selection and then set the various parameters. .

When analyzing Levels, information is provided on the distance of planarlevels from a reference plane. This information can be used as an aid indetermining the length of the tool(s) that is needed.


5

NC Assistant

Analysis of Corner Radius provides information on the minimum corner radiiof the faces selected. This information will aid you in determining propertool diameter(s).

Analysis of Fillet Radius displays the minimum fillet radius of the selectedfaces with reference to a vector. This information will help you to determinethe tool nose radius, required, if any.

Analysis of Draft Angle will determine the slopes of the faces selected withreference to a specified vector. This information will help you to determinethe taper of the tool (also can be a quick aid in determining various areas ofdraft on a casting or injection mold).

When analyzing the various types, limits can be set. For example, if youwanted to check for all corner radii that were greater than .500 inchesand less than .750 inches, values can be set for the minimum of .500 andmaximum of .750.


5

NC Assistant

Activity: The NC Assistant

In this activity, you will become familiar with the various features of the NCAssistant. You will use the NC Assistant to determine the length, cuttingdiameter and corner radius of the tool(s) necessary to finish all pockets of thepart. Since you will only be analyzing this part, there is no need to rename orsave it.

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

Open the part analyzing_part_mfg_setup_1.

Rename the part ***_ analyzing_part_mfg_setup_1 usingFile→Save As on the menu bar.


Step 2: Activate the NC Assistant.

You will need to determine the tool configuration(s) necessary tofinish machine this part. Visually, it is sometimes difficult to detectdraft, if any, on parts. You will use the NC Assistant, to analyzethe geometry configuration.

Choose Analysis → NC Assistant.

The NC Assistant dialog box is displayed.

Step 3: Use the NC Assistant to determine cutter length.

If you look at the cue line, you will see that you are being asked toset parameters or select faces. You will accept the defaults for allparameters and select the entire part for face selection.

First you will analyze the Levels (height or depth) of variousfeatures to determine tool length requirements.


5

NC Assistant

The cue line ask you to set parameters or select faces. You will setthe Reference Plane to the top of the stock.

Click the Reference Plane button and select the top face ofthe stock block.

Click OK to return to the NC Assistant dialog box.

Drag a rectangle around the entire part.

Click Apply.

An Information Window listing the colors, the number of faces, andtheir depth is shown. These colors are displayed on your model inthe graphics window. The deepest face is 3.25, thereby requiring atool length of 3.25 for the roughing operation.

Step 4: Use the NC Assistant to determine cutter diameter.

The second item for consideration is to determine the diameter ofcutters that will be required. For this determination you will usethe NC Assistant to determine the various corner radii of the part.

Choose Corner Radii from the Analysis Type pull-down menu.

The dialog box for Corner Radii analysis is displayed.

Notice the limits for Minimum and Maximum Radius. These canbe used to isolate different sized geometry.

Click and drag a rectangle around the entire part.

Click Apply.

Corner Radii analysis results are displayed, only one .188 radius isfound. The rest of the blends are tapered.

Step 5: Use the NC Assistant to determine cutter corner radius.

Now we will determine the fillets on the model which will controlthe corner radius of our tools.

Choose Fillet Radii from the Analysis Type pull-down menu.

The dialog box for Fillet Radii analysis is displayed.

The cue line asked you to set parameters or select faces.

Accept the defaults and click and drag a rectangle around theentire part.

Click Apply.


5

NC Assistant

Fillet Radii analysis results are displayed with colors, number offaces and their sizes in the information window.

Step 6: Use the NC Assistant to determine draft angle on walls.

The fourth item for consideration is to determine any draft angleson the part that are machinable through the use of a tapered cutter.

Choose Draft Angles from the Analysis Type pull-down menuin the NC Assistant.

The dialog box for Draft Angles analysis is displayed and the cueline asked you to set parameters or select faces.

Under Tolerances, change Angle to 1.0.

Click and drag a rectangle around the entire part.

Draft Angle analysis results are displayed with colors, number offaces and their angle values in the information window.

Click Apply.

Cancel the NC Assistant dialog box and dismiss theInformation window

Save and Close the part.


5

NC Assistant

SummaryThe NC Assistant is an efficient tool to use for analyzing part geometryfor various corner radii, fillet radii, floor depths and draft angles. Thisinformation is beneficial in the determination of cutter parameters used forcutting your part.

In this lesson you:

• Became familiar with the functionality of NC Assistant.

• Performed various analysis functions which were used to determine cutterlength, diameter, corner radius and draft angle


6

Lesson

6 High Speed Machining

Purpose

This lesson will introduce you to some of the parameters and settings thatwill assist in the creation of High Speed Machining (HSM) operations. Theseoperations will allow for constant material removal and smooth cutter motion.

Objective


• Generate High Speed Machining operations.


6

High Speed Machining

High Speed MachiningHSM technology has shown increases in productivity and improved partquality. Characteristics of HSM are high spindle speeds, fast feed rates, lightcuts, smooth tool movement and constant volume removal. Due to the rapidchanges in dynamics of chip removal at these very high speeds, cut methodsand characteristics of the tool path are critical factors in the success of thecutting process. Factors such as sudden stops, sharp corners, reversal ofcut direction and erratic tool movements will directly affect the speed atwhich cuts are made.

There are two basic goals for HSM. They are:

• Maintain constant material volume removal

• Generate smooth tool moves throughout the entire cutting path

Applications abound in the aerospace and mold and die industry for HSMtechnology. Cutting thin wall parts in the aerospace industry is a typicalapplication. In the mold and die industry, contoured surface cutting canbe accomplished at high spindle speed and feed rates. Incorporating verysmall step overs results in very fine finishes that generally require no handfinishing work. Since tool deflection is at a minimum, greater accuraciescan be achieved.


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Machining options that require change for High Speed Machining

• Stepover allows you to control the distance between cut passes, smallerstopover for lighter cutter loads.

• Helical Engage with shallow ramps controlled by cutter manufacturerspecifications.

• Cut Levels can be adjusted for shallower cut depths.

• Feedrates and Spindle Speeds need to be adjusted for high speedmachining.

• Mixed Cut Directions in Z-Level Profile can be used to help maintaincontact with the part material.

• Level to Level – Direct on Part can help maintain contact with the part inZ-Level Profile when changing cut levels.

• Intol/Outol between 0.001 and 0.0005 will increase the size of the programbut will greatly decrease the amount of hand work to finish the part thatmust be done.

• Cut Order can be set to cut the level first in all multiple features beforeprogressing to the next level. This should be done in both roughing andfinishing to maintain rigidity in the thin walls

• Trochoidal cut patterns reduce slotting on the initial pass of pocketingpaths.


6


Activity: Create a High Speed Machining operation

In this activity, you will edit a conventional pocketing operation, changingparameters that will make the operation ideal for High Speed Machining.

Step 1: Open, then rename the part file and review an existing operation.

Open the part center_rib_mfg_setup_1.

Save as ***_ center_rib_mfg_setup_1 where *** representsyour initials.


This part file contains three operations that rough the part withdefault template settings. Normally one operation would work, butfor training purpose there are three operations. You will edit theseoperations and change numerous parameters that will make theseoperations more applicable to High Speed Machining.

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

Expand Program.

Right-click the cm_rough_2 operation and chooseToolpath→Verify.

In the Tool Path Visualization dialog box, in theMotion Displaygroup, set Display to Current Level.

The tool path is displayed. Review the method of engagement, thesharp corners generated within the tool path, the depth of cut, etc.


6


You will now edit the operation and modify parameters that areapplicable for High Speed Machining.

Cancel the Tool Path Visualization dialog box.

Step 2: Edit the existing operation and modify parameters suitable forHigh Speed Machining.

Double-click on the operation cm_rough_2.


Currently, all parameters set are default parameters. You will nowchange parameters for High Speed Machining.

From the Stepover list select Constant.

Type 0.10 in the Distance box.

In the Global Depth per Cut box type .10.

Currently all of the engage and retract parameters are still atthe default settings. We are going to set a few to show differentresults. Some of these values will vary at your shop due to cutterconfiguration, center cutting versus non-center cutting.

Click Non Cutting Moves and set the following parametersin the Closed Area of this dialog box:

Diameter 50.0Ramp Angle 4.0Height .02Minimum Ramp Angle 40.0

Diameter and Ramp Angle make a smaller tighter helical engage,Height value controls how far above the stock the helix starts.Minimum Ramp Length controls the material under non-centercutting tools.

Click OK.

Cutter geometry determines specific ramp angles andoverlap distance requirements.

Select Cutting Parameters .

Click the Stock tab.


6


The Intol and Outtol values shown are inherited from theMILL_ROUGH Method that was chosen when the operation wasmade. There should be no need for making these any tighter forroughing.

Select the Corners tab..

This option will add a fillet at all corners (corner roll) whicheliminates sharp moves.

Select All Passes from the Smoothing list.

From the Slowdown Distance list select Current Tool.

Slowdown is used to slow the feed rates as you approach cornersor obstructions in the tool path. Slowdown can be controlled bylength, starting location and the rate of slowdown.

Number Of Steps allows you to set the abruptness of slowdown.The greater the number, the more even the slowdown.

Set the Number of Steps to 4.

Click OK.

Select Feeds and Speeds .

The Feeds and Speeds dialog box is displayed.

Click Set Machining Data .

There are now values in the various windows that came from theMachining Data Base that is provided with the software. This partis made from P20 Prehardened steel, and we are using a BullnoseInserted endmill and we are using a HSM Rough Milling method.

Expand More under the Feed Rates group.

Various values are listed for the cutting of this part.

Click OK.

Step 3: Create the tool path.


Click Verify .


6


In the Tool Path Visualization dialog box, in theMotion Displaygroup, set Display to Current Level.

Check the corners on all the passes for the fillets.

Another change could be the decreasing of the helical engagediameter. All of these settings should be customized for individualshop and programmer preferences.

Click OK to accept the operation.

Save but do not close as we will continue to use this file.


6


Mixed Cut Directions

Cut patterns for high speed machining must allow constant volume removaland eliminate burying the cutter into material. They must also providea smooth transition from level to level, eliminating constant retracting,traversing and engaging.

Mixed cut directions are useful when large open areas are cut and you wantthe cutter to cut back and forth instead of beginning each cut at the same endof the part. This will minimize the time that is spent traversing between thevarious cut levels and from the end of one cut to the beginning of the next.

The next activity will familiarize you with using mixed cut directionsand making direct moves when cutting between levels in a Zlevel cuttingoperation.


6


Activity: Mixed Cut Directions

In this activity, you will use the part file from the previous activity andexplore the use of the Mixed Cut Direction option in Z-Level Profile.

Step 1: Edit the existing operation and modify parameters so that the toolis in constant contact with the part.

Continue with the part file ***_ center_rib_mfg_setup_1.

Double-click on the operation ZL_PRO_POCKET.


Click Verify , then Play to view the tool path.

You may want to slow down the display speed.

Notice that the tool retracts and engages for each cut level.

Click OK to dismiss the Tool Path Visualization dialog.

You will now change the cut parameters to allow the cutter tomove directly from one cut level to the next without engaging,traversing and retracting.


If necessary choose the Strategy tab.

From the Cut Direction list select Mixed.

Click the Connections tab, and select Direct on Part from theLevel to Level list.

Click OK to accept the Cut Parameters.


6


Step 2: Create the tool path.


Notice how the cutting tool engages the part, feeds down the wallof the part to get to the next level, and alternates the direction ofcut from one level to the next.

Click OK to complete the operation.

Save the part file, but do not close as it will be used for thenext activity.


6


Trochoidal Cut pattern

The Trochoidal Cut pattern is used when there is a need to control or preventtool embedding, as when the operation needs to rough out a closed area(pocket) and the first pass will have the cutter machining with the wholediameter. This is also an issue in tight (<90) corners or between islands.

This Trochoidal pattern (Moving circular loop) opens up a slot in the excessmaterial and then steps away from that initial slot with normal smoothpattern step over to finish the material removal. This pattern is controlledby a stepover and path width values that provide maximum and minimumsettings.

• (1) Step Over

• (2) Path Width

The following figure illustrates the Trochoidal Cut pattern. Note the loopingpattern. The cutter machines the material in small looping motions.


6


Activity: Trochoidal cut pattern

In this activity, you will first examine an existing planar milling operationthat uses the Follow Part cut method. You will then change the cut methodto Trochoidal, select a different cutting tool and regenerate the operation toobserve the changes in the corresponding tool paths.

Step 1: Continue using the ***_ center_rib_mfg_setup_1 part from theprevious activity.

Step 2: If necessary, enter the Manufacturing application and display theOperation Navigator.

If necessary, change to the Program Order view of theOperation Navigator and expand the group objects.

We are going to use CM_ROUGH_1 for this activity.

This operation will be replayed and then modified by applying theTrochoidal Cut method.

Step 3: Replay and then modify the CM_ROUGH_1 operation to utilizethe Trochoidal Cut method.

Double-click the CM_ROUGH_1 operation.


Click Replay .


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The tool path is displayed.

You will now modify the operation by changing the Cut Methodto Trochoidal.

From the Cut Pattern list select Trochoidal.

Type 30 in the Percent of Flat Diameter box.


In the Trochoidal Width box type 50..

In the Min Trochoidal Width box type 15.

In the Stepover Limit % box type 120.

In the Trochoidal Step Ahead box type 20.

Click OK.

Generate the tool path.

Step 4: Examine in detail, the tool path created using the Trochoidal Cutmethod.

Click Verify .

From the Display list select Current Level.

Zoom in on the various cut areas and examine the tool path indetail.

Click OK twice.

Save and Close the part file.


6


SummaryHigh Speed Machining technology has shown dramatic increases inproductivity and improved part quality. The characteristics of HSM such ashigh spindle speeds, fast feed rates, light cuts, smooth tool movement andconstant volume removal are obtainable through various parameter settings.

In this lesson you:

• Explored various parameters within operations that lend themselves toHigh Speed Machining concepts.

• Generated operations, using parameters that were conducive to HSM.

• Used the Trochoidal Cut method to generate tool paths that avoidsembedding the tool in material and limits the amount of step over.


7

Lesson

7 Fixed Contour operation types

Purpose

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

Objective


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

• Create Geometry Groups used for Fixed Contouring operations

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

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


7

Fixed Contour operation types

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

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

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

Terminology used in Fixed Contour operations

• Part Geometry - Geometry selected to cut.

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

• Drive Geometry - Geometry used to generate drive points.

• Drive Points - Generated from the drive geometry and projected onto thepart geometry.

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

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

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


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Drive methods for Fixed ContouringThe Drive method defines the method of creating drive points.

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

Curve/Point drive method

The Curve/Point drive method enables you to define Drive geometry byspecifying points and selecting curves. When specifying points, the DrivePath is created as linear segments between the specified points.

Spiral drive method

The Spiral drive method enables you to define Drive Points that spiraloutward from a specified center point. The drive points are created within theplane normal to the projection vector and containing the center point.

Boundary drive method

The Boundary drive method enables you to define cut regions by specifyingBoundaries and Loops. Boundaries are not dependent on the shape and size ofthe Part Surfaces while Loops must correspond to exterior Part Surface edges.

Area Milling drive method

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

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

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

Surface drive method

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

Tool Path drive method

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


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Radial Cut drive method

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

Flow Cut drive method

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

Text drive method

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

User Function drive method

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


7


Geometry groups associated with Fixed Contour operationsThere are three different Geometry groups available for use in Fixed Contouroperations. They are:

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

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

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

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


7


Fixed Contour operation typesThe Fixed Contour operation types are:

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

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

• CONTOUR_AREA_NON_STEEP — Controls how steep you can cut upand down due to cutter issues.

• CONTOUR_AREA_DIR_STEEP — Allows steep areas to be cut withrespect to the direction of cut.

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

• STREAMLINE — The Streamline drive method builds an implieddrive surface from the selected geometry. Streamline enables completelyflexible tool path creation. A well ordered grid of regular faces is notrequired.

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

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


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

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

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


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


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


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

Step 1: Open the part, rename and start the Manufacturing application.

Open the part male_cover_mfg_3_setup_1.

Save As ***_male_cover_mfg_3_setup_1 .

Start the Manufacturing application and display the OperationNavigator in the Program Order.

Step 2: Hide the stock for clarity

Click the Assembly Navigator tab.

Expand male_cover_mfg_3.

Right-click male_cover_stock and choose Hide.

Step 3: Review the Cavity Milling roughing operation.

This part has been rough cut using a Cavity Mill operation.

Click the Operation Navigator tab.

Right-click the ROUGH_CM operation and choose ToolPath®Verify.

Click the 3D Dynamics tab

Select the Suppress Animation check box.


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

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


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

Step 4: Create a Fixed Contour operation to semi-finish the part.

On the Manufacturing toolbar, select Create Operation .

In the Operation Subtype group, click CONTOUR_AREA .

In the Location group, set:

Program MALE_COVERTool BALLMILL-1.00Geometry WORKPIECEMethod MILL_SEMI_FINISH

Enter the Name as semi_rough_fc.

Choose OK.

The Contour Area dialog box is displayed.

In the Geometry group, next to Specify Part click Display .

In the Drive Method group, click Edit .

The Area Milling Drive Method dialog box is displayed.


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

• Select Zig Zag from the Cut Pattern list.

• From the Stepover list select % Tool Flat

• Type 25 in the Percent box.

• From the Cut Angle list select Automatic.

Click OK.

Click Generate .

OK to accept the operation.

Step 5: Create a Fixed Contour finishing operation using the ContourArea operation type.

On the Manufacturing Workpiece toolbar, click Create

Operation .

In the Operation Subtype group, click CONTOUR_AREA .

In the Create Operation dialog box, set the following:

Program MALE_COVERTool BALLMILL-1.00Geometry WORKPIECEMethod MILL_FINISH

Type finish_fc in the name box.

Click OK.

The Contour Area dialog box is displayed.


The Area Milling Method dialog box is displayed.


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From the Cut Pattern select Follow Periphery.

From the Pattern Direction select Outward.

From the Stepover list select Scallop

Type .002 in the Scallop Height box.

From the Stepover Applied list select On Plane.

Choose OK.

Click Generate .


Step 6: Create a Flow Cut finishing operation.

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

On the Manufacturing toolbar, select Create Operation .

The Create Operation dialog box appears.In the Operation Subtype group, click FLOWCUT_REF_TOOL

.

In the Location group, set:

Program MALE_COVERTool BALLMILL-.500


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Geometry WORKPIECEMethod MILL_FINISH

Enter the Name as flow_fc.

Click OK.

The Flowcut Reference Tool dialog box is displayed.

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

Step 7: Change the Reference Tool setting.

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

Expand Reference Tool.

Enter 1.00 in the Ref. Tool Diameter value field.

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


Click Generate .

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

Choose OK.

Save and Close the part.


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Cut AreaIn the previous activity, youmachined the entire part with our operationsfor semi-finish and finishing. Now you are going to break our part downinto smaller pieces.

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

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


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

Step 1: Open the part, rename it, and start the Manufacturing application.

Open the part male_cover_mfg_2_setup_1.

Rename the part ***_male_cover_mfg_2_setup_1 usingFile→Save As on the menu bar.


Change the Operation Navigator to the Geometry View.

Expand the MCS_MILL andWORKPIECE geometry groups.

Step 2: Replay the current operation.

Right-click the FC_FINISH_RIBS operation and choose Replay.


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This Fixed Contour operation machines the entire part.

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

Refresh the graphics screen.

Step 3: Create the MILL_AREA geometry group.

On the Manufacturing Create toolbar, click Create Geometry

.

Set the Geometry Subtype to MILL_AREA .

In the Location group, set Geometry to WORKPIECE.

In the Name field, type two_ribs.

Click OK.

The MILL_AREA dialog box is displayed.

Step 4: Define the Cut Area geometry.

Click Specify Cut Area .

At this time, it will make it easier to select the rib faces byclicking the Assembly Navigator tab and unchecking the redcheck mark in front of the male_cover_stock, bolt_5 and themale_cover_mach_plate components. This will prevent theselection of faces that are not part of the Workpiece.


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

Choose the faces of the ribs, as shown.

When finished selecting the faces, choose OK.

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

Choose OK again to accept the dialog box.

Step 5: Change the inheritance of the operation.

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

Drag the FC_FINISH_RIBS operation so that it resides underthe TWO_RIBS Parent Group, then release the mouse button.

Right-click the FC_FINISH_RIBS operation and choose Edit.

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

Click Edit next to Area Milling.

From the Cut Pattern list select Zig Zag.

Click Generate .


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Save the part, but do not close, as it will be used in the nextactivity.


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

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


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

Step 1: Continue using the part.

Continue using ***_male_cover_mfg_2_setup_1.

Step 2: Create a Trim Boundary.

Change the view to TOP.

Change the Operation Navigator to the Geometry View.

You will now edit the operation.

Double-click on the TWO_RIBS geometry.

Click TRIM .

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

For Filter Type click Point Boundary .

Change the Point Method to Cursor Location.

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

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


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

Choose OK to return to the main dialog box.


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

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


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Save and close the part.


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

In this lesson you:

• Created Area Milling and Flow Cut operations.

• Made extensive use of the MILL_AREA parent group.

• Created Trim Boundaries


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Lesson

8 Streamline drive method

Purpose

In this lesson you will use Streamline Milling operations to create tool pathson contoured faces. The Streamline drive method builds an implied drivesurface from the selected geometry. Streamline enables completely flexibletool path creation.

Objective


• Create Streamline milling operations

• Create Streamline operations using Automatic Flow and Cross Curves

• Create Streamline operations by defining Specified Flow and Cross Curves

• Add cross curves to further define the tool path


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Streamline drive method

Streamline drive methodThe Streamline drive method allows great flexibility creating a drive path.The drive path can be generated automatically or it can be specified. Thedrive path is created using Flow and Cross curves, these curves contain thedrive path and determine the drive path shape.


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Flow and Cross curves

Flow and cross curves create:

Typical 4–sidedconfiguration.

Intermediate cross curveselected to give moreshape control for thedrive surface.

Intermediate flow curveselected to give morepattern control for thedrive surface.

Four–sided drive surfacewith one intermediateflow (for better patterncontrol) and oneintermediate cross (forbetter shape control)added. You can addas many intermediatecurves as needed.

Three–sided with twoflows and one cross.

Three–sided with twoflows and two cross curvesets. The second flowcurve set contains asingle point.

Two sided drive surface.Two sided drive surfacewith a cross curve added

Two closed loopsselected. A cross curve


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to better define theshape.

gives shape to the drivesurface and defines thestart points.

Two closed loopsselected. (The pointat top is technically thesecond closed loop.) Twocross curves give morecontrol over the shape ofthe drive surface.

Automaticselection onlyidentifies the twoexterior loops ofthe cut area. WithSpecify you canmanually selectany number ofclosed loops tocreate flow curvesets.


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Activity: Create an Automatic Streamline operation

In this activity, you will create a new Streamline drive method operation.

You will use the predefined WORKPIECE along with the new Cut Areageometry and use Automatic Flow and Cross curves.

Step 1: Open, rename the part, and enter the Manufacturing application.

Open the cap_setup_1 part.

Rename the part ***_cap_setup_1 using File→Save As on themenu bar.


Step 2: Select the geometry for the operation.

On the Manufacturing Create toolbar, click Create Geometry

.

The Create Geometry toolbar appears.

Select mill_contour from the Type list.

In the Geometry Subtype group, click Mill Area .

In the Location group select WORKPIECE from the Geometrylist.

Type MILL_AREA in the Name box (if necessary).

Click OK.

In the Geometry group, click Specify Cut Area and selectthe faces as shown.


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Click OK to return to the MILL_AREA dialog box.

Click OK to return to the Operation Navigator.

Step 3: Create a new Streamline operation.

In the Manufacturing Create toolbar click Create Operation

.

The Create Operation dialog box appears.

Select mill_contour from the Type list (if needed).

Click STREAMLINE .

Set the Location groups as shown:

Program 1234Tool BMILL_.75Geometry MILL_AREAMethod MILL_FINISH

Name the operation SCOOP_END.

Click OK to create the operation.

Step 4: Edit the Drive Parameters to preview the tool path.

In the Streamline dialog box, in the Drive Method group, click

Edit .

The Streamline Drive Method dialog box is displayed.

The Flow and Cross curves are displayed. The Drive Path Previewis also displayed.


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Click OK.

Click Generate .

Click OK to complete the operation.

The Flow and Cross curves were selected using the Automaticsetting. The curves were selected as shown below.

Step 5: Edit the Streamline path to examine the Flow and Cross curves.

Double-click the SCOOP_END operation in the Program Viewof the Operation Navigator.



Expand the Preview group

Clear the Preview check box.


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Refresh the graphics screen.

In the Flow Curves group, expand the List.

Click Flow 1 in the list to see the first flow curve.

Click Flow 2 in the list to see the second flow curve.

In the Cross Curves group, expand the List again.

Click Cross 1 in the list to see the first cross curve.

Click Cross 2 in the list to see the second cross curve.

In the Preview group, select the Preview check box.

The drive path is displayed on the graphics screen.

In the Drive Settings group, set the Number of Stepovers to 20.

In the Preview group, click Display .

Click OK.

Click Generate .

Review the tool path.


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Click OK.

Save the part, but do not close.


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Activity: Create a Manual Streamline operation

In this activity, you will create a new Streamline drive method operationusing the pre-defined WORKPIECE and the MILL_AREA from the lastactivity. You will Specify the Flow and Cross curves.Step 1: Continue to use the ***_cap_setup_1 part.

If necessary, open the ***_cap_setup_1 part.

Choose Start → Manufacturing if necessary.

Step 2: Create a new Streamline operation.In the Manufacturing Create toolbar click Create Operation

.

The Create Operation dialog box appears.

In the Operation Subtype group, click STREAMLINE .

Set the Location parameters as shown:

Program 1234Tool BMILL_.75Geometry MILL_AREAMethod MILL_FINISH


The Streamline dialog box appears.

Step 3: Edit the Drive Parameters to remove the Automatic Flow andCross curves.

In the Drive Method group click Edit next to Method.



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In the Drive Curve Selection group, select Specify from theSelection Method list.

In the Flow Curves group expand the List.

Highlight Flow 1 and click Remove .

Highlight Flow 2 and click Remove .

In the Cross Curves group expand the List.

Highlight Cross 1 and click Remove .

Highlight Cross 2 and click Remove .

Step 4: You will select the new Flow and Cross curves to generate adifferent path.

In the Flow Curves group click Curve .

Select the following curves.


8


In the Flow Curves group, click Add New Set .

Select the curves as shown below.

The Flow Curves direction vectors should point in the directionshown.

If the vectors do not match, highlight the appropriate Flow

Curve and select Reverse Direction .


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The Flow curves are complete. You will now select the Crosscurves.

In the Cross Curves group click Select Curve .

Choose Single Curve from the Curve Rule list.


In the Cross Curves group click Add New Set .


When finished, the Flow and Cross must align correctly. Each setof curves should point in the same direction.

If the direction vectors are not correct, highlight one of the

curves in the list and click Reverse Direction .

In the Drive Settings group, select Contact from the ToolPosition list.

Click OK.


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Click Generate .

The same curves are used in the Automatic and Specify operations.The selection of Flow and Cross curves has changed the resultingtool path.

Compare the results from the Automatic and Specified paths.

Click OK.

Save the part, but do not close as you will use it in the nextactivity.


8


Activity: Add additional curves for more controlIn this activity, you will create a new Streamline drive method operation. Youwill use the predefined WORKPIECE along with a new Cut Area geometryand use Automatic Flow and Cross curves, then add additional Cross curves.

Step 1: Continue using ***_cap_setup_1 from the previous activity.


Step 2: Select the geometry for the operation.

In the Manufacturing Create toolbar, click Create Geometry

.

The Create Geometry dialog box appears.

In the Geometry Subtype group click Mill Area .

In the Location group, set Geometry to WORKPIECE.

Type MILL_AREA_1 in the Name box.

Click OK.

In the Geometry group, click Specify Cut Area and selectthe faces as shown.


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Click OK to return to the MILL_AREA dialog box.

Click OK to return to the Operation Navigator.

Step 3: Create a new Streamline operation.


.

In the Operation Subtype group, click STREAMLINE .

Set the Location groups as shown:

Program 1234Tool BMILL_.75Geometry MILL_AREA_1Method MILL_FINISH


Step 4: Edit the Drive Parameters to preview the tool path.

In the Drive Method group click Edit .



Click OK and Generate the tool path.


8


The tool path could be smoother with the addition of more crosscurves.

Step 5: Add more Cross curves to control the drive path.

In the Drive Method group click Edit .


In the Cross Curves group expand the List and click Add NewSet.

Select the first set of curves as shown.

In the Cross Curve group, click Add New Set.

You will select the same curves on the opposite side of the part.

Select the first set of curves as shown.

Click OK.


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Click Generate.

The tool path is more smooth.

Step 7: Modify the Projection Vector to improve the path.

The projection vector determines how the drive points are projectedonto the part geometry. This part has steep walls to projectingalong the tool axis is not the best option.

Expand Projection Vector.

Select Toward Drive from the Vector list.


Click Generate.

The tool path is improved.

Step 9: Change the tool position to further control the tool path.

The current tool path is rolling over the top of the part geometry.


In the Drive Settings section of the dialog box choose Contactfrom the Tool Position list.


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Click Generate.

The tool path is complete.


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SummaryThe Streamline drive method simplifies geometry selection and providesadditional drive path control.

You examined the following in Streamline:

• Used Automatic Flow and Cross curves to create a tool path.

• Selected user defined Flow and Cross curves to create a tool path.

• Added additional cross curves to control the drive path.


Index

CCavity MillCut Levels . . . . . . . . . . . . . . . . . . 2-2Cut Patterns

Cut Pattern . . . . . . . . . . . . . . 2-6Cavity Millingcut region start points . . . . . . . . . 2-21Cut Area GeometryZ-Level Milling . . . . . . . . . . . . . . . 4-3Cut Levels . . . . . . . . . . . . . . . . . . . . 2-2Cut Patterns . . . . . . . . . . . . . . . . . . 2-6

FFixed Contourdrive geometry . . . . . . . . . . . . . . . 7-2drive methods

flow cut . . . . . . . . . . . . . . 7-4, 7-7radial cut . . . . . . . . . . . . . . . . 7-4tool path . . . . . . . . . . . . . . . . 7-3User Function . . . . . . . . . . . . 7-4

drive points . . . . . . . . . . . . . . . . . 7-2operation types . . . . . . . . . . . . . . . 7-6

contour_area . . . . . . . . . . . . . 7-6contour_surface_area . . . . . . . 7-6fixed_contour . . . . . . . . . . . . . 7-6

terminology . . . . . . . . . . . . . . . . . 7-2check geometry . . . . . . . . . . . 7-2drive geometry . . . . . . . . . . . . 7-2drive method . . . . . . . . . . . . . 7-2drive points . . . . . . . . . . . . . . 7-2part geometry . . . . . . . . . . . . 7-2projection vector . . . . . . . . . . . 7-2

use of . . . . . . . . . . . . . . . . . . . . . . 7-2

GGeometry TypesZ-Level Milling . . . . . . . . . . . . . . . 4-3

HHigh Speed Machiningapplication of . . . . . . . . . . . . . . . . 6-2characteristics . . . . . . . . . . . . . . . 6-2mixed cut directions . . . . . . . . . . . 6-8specific goals . . . . . . . . . . . . . . . . . 6-2

NNC Assistantanalysis types available . . . . . . . . 5-2

draft angle . . . . . . . . . . . . . . . 5-3fillet radius . . . . . . . . . . . . . . 5-3levels . . . . . . . . . . . . . . . . . . . 5-2

PPart GeometryCheck Geometry

Z-Level Milling . . . . . . . . . . . 4-3

TTrim GeometrySteep Angle

Z-Level Milling . . . . . . . . 4-3, 4-7

WWAVE Geometry Linker . . . . . . . 1-2, 1-5Assemblies and Wave . . . . . . . . . . 1-8Create Associative . . . . . . . . . . . . 1-2definition of . . . . . . . . . . . . . . . . . 1-2deleting parent geometry . . . . . . . 1-7editing links . . . . . . . . . . . . . . . . . 1-4Hide Original . . . . . . . . . . . . . . . . 1-2linking procedure . . . . . . . . . . . . 1-12Links

Associative . . . . . . . . . . . . . . . 1-5broken . . . . . . . . . . . . . . . . . . 1-6

Fixed Axis Techniques – Student Guide Index-1

Index

deleting of . . . . . . . . . . . . . . . 1-8simplify

Simplify Body . . . . . . . . . . . 1-15

ZZ-Level MillingCheck Geometry . . . . . . . . . . . . . . 4-3

Cut Area Geometry . . . . . . . . . . . . 4-3Geometry Types . . . . . . . . . . . . . . 4-3Part Geometry . . . . . . . . . . . . . . . 4-3Steep Angle . . . . . . . . . . . . . . . . . 4-7Trim Geometry . . . . . . . . . . . . . . . 4-3Types . . . . . . . . . . . . . . . . . . . . . . 4-2

Index-2 Fixed Axis Techniques – Student Guide mt11065_s NX 6

LEARNING

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Course Agenda

Fixed Axis Techniques - Course Agenda

Day One • Course Overview • Lesson 1. WAVE Geometry Linker in Manufacturing • Workbook Machining Preparation • Lesson 2. Advanced Cavity Milling Topics

Afternoon • Lesson 2. Advanced Cavity Milling Topics • Lesson 3. Plunge Milling

Day Two • Lesson 4. Z-Level Milling • Lesson 5. NC Assistant

Afternoon • Lesson 6. High Speed Machining • Workbook Plunge and Cavity Milling

Day Three • Lesson 7 Fixed Contour Operation Types • Lesson 8 Streamline drive method

Afternoon • Workbook Fixed Contour Finishing Operations

Accelerators

The following Accelerators can be listed from within an NX session by choosing Information→Custom Menubar→Accelerators.

Function Accelerator File→New... Ctrl+N File→Open... Ctrl+O File→Save Ctrl+S File→Save As... Ctrl+Shift+A File→Plot... Ctrl+P File→Execute→Grip... Ctrl+G File→Execute→Debug Grip... Ctrl+Shift+G File→Execute→NX Open... Ctrl+U Edit→Undo Ctrl+Z Edit→Redo Ctrl+Y Edit→Cut Ctrl+X Edit→Copy Ctrl+C Edit-Paste Ctrl+V Edit→Delete... Ctrl+D or Delete Edit→Selection→Top Selection Priority - Feature F Edit→Selection→Top Selection Priority - Face G Edit→Selection→Top Selection Priority - Body B Edit→Selection→Top Selection Priority - Edge E Edit→Selection→Top Selection Priority - Component C Edit→Selection-Select All Ctrl+A Edit→Show and Hide→Show and Hide... (by type) Ctrl+W Edit→Show and Hide→Hide... Ctrl+B Edit→Show and Hide→Invert Shown and Hidden Ctrl+Shift+B Edit→Show and Hide→Immediate Hide… Ctrl+Shift+I Edit→Show and Hide→Show... Ctrl+Shift+K Edit→Show and Hide→Show All Ctrl+Shift+U Edit→Transform... Ctrl+T Edit→Move Object Ctrl+Shift+M Edit→Object Display... Ctrl+J View→Operation→Zoom... Ctrl+Shift+Z View→Operation→Rotate... Ctrl+R View→Operation→Section... Ctrl+H View→Layout→New... Ctrl+Shift+N View→Layout→Open... Ctrl+Shift+O View→Layout→Fit All Views (only with multiple views) Ctrl+Shift+F View→Layout→Fit Ctrl+F View→Visualization→High Quality Image... Ctrl+Shift+H View→Information Window F4 Hide or show the current dialog box F3

View→Reset Orientation Ctrl+F8 Insert→Sketch... S Insert→Design Feature→Extrude... X Insert→Design Feature→Revolve... R Insert→Trim→Trimmed Sheet... T Insert→Sweep→Variational Sweep... V Format→Layer Settings... Ctrl+L Format→Visible in View... Ctrl+Shift+V Format→WCS→Display W Tools→Expression... Ctrl+E Tools→Update→Make First Feature Current Ctrl+Shift+Home Tools→Update→Make Previous Feature Current Ctrl+Shift+Left Arrow Tools→Update→Make Next Feature Current Ctrl+Shift+Right Arrow Tools→Update→Make Last Feature Current Ctrl+Shift+End Tools→Journal→Play... Alt+F8 Tools→Journal→Edit Alt+F11 Tools→Macro→Start Record... Ctrl+Shift+R Tools→Macro→Playback... Ctrl+Shift+P Tools→Macro→Step... Ctrl+Shift+S Tools→Movie→Record Alt+F5 Tools→Movie→Stop Alt+F7 Information→Object... Ctrl+I Analysis→Curve→Refresh Curvature Graphs Ctrl+Shift+C Preferences→Object... Ctrl+Shift+J Preferences→Selection... Ctrl+Shift+T Start→Modeling... M or Ctrl+M Start→All Applications→Shape Studio... Ctrl+Alt+S Start→Drafting... Ctrl+Shift+D Start→Manufacturing... Ctrl+Alt+M Start→NX Sheet Metal... Ctrl+Alt+N Start→Assemblies A Help→On Context... F1 Refresh F5 Fit Ctrl+F Zoom F6 Rotate F7 Orient View-Trimetric Home Orient View-Isometric End Orient View-Top Ctrl+Alt+T Orient View-Front Ctrl+Alt+F Orient View-Right Ctrl+Alt+R Orient View-Left Ctrl+Alt+L Snap View F8

Evaluation – Delivery

NX 6 Sheet Metal Design, Course # TR16020 Dates thru

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Comments on overall impression of instructor(s):

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What you liked best about the course delivery:

Class Logistics: 1. The training facilities were comfortable, clean, and provided a good learning

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1. Name of the hotel Best hotel I’ve stayed at

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3. Problem? (brief description)

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Evaluation - Courseware

NX 6 Sheet Metal Design, Course # TR16020

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