Академический Документы
Профессиональный Документы
Культура Документы
MANUFACTURING ESSENTIALS
The Operation Navigatior
The Manufacturing application allows you to interactively create NC machining programs,
generate tool paths, visualize material removal, and postprocess.
This course will familiarize you with the essential functions used throughout the
Manufacturing application. You will learn how to use the Operation Navigator and step
through the process of creating a program. With few exceptions, this process is consistent
throughout the Manufacturing application.
Once you have completed this course, you will be ready to move on to courses that pertain to
your specific areas of interest such as milling, drilling, turning, or wire edm.
Audience
This course is intended for users who require a general overview of the Manufacturing
application. New users should complete this course before moving on. Subsequent courses
allow you to selectively examine your particular areas of interest.
Prerequisites
The prerequisite for this course is the Unigraphics NX Essentials CAST Online Library
course. In addition, you should be familiar with basic manufacturing processes and
terminology.
Course Contents
The Operation Navigator You will learn about the relationship between parent groups
and operations, how the Operation Navigator organizes objects, and how operations inherit
parameters from parent groups. You will explore some of the essential functions of the
Operation Navigator, including how to change views, edit parameters, cut and paste objects,
and specify a machining environment.
2
Creating Objects You will learn how to create Program, Tool, Geometry, and Method
objects.
Creating Operations You will learn how to create operations individually and how to edit
and respecify parent groups from within the operations.You will also learn how to customize
dialogs to update legacy operations by adding the Main, Groups and Viewing tabs that are
found on newly created operations.
Creating Operation Sequences You will learn how to use a Process Assistant to create a
Source File (CLSF) and how to postprocess the CLSF using the Graphics Postprocessor
Module (GPM).
Shops You will learn how to use Shops, a product designed to step the occasional user
(such as the shop floor machine operator) through the process of creating an operation using a
Process Assistant.
Shop Documentation You will learn how to create shop documentation in HTML format
In the above illustration, the WORKPIECE object inherits parameters from its parent, the
MCS_MILL object. The MILL_AREA object inherits parameters from its parent, the
WORKPIECE object (which inherits parameters from the MCS_MILL object). The
operations all inherit parameters from the MILL_AREA object (which inherits parameters
from the WORKPIECE and MCS_MILL objects).
Manufacturing.
4
In Windows, you can display the Operation Navigator by clicking or double-clicking on the
Operation Navigator tab in the resource bar. Clicking on the tab temporarily displays the
Operation Navigator by sliding it to the left over the graphics display. Once you move the
cursor out of the Operation Navigator the Operation Navigator disappears from the screen.
Clicking on the pin at the upper left corner of the Operation Navigator allows the Operation
Navigator to remain on the screen when you move the cursor out of the area.
Double-clicking on the tab displays the Operation Navigator in a separate window which can
then be moved and docked (Ctrl key undocks).
Clicking the Close icon at the upper right corner closes the window and restores the tab.
Practice using the Operation Navigator tab, pinning, docking, and undocking as described
above.
Click MB3 on the Operation Navigator background and choose Columns and Configure.
Turn the Tool Description option off.
8
OK to accept the Operation Navigator Properties dialog.
Operation
in the toolbar.
Click on the plus (+) sign to fully expand the PROGRAM object.
The Program Order View displays the program that each operation belongs to and the order in
which operations will be executed on the machine tool. This is the only view in which the
order of the listed operations is relevant or important.
in the toolbar.
10
in the toolbar.
Remember, the only view in which the order of the listed operations is relevant is the Program
Order view.
11
in the toolbar.
Cut.
The object you choose in the next step is the operation below which the pasted operation will
appear.
Choose the CONTOUR_AREA_DIR_STEEP icon and MB3
Paste.
12
in the toolbar.
The CONTOUR_FOLLOW_1 operation currently uses MILL_1 as the parent group that
defines cutting tool.
Choose the CONTOUR_FOLLOW_1 icon and MB3
Cut.
The object you choose in the next step is the parent group inside of which the operation will
be pasted.
Choose the MILL_2 icon and MB3
Paste Inside.
13
A slashed red circle now appears in front of the pasted operation. This indicates that
operation parameters have changed and that the tool path must be regenerated to reflect the
change.
Operations and program groups in the Operation Navigator are preceded by one of three
status symbols; Complete, Regenerate, or Repost as illustrated below.
A green check mark
Complete status means that the operation or program has been generated, incorporating the
current operation parameters, and has been either postprocessed or output to an operating
system text file.
A slashed red circle
Regenerate means that a tool path has not been generated for the operation or that operation
parameters have changed and that the tool path must be regenerated to reflect the change.
An exclamation point
Repost status means that the tool path for the operation has been generated, but it has not been
postprocessed or exported from the part file.
The status symbols are dynamic and will update as the status of the operation or group
changes.
14
Generate.
An exclamation point now appears in front of the operation and PROGRAM object
indicating that the operations have been generated but have not yet been postprocessed or
exported.
15
in the toolbar.
Replay.
You can replay tool paths selectively by holding down the Ctrl key and choosing individual
operations.
Toolpath
Verify.
16
The Toolpath Visualization dialog displays with the Replay tab chosen.
17
The tool paths replay in the program sequence with the tool tip tracing each path. Each
operation highlights in the Operation Navigator as it replays.
The material removed by each successive tool path is displayed in a contrasting color.
OK to complete the tool path visualization.
More About: Dynamic Material Removal Colors
The colors displayed for dynamic material removal are determined by the Preference settings
(Preferences Manufacturing).
18
Once the colors have been defined in the Manufacturing Preferences dialog, the Verify
function uses these colors in the order defined when displaying Dynamic Material Removal.
19
Operation Navigator
A confirmation message warns you that all manufacturing data will be deleted and cannot be
recovered.
OK to delete the setup.
All CAM data, operations, tools, geometry, etc., have been deleted from the part file. The
Machining Environment dialog displays requiring you to specify a configuration file and
setup.
The Machining Environment dialog displays when a part file has been brought into the
Manufacturing module for the first time or when the setup has been deleted.
When Unigraphics NX starts, it reads the ugii_env.dat file to define a large number of
environment variables setting system defaults, the location of resource files, etc.
One of the things that is set by the ugii_env.dat file is the location of the configuration
directory. This is done by the environment variable UGII_CAM_CONFIG_DIR. This
directory contains a number of files with the file extension. ".dat".
20
Unigraphics NX reads the names of these files and displays this list in the top half of the
Machining Environment dialog, in the CAM Session Configuration list box.
A default Configuration is also defined in the ugii_env.dat file by the environment variable
UGII_CAM_CONFIG. It is set to point to cam_general.dat. That is why the Machining
Environment initially displays with the cam_general configuration highlighted.
Cam_general.dat sets up a number of environment variables pointing towards template files
for documentation, postprocessors that are correct for the machine tool you're using, feeds and
speeds, etc. One environment variable it defines is TEMPLATE_OPERATION. This is
pointed towards an "opt" file. By default, for cam_general.dat, this environment variable
points towards cam_general.opt.
Cam_general.opt contains a list of template part files:
mill_planar.prt mill_contour.prt mill_multi-axis.prt drill.prt turning.prt wire_edm.prt
A list of these part files is displayed in the CAM Setup list box.
21
When you selected the lathe configuration, the CAM Setup list box was updated to show the
only files listed in lathe.opt, lathe.prt and legacy_lathe.prt.
The general flow of definition of environment variables is something like the illustration
below:
22
Any changes to all these dat and opt files to customize them to your own manufacturing
environment must be done carefully. In most cases, it will require system administrator
privileges to make these changes.
23
The cam_general configuration allows you to create all types of operations including Milling,
Drilling, Turning, and Wire EDM. Other session configurations such as lathe or mill_contour
restrict you to a specific type of operation.
Choose Initialize.
The new machining environment is complete. The geometry objects required to create planar
mill operations are created automatically. They give you a basic starting point from which you
can begin creating operations and other objects.
in the toolbar.
in the toolbar to fully expand the objects.
Notice that the MCS_MILL and WORKPIECE geometry objects have been created.
The machining method objects required to create planar mill operations are also created
automatically.
24
in the toolbar.
In the next lesson, you will learn more about creating objects and the parameters they define.
Close the part file.
Creating Objects
In this lesson, you will learn how to create Program, Tool, Geometry, and Method objects.
Tool, Geometry, and Method objects define operation parameters. These parameters can be
inherited by operations contained within the objects. By specifying these objects as parent
groups, you can eliminate the repetitious and tedious task of respecifying parameters each
time you create an operation.
Program objects do not define operation parameters. Instead, they simply contain operations
and determine the sequence in which operations are executed on the machine tool. For
25
example, the sequence of operations required to machine the top of a part may be contained in
one program while the sequence of operations required to machine the end of a part may be
contained in another program.
Manufacturing.
Operation
Operation
The Operation Navigator shows that both the PLANAR_MILL and FACE_MILLING
operations use the same tool: MILL.
26
in the toolbar.
The Type determines the available Subtypes you have to choose from.
In the Create Tool dialog, Set the Type option to mill_planar.
The Subtype section displays only tools that are appropriate for milling operations.
Choose the FACE_MILL icon.
Be sure GENERIC_MACHINE is chosen as the parent group. This way, the tool you create
will have the same parent as the existing mill tool.
The tool name defaults to FACE_MILL based on the subtype you chose. You may name the
tool using the following rules:
Up to 20 characters
Start with an alphabetic character
The only acceptable special characters are the dash (-) and period (.)
No spaces are allowed.
OK to begin defining the FACE_MILL tool parameters.
27
The tool material is one of several parameters that the Reset from Table option uses to
determine the speeds and feeds for cutting.
Choose Material: CARBIDE.
28
to drop the operation.
This can also be accomplished by cutting and pasting the operation inside the tool object.
The slashed red circle indicates that operation parameters have changed and that the tool
path must be regenerated to reflect the change.
Generate.
29
An exclamation point now appears in front of the operation indicating that the operation has
been generated not yet been postprocessed or exported.
in the toolbar.
Toolpath
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Dynamic tab.
Drag the slider bar to the left to slow down the Animation Speed to 7.
Verify.
30
Auto Block creates a solid body bounding the part geometry with faces parallel to the WCS.
The material removed by each successive tool path is displayed in a contrasting color
allowing you to clearly see that the face milling operation leaves some uncut material behind.
The tool changes to the FACE_MILL tool for the second operation.
OK to complete the tool path visualization.
31
in the toolbar.
Click on the plus (+) sign next to Milling to expand the list and choose End Mill (non
indexable).
A number appears next to the button (in this example, 64). This indicates the number of tools
in the library that match the parameters you have specified so far.
You can narrow the search even further by specifying exact numeric values or a range of
values using <, >, <=, and >= signs.
32
Key in 0.50 in the Diameter field.
33
in the toolbar.
The tools retrieved from the library appear in the Machine Tool view of the Operation
Navigator and are now available to be used in operations.
Properties.
34
The red circle indicates that operation parameters have changed and that the tool path must
be regenerated to reflect the change.
Generate.
35
Open part file mfe_objects_2.prt from the mfe subdirectory.
Choose Application
Manufacturing.
in the toolbar.
The PLANAR_MILL operation uses the MILL_ROUGH method and the FACE_MILLING
operation uses the MILL_FINISH method. The SEMI_FINISH_LEVELS operation does not
use a method.
in the toolbar.
36
The Type determines the available Subtypes.
Choose mill_planar as the Type.
MILL_METHOD is the only available Subtype.
Be sure METHOD is chosen as the parent group. This way, the object you are creating will
have the same parent group as the other machining method objects.
Key in SEMI_FINISH for the name.
37
Generate.
38
in the toolbar.
in the toolbar.
Drag the slider bar to the left to slow down the Animation Speed to 7.
Choose the Play Forward icon.
39
Because the part does not contain or inherit blank geometry, the Automatic Blank for
Visualize dialog displays allowing you to define blank geometry temporarily to perform
dynamic material removal.
The material removed by each successive tool path is displayed in a contrasting color.
OK to complete the tool path visualization.
Close the part file.
Manufacturing.
40
in the toolbar.
Like other applications, Manufacturing uses the WCS, or Work Coordinate System. However,
the Manufacturing application has its own coordinate systems as well - the Machine
Coordinate System (MCS).
As illustrated below, the WCS and MCS are in the same location. The MCS is displayed
similar to the WCS, but the axes are labeled XM, YM, and ZM.
41
What is the significance of these coordinate systems for the Manufacturing application?
WCS - All the parameter values that you input (for example, values for the Start Point, a Z
value for the Clearance Plane, or I,J,K values for the tool axis vector, and other vector data)
will be in relationship to the WCS.
MCS - All coordinate values in the tool path (all of the output coordinates) are in relationship
to the MCS. The ZM axis of the MCS is particularly important since, if no tool axis is
specified, the ZM axis is the default tool axis.
The output tool path consists of a number of different commands. The most frequent
command is probably the linear positioning move, GOTO. There are at most 6 coordinate
fields in a GOTO: X, Y, Z, I, J and K. The X, Y and Z fields are the coordinates of the tool tip
relative to the MCS and the I, J, K values indicate the tool axis vector.
Depending on the circumstances, you may want to specify your Machine Coordinate System
and Work Coordinate System in the same location to avoid confusion.
Before you start creating any machining operations, you should always display the Work
Coordinate System and Machine Coordinate System and check their location and orientation.
A MCS is one of the default CAM objects created by all templates. The name assigned to this
MCS varies, dependent upon the CAM template part file selected in creating the setup. The
default MCS is created coincident with the absolute coordinate system. You can edit the
location of the default MCS to change the coordinates of the output tool path or create a new
MCS. Even though you may have many MCS objects created, only one machine coordinate
system is displayed at a time.
in the toolbar.
The Type determines the available Subtypes you have to choose from.
Be sure mill_planar has been chosen as the Type.
Choose the MILL_BND icon.
42
Be sure MCS_MILL has been chosen as the Parent Group.
The object you are creating inherits the Machine Coordinate System parameters.
The name defaults to MILL_BND based on the chosen subtype.
OK to begin defining the MILL_BND object.
This specifies that the material retained is outside the boundary and allows the tool to cut only
inside the boundary.
Choose the Custom Data tab.
Turn on the Offset option under Custom Boundary Data and key in -0.1.
This defines a negative stock that assures the material along the outside edge of the part is
completely removed.
43
44
You will create boundaries that define the top of each island.
Choose the Face Boundary icon.
45
Cut.
Paste Inside.
Cut and paste the SEMI_FINISH_LEVELS operation inside the MILL_BND object so that
MILL_BND contains both operations.
46
MB3
Generate.
MB3
47
You will create a workpiece object that defines the part material and the blank geometry. The
part material is one of several parameters used in determining the cut feed rate. Adding
operations to the program such as Cavity Milling will require blank geometry.
Choose Edit
Blank
This displays the body you will select to define the blank geometry.
in the toolbar.
Be sure MCS_MILL is chosen as the parent group so that the object you are creating inherits
the Machine Coordinate System parameters defined in MCS_MILL.
48
Choose Material: CARBON STEEL.
Choose Edit
Blank
49
You will cut and paste the MILL_BND object into the WORKPIECE object. In doing so, you
will also move the operations.
Highlight the MILL_BND object and MB3
Cut.
Paste Inside.
Generate.
50
OK to accept the second tool path generation.
Because the part inherits blank geometry from the workpiece object, the Automatic Blank for
Visualize dialog does not display as it did in the previous examples.
OK to complete the tool path visualization.
Close the part file.
51
Manufacturing.
52
53
in the toolbar.
Copy.
The object you choose in the next step is the object below which the pasted objects will
appear.
54
With TOP chosen, MB3
Paste.
Operation Navigator
55
Choose the PLANAR_MILL operation and hold down the Ctrl key to choose the
SEMI_FINISH_LEVELS and FACE_MILLING operations.
MB3
Cut.
Paste Inside.
56
Delete.
57
OK to complete the tool path visualization.
Choose the SIDE object and visualize the program as you did for the TOP object.
You can visualize the entire program by choosing the NC_PROGRAM object.
OK to complete the tool path visualization.
Close the part file.
Creating Operations
In this lesson, you will learn how to create individual operations and edit and respecify parent
groups from within the operations.
You will also learn how to customize dialogs to update legacy operations by adding the Main,
Groups and Viewing tabs that are found on newly created operations.
Creating an Operation
58
Although some of the parameters for milling, drilling, turning, and wire edm operations differ,
the process of creating any operation is basically the same. You first specify the Type,
Subtype, and Parent Groups. You then define any additional parameters required for the
specific operation. Finally, you generate the tool path and make any necessary modifications.
Open part file mfe_operation_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.
Creating an Operation
Beginning the Operation
You will begin creating a planar mill operation that roughs out material in multiple cut levels.
in the toolbar.
The Type determines the subtype icons and the parent groups that are available to choose
from in the dialog.
Choose ROUGH_FOLLOW as the subtype.
Choosing the appropriate operation subtype will set many of the required operation
parameters and can save a significant amount of time and effort in defining the operation.
59
Specify the following parent groups.
Parent groups determine common parameters that can be used by multiple operations.
This operation is automatically named ROUGH_FOLLOW based on the Subtype you chose.
OK to begin creating the operation.
Creating an Operation
Specifying the Cut Depth
You will specify multiple cut levels at a fixed depth.
Choose Cut Depths.
Choose Fixed Depth.
Maximum defines the largest allowable cut depth for each level.
OK to accept the cut depth.
Creating an Operation
Calculating Feeds and Speeds
60
You will allow the system to recommend appropriate feed rates and speeds based on the user
specified part material, tool type and material, cut method, and cut depth parameters.
Choose Feed Rates.
Notice that the current Surface Speed and Feed per Tooth values are set to zero.
Creating an Operation
61
Creating an Operation
Displaying the Part Boundaries
A planar mill operation must contain properly defined part boundaries in order to generate a
tool path. You will display the part boundaries for visual verification.
Choose the Part icon.
Choose Display to highlight the part boundaries.
Notice that the Select/Reselect button is blanked. Part boundaries are inherited from the
MILL_BND parent group and can only be modified by editing the parent group. In just a
moment, you will see how to edit the MILL_BND parent group from this dialog.
62
Creating an Operation
Displaying the Floor Plane
A planar mill operation must contain a floor plane in order to generate a tool path. You will
display the floor plane for visual verification.
Choose the Floor icon.
Choose Display to highlight the floor.
Notice that the Select/Reselect button is blanked. The floor plane is inherited from the
MILL_BND parent group and can only be modified by editing the parent group that defines
it.
Refresh the graphics display.
Creating an Operation
Visualizing the Tool Path
63
You will use the Toolpath Visualization options to animate the cutter movement and
dynamically display material removal for the program.
Choose the Verify icon
Creating an Operation
Editing the Geometry Parent Group
You will edit the MILL_BND parent group so that the material along the outside edge of the
part is completely removed. The options at the top of the operation dialog allow you to edit
and reselect parent groups.
Choose the Groups tab.
Choose Geometry: MILL_BND and Edit.
64
A message displays informing you that the MILL_BND parent group contains more than one
member and that editing it will affect all members. MILL_BND is a parent of the operation
you are currently creating as well as the existing FINISH_FLOOR operation. Editing the part
boundaries defined in this parent group will therefore affect both operations.
OK the message.
The MILL_BND dialog displays allowing you to edit the parent group.
Creating an Operation
Editing the Main Containment Boundary
You will edit the main containment boundary so that the operation no longer leaves a thin
wall of uncut material along the outside edge of the part.
Choose the Part icon and Edit.
The part boundaries highlight with the main containment boundary selected.
65
This defines a "negative stock" that assures the material along the outside edge of the part is
completely removed.
OK to accept the part boundary offset.
OK to finish editing the MILL_BND parent group.
OK to complete the ROUGH_FOLLOW operation.
The ROUGH_FOLLOW operation now appears in the Operation Navigator.
Creating an Operation
Generating Tool Paths
You will generate the tool path to remove the material along the outside edge of the part.
in the toolbar.
Notice that slashed red circles appear in front of both operations. This indicates that the
tool paths for both operations must be regenerated to reflect the changes made in the
MILL_BND parent group.
Choose the PROGRAM icon and MB3
Generate.
66
Creating an Operation
Reordering Operations
The Program Order View displays the order in which operations will be executed on the
machine tool. Notice that the finishing operation precedes the roughing operation.
You will change the order in which operations are listed in the program so that the finishing
operation follows the roughing operation.
Choose the FINISH_FLOOR icon and MB3
Cut.
The operation you choose in the next step is the object below which the pasted operation will
appear.
Choose the ROUGH_FOLLOW icon and MB3
Paste.
Creating an Operation
Visualizing the Tool Paths
67
You will now verify that the negative boundary offset you specified earlier in the parent group
removes the excess material along the outside edge of the part.
Choose the PROGRAM object.
in the toolbar.
Creating an Operation
Reselecting the Tool Parent Group
You will change the tool used in the finishing operation.
in the toolbar.
68
The Reselect Tool dialog displays, allowing you to choose a new parent group or to define a
new tool.
Choose UGTI0201_076.
The tools available in this list are the same as those that appear in the Machine Tool view of
the Operation Navigator.
OK to accept the tool.
The dialog now displays UGTI0201_076 as the tool used in the operation.
Remember, you can also respecify the tool by dragging and dropping, or by cutting and
pasting the operation onto the tool object.
69
Creating an Operation
Completing the Operation
You will complete the operation and observe how the Operation Navigator now displays
UGTI0201_076 as the parent group.
OK to complete the FINISH_FLOOR operation.
Expand the object to see the operation.
The Operation Navigator now displays UGTI0201_076 as a parent of the FINISH_FLOOR
operation.
indicates that the tool path must be regenerated to reflect the tool
Creating an Operation
Generating the Tool Path
You will generate the tool path to update the operation status.
Choose the FINISH_FLOOR icon and MB3
Generate.
70
Manufacturing.
71
ROUGH_TURN_OD icon to display the operation parameters dialog.
The dialog is very large and in some cases it may be too large for the viewing screen.
Click on the dialog so that it is active and press the Esc key to dismiss it.
Customize.
72
Key in Main in the Label field and choose the Property Pages icon.
Start Page Main and End Page Main are added to the Items Used list box. Moving the End
Page Main to the bottom of the items used will put all those items on the Main page.
With End Page Main highlighted, choose the Move Down arrow until End Page Main is
the last item in the list.
When you are finished moving End Page Main to the bottom, the list box will appear as
illustrated below.
73
Start Page Groups and End Page Groups are displayed at the bottom of the list box.
Scroll to the top of the Items Used list box, highlight Group Editing, and choose the Move
Down arrow until Group Editing is between the Start Page and End Page of Groups.
When you are finished moving Group Editing, the list box will look as illustrated below.
74
Key in Viewing in the Label field and choose the Property Pages icon.
Move End Page Viewing and Start Page Viewing to the end of the list box using the
Move Down arrow.
The list box should look as illustrated below.
Choose the Move Up arrow so that Save View is between the Start Page and End Page of
Viewing as illustrated below.
75
The parameters have been divided among three property pages.
Double-click on the ROUGH_TURN_OD icon to display the operation parameters
dialog.
The top of the dialog displays the three tabs found in newly created turning operations.
76
Creating a Sequence
You will create a sequence of operations designed to machine a die. Although specific
parameters may vary, the process of creating any sequence is similar.
77
Choose Application
Manufacturing.
Creating a Sequence
Defining the Machining Environment
Because this part has not yet been saved in the Manufacturing application, the Machining
Environment dialog displays. You will choose a CAM Session Configuration and a CAM
Setup
Choose mill_contour as the CAM Session Configuration.
Die_Sequences and Mold_Sequences are generic sequence setups supplied with the system.
Other setups may also be available depending on your working environment.
Choose die_sequences as the CAM Setup.
Choose Initialize.
Creating a Sequence
Using the Process Assistant
78
You will begin following the step-by-step instructions provided by the CAM Process
Assistant.
OK to continue with the assistant.
Creating a Sequence
Defining the MCS
Step 1 of the Process Assistant prompts you to define the Machine Coordinate system. You
may specify new MCS parameters or accept the current MCS.
OK to accept the current MCS.
Creating a Sequence
Defining the Clearance Plane
Step 2 of the Process Assistant prompts you to define the clearance plane.
Be sure Clearance has been turned on and choose Specify.
79
Creating a Sequence
Defining the Part Geometry
Step 3 of the Process Assistant prompts you to define the part geometry.
Choose Select.
Select the part body as illustrated below.
80
Creating a Sequence
Defining the Blank Geometry
Step 4 of the Process Assistant prompts you to define the blank geometry.
Choose Select.
Select the blank body as illustrated below.
81
OK to continue.
Creating a Sequence
Creating the Geometry Parent Group
The next set of steps defines the geometry parent group. You will follow these steps to create
a sequence of operations:
in the toolbar.
Creating a Sequence
Defining the Cut Area
The next step prompts you to define the cut area.
Choose Select.
82
Select the Surface Region as illustrated below.
Creating a Sequence
Defining the Trim Boundary
The next step prompts you to define the trim boundary. A trim boundary is used to constrain
the cut area. Because you are going to machine the entire part, the program does not require a
trim boundary.
OK to proceed to the next step.
Creating a Sequence
Choosing the Operation Types
The next step prompts you to choose optional flowcut operations to include in the sequence.
Creating a Sequence
83
Creating a Sequence
Respecifying the Session Configuration
84
The CAM Session Configuration you specified at the beginning of this lesson provides CAM
Setups only for mill contour type operations. Before continuing on to other courses, you
should choose a CAM Session Configuration that allows you to create all types of operations
including Milling, Drilling, Turning, and Wire EDM.
Choose Tools
Operation Navigator
UG/Post
Postprocessing is the preparation of machine code used to drive a specific machine tool. In
this lesson, you will learn how to postprocess using UG/Post.
85
Choose Application
86
Choose MB3
Replay.
87
Choose MB3
Toolpath
List.
UG/Post converts the internal tool path containing events and motions into a format
compatible to the machine tool's controller. For example, the FEDRAT/MMPM,250.0000
command might be converted to the format F250.0 and the GOTO/0.0000.45,0000,3.0000
might be converted to G00X0.0000Y45.0000Z3.0000.
Dismiss the Information window.
88
Operation Navigator
All of the operations contain 3 axis tool paths, so the MILL_3_AXIS machine is appropriate
to use here.
The postprocessors provided by the system are displayed in the Available Machines list box.
89
Set the Look in: field to a directory you can write to.
Key in ugpost_output.ptp in the File name: field.
The file extension "ptp" is an abbreviation for paper tape punch file, a historical holdover
from the use of paper tape to read n/c programs into machine tool controllers. You can use
any file extension you prefer.
90
OK to accept the output specification.
OK to postprocess the tool paths. This will take some processing time.
The tool paths are postprocessed and listed in an Information window. The file has been
created and saved in the specified directory.
Dismiss the Information window.
Close the part file.
91
GPM is a legacy product. It is covered here because it is still commonly used at many sites.
Postprocessing should now be done using UG/Post.
Creating a CLSF
The CLSF is an ASCII text file containing Standard APT commands. A CLSF is required
when using a 3rd party postprocessor or the legacy Graphics Postprocessor Module (GPM).
The first step in creating a Cutter Location Source File (CLSF) is to select the operations from
which you would like to write the internal tool paths to the operating system file.
A single part file might contain tool paths for different machine tools (for example, lathes and
3 axis mills) and you would not want to have tool paths for different machine tools in the
same CLSF. If this were the case, you would organize the different types of machining into
separate programs, such as a 3 axis mill program and a lathe program, so that you could create
separate CLSF's.
In the current part file, all the tool paths are for a 3 axis milling machine and are all included
in the NC_PROGRAM object.
Creating a CLSF
Opening the Part File
92
Open part file mfe_post_1.prt from the mfe subdirectory.
Choose Application
Ten operations with a Repost status ( ) are displayed in the Program Order View of the
Operation Navigator. Repost status means that the tool path for the operation has been
generated, but it has not been postprocessed or exported from the part file.
Creating a CLSF
Selecting the Operations
You will select the operations from which you would like to write the internal tool paths.
Highlight the NC_PROGRAM object.
Highlighting the object selects all of the operations contained within the object.
Creating a CLSF
Outputting the CLSF
You will specify the file name and directory to which you will output the CLSF.
93
Operation Navigator
Output
Choose Browse.
Make sure the Look in field is a directory to which you have write access.
Key in 3axis_mill_program in the File Name field and OK to accept it.
94
The first of the formats listed, CLSF_STANDARD, uses two files to create output in the
APT-like format familiar to Unigraphics NX users. These two files are clsf.tcl and clsf.def.
clsf.tcl is a tcl file -Tcl (Tool Command Language) is a programming language.
Tcl is distributed free from a number of different web sites and the programs written in it are
very portable between different operating systems. The clsf.tcl file is an event handler; it tells
the Manufacturing Output Manager (MOM) what to do with the information stored in the
operations which have been selected for output.
One command in this tcl file, set mom_kin_clsf_generation TRUE, is particularly important
as it tells MOM to use an alternate path to a faster, optimized C code executable for
generating either the GOTO values or the Post commands.
clsf.def defines the format for the output generated by MOM from the event handler,
clsf.tcl and the post commands generated by the parameters stored in the operations
being processed.
The MOM is multifunctional in managing manufacturing output. Some of its functionality can
be visualized in the illustration below:
95
The Output CLSF selection on the left leads to various intermediate clsf formats, while the
UG/Post Postprocessor option on the right leads directly to machine code.
The MOM analyzes the relationships between the various CAM objects and the pointers from
operations to sections of the Internal Tool path. These relationships and the tcl and def files,
determine the format of the output.
The CLSF_STANDARD is designed to handle legacy manufacturing data. To run faster, the
switch set mom_kin_clsf_generation TRUE is set to use previously generated post
commands.
96
CLSF_COMPRESSED provides a shortened form of the CLSF useful for determining which
tools are used and when. The output is the same as CLSF_STANDARD, without the GOTO
values.
CLSF_ADVANCED will extract operation parameters, such as tool information and
automatically generated post commands, in addition to the tool positioning (X,Y,Z,I,J,K) data
CLSF_BCL generated binary centerline information for controllers requiring that output.
CLSF_ISO will generate International Standard format center line files.
A user defined output format can be added by editing the template_clsf.dat file and adding a
format type, e.g. MY_CUSTOM_OUTPUT, linked with a tcl file and a def file. A good
starting point for these would be to copy and rename the bcl.tcl and bcl.def files, perhaps to
something like custom.tcl and custom.def.
CLSF_IDEAS_MILL and CLSF_IDEAS_MILL_TURN are formats specifically for the
IDEAS postprocessor.
Creating a CLSF
The CL Source File Manager
The CLSF exists as an independent ASCII file. You will now use the CLSF Manager to
examine CLSF file. The CLSF Manager allows you to Edit, Reorder, Delete and Replay tool
paths, and to List the CLSF.
Editing the CLSF should be avoided if possible, and will therefore be discussed only briefly.
It is always better to edit the operation and regenerate the tool path because the operation
parameters are permanently stored with your part file.
Choose Tools
You must choose the CLSF that you want to open. The file mfe_tpmgr_1.cls is the same as
the file you just created.
Select mfe_tpmgr_1.cls from the mfe directory and then OK.
The CLSF Manager dialog displays. The dialog contains a list of all the tool paths in the
current CLSF.
97
Creating a CLSF
Filtering the Tool Path Names
You can restrict the list of tool paths to only those that are blanked or unblanked, or to only
those that do not have an associated operation in the part file.
A Blanked tool path is temporarily removed from the paths displayed during a tool path
replay.
An Orphan is a tool path that has no associated operation. An Orphan is also anything that can
be inserted into the CLSF ( a PPRINT, macro call, etc.) that does not have a Start-of-Path or
End-of-Path statement.
Choose Blanked from the option menu.
Notice that one tool path, CORNER5, is listed.
Set the Show option back to All.
All the tool paths are listed again.
Creating a CLSF
Reordering Tool Paths
You can use Cut and Paste to remove one or more tool paths or to reposition them in the
CLSF. You will cut the MULTI-LEVEL tool path that roughs out the pocket and paste it
before POCKET1.
Choose MULTI-LEVEL from the listing window.
98
Choose Cut.
Highlight TLCHG1.
The cut tool path will be pasted after the highlighted tool path (after TLCHG1).
Choose Paste.
If you had not highlighted TLCHG1, the cut tool path would have been placed as the first tool
path in the list.
Creating a CLSF
Deleting Tool Paths
You can also permanently delete one or more tool paths from the CLSF. Remember that you
are only removing the tool path from the CLSF - the operation and the internal tool path
which are stored in the part file are not affected.
Highlight POCKET2 and choose Delete.
99
A confirmation message appears listing the names of the tool paths that will be deleted. If you
delete the tool path, you will not be able to get it back using Paste. To get it back, you would
have to regenerate the tool path and create another CLSF.
OK to delete the tool path from the CLSF.
Creating a CLSF
Listing Tool Paths
You can list the text of one or more tool paths in the CLSF.
Select CORNER1 in the list box.
Be sure you do not use the List button in the CLSF Actions section - that will list the entire
CLSF.
Choose List in the Tool Path Actions section.
100
Creating a CLSF
Replaying Tool Paths
You can replay the tool paths in the CLSF. First, you will use the Filter Methods section to
display just the corner tool paths.
Key in c* in the By Name field.
Turn on the By Name button.
Only those tool paths beginning with "c" are now listed.
Choose Select All.
You can stop the display of the tool paths at any time by choosing Stop on the Work in
Progress dialog.
Choose Replay in the Tool Path Actions section.
101
The tool paths display graphically on the part.
Turn off the By Name option to deselect the tool paths.
All the tool paths are listed again.
Creating a CLSF
Optimizing the CLSF
Optimization is very useful when it is time to send the program to the shop floor. It can help
with some of the tedious cleanup.
Optimization allows you to:
preselect a tool for the next tool path.
suppress duplicate tool change commands in consecutive tool paths.
remove postprocessor commands which are generated (or inserted) at the end of each
tool path.
verify that a tool change command is output when the tool parameters change.
Choose List from the CLSF Actions section.
All of the tool paths in the CLSF are listed in the Information window. Look at line 50 in the
listing. It is the first LOAD/TOOL, 1 ... command.
Look at line 160 in the listing. It is an unnecessary duplicate LOAD/TOOL , 1 ... command.
102
Choose Optimize.
The CLSF CONTROL dialog displays. The default settings will remove the duplicate tool
changes.
OK to optimize the CLSF.
Creating a CLSF
Verifying the Optimization
You can verify that the duplicate tool changes have been removed.
Choose List from the CLSF Actions section.
The duplicate tool change that was located at line 160 has been removed.
103
The Machine Data File (MDF) describes the characteristics of a machine and the required
format for its accompanying controller. Each MDF contains data the GPM needs for
postprocessing tool paths. The MDF is an ASCII file and has an extension of .mdfa.
When you are postprocessing, the GPM does the following in this order:
Reads a specified CLSF and MDF
Formats the CLSF according to the MDF instructions
Outputs a postprocessed tool path
This sounds involved, but it actually is not. The GPM is provided by Unigraphics NX and the
MDF probably already exists at your company.
First, you must specify the GPM, CL file, and MDF. You can change the GPM using the
Specify option under Postprocessor Name.
You will not need to specify a different postprocessor for this exercise because the system
defaults to the GPM program provided with the current distribution of Unigraphics NX.
You can use the Specify option under Input File Name to change the CLSF. Notice that it has
defaulted to mfe_tpmgr_1, which is the CLSF you want to postprocess.
104
105
NC Output - Selects the destination for the finished machine tool program. This
program is frequently referred to as the tape image, punch file (in the past it was
usually punched out on paper tape) or M and G code file.
Listing Output - Selects the destination for the listing output. The Listing Output is a
combination of the CLSF input and the NC Output and is frequently used for
debugging and other tasks.
Input Units - Specifies the input units to be used.
Listing Format - Can be set to Column (the listing is formatted into columns), Packed
(the listing is packed without column divisions), or MDF Defined.
Listing Commentary - Controls the listing of commentary data. It can be set to Yes,
No, or MDF Defined.
File - The output is an ASCII format file having a ".ptp" extension. You can edit this
file.
Paper Tape - Outputs the file to a tape punch.
None - All postprocessor output is suppressed.
MDF Defined - Defaults to the setting in the MDF.
Set NC Output to None.
106
File - Sends the listing to a file with the specified file name.
Line Printer - Sends the output to the system printer.
Terminal - The listing is displayed in the status window of your terminal.
None - All postprocessor output is suppressed.
MDF Defined - Defaults to the setting in the MDF.
Set Listing Output to Terminal.
107
If you had directed the postprocessing output to a file, machine code as below would have
been written to the file:
A Message is displayed informing you that the postprocessing is finished and instructing you
to press Return to continue.
Press the Enter key.
Cancel the NC Postprocessing dialog.
Cancel the CLSF Manager dialog.
Ordinarily, you would save the file at this time.
Cancel the Save CLSF dialog.
Close the part file.
Shops
Shops setups are template files that utilize a Process Assistant designed to step the occasional
user (such as the shop floor machine operator) through the process of creating an
operation.This lesson provides one general example of how to use a Shops template and how
to follow the Process Assistant to create a single operation.
108
Manufacturing.
109
Because this part has not yet been saved in the Manufacturing application, the Machining
Environment dialog displays requiring you to choose a configuration and a setup.
Choose shops_diemold as the CAM Session Configuration.
If you have purchased the Shops bundle, only one Shops choice appears here.
Shops setups are templates supplied with the system. Additional setups may also be available,
depending on how your system has been customized.
Choose shops_mill_contour as the CAM Setup.
Choose Initialize.
110
111
112
expand the object.
The MCS_MILL and WORKPIECE objects have been created using the parameters you just
defined.
Insert
Operation.
Choosing WORKPIECE assures that it will the parent group of the operation.
Be sure shops_mill_contour is displayed as the Type.
The Type determines the available Subtype icons and parent groups.
Choose ZLEVEL_FOLLOW_CORE as the Subtype.
The Subtype determines parameters specific to the operation such as the cut pattern.
OK to begin creating the operation.
113
A sequence of Process Assistant dialogs will now begin stepping you through the process of
defining the operation.
The first step in creating the operation is to define the tool and the method.
Be sure Tool: None is chosen.
Choose Select.
Choose New.
Choose the MILL icon.
The tool name defaults to MILL based on the Subtype you chose.
OK to begin defining the MILL tool parameters.
Key in the following values to define the tool.
114
115
116
OK the error.
The error message simply informs you that the tool cannot cut to the bottom of the part.
At this point in the process, you are free to modify operation parameters as you choose.
OK to complete the ZLEVEL_FOLLOW_CORE operation.
Refresh the display.
Choose Edit Blank Blank in the toolbar and select the blank geometry so that only
the part geometry displays as illustrated below.
117
Choose ZLEVEL_FOLLOW_CORE and MB3
Workpiece
Show 3D.
The faceted model graphically represents the uncut material that remains after generating the
ZLEVEL_FOLLOW_CORE operation.
Refresh the display.
Close the part file.
Shop Documentation
In this lesson, you will learn how to create shop documentation for use by machine tool
operators.
There are two formats for shop documentation: text format and HTML (Hyper Text Markup
Language) format. The text format is standard plain text. HTML format (illustrated below) is
the type of format read by web browsers and allows you to include graphics and other visual
enhancements to your documentation.
118
Choose Application
Manufacturing.
119
in the toolbar.
Templates defining different formats for the output of shop documentation display in the Part
Documentation dialog.
Choose Tool List (TEXT).
Choose Browse and select a directory to which you have write access.
120
The default output file name is the same as the part file, with the extension .txt.
OK to accept the default output file name.
The text file is written to the specified directory and displayed in an Information window.
This file can be sent with the N/C program to the machine operator with instructions on how
to set up the stock for machining, etc.
Dismiss the Information window.
Close the part file.
121
To create a tool list for a program, select the program in the Operation Navigator, choose the
UG/Post Postprocess icon in the toolbar, and choose one of the Program Tool List templates
in the list box.
Choose Application
Manufacturing.
in the toolbar.
122
Choose Tool List (text).
Choose Browse and select a directory to which you have write access.
The default output file name is the same as the part file, with the extension .txt.
OK to accept the default output file name.
The text file is written to the specified directory.
This file can be sent with the N/C program to the machine operator with instructions on how
to set up the stock for machining, etc.
Close the Browser.
Close the part file.
123
Planar Milling is intended for parts with vertical walls and planar islands and floors normal to
the tool axis. Part and blank material is defined using boundaries. It is used for roughing and
finishing.
Cavity Milling is intended for parts with tapered walls and contoured floors. Part and blank
material can be defined using boundaries, faces, curves, and bodies. It is used for roughing.
Audience
The audience for this course is Unigraphics NX Manufacturing application users who want to
machine 3-axis parts containing pockets, profiles, or cavities.
Prerequisites
The prerequisite for this course is the Manufacturing Essentials CAST Online Library course.
Course Contents
Planar Milling - Profiling You will learn how to create single pass Planar Milling tool
paths that follow open boundaries to machine reference surfaces for precise placement in
fixtures.
Planar Milling - Single Level You will learn how to create a single-level Planar Milling
operation.
124
Planar Milling - Multi-Level You will learn how to create multi-level Planar Milling
of a part. You will also learn several ways to cut across open and closed voids and learn how
to create mixed and manual cut patterns.
Cavity Milling You will learn how to create Cavity Milling operations that rough out
cavities and cores. You will also learn how to use a faceted body to perform rest milling.
Z-Level Milling You will learn how to profile the part at each cut level and then constrain
the cut region using the silhouette or "shadow" of the part. You will specify a Steep Angle to
profile only the steep areas left unmachined by a previous Fixed Axis Surface Contouring
operations. You will also learn how define a Cut Area and then further constrain the cut
region using a trim boundary.
Planar and Cavity Milling Project You will create a program that roughs, semi-finishes,
You will enter the Manufacturing application and define the part and blank geometry in the
Workpiece parent group. Operations can then inherit the parameters defined in the Workpiece
parent group.
125
Assemblies.
126
Manufacturing.
The Machining Environment dialog displays because the part file has never been saved in the
Manufacturing application.
Be sure cam_general has been chosen in the CAM Session Configuration listbox.
Choose mill_planar in the CAM Setup: listbox.
Choose Initialize.
You will create an open boundary using the line extending across the top of the part. You will
make it an "On" condition boundary so that the the tool center point positions directly on the
boundary.
127
Choose Create.
Set Tool Position to On and Boundary Type to Open.
Select the line at the left end as illustrated below.
in the toolbar.
128
129
in the toolbar.
Highlight PROGRAM.
Choose MB3
Rename.
This program name is easy to recognize as containing all the roughing operations. Finishing
operations could be contained in another program such as FINISHING_PROG.
130
in the toolbar.
You will create a 100 mm diameter tool that is 25 mm long and has 20 inserts.
Choose the T_CUTTER icon and key in TMAX100 in the Name field.
The tool diameter and number of flutes are used in the calculation of the feeds and speeds
generated by using the Reset from Table option on the Feeds and Speeds dialog. The Material
for the tool is set to HSS, High Speed Steel. Choosing this option and changing the tool
material will also affect the speeds and feeds.
in the toolbar.
131
You will create a Planar Mill operation that uses a large cutter (100 mm diameter) to machine
the top face in a single pass.
in the toolbar.
132
The tool will cover the entire top of the stock in one pass.
133
cool the tool and workpiece. You will define several beginning of path and end of path
commands.
Choose the Main tab.
Choose Machine.
The number and types of available events in the Available list is determined by the setup of
the configuration files.
At the bottom of the dialog, the Add option is now available allowing you to add the Tool
change command to the top of the tool path.
Choose Add.
Since this is the first tool to be used in the program, you might want to have it loaded into tool
position one in the magazine.
Key in 1 in the Tool Number field and OK to accept it.
134
The User Defined Events dialog displays with the Tool Change event set to
"Status=Active,Tool Number=1,Head Designation=None,Manual Tool Change-FALSE".
The Spindle On user defined event displays in the Defined list listbox.
135
Three startup events have been defined so far.
These three commands are probably the most frequently used. There are many more
commands listed under the Available list.
The postprocessor might not require these user defined events in order to output the machine
tool commands to load a tool or turn on the spindle to a given RPM. These T and S words can
be automatically output based upon the stored data in the generated tool path and the structure
of the machine tool's definition files. Highly variable commands, such as coolant, which can
be set to on, flood, mist or tap, might be most easily defined as user defined events. User
defined events might override the automatic events which would be output by UG/Post. The
output is ultimately determined by the structure of the machine tool's postprocessor.
OK to return to the Machine Control dialog.
Note that the Startup Commands option is now On.
Highlight Coolant Off in the Available Functions list and choose Add.
OK to return to the User Defined Events dialog.
The user defined event Coolant Off is listed in the Defined list box.
136
Highlight Spindle Off and choose Add
The Spindle Off dialog displays.
OK to return to the User Defined Events dialog.
The Spindle Off event is listed in the Defined list.
To select the boundary, you should center the cursor on the tic mark.
Select the boundary.
137
The Distance, Angle 1, and Angle 2 text fields are now available.
The Distance is the length of the engage move.
Angle 1 is measured from the direction of the first cut move, counterclockwise in the
plane of the part surface.
Angle 2 is measured clockwise in a plane normal to the part surface.
Specify the following Distance, Angle 1, and Angle 2 values.
138
These values will create an engage move in the direction of the cut, moving down at an angle
of 45 degrees for a distance of 40 mm.
139
Select the top of the part (the top of the narrow wall).
140
You want the cut direction to be from left to right, so you must change the type of cut from
Climb to Forward. By setting the Cut Direction to Forward, the tool motion is from the origin
of the boundary (indicated by the small circle) to the end of the boundary in the direction
indicated by the "tic" marks on the boundary.
Choose Cutting.
Choose Follow Boundary as the Cut Direction.
141
The cut feed rate depends on the spindle rpm, type of cutter being used, the type of material
being cut, and several other factors. The system will calculate these feed rate and spindle rpm
values for you from data that your system administrator can customize.
Choose Feed Rates.
Note the Reset from Table option at the bottom of the dialog. Choosing this option will
automatically set the spindle RPM and feed rates to those appropriate for the current tool and
calculated from information in a database that can be customized for your site and machine
tools.
Choose Reset from Table.
The values for the various feeds and speeds are automatically entered into the appropriate
fields. Notice that the Spindle Speed has been calculated to be 194.0000 rpm, which you
already set.
OK to return to the PLANAR_MILL dialog.
142
The default Part Stock is set to 1.0 mm. This value is automatically set by the selected
Method, which is MILL_ROUGH. You will change the part stock value to bring the cutter
into contact with the top of the part face selected as the floor.
Choose Cutting.
Change the Part Stock to 0.00 and OK to accept it.
143
144
Choose Reselect with the Tool option turned on.
Choose New.
Choose the Mill icon, key in EM40 in the Name field, and OK to begin creating the tool.
Key in 40 in the Diameter field, 100 in the Length field and 8 in the Number of Flutes
field.
OK to finish creating the tool.
145
You will create a boundary that the operation will use to define the cut path. Unlike the part
boundaries defined in the Workpiece parent group, this boundary can only be used by this
operation.
Choose the Part icon and Select.
Set the Type option to Open and the Tool Position option to on.
146
147
The temporary boundary displays in magenta. Notice that the tic marks are displayed on each
side of the boundary, indicating that it is an On condition boundary.
148
149
The tip of the tool will position to this floor plane.
150
151
Note the 200.0000 mmpm feed rate between the moves at 98.0000 mmpm for the circular
move which you specified. The User Defined Events are displayed as Standard APT
commands.
152
153
In this lesson, you will learn how to create single-level Planar Milling tool paths.
154
This is a simple part, designed to illustrate the basic procedures involved in removing material
from a pocket containing an island.
Choose Application
Manufacturing.
in the toolbar.
155
156
Choose the Main tab.
Choose the Part icon and Select.
157
OK to complete the part boundary creation.
158
159
160
Be sure mill_planar is specified as the Type.
Choose the PLANAR_PROFILE icon.
Key in PLNR_M_PKT_2 in the Name field.
Specify the following parent groups.
161
162
Output Contact Data complements the traditional application of cutter compensation, which is
to compensate for the wear of the cutter. By using the contact data, the machine operator has
the flexibility of choosing a range of cutter sizes (based on the nominal cutter size specified in
the operation) with which to machine the part while maintaining the same cutting accuracy
along the tool path. This feature is only available for Planar Profile operations.
Choose Machine.
Choose Cutter Compensation.
Set the Cutcom option to Engage/Retract.
Turn the Output Contact Data option on.
OK twice to accept Output Contact Data and return you to the Planar Profile dialog.
163
164
OK to continue processing the tool path.
This time the tool does not follow the boundary. Instead, it makes parallel cuts back and forth
with a stepover between cuts.
Change to a Front view.
You can see that the rapid moves (dashed red) cut into the island. There are options that you
can set to avoid collisions like this, but for now you will only look at the cut types methods.
Reject
Follow Part creates a tool path using concentric offsets from the part geometry. This method
computes the tool path by offsetting from the outer edges of the pocket and the island.
Climb (or Conventional) cutting is maintained throughout the tool path.
165
The tool path is generated. The tool does not collide with the island. This cut type is better
suited for this part because the island's edges are taken into account when calculating the tool
path.
Reject the tool path.
The stepover distance can be constant or variable. You have four options for controlling it.
Constant - A fixed distance between passes.
Scallop - The stepover is calculated based on the height of the scallops left between passes.
166
Tool Diameter - The stepover is determined based on the percentage of the effective tool
diameter.
Variable - Uses a variable stepover and number of passes or a minimum and maximum.
Currently, the stepover distance is being controlled using a percent of the tool diameter. It is
actually calculated using the effective tool diameter, which is the flat bottom of the tool.
The increased stepover causes the cutting moves to be calculated differently. Compare your
current tool path with what the tool path looked like with a 50% stepover.
Reject the tool path.
167
The Scallop size is the height of material left by the corner radius of the tool. The stepover
taken may vary from cut to cut depending on the boundary.
1. Scallop Size
2. Calculated Stepover
3. Cutter Corner Radius
The tool makes fewer passes to cut the material while maintaining the scallop height.
168
Reject the tool path.
Try some different combinations of Cut Method and Stepover. After you generate each tool
path Reject it. (Do not change any defaults. Just compare the differences you get).
After your last combination, refresh the graphics screen and continue with the lesson.
169
Choose Application
Edit.
170
There are two types of Engages and Retracts. Initial Engage is the first engage of the
operation. Internal Engage is an engage move to a new cut region.
Final Retract is the last retract move of the operation. Internal Retract is a retract move prior
to moving to a new cut region.
The clearance distances are the distances the tool stays away from the machining geometry
when it moves to a cutting region.
In the following illustration, the tool begins the engage .100 away from the bottom of the part.
This distance is called the Vertical Clearance distance.
171
The last option that you will look at is the Transfer Method. This option defines where the
tool will retract to when moving from one cut level or one region to another. The tool path
that you have just generated does not make any transfer moves. You will see this later in the
Planar Milling Multi-Region lesson.
All of the moves are set to automatic, meaning that they are calculated for you. The engage
and retract moves are based on the cutting condition of the operation, the geometry of the
part, and different parameters that you enter.
Cancel to return to the PLANAR_MILL dialog.
It is difficult to see the engage move in your tool path because the cutting tool moves are
covering up the ramp engage.
172
Later you will learn how to apply a Helical Engage for the Initial Engage.
Cancel to return to the PLANAR_MILL dialog.
You also have circular retracts applied when the tool leaves the part wall and on the Final
Retract.
Circular Engage and Retract does not apply to Zig-Zag or any other Zig routine.
173
Choose Reject.
The tool cuts past the start point of the cut before it retracts. This is because of the Overlap
Distance.
174
This move assures a full cleanup at the point where the engage and retract occur.
The Overlap distance is also applied to engage moves.
This time you will change the overlap distance and the Retract Clearance and look at the
difference.
Refresh the graphics display.
Key in 0.000 in the Overlap Distance field.
Key in .300 in the Retract Clearance field.
175
Choose Reject.
Choose Reject.
Next you will create a helical engage for your initial engage move into the part.
176
177
The Avoidance option lets you define clearance motions for the tool as it moves toward or
away from the part. This is different from the Engage and Retracts in that the tool moves
toward or away from points in the tool path.
Choose Avoidance.
Avoidance Options
178
GOHOME Point - The GOHOME Point defines the final tool location. The From Point is
often used as the GOHOME point. This point is a physical location that the tool moves to.
GOHOME Point outputs a GOHOME/ command as the final entry in the tool path.
Clearance Plane - The Clearance Plane defines a safe plane for the tool to move before and
after an operation and when moving from one cutting region to another.
Lower Limit Plane - The Lower Limit Plane is a plane which, when violated by the tool,
issues a warning in the CLSF. You can specify what to do with points that occur below the
lower limit plane.
Redisplay Avoidance Geometry - Displays the active Avoidance Geometry (points and plane
symbols) and the Reference Coordinate System (RCS).
The Clearance Plane dialog displays. You can use the Specify option to define the Clearance
Plane. Then you can use the other options to temporarily omit and then reinstate the Clearance
Plane, to verify the settings you have specified, and to graphically display the Clearance
Plane.
Choose Specify.
Choose Plane Subfunction.
Choose Principal Plane.
Choose ZC Constant.
You will create a clearance plane one inch above the XC-YC plane.
Key in 1.0000 in the ZC field.
179
OK to accept the value.
Notice that the ZC value for the Clearance Plane displays in the dialog and a plane symbol
displays in the graphics window at ZC=1.0000.
The options for the use of the Clearance Plane are displayed. These settings will cause retract
to the Clearance Plane when the tool moves from one cutting region to another. As you saw in
the previous tool paths, this is necessary to prevent the tool from crashing into the island.
OK to accept the default of Start and End.
OK again.
OK to return to the PLANAR_MILL dialog.
180
Choose Specify.
Key in the following values for the Base Point and OK to accept them.
The FROM Point displays in the graphic window. You may have to rotate the view to see the
displayed point.
181
OK to accept the From Point.
The From Point is defined. Next, you will define the Start Point.
Choose Specify.
The Point Constructor dialog displays. You are going to use XC, YC, ZC coordinates again.
Key in the following values for the Base Point and OK to accept them.
182
183
You are going to move the outermost boundary to the top of the part and the island boundary
to the top of the island.
Choose Edit in the Geometry section.
184
You have defined the new boundary plane for the outermost boundary.
The island boundary highlights in white. Also notice that the outermost boundary now
displays at the top of the part.
185
186
This time the tool moves to the Clearance Plane (ZC 1.0), down to the Start Point (ZC .4) then
to the Engage Point. Remember, you set the Vertical Clearance in a previous operation to .300
above the Engage Start Point. The tool is moving at the Engage Feed Rate the Vertical
Clearance distance into the material. It is also using the Helical engage motion.
Choose Reject.
Refresh the graphics window.
187
Choose the Previous or Next icon to highlight the member illustrated below.
You will slow down the feed rate inside the "U" shape.
Choose Custom Member Data.
The Edit Member dialog expands to display the custom values which can be applied to a
boundary member. You can customize each object in the boundary in many ways. You can
add Post Commands, add Stock, or even change the selected geometry to be the first member
of the boundary.
Turn the Cut Feedrate option on and key in 6.00 into the value field.
188
Turn the Cut Feedrate option on and key in 5.00 into the value field.
Turn the Cut Feedrate option on and key in 5.00 into the value field.
Choose the Previous icon to highlight the previous boundary member.
Turn the Cut Feedrate option on and key in 5.00 into the value field.
Choose the Previous icon to highlight the previous boundary member.
189
Turn the Cut Feedrate option on and key in 6.00 into the value field.
OK the Edit Member dialog.
OK to return to the PLANAR_MILL dialog.
190
In the Display Options dialog, notice that the paint speed is still set to 8, as you set it earlier in
the lesson.
Set the Tool Display option to 3-D.
Key in 5 in the Frequency field.
This specifies that the tool will be displayed at every fifth Cutter Location point.
Choose Other Options.
Paint Feeds - Displays the feed rate each time it changes.
Paint Arrows - Displays an arrow at the end of each tool path segment showing its
direction.
Paint Line Numbers - Displays the CLSF line number of the first CL-point of each
tool path when you Replay an accepted tool path.
Turn the Paint Feeds and Paint Arrows options on.
The tool displays as a wireframe at every fifth point in the tool path
There is an arrow at the end of each tool path segment
Feed rate changes are shown as "F#"
191
Because the Display settings are modal, they remain in effect until they are changed.
OK to accept the tool path.
You are finished using this part file. Next you are going to learn more about blank geometry
and boundaries.
Close the part file.
Choose Application
Manufacturing.
in the toolbar.
192
The Boundary Geometry dialog displays. The Material Side is set to Inside. This means that
the material will be retained inside the boundary.
Set the Mode option to Curves/Edges.
Select the four curves in order as illustrated below.
193
194
This creates an extra inch of stock surrounding the part that will be used as the Blank
boundary. The tool will cut from the 1 inch outer edge of the Blank boundary to the Part
boundary.
Be sure the Mode is set to Face.
Select the bottom face of the part.
195
196
In this lesson, you will learn how to create multi-level tool paths, clean up islands, create and
edit boundaries, and control many other aspects of multi-level planar mill operations.
197
Choose Application
Manufacturing.
Before you start, there are two terms that you should understand.
Region - this is the area within the cut levels that can be accessed by the tool without it
having to retract from within the part. There can be multiple regions cut in one
operation.
Cut Level Planes - are planes that define the levels in the pocket where the cuts take
place.
198
Choose MB3
Edit.
199
You are cutting a pocket, so the material to remain is on the outside of the pocket boundary.
The Material Side option needs to be changed to Outside.
Set the Material Side option to Outside.
You are ready to select the objects for the first boundary.
200
The system will automatically bridge the gap to create a closed boundary.
201
Because the Type was set to Closed, the boundary was automatically closed by extending the
first element to meet the last.
202
You are cutting the top of an island, so the Material Side is on the inside of the boundary this
time. The material will be retained on the inside of the boundary, preventing the island from
being cut away.
Set the Material Side option to Inside.
The tool will not remove material from inside the boundary.
The plane of island boundaries should be located at the top of the island, so you can let the
system use the edges you select to automatically define the plane for this boundary.
203
When you are chaining, the crosshair placement determines the success of the chaining
operation.The selection ball must capture the edge that you are selecting and The crosshair
must pierce the island face that contains the edges you wish to chain.
Select the first linear edge toward the right end as shown.
Make sure your Cue line says "Select object #9". This means you have successfully selected 8
objects.
204
use the chaining method.) Material Side should be set to Inside. The material will be retained
on the inside of the boundary, preventing the island from being cut away.
Choose Create Next Boundary.
Choose Chaining.
Select the linear edge toward its lower end, as shown below.
After you accept the selection, all the elements on the top of the island are selected
highlighted.
OK to create the boundary.
205
The floor plane is the lowest plane in your pocket. The cut levels of the tool path will be
parallel to this plane. The default of the XC-YC plane is currently set.
With the Floor icon selected, choose Select.
206
You are going to define the cut depths by defining the maximum and minimum depths. First
you will define the largest amount of material to be cut at any level. If you use the default of
0, you would generate a single level tool path at the floor plane.
207
Key in 1.30 in the Maximum field.
Now you will set the Minimum cut depth to 0.100. This is the smallest amount of material
that you can cut at any level.
Key in 0.10 in the Minimum Field.
If you accept the Minimum default value of 0, and specify a larger Maximum value, the tool
will cut at the Maximum value depth and,at the top of each island.
Cut Levels
User Defined - You define the depths of cut. You can set the Maximum, Minimum, Initial,
and Last depths of cut
Floor Only - Generates a single cut level at the floor plane.
Floor & Island Tops - Generates one cut level at the floor plane and then generates a cleanup
cut at the top of each island.
Levels at Island Tops - Generates a cut level at the top of each island.
Fixed Depth - Generates cut levels at a constant depth, using the Maximum field.
Initial - Defines the depth of cut for the first cut level of the tool path.
208
Final - Defines the depth of cut for the last cut level of the tool path.
Increment Side Stock - Adds side stock to each cut level. Cut level one will leave the
specified stock. Cut level two will leave twice the specified stock, and so on.
Top Off Islands - Causes the tool to cut the tops of the islands if they could not be cut at one
of the cut levels. Notice that this option is on by default.
When there are islands in the part file and the maximum and minimum depths of cut are
defined, the system will try to use the tops of the islands as one of the cut depths. This is
subject to the number of islands defined and the specified maximum and minimum cut depths.
209
Part Stock - This is the remaining material on the walls at the completion of the tool path.
Final Floor Stock - This is the amount of material that is left on the floor and on top of the
islands at the completion of the tool path.
Blank Stock - This is the distance the tool will be positioned from the defined blank geometry.
Blank Distance - This is the offset distance applied to the part boundary or part geometry to
produce the blank geometry.
Check Stock - Is the distance the tool will be positioned from the check geometry.
Trim Stock - Is the distance the tool will be positioned from the trim geometry.
210
211
You will eliminate this unnecessarily large tool move by changing the Transfer Method.
The tool path displays in the Information window. Notice that the depth of the first cut is .900. You specified 1.3.
The distance from the top of the part to the top of the first island is 1.800. You also specified
Top of Island as a cut level. Since this distance (from the top of the part to the top of the first
island is greater than the 1.300 the maximum depth you specified, the actual distance of 1.800
is divided into two equal steps of .900.
1. First Cut Level
2. Second Cut Level (top of island)
3. Top of Part
212
Dismiss the Information window.
Reject the tool path.
Transfer Methods
213
The default Vertical and Horizontal Clearance Distances are .1. This means that the tool will
retract .1 above the previous plane before engaging to the next cut and come no closer than .1
inch to any wall geometry.
You will change these values to ensure that the tool will not gouge the top of the island.
Key in .200 in the Horizontal value field.
Key in .200 in the Vertical value field.
214
Notice the dashed lines, indicating the move between levels at the previous plane plus the
vertical distance of .2.
215
The tool cuts the part using the conventional cut direction. The resulting tool path is the same,
but the tool path is developed differently. When the last level is cut the tool starts on the right
side of the part rather than the left. The tool also cuts around the island in the opposite
direction.
Refresh the graphics display.
Reject the tool path.
216
Helical Diameter %
The most effective way of engagement is through the milling of a "start" hole using helical
interpolation. Associated with this method of ramping is the parameter Helical Diameter % which describes the maximum diameter path used by the tool for a Helical engage and is used
for the Helical ramp type only.
When using the helical method, there is a minimum and maximum hole diameter that can be
utilized, leaving no center or cone material at the bottom of the hole. The maximum hole
diameter is equal to:
217
If the hole diameter is greater than the calculated maximum hole diameter, material remains in
the center of the hole but has no effect on the tool since the material is on the outside of the
cutter.
If the hole diameter is less than the calculated minimum hole diameter, material remains in
the center of the hole, causing the tool to break.
If the hole diameter is equal to the calculated minimum hole diameter, no material remains in
the hole and the cutting tool will cut normally.
218
If the hole diameter is equal to the calculated maximum hole diameter, the bottom of the hole
is completely flat. This is the preferred method for helical interpolation.
If the area is not large enough to allow the Helical Diameter, the diameter of the path will be
reduced and an attempt is made to perform the engage again.
This process will continue until either the Helical Engage is successful or the path diameter
becomes less than the Minimum Ramp Length. If the area is not large enough to allow the
path diameter that is equal to the Minimum Ramp length, the system will attempt to ramp into
the area.
219
When using an inserted cutting tool, the ramping motion must be long enough to eliminate
any uncut material. Associated with the ramp method is the parameter Min Ramp LengthDia% - which is used by all three Ramp Types (On Lines, On Shape, Helical). For On Shape
and On Lines, the Minimum Ramp Length-Dia% represents the minimum path distance used
by the tool from the top to the bottom of the ramp. For Helical Ramp Type, the parameter
represents the minimum diameter path used by the tool. The minimum ramp length can be
calculated as follows:
2 x Tool diameter - 2 x Insert Width
220
If the ramp length is less than the calculated minimum, material remains which results in tool
breakage.
If the ramp length is greater than or equal to the calculated minimum, no material remains and
the tool will cut normally.
221
Choose MB3
Toolpath
Verify.
222
Cancel the tool path visualization.
MB3
223
of displaying and saving the uncut regions. This interactive method allows you some
control over the number and location of the boundaries which will be created.
Under the Cutting section of the Planar Mill dialog, the Auto Save Boundary option
can be selected. This method will automatically create boundaries at all the locations
where uncut material is detected.
Double-click on UCUT.
OK the settings.
224
The first cut level displays along with the Display Parameters dialog.
The Overlap Distance is an offset to be applied to the boundary into the cut region to insure
clean up.
Four uncut regions are displayed in this cut level.
You can see the material left in the corners. You could select the Save option, but you will
wait for the last cut level before saving.
OK to continue processing the tool path.
The Display Parameters dialog displays. Notice that you do not have the option of saving the
uncut regions at this time.
OK to continue processing the tool path.
The second cut level displays along with the Display Parameters dialog. Once again, you have
the option to Save the uncut regions but you will not.
OK to continue processing the tool path.
The Display Parameters dialog displays without the Save Uncut Region option.
OK to continue processing the tool path.
The third cut level displays along with the Display Parameters dialog.
225
There are more boundaries displayed this time. Continue to process this tool path. You will
save on the next level.
Choose OK to continue processing the tool path.
OK to continue processing the tool path.
The final cut level displays along with the Display Parameters dialog. Now there are
additional Uncut Regions displayed at the U shape near the island.
226
At this point you will get an Uncut Boundary Output Warning message saying "Previously
saved Uncut Boundaries will be replaced. Do you want to proceed?". This means that the
boundaries you did not create at the higher levels in this operation will be overwritten by the
boundaries you are about to create. This is just an informative message and will cause no
problems.
OK the warning.
The boundaries are created and displayed in green. As you have developed this operation, you
may have noticed that some of the same boundaries are displayed at each level. Only one
boundary is saved for each location thus eliminating boundary duplication.
227
Choose Cutting.
The Cut Parameters dialog displays. Notice the Auto Save Boundary option in the Uncut
Regions section at the bottom of the dialog.
Choose the Auto Save Boundary option to turn it on.
OK to return to the PLANAR_MILL dialog.
OK the settings.
228
You will set up the current operation so that it will remove the part stock. You only need to
machine the walls of the part and its island. The profile cut method will eliminate the interior
tool motion that was generated in PMMULTI.
Set the Cut Method to Profile.
229
Choose MB3
Paste.
The copied operation displays in the Operation Navigator underneath operation UCUT with
the name UCUT_COPY.
230
231
232
The tool cuts all of the boundaries at each level, then moves down to the next level to cut all
of the boundaries at that level. This continues until all boundaries are cut to the floor plane.
You could specify that the tool cut one boundary to the finish depth before moving to the next
boundary.
Reject the tool path.
233
Turn Off the Pause After Display and Refresh Before Display options.
OK to continue generating the tool path.
The tool path is generated. This time the tool cuts each boundary to the finish depth before
moving to the next boundary.
234
in the toolbar.
235
Manufacturing.
236
237
Choose Edit.
The Edit Member dialog displays. Notice that the first boundary member is highlighted.
The Modify Boundary Start Point dialog displays and a directional arrow displays in the
graphics window to indicate the boundary direction.
238
239
The shortened boundary displays. The white cone head indicates the boundary direction.
Key in .06 in the Distance field and 1 in the Additional Passes field.
240
241
242
Notice that the Automatic Type is set to Circular and the activation range is set to .100. You
will change the Activation Range to 0.
Key in 0 in the Activation Range field.
The tool path that you generate with this setting will use a circular engage on the final pass
only.
OK to return to the PLANAR_MILL dialog.
Notice that the first pass is .060 away from the part wall. The tool makes a circular engage
into the wall on the final pass, then moves to cut the radius and retracts in a circular fashion
along the remaining wall.
You can also see the feed rate changes as the tool machines the corner. There are several
stacked up in the corner where the slowdown occurred.
243
The feed rate changes as the tool slows down going into the corner and then accelerates as it
moves away from it. The number of acceleration moves is approximately half of the
decelerations.
Dismiss the Information window.
OK to complete the operation.
Close the part file.
244
Choose Application
Manufacturing.
245
The Boundary Geometry dialog displays with the Material Side set to Inside. This is the
correct setting for this operation.
Choose Custom Boundary Data.
Turn on the Blank Distance option and key in 1.00.
This creates an extra inch of stock surrounding the part boundary that will be used as the
blank material.
You are going to use the top outer edge of the part. The boundary b1 has been created for you.
Set the Mode option to Boundary.
Key in b1 into the Name field.
246
Turn off the Blank Distance option.
You want the boundary located at the top of the part, on the inside of the pocket, with the
Material Retained Outside/Right.
Set the Material Side to Outside/Right.
Key in b3 into the name field.
OK to accept the boundary.
247
248
249
250
251
252
You will develop a Planar Mill tool path that will cut many pockets (regions) with varying
depths. You will cut one pocket, then edit the tool path and add more pockets.
Choose Application
Manufacturing.
253
You want the tool to cut the inside of this closed boundary, so the material remaining should
be outside.
Set the Material Side to Outside/Right.
254
255
You have now defined the top and bottom of the large pocket.
256
This option cuts each pocket to full depth and does not leave the pocket until reaching the
bottom.
OK to accept the cut parameters.
257
258
The error message "Tool Cannot Fit into Level 3" will display. This is because the tool cannot
reach the specified floor, which is below the bottoms of the pockets.
OK the error message to continue.
Reject the tool path and Refresh the graphics window.
This region contains a pocket within a pocket. The top boundary of the smaller pocket will
define the lower boundary of the larger pocket.
259
Choose the Part icon, then Edit.
260
Continue to choose OK as necessary.
OK the warning.
The tool path is generated. The tool cuts to the bottom of each pocket.
Append
Remember, in order to cut multiple pocket depths, you must specify the top of a pocket as
Material Retained Outside (creating a pocket boundary) and the bottom of the pocket as
Material Retained Inside (creating an island boundary).
Top of Pocket=Outside/Right B7
Top of Pocket (island)=Outside/Right B8
Bottom of Pocket-Inside/Left B9
261
The pocket with the open end also requires a Closed Boundary
Top of Pocket=Outside/Right B11
Bottom of Pocket=Inside/Left B12
262
Analysis Tools
The Analysis Tools are used to visually inspect the cutting areas in the tool path.
263
Analysis Tools
Analyzing Tool Paths
Double-click on the PMREG_ANAL icon in the Operation Navigator.
Analysis Tools
Analyzing the Tool Path by Level
Note that the number of levels in the tool path is displayed at the top of the dialog.
This dialog acts like a replay tool. It will only display the tool path at a specified level.
Key in 4 in the Current Level field and press the Enter key.
The tool movement at level 4 is replayed in the graphics window.
264
The Previous and Next arrows on the dialog select the tool path at the next level or the
previous level.
Choose the Previous or Next arrow.
The tool path at that level is replayed.
OK until you return to the PLANAR-MILL dialog.
Cancel the PLANAR-MILL dialog.
Analysis Tools
Generating the Tool Path
Double-click on the PMREG_ANANL_2 icon in the Operation Navigator
Generate the tool path.
265
Analysis Tools
Analysis Tools Level Option
Look at the top of the dialog and note the two settings, Region and Level.
The Level setting displays all of the offset shapes and regions at the current level.
You can use the Previous and Next arrows to cycle through the different levels. This option is
the same as the previous Analysis Tool.
Choose Show Cut.
Analysis Tools
Displaying Blank Cut Shape
Choose Blank Cut Shape.
266
Only the blank material offset shape displays.
If you use the arrows now, the system will cycle through only the Blank Shape Traces.
Choose the Previous or Next several times to cycle through the Blank Cut Shape at each
level.
Analysis Tools
Displaying Part Shape
Choose Part Shape.
You should see only part shapes displayed in the graphics window.
If you cycle through the levels now, you will only see cut levels for the part displayed.
Choose the arrow several times to cycle through the Part Shapes at each level.
Key in 2 into the Current Level field and press Enter.
Analysis Tools
Displaying Uncut Regions
Choose Uncut Regions.
267
Analysis Tools
Displaying Cut Regions
Choose Cut Regions.
Analysis Tools
Using the Cycle Option
The Cycle option enables you to specify a subset of a specified shape.
A drop down menu displays three options:
All - displays all of the specified shapes within each level as you cycle from one level
to the next.
Shape - highlights each specified shape in sequence (only within the currently
displayed level) as you select the arrows.
Segment - highlights each segment of the displayed shapes in sequence (only within
the currently displayed level) as you select the arrows.
Set the Cycle option to Shape.
268
Analysis Tools
The Dump Level Option
This option is only available when using the Level option and when Cycle is set to All. Dump
Level allows you to write just the current level to a file so that problems occurring in that
level can be analyzed by CAM Development.
Analysis Tools
Analysis Tools Region Option
The Region setting displays each cut region individually within the operation.
Choose the Region option.
269
The cut regions are displayed in the graphic window. Although you no longer have control of
the cut levels, the cut regions for level 2 are displayed. This is because you were at level 2
when you changed from Level to Region.
Use the Previous and Next arrows to cycle through the different Cut Regions.
OK two times to return to the PLANAR-MILL dialog.
Cancel the Analysis Tools dialog.
Cancel the operation.
Close the part file.
Face Milling
Face Milling is a fixed axis milling method similar to Planar Milling, but designed
specifically to rough and finish the planar faces of a part. It allows you to specify the face
geometry simply by selecting the faces to be machined. It also allows you to define face
geometry by selecting existing curves and edges or by specifying a sequence of points in
much the same way as Planar Milling.
270
The tool axis is automatically defined as the normal of the first selected face boundary plane.
Since Facing removes material in planar levels with respect to the tool axis, the normal of a
face boundary plane must be parallel to the tool axis. If it is not, the face will be ignored
during tool path generation.
In this lesson you will create a Face Milling operation that finishes the faces of a part. You
will also learn several ways to cut across open and closed voids and learn how to create mixed
and manual cut patterns.
271
Choose Application
Manufacturing.
272
The part geometry has already been defined in the WORKPIECE parent group.
With the Face Boundary icon chosen, select the six faces illustrated below.
273
Face boundaries are processed as blank boundaries. The center line of the tool cuts all the way
to the boundary (where it does not gouge the part), which results in the material being
removed along the edge of the face.
OK to complete the selection.
Choose Follow Periphery as the Cut Method.
Notice that the tool path does not avoid the clamps. You will need to define the clamps as
check geometry.
274
Choose the Check Body icon and Select.
275
in the toolbar.
276
Manufacturing.
Choose Cutting.
Notice that Across Voids is set to Follow. This option excludes the cut pattern from closed
voids, causing the cut pattern to follow the shape of the cut region.
277
This option maintains the cut pattern across closed voids at the cut feed rate.
OK to accept the Cut Parameters.
Generate the tool path.
278
This option maintains the cut pattern across closed voids but uses the cut feed rate only while
the tool is in contact with material. The traversal feed rate is used when the tool is not cutting
material.
Notice the Traverse Distance is set to zero. The Traverse Distance represents the minimum
amount of empty space the tool must cut to employ a traversal feed rate inside a void. A
Traverse Distance of zero ensures that a traversal feed rate will always be used when the tool
is not cutting through material.
OK to accept the Cut Parameters.
Generate the tool path.
279
Choose Cutting.
Key in 25 to define the Blank Overhang distance as a percentage of the tool diameter.
280
Tool Run-Off
When finish milling using a Zig or Zig-Zag cut pattern, it is often desirable to retract the tool
completely off the part after each cutting pass to achieve a quality surface finish. However,
when roughing production parts, it is sometimes desirable to allow the tool to stay on the part
after each cutting pass to minimize toolpath time
The Tool Run-Off parameter satisfies both cases. Tool Run-Off is supported for Zig and ZigZag cut types in face milling, planar milling, and cavity milling operations and is only applied
to operations which employ an Automatic Retract.
When Tool Run-Off is On, the tool will automatically retract off the part after each cutting
pass by a distance equal to the horizontal clearance.
When Tool Run-Off is Off, no attempt is made to retract the tool off the part after each cutting
pass. Depending upon the amount of the Blank Overhang, the tool may or may not remain on
the part.
The tool will always engage from the safe shape for a Zig or Zig-Zag cut. The tool will retract
to the safe shape only if the Tool Run-Off option is On and and an Automatic Retract is
employed by the operation.
281
Choose Method.
Notice that Tool Run-Off is On.
The tool will retract off the part after each cutting pass by a distance equal to the horizontal
clearance. You will increase the horizontal clearance so you can see the Tool Run-Off a little
more clearly.
Key in 0.30 in the Horizontal field and OK to accept it.
Change to a Top view.
282
283
Manufacturing.
284
Choose 2-D for the Tool Display and Silhouette for the Path display.
Choose Generate.
The Mixed Cut Pattern dialog displays. The current cut level being processed and the region
number at that level are displayed at the top of the dialog.
The order in which the regions are cut is determined by Region Sequencing. In this example,
the Region Sequencing is set to Standard, so the regions will be cut in the order the faces were
selected.
The first cut region is displayed.
285
OK to complete the cut pattern and display the next cut region.
286
Notice that the follow periphery cut pattern has been added to the list box.
The most efficient tool path for this next cut region is one that cuts in straight line segments
where possible rather than following the exact shape of the region. A manual cut pattern will
allow you to do this.
Replace View
TOP.
287
288
Select the hole illustrated below to define the center as the reposition point.
289
Select the small hole to define the center as the point the tool will cut to.
These options allow you to create a point on the cut region shape close to where you indicate.
Be sure Cut Region is specified as the shape to be selected.
290
Indicate on or near the center of the cut region segment as illustrated below.
The indicated point projects at a minimum distance to the cut region shape where the system
defines the point the tool will cut to.
The face is cut with a simple linear move.
291
This option assures that the vertex of the cut region shape closest to where you indicate is
defined as the point the tool will cut to.
Indicate on or near the cut region vertex as illustrated below.
292
The tool should now move along the shape in the opposite direction.
293
Indicate on or near the center of the cut region segment as illustrated below.
294
Select the end point of the arc as the next point the tool will cut to.
Select the small hole to define the center as the next point the tool will cut to.
295
Select the small hole to define the center as the last point the tool will cut to.
Layout
Replace View
296
297
Choose the Play Forward icon.
298
You will change the cut pattern for this region to Profile.
Choose Profile.
299
Choose the Dynamic tab.
Choose the Play Forward icon.
Choose Offset from Part and key in 0.10 for the Offset.
OK to accept the blank material and begin the visualization.
Material is now cut from every cut region.
Cavity Milling
Cavity Milling is designed to rough out large volumes of material from cavities and cores,
especially those with tapered walls such as dies and molds. Cavity Milling is similar to Planar
Milling in that it uses a fixed tool axis and removes the material in planar cut levels.
300
In this lesson you will create Cavity Milling operations that rough out cavities and cores.You
will also learn how to use a faceted body to perform rest milling.
301
Choose Application
Manufacturing.
in the toolbar.
Choose MB3
Edit.
302
The Part Material listing displays in a Search Result dialog.
Highlight MATO 00266 ALUMINUM and OK to accept it.
303
Choose the Blank icon and then Select.
in the toolbar.
304
305
The range depth is currently indicated as 35.00 mm in the Range Depth field and on the slider
bar.
Use MB3
306
You will reference the new range from the bottom of the currently highlighted range.
Change the Reference option to Range Bottom.
307
308
Selecting the up or down arrow will change the range being modified.
Enter 1.00 in the Depth per Cut field and press Enter.
The graphics display indicates the new, smaller, depth per cut by displaying six plane symbols
between the large range symbols.
The Cut Levels dialog allows you to adjust the planes of the cuts and the depths of the cuts.
Some definitions are in order to clarify the terminology:
A Range is a specified amount or depth of material within the cavity to be removed. You can
specify up to 10 Ranges.
A Cut Level is a specified depth of cut within a Range to be removed.
309
The dialog displays the exact depth of this range - both in the Range Depth field and at the
end of the slider bar.
You can use one or more ranges to cut the cavity.
Assigning multiple ranges allows more control over the amount of material being removed
within the cavity.
For example, you may want to remove more material per cut in the upper portion of the cavity
and smaller amounts of material towards the bottom of the cavity. Defining several ranges
would accomplish this.
Because the first range is defined for you, you must choose Modify in order to make any
changes to the range. You must be certain the Modify Ranges icon is depressed for any
changes to be applied.
By default, the Reference option is set to Top Level. This option determines where the Range
Depth value you specify is referenced from.
Notice the graphics area, several plane symbols are displayed. The system automatically
determines the first range based on the highest and lowest points defined by the part and blank
geometry. The top and bottom of the range are indicated by the two large plane symbols.
310
By default, only the Cut feed rate is defined at 250.000 mmpm. The feeds and speeds can be
automatically calculated and set to values appropriate for your tool geometry and material and
your part material by selecting Reset from Table.
311
Choose Reset from Table.
An Error dialog displays.
The Error displays because there is no data in the Feeds and Speeds data file for the
combination of a ceramic tool and aluminum part material.You will change the tool material
in the next step.
OK the Error dialog.
OK the Feeds and Speeds dialog.
312
OK several more times to display the traces and tool paths at each level.
313
The last cut level is generated and displayed showing how the curved face of the bottom of
the cavity has narrowed the tool path.
After the lowest cut level is generated, the Processor Error message "Tool cannot fit into level
8" displays.
This message indicates that there is still material to be removed below the lowest level cut,
but the tool cannot fit into the remaining volume. You must finish cutting this material with
either a smaller tool or a different cutting method.
OK the Warning dialog.
314
The white area indicates that further finishing is required to machine to the specified Outtol.
315
You will create a Cavity Mill operation that uses a small tool to rough out the neck of the
bottle.
in the toolbar.
Enter RUF_NECK in the Name field and OK to begin creating the operation.
316
Choose Boundary as the Mode, Outside/Right as the Side Trimmed, and Trim as the
Geometry Type.
317
These parameters will restrict the tool path to the inside of the inside of the selected boundary.
Choose the boundary.
The follow periphery cut method creates cut patterns using only the outside part geometry.
318
If the depth field is left with the 0.00 default value, the Pre-Drill Engage Point will be applied
to all cut levels.
Choose Generic Point.
Choose the Cursor Location icon.
Indicate a point at the approximate screen position illustrated below.
319
320
in the toolbar.
321
This cumulative display of the material removed is helpful in indicating areas requiring
further machining.
Choose Compare.
The white areas indicate the areas where further finishing is required to machine to the
specified Outtol.
OK the Toolpath Visualization dialog.
Close the part file.
Machining a Core
You will use Cavity Mill to rough out a core.
322
Machining a Core
Opening the Part
Open part file pln_cavity_2.prt from the pln subdirectory.
Choose Application
Manufacturing.
Machining a Core
Choosing the Operation to Edit
You are going to edit an existing Cavity Mill operation.
Expand the WORKPIECE object in the Geometry View of the Operation Navigator.
Double-click on the operation named BLNK_GEOM.
323
The CAVITY_MILL dialog displays. Some of the options that have been set for you are:
Machining a Core
Looking at the Part Geometry
With the Part icon chosen, choose Display.
The part geometry highlights.
Machining a Core
Defining the Blank Geometry
Choose the Blank icon, then Select.
324
Machining a Core
Defining the Cut Levels
You are going to define Cut Levels by specifying Ranges and Cut Depths.
Choose Cut Levels.
The blank geometry is a little more than .5 inches above the top of the part geometry. You
will move the cut range to the top of the blank geometry and set the depth of each cut level to
.25 inches.
Machining a Core
325
Machining a Core
Modifying the Range
The current range is referenced from the top of the Blank geometry and extends to the top of
the part geometry. You will extend the bottom of the range to a lower level so that it removes
more of the blank material.
326
The Range Depth field will read 2.50. The range will remain associative to this face. If the
face is modified or deleted, the range is adjusted or deleted with it.
Machining a Core
Modifying the Depth per Cut
Key in 0.250 for the Depth per Cut and Apply.
Small plane symbols indicate the depth per cut for the current range.
Machining a Core
Defining the Second Range
327
Choose the Add Ranges icon.
Moving the slide bar to 5.50 sets the range bottom to the bottom of the Blank geometry.
Key in 1.000 for the Depth per Cut and Apply.
Machining a Core
Generating the Tool Path
Generating this tool path may take a little longer than other tool paths you have generated due
to the complexity of the part and the number of cut levels.
328
Generate the tool path.
The first cut region and the Display Parameters dialog are displayed.
329
Machining a Core
Visualizing Material Removal for the Cavity Mill Operation
MB3 Expand in the TFR-ISO view so that this is the only view that appears in the
window.
Choose the Verify icon at the bottom of the dialog.
Choose the Dynamic tab.
Choose the Play Forward icon.
The roughing operation leaves large scallops for the subsequent finishing operations to
remove.
330
OK to complete the tool path visualization.
OK to complete the operation.
MB3
Machining a Core
Making the Blank Geometry Invisible
You are going to remove the modeled blank geometry from the display so you can later define
blank geometry by specifying a blank distance.
Choose Format
Layer Settings.
Machining a Core
331
Machining a Core
Defining the Blank Distance
You are going to define blank geometry uniformly to the entire part by specifying a blank
distance.
Choose Cutting.
Key in 0.250 for the Blank Distance.
Also note that there is a Blank Stock setting as well. Blank Stock is the additional stock that is
applied to blank geometry.
OK to accept the cut parameters.
Machining a Core
Generating the Tool Path
Generate the tool path.
The first cut regions are displayed.
OK to continue processing the tool path.
The tool cuts around the islands taking into consideration the Blank Distance. This is a very
different tool path than the previous tool path you generated using the modeled blank
geometry.
332
Machining a Core
Using Blank Geometry to Isolate Areas
You can use blank geometry to isolate and cut specific areas of the part.
Choose Format
Layer Settings.
333
Machining a Core
Choosing the Operation to Edit
Double-click on the operation named BLNK_ISO.
Machining a Core
Displaying the Part Geometry
With the Part icon chosen, choose Display.
334
This time all of the faces have not been selected. You could have used all of the faces, but
adding unnecessary part geometry will increase the time required for the tool path to generate.
What is important is that the part geometry you wish to cut be contained within the blank
material.
Machining a Core
Defining the Blank Geometry
Choose the Blank icon and then Select.
Select the white rectangular block.
Machining a Core
Displaying the Cut Levels
Choose Cut Levels in the Control Geometry section.
The cut levels start at the top of the blank geometry and extend to the bottom of the blank
geometry
Machining a Core
Generating the Tool Path
335
Generate the tool path.
The first cut region is displayed.
OK once to continue processing the tool path.
The tool cuts the top of the part within the blank geometry.
OK twice to continue processing the tool path.
The tool cuts around the island.
Machining a Core
Changing the Cut Direction
You are going to change the cut direction so that the tool starts machining from the outside of
the stock and cuts inward.
Choose Cutting.
Change the pocket direction to Inward.
336
OK to return to the CAVITY_MILL dialog.
Machining a Core
Generating the Tool Path
Generate the tool path.
The first cut region displays.
OK once to continue processing the tool path.
The tool cuts from the outside in.
Machining a Core
Using Blank Distance with Blank Geometry
You can use modeled blank geometry and Blank Distance to machine parts which are more
heavily stocked in some areas than others. The following figure illustrates rectangular blank
geometry surrounding the left top side of the part. The remaining part area has a Blank
Distance value of 0.1 specified because it was cast closer to size.
You will modify operation BLNK_ISO_DIST to generate a tool path with the stock defined
as above.
337
Double-click on the operation named BLNK_ISO_DIST in the Operation Navigator.
Machining a Core
Displaying the Part Geometry
Choose Display from the Geometry section.
Machining a Core
Defining the Blank Geometry
You are going to define the blank geometry using the same rectangular block used in the
operation you just generated.
Choose the Blank icon, then Select in the Geometry section.
Select the white rectangular block that surrounds the part and then OK to accept it.
Machining a Core
Defining the Blank Distance
Choose Cutting.
Key in .25 for the Blank Distance.
338
Machining a Core
Specifying the Cut Levels
Choose Cut Levels.
You will define the cut range and levels to machine the top of the part.
Choose Modify Ranges.
339
Machining a Core
Generating the Tool Path
Generate the tool path.
Turn all of the Display Parameter options off.
340
Choose Application
Manufacturing.
341
Tolerant Machining uses a reliable algorithm to find the correct machinable regions without
gouging the part. In the following figure, the shank of the tool does not gouge the canted rib
when using Tolerant Machining.
Unlike Undercut Handling, it does not apply a horizontal clearance to the tool shank.
Choose Cutting.
Notice that when Tolerant Machining is turned on, Undercut Handling is not available.
342
You will now turn off both Tolerant Machining and Undercut Handling and observe the
behavior of the tool path.
Choose Cutting.
Note that Undercut Handling is grayed out. You can only turn off the Undercut Handling
option after you have turned off the Tolerant Machining option.
Turn the Tolerant Machining option off.
Turn the Undercut Handling option off.
Undercut Handling
When you use the Undercut Handling option the system applies the Horizontal Clearance
(specified under Engage/Retract Method) to the shank of the tool (the portion above the
flutes) unless the Horizontal Clearance is greater than the tool radius, in which case the tool
radius is used.
As the tool progresses deeper through the cut levels, the Horizontal Clearance will keep the
shank from rubbing against the part geometry forming the undercut.
343
In this operation, the Horizontal Clearance uses the default of .100. The tool radius is .120. So
the tool will be offset from the undercut face .100.
Undercut Handling applies only to non-tolerant machining (i.e., the Tolerant Machining
option is toggled OFF).
344
Generate the tool path.
Notice that the tool is offset from the wall to avoid rubbing the shank of the tool on the wall.
Rest Milling
Cavity Milling allows you to perform rest milling by creating an associative In-Process
Workpiece (IPW) in an operation and using it as blank geometry in the next operation. It also
allows you to display the previous IPW and the resultant IPW for each operation.
To use the IPW, operations must be in the correct program sequence in the MILL_GEOM or
WORKPIECE geometry group. The tool path must be generated and accepted in all previous
operations in the sequence before the IPW can be used in the next operation.
Rest Milling
Opening the Part File
The Initial IPW is defined as the Blank in the geometry parent group MILL_GEOM or
WORKPIECE geometry parent group.
345
You will define the BLANK in the MILL_GEOM parent group, activate the use of the 3D
IPW and generate the operation. You will use the subsequent IPW that was generated as the
blank for the next operation.
Open part file pln_rest_mill.prt from the pln subdirectory.
Choose Application
Manufacturing.
Display the Geometry View in the Operation Navigator and expand the objects.
Rest Milling
Displaying the Part Geometry
The part geometry has been defined in the WORKPIECE parent group.
Double-click the WORKPIECE parent group.
346
Rest Milling
Defining the Blank Geometry
You will define the blank geometry using a method that automatically creates a solid body
enclosing the part geometry.
Choose the Blank icon and Select.
A solid body bounding the part geometry is created. The XM, YM, ZM fields allow you to
modify the size of the body by specifying offsets from each face.
347
Rest Milling
Creating a Roughing Operation
You will create a roughing operation that uses the blank geometry you just defined.
Be sure the Type option is set to mill_contour and choose Cavity Mill.
348
Rest Milling
Generating the Tool Path
Generate the Tool Path.
Turn the three Display Parameter options off and OK to continue generating the tool
path.
Rest Milling
Creating a Semi-Finish Operation
You will create a semi-finish operation that uses the IPW defined by the roughing operation
as blank geometry.
Choose the Create Operation icon from the toolbar.
Be sure Cavity Mill is still chosen as the subtype.
Specify the following parent groups.
349
Rest Milling
Using the IPW as Blank Geometry in the Current Operation
You will use the IPW generated by the roughing operation as the blank geometry in this
operation.
Choose Cutting from the CAVITY_MILL dialog.
Turn the Use 3D IPW option on.
Rest Milling
Displaying the Previous IPW
The Previous IPW icon replaces the Blank icon at the top of the CAVITY_MILL dialog.
350
Rest Milling
Generating the Tool Path
You will generate a tool path that semi-finishes the part.
Generate the Tool Path.
Turn the three Display Parameter options off and OK to continue generating the tool
path.
Rest Milling
Displaying the Resulting IPW
You will display the resulting IPW that will be passed on to the next operation.
Choose the Display Resulting IPW icon.
The system may require some processing time to display the faceted body.
351
Rest Milling
Creating a Finishing Operation
You will create a finishing operation that uses the IPW defined by the semi-finish operation as
blank geometry.
Choose the Create Operation icon from the toolbar.
Be sure Cavity Mill is still chosen as the subtype.
Specify the following parent groups.
Rest Milling
Using the IPW as Blank Geometry in the Current Operation
You will use the IPW generated by the semi-finish operation as the blank geometry in this
operation.
Choose Cutting from the CAVITY_MILL dialog.
Turn the Use 3D IPW option on.
352
OK to accept the Cut Parameters dialog.
Key in 3.000 in the Depth Per Cut field.
Rest Milling
Generating the Tool Path
Generate the Tool Path.
Turn the three Display Parameter options off and OK to continue generating the tool
path.
Rest Milling
Displaying the Resulting IPW
Choose the Display Resulting IPW icon at the bottom of the dialog.
The system may require some processing time to display the faceted body.
353
Rest Milling
Displaying the IPW Column in the Operation Navigator
Click MB3 on the Operation Navigator background and choose Columns and Configure.
354
If an new operation is inserted in the program sequence, if an operation is deleted, or if the
operations are reordered, clock icons indicate that the resulting IPW's are out of date. This
simply means that when generating the tool paths, the IPW's will need to be updated
internally, requiring additional processing time.
Remove the IPW column from the Operation Navigator.
Close the part file.
Z-Level Milling
Z-Level Milling is designed to profile a part at multiple cut levels using a fixed axis. It allows
you to cut either the entire part or steep areas only.
When the Steep Angle option is toggled on, only areas with a steepness greater than or equal
to the specified Steep Angle are profiled. This allows you to profile areas left unmachined by
the Area Milling Drive Method in Fixed Axis Surface Contouring.
In this lesson, you will profile the part at each cut level and then constrain the cut region using
the silhouette or "shadow" of the part. You will then specify a Steep Angle to profile only the
steep areas left unmachined by a previous Fixed Axis Surface Contouring operation. In
addition, you will learn how to define a Cut Area and then further constrain the cut region
using a trim boundary.
355
You will use Z-Level Milling to profile the part. You will observe how the Trim By option
can be used to profile the entire part at each cut level or to constrain the cut region by the
silhouette or "shadow" of the part.
Choose Application
Manufacturing.
356
The WORKPIECE object does not yet define the part geometry and must be edited.
Double-click on the WORKPIECE object.
This displays the MILL_GEOM dialog so you can define Part, Blank, and Check Geometry.
Choose the Part icon and Select.
357
You can choose either of the two subtypes outlined below to create a Zlevel Profile operation.
The ZLEVEL_PROFILE icon creates an operation with no Steep Angle, allowing the entire
cut region to be profiled. The Steep angle option is turned off by default.
The ZLEVEL_PROFILE_STEEP icon creates an operation that allows only areas with a
steepness greater than or equal to a specified Steep Angle to be profiled. The Steep angle
option is turned on by default.
358
The off condition allows the entire cut region to be profiled regardless of the steepness of the
surface being cut.
359
360
361
Choose Application
Manufacturing.
In the Program Order view of the Operation Navigator, expand the PROGRAM object to
display the two operations.
Notice that the Select/Reselect option is blanked, indicating that the part geometry is inherited
from the WORKPIECE object.
362
363
In the Area Milling Method dialog, notice that the Steep Containment is specified as Nonsteep and the Steep Angle is specified as 70 degrees. This allows only areas where the tool
path is less than or equal to 70 degrees to be machined by this operation. The steepness of the
part at any given point is defined by the angle between the tool axis and the normal of the
face.
364
This will allow only the areas with a steepness greater than or equal to 70 degrees to be
profiled.
By comparing the tool paths, you will notice that the entire part is machined by the two
operations. The CONTOUR_AREA operation zig-zags the areas where the steepness is less
than or equal to 70 degrees. The ZLEVEL_PROFILE operation profiles the areas where the
steepness is greater than or equal to 70 degrees.
365
Manufacturing.
366
In the Geometry view of the Operation Navigator, expand the MCS_MILL object and the
WORKPIECE object to display the ZLEVEL_PROFILE operation.
Double-click on ZLEVEL_PROFILE to edit the operation.
The entire solid model highlights indicating that it has been defined as the part geometry.
367
368
This option profiles all shapes (islands) at a given level before profiling the next level.
Refresh the display.
369
370
This will allow you to select surface regions (and only surface regions) to define the cut area.
You may not mix features and geometry when defining a cut area.
Select the surface region illustrated below and OK.
371
The Display Parameters dialog displays.
Turn the Pause After Display option off and OK the dialog.
The tool path is generated and restricted to the feature you selected.
372
This will exclude all portions of the cut region falling outside of the trim boundary.
Choose Point Boundary as the Filter Type and Control Point as the Point Method.
This will allow you to create the trim boundary by specifying a sequence of points.
Specify the four control points in order as illustrated below and OK to accept them.
373
Choose Display (in the Geometry section of the dialog) to display the trim boundary.
Notice that the cutter retracts, traverses, and engages between each cut level. A more effecient
cut pattern would be to allow the cutter to remain in contact with the part between cut levels.
Refresh the graphics display.
374
375
Notice how the cutting tool engages the part, feeds down the wall of the part to get to the next
level, and alternates the direction of cut from one level to the next.
OK to complete the operation.
Close the part file.
Manufacturing.
376
Choose Cutting.
Set the Cut Direction option to Mixed and the Level to Level option to Direct on Part as
you did before and OK to accept the cut parameters.
Generate the tool path.
Notice the reduction in engage, traverse, and retract moves.
377
Notice the two 4.0 mm slots cut into the part. The Merge Distance option determines whether
the tool will retract or continue profiling when it reaches the slots.
Choose Application
Manufacturing.
378
Because this value is smaller than the width of the slots, the tool will not profile across the
slots and will instead retract each time it encounters them.
Replay the tool path.
Now that the Merge Distance is greater than the width of the slots, the tool path will connect
the disjointed cutting motions and cut across the slots.
379
Notice that the tool does not retract, but instead cuts directly across the slots.
OK to complete the operation.
Close the part file.
To complete this project, you should be familiar with the following operation subtypes.
CONTOUR_AREA_NON-STEEP
CONTOUR_ZIGZAG
380
CONTOUR_AREA_DIR_STEEP
In addition, you should know how to use Verify Toolpath to graphically simulate material
removal and compare the in-process workpiece to the part.
Create a FACE_MILLING operation that uses a manual cut pattern to finish the top
face.
381
Use Verify Toolpath to graphically simulate material removal for the entire program.
Compare the in-process workpiece to the part by displaying the excess material.
382
The completed program must cut the finished part from a solid block of material using a
sequence of roughing, semi-finishing, and finishing operations while applying acceptable
standard machining techniques.
Replay.
These Fixed Axis Surface Contouring operations semi-finish and finish the part. You will
create three more operations that rough out the initial material, semi-finish the non-steep
areas, and finish the top face of the part, and then place them in the correct program sequence
as illustrated below.
383
384
385
Notice that the tool path finishes each cut level by traversing from one region to the next
before beginning the next cut level.
386
In this case, it would be more efficient to completely finish machining each region from top to
bottom before traversing to the next region.
387
Notice that the tool path completely machines each region from top to bottom before
traversing to the next one.
388
The operation you choose in the next step is the object below which the pasted operations will
appear.
Choose ZLEVEL_FOLLOW_CAVITY and MB3
Paste.
389
390
Each cavity is a separate cut area. The cut area geometry is inherited from the Mill_AREA
object.
Refresh the graphics display.
This will allow only the areas with a steepness greater than or equal to 55 degrees to be
profiled.
391
The current Range Depth is defined by the depth of the Cut Area geometry and should be
1.0000.
Notice that the tool path completely machines each region from top to bottom before
traversing to the next one. Only the steep areas are machined.
392
The operation you choose in the next step is the object below which the pasted operation will
appear.
393
Choose CONTOUR_AREA_NON_STEEP and MB3
Paste.
394
Notice that large scallops remain on the top face of the part. Next, you will create a face
milling operation that that uses a manual cut pattern to finish the top face.
Cancel to dismiss the Toolpath Visualization dialog.
395
396
Replace View
TOP.
397
Specify a 2-D Tool display and a Silhouette Path Display.
Choose the Edit Display icon under Tool Path.
Choose 2-D for the Tool Display and Silhouette for the Path Display.
398
Be sure the Reposition to Point icon is chosen.
Choose Cursor Location as the Point Method.
Indicate a point in space to the right of the corner of the part.
399
Select the four end points in order as illustrated below to define the sequence of
linear cutting moves.
400
401
402
Choose Cursor Location as the Point Method.
Indicate near the center of the side of the part.
403
Replace View
TFR-ISO.
404
Notice that the scallops have been removed from the top of the part.
405
406
SURFACE CONTOURING
Area Milling Drive Method
The Area Milling drive method generates a fixed axis surface contouring tool path by
specifying a cut area and, if desired, adding steep containment and trim boundary constraints.
Cut areas may be defined by selecting surface regions, sheet bodies, or faces.
You can restrict cut areas based on the steepness of the tool path. By cutting non-steep areas
and then profiling steep areas, you can avoid plunging the tool directly into the material along
vertical walls.
Steep areas can be profiled with a subsequent Z-Level Milling operation or a Surface
Contouring operation that uses a Directional Steep containment.
The Area Milling drive method is similar to the Boundary drive method but has no drive
geometry and uses a more robust and automated computation of collision-free containment.
For these reasons, you should use the Area Milling drive method in place of the Boundary
drive method whenever possible.
In this lesson, you will create several fixed axis surface contouring operations using the Area
Milling drive method. You will see how the Area Milling drive method works together with
Z-Level Milling operations to machine both steep and non-steep areas of a cavity and a core.
You will also learn to graphically simulate material removal using a shaded image and display
areas where excess material remains.
Machining a Cavity
407
You will first examine a program that consists of three milling operations and observe how
these three operations work together to machine the entire cavity.
Machining a Cavity
Opening the Part
Open part file srf_area_mill_1.prt from the srf subdirectory.
Choose the Shaded icon
Notice that the sides of the cavity are very steep (vertical or nearly vertical).
Machining a Cavity
Entering the Manufacturing Application
Choose Application
Manufacturing.
to fully
408
The operations inherit parameters from the MILL_GEOM and MILL_ORIENT parent groups.
Machining a Cavity
Examining the MILL_GEOM Group
The MILL_GEOM parent group defines the part geometry used by all three operations.
Double-click on the MILL_GEOM icon.
409
Refresh the graphics display.
Cancel out of the MILL_GEOM dialog.
Machining a Cavity
Replaying the Cavity Mill Tool Path
Choose the Program Order View
Choose Replay.
Machining a Cavity
Visualizing Material Removal for the Cavity Mill Operation
The Verify option allows you to graphically simulate material removal using a shaded image.
This function requires blank material to be defined. If it is not already defined in the
Workpiece group or within the operation, it can be temporarily defined for display purposes
when performing the tool path visualization.
410
Auto Block creates a solid body bounding the part geometry with faces parallel to the WCS.
Offsets can be added to each of the six faces by entering values in the dialog or by dragging
the handles.
OK to begin the tool path visualization.
The roughing operation leaves large scallops for the subsequent finishing operations to
remove.
OK to complete the tool path visualization.
OK to complete the operation.
Machining a Cavity
Replaying the Non-Steep Tool Path
Double-click on the CONTOUR_AREA_NON_STEEP icon in the Operation Navigator
411
to display the operation dialog.
Replay
the operation.
Notice that the tool does not cut all the way to the edge of the cavity. The Steep Containment
parameters restrict the cut area, allowing the tool to cut from side to side but preventing it
from cutting downward and plunging directly into the material.
Machining a Cavity
Visualizing Material Removal for the Non-Steep Operation
Choose the Verify
412
Machining a Cavity
Replaying the Steep Tool Path
Double-click on the ZLEVEL_PROFILE_STEEP operation.
Machining a Cavity
Visualizing Material Removal for the Steep Operation
Choose the Verify icon at the bottom of the dialog.
Choose the Dynamic tab.
Choose the Play Forward icon.
Be sure Auto Block is chosen as the Blank Type.
OK to begin the tool path visualization.
413
Manufacturing.
414
This subtype defines most of the operation parameters you will need to cut non-steep areas.
The system automatically names the operation CONTOUR_AREA_NON_STEEP.
Specify the following groups in the Create Operation dialog.
415
The operation will inherit the parameters defined by these parent groups.
OK to begin creating the operation.
The CONTOUR_AREA_NON_STEEP subtype that you chose earlier determined this option
as the default.
416
Choose the Cut Area icon and Select.
417
Notice that the Steep Containment parameters default to non-steep with a steep angle of
65.0000 degrees. The CONTOUR_AREA_NON_STEEP subtype you chose earlier
determined these as the defaults.
Key in 55 for the Steep Angle.
The operation will now cut only the areas where the steepness of the tool path is less than or
equal to 55 degrees.
418
Notice, however, that the operation also creates small zig-zag cuts along the edge of the
cavity.
These small zig-zag cuts are non-steep tool paths that occur as a result of edge tracing.
Edge tracing occurs when the tool "rolls over" the edge of the cut area. The steepness of these
edge traces falls within the specified 0-55 degree Steep Angle as illustrated below.
419
The Program Order View determines the order in which operations will be executed on the
machine tool.
420
For additional information on creating Z-Level Milling operations, refer to the Z-Level
Milling lesson in the Planar and Cavity Milling course.
in the toolbar.
as the subtype.
This subtype defines most of the operation parameters you will need to cut steep areas.
The system automatically names the operation ZLEVEL_PROFILE_STEEP.
Specify the following groups in the Create Operation dialog.
421
422
The Steep Angle determines which portions of the Cut area will be machined based on the
steepness of the area.
Notice that the Steep Angle option has already been turned on. The
ZLEVEL_PROFILE_STEEP subtype you chose earlier determined this as the default.
Key in 55 for the Steep Angle.
This will allow only the areas with a steepness greater than or equal to 55 degrees to be
profiled. In other words, all the steep areas left uncut by the previous Area Milling operation
will now be profiled.
Choose Cut Levels.
Key in 0.0500 in the Depth per Cut field.
423
The ZLEVEL_PROFILE_STEEP operation now appears as the third operation in the Program
Order View of the Operation Navigator.
By comparing the Contour Area Non-Steep tool path and the Z-Level Profile Steep tool path,
you can see that the two operations finish the entire cavity.
You will copy and paste an existing operation and then edit the parameters.
424
This operation uses many of the same parameters as the existing
CONTOUR_AREA_NON_STEEP operation. It will be easier to copy and modify the
existing operation than to create a new operation.
In the Program Order View of the Operation Navigator, highlight
CONTOUR_AREA_NON_STEEP and MB3 Copy.
Paste.
425
With Tool:T2 chosen, choose Reselect.
The dialog now displays T3 as the tool the operation will use.
Choose the Main tab.
Decreasing the stepover size will reduce the scallop height on the machined part.
OK to accept the changes.
426
and Select.
The Trim Boundary dialog displays. Notice that Outside is specified as the Trim Side.
This will exclude all areas of the cut region outside of the boundary. The tool path will only
be created inside of the boundary.
Choose the Point Boundary icon and Existing Point as the Point Method.
Select the four points in order as illustrated below.
427
Choose Display to verify that the boundary has been created correctly.
428
429
You will then create a tool with a holder and observe how the system alters the tool path to
avoid collision between the tool holder and check geometry.
Manufacturing.
Display the Machine Tool View of the Operation Navigator and expand the objects.
430
In the Machine Tool View of the Operation Navigator, highlight the FIXED_CONTOUR
operation.
in the toolbar.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
The operation uses a tool without a holder. Notice how closely the tool cuts to the check
geometry.
431
OK to accept the parameters and create the tool with the holder.
432
433
The system has altered the tool path to avoid collision with the tool holder and the check
geometry. Notice the Tool holder Collision Warning.
434
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
in the toolbar.
and OK.
435
Notice that the number "64" appears next to the option. This indicates there are sixty-four
tools in the library that match the parameters you have specified so far.
You can narrow the search even further by specifying exact numeric values or a range of
values using <, >, <=, and >= signs.
Key in .50 for the Diameter.
Choose Count Matches.
Notice that the number "7" now appears next to the option. You have narrowed the search to
only those tools in the library with a diameter of .50.
Choose Result Info.
This displays an Information listing of all the tools matching the search criteria. It will allow
you to determine which values (Flute Length and Corner Radius for example) can be
specified to continue narrowing the list.
Dismiss the Information window.
Key in the following expressions.
The >1 means that the flute length should be greater than 1 inch long and the >=.05 means
that the corner radius should be greater than or equal to 0.05.
Choose Count Matches.
436
Notice that the number "3" now appears next to the option. You have narrowed the search to
the only three tools in the library with a flute length greater than 1 and a corner radius greater
than or equal to .05 .
OK to accept the search criteria.
437
FIXED_CONTOUR operation onto the UGTI0203_016 tool.
MB3
Generate to generate the tool path and OK to accept the tool path generation.
438
Zoom Out if necessary to see the tool holder.
Choose the Play Forward icon.
Machining a Core
You will create two fixed axis surface contouring operations that use the Area Milling drive
method to machine a core.
The first operation will use None as the Steep containment to mill the entire cut area. It will
leave large scallops on the sides.
The second operation will use Directional Steep as the Steep Containment to cross cut only
the steep areas and remove the large scallops left by the first operation.
439
Machining a Core
Opening the Part
Open part file srf_area_mill_4.prt from the srf subdirectory.
Choose Application
Manufacturing.
In the Geometry View of the Operation Navigator, expand the objects as illustrated below.
The WORKPIECE group defines the part geometry that both operations will use.
Machining a Core
Defining the Cut Area
The cut area defines the area of the part the operation considers for cutting when generating
the tool path. It may be specified in a geometry group and then inherited or it may be
specified within individual operations. If you do not specify a cut area, the system cuts the
entire Part Geometry.
In this example, you will define the cut area in a geometry group so that subsequent
operations can inherit the same set of cut area parameters.
440
Choose WORKPIECE as the Parent Group.
Surface Regions (Tools Prepare Geometry Surface Region) are CAM features that
contain faces on a single solid body or sheet. The ability to select a single entity makes the
specification of Part and Blank geometry very easy. Surface Regions are also easy to identify
and select as features using the Model Navigation Tool.
Surface Regions are associative to the solid. That is, when you modify the solid, the
associated Surface Regions update automatically to match the solid.
441
Surface Regions are created by selecting faces of a body. All faces of a Surface Region
Feature must be on the same body. Three methods of defining Surface Regions (Seed, All
Faces, and Selected Faces) are available in the Surface Regions dialog box under Region
Type.
To summarize, the purpose of creating Surface Regions is to organize the areas to be
machined, to make the selection of Part and Blank Geometry easier by enabling you to use the
Surface Region selection method, and to establish associativity with bodies.
This subtype defines most of the operation parameters you will need to mill the entire cut
area.
The system automatically names the operation CONTOUR_ZIGZAG.
442
Specify the following groups in the Create Operation dialog.
The part geometry is defined by the entire body. This operation inherits the part geometry
from the Workpiece group.
Refresh the display.
443
This operation inherits the cut area from the Mill Area group you created.
Refresh the display.
The CONTOUR_ZIGZAG subtype that you chose earlier determined this as the default.
Choose Area Milling under Drive method.
Notice that the Steep Containment parameter defaults to None. The CONTOUR_ZIGZAG
subtype you chose earlier determined this as the default.
444
The Cut Angle dialog displays. The Cut Angle determines the angle of rotation of the cutting
pattern about the ZC axis with respect to the XC axis.
The next operation in the program must have a cut direction defined at 90 degrees to this one
in order to cross cut and remove the scallops remaining on the steep surfaces.
OK to return to the CONTOUR_ZIGZAG dialog.
445
You will use Directional Steep in the next section to remove these scallops.
OK to complete the tool path visualization.
OK to complete the operation.
446
This subtype defines most of the operation parameters you will need to mill only the steep
areas.
The system automatically names the operation CONTOUR_AREA_DIR_STEEP.
Specify the following groups in the Create Operation dialog.
447
The operation will inherit the parameters defined by these groups.
OK to begin creating the operation.
448
The operation will now cut only the areas where the steepness of the tool path is greater than
55 degrees.
449
Generate the tool path.
Notice that only the steep areas relative to the cut direction are machined.
OK to complete the operation.
By comparing the Area Milling operation that uses Steep Containment set to None with the
operation that uses Steep Containment set to Directional Steep, you can see that the two
operations finish the entire core.
450
By calculating the tool path directly on the part, scallop heights are consistent and both steep
and non-steep surfaces can be effectively machined in the same operation.
Manufacturing.
451
452
The Apply option is currently set to On Plane. This causes the drive path to be calculated on
XM-YM plane and then projected onto the part surface. The On Part option calculates the tool
path directly on the part.
Set the Apply option to On Part.
This option is only available for the Follow Periphery cut pattern.
OK to accept it.
453
Machining a Cavity
You will create four fixed axis surface contouring operations that use the Area Milling drive
method to semi-finish and finish a cavity.
The program begins with a Cavity Mill operation, ZLEVEL_FOLLOW_CAVITY, that
roughs out the cavity.
454
The first operation you create, CONTOUR_FOLLOW, will semi-finish the bottom of the
cavity.
The second operation you create, CONTOUR_FOLLOW_1, will semi-finish the entire cavity.
The third operation you create, CONTOUR_ZIGZAG, will use None as the Steep
Containment to finish the entire cavity.
The fourth operation you create, CONTOUR_AREA_DIR_STEEP, will use Directional Steep
as the Steep Containment to cross cut only the steep areas and remove the scallops.
455
Machining a Cavity
Opening the Part
Open part file srf_area_mill_5.prt from the srf subdirectory.
Choose Application
Manufacturing.
Machining a Cavity
Examining the WORKPIECE Group
The WORKPIECE group defines the part and blank geometry.
Expand the objects in the Geometry View of the Operation Navigator.
The ZLEVEL_FOLLOW_CAVITY operation inherits parameters from the WORKPIECE
and MCS_MILL groups.
Highlight the WORKPIECE group.
456
in the toolbar.
Machining a Cavity
Visualizing the Cavity Mill Operation
You will use Verify Toolpath to graphically simulate material removal for the existing Cavity
Mill operation.
Highlight the ZLEVEL_FOLLOW_CAVITY operation.
457
This subtype defines most of the operation parameters you will need to mill the cut area.
458
Specify the following groups in the Create Operation dialog.
459
Notice that the tool path does not cover the entire cut area. Part of the cut area is left uncut
because the tool movement is limited by the sides of the cavity.
Choose the Edit Display icon under Tool Path and choose 3-D for the Tool Display.
460
OK to accept the tool display.
Change to a Front view and Replay the tool path.
The tool comes close to the sides of the cavity, but does not gouge the part. The operation
machines as much of the cut area as possible without violating the part geometry.
The distance between the tool and the part is defined by the Part Stock in the
MILL_SEMI_FINISH Method group. This is the material that is left for the finishing
operations to remove.
Change to a TFR-ISO view.
OK to complete the operation.
461
This subtype defines most of the operation parameters you will need.
Specify the following groups in the Create Operation dialog.
462
Cut Areas require additional processing time when generating a tool path. It is therefore a
good idea to not define a cut area unless it is necessary.
For this operation, you will not define the cut area.
463
Notice that the tool rolls over the outer edge of the part. This occurs as a result of edge
tracing. In this case, because a cut area was not defined, edge tracing cannot be removed by
simply turning on the Remove Edge Traces option.
Choose Cutting.
Note that the Part Stock is set at 0.25 mm and the part tolerance is set at +/- 0.03. These
values were determined when the MILL_SEMI_FINISH method was chosen.
464
Choose mill_contour as the Type.
Choose the MILL_AREA icon and WORKPIECE as the Parent group.
465
This operation will now inherit the parameters defined in the MCS_MILL, WORKPIECE,
and the MILL_AREA groups.
466
Generate
Notice that the tool path no longer rolls over the outer edge of the part.
The remaining operations you create will also require the Trim boundary defined in the
MILL_AREA group.
OK the tool path Generation dialog.
467
468
The Cut Angle determines the angle of rotation of the cutting pattern about the ZC axis with
respect to the XC axis.
Choose User Defined as the Cut Angle.
The next operation must have a cut direction defined at 90 degrees to this one in order to
remove the scallops left on the steep surfaces.
469
You will generate the tool path and observe how the operation finishes the entire cavity.
Generate the tool path.
470
Choose CONTOUR_AREA_DIR_STEEP as the subtype.
Remember that the Cut Angle for the previous operation was 0.000 degrees. This operation
must cross cut the steep areas to remove the large scallops. Notice that the Cut Angle defaults
to 90.0000 degrees.
471
OK to accept the cut angle.
The operation will only cut areas where the steepness of the tool path is greater than 60
degrees.
472
473
474
You will first use the Show 3D option to create a faceted model of the uncut material that
remains after generating a specific operation or sequence of operations.
You will then use the Show Excess option to compare the faceted model to the specified
Excess Material. Excess Material is an offset value that defines the allowable material
measured from the part. Areas of the faceted model that exceed this offset are graphically
displayed as excess material when you choose Show Excess.
Manufacturing.
475
The faceted model was created from a roughing operation that uses a 0.1200 mm Outtol and a
1.0000 mm Part Stock. Therefore, any uncut material within a 1.1200 mm offset of the part is
allowed by the operation. Any uncut material beyond the 1.1200 mm offset is excess material.
Choose Delete to remove the currently displayed faceted model.
476
In the Toolpath Visualization dialog, choose Excess and key in 1.1200 for the Excess
Material.
Choose Create.
The excess material graphically represents the uncut material outside of the specified 1.1200
mm Excess Material offset. This is the material that must be removed by subsequent
operations in the program.
Manufacturing
The thickness of the excess material can determine whether or not the subsequent operations
are appropriate. If it is too thick, additional roughing operations may need to be added.
Choose Delete to remove the displayed excess material.
477
Excess material continues to display, although there is now less of it. The displayed excess
material is thicker than 0.4000 mm.
Choose Delete to remove the currently displayed excess material.
OK to complete the tool path visualization.
478
The finishing operations use a 0.0300 mm Outtol and a 0.0300 mm Intol. Any uncut material
within 0.0300 mm offset of the part is allowed by the program. Any uncut material outside of
the 0.0300 mm offset is excess material.
Choose Delete to remove the currently displayed faceted model.
Choose Create.
479
Notice that there is quite a bit of excess material remaining on the finished part. You can
reduce the amount of excess material by reducing the stepover to create smaller scallops and
also by changing the part Intol and Outtol smaller values. Making these values smaller will
increase the size of the calculated tool path and also increase the time required for its
calculation.
Choose Delete to remove the currently displayed excess material.
OK to complete the tool path visualization.
480
Key in 10.0 for the Stepover Percent.
481
Notice that there is less excess material remaining on the finished part.
OK to complete the tool path visualization.
Close the part file.
482
flow cutting based on bi-tangency contact points and the angle between part surfaces. You can
create single pass or multiple pass operations.
The resulting tool path is optimized in such a way that the tool remains in contact with the
part as much as possible and minimizes non-cutting moves.
The Flow Cut drive method, like the Area Milling drive method, allows you to define a
simple tool holder to ensure a collision free tool path.
It is recommended that only Ball Nose tools be used in flow cut operations. Unsatisfactory
results in the tool path can occur if Bull Nose or Flat Nose tools are used.
In this lesson, you will create Single Pass, Multiple Pass, and Reference Tool Flow Cut
operations.
Machining a Cavity
In this section, you will examine the geometry groups and the sequence of operations. You
will observe how the rough, semi-finish, and finish operations inherit parameters and work in
sequence to machine the entire cavity.
Machining a Cavity
Opening the Part
483
to display a wireframe.
Manufacturing.
Machining a Cavity
Examining the WORKPIECE Group
The WORKPIECE group defines the part geometry used by all of the operations.
In the Geometry View of the Operation Navigator, fully expand the objects and doubleclick on the WORKPIECE icon to edit the group.
484
The part geometry highlights.
Machining a Cavity
Examining the MILL_AREA Group
The MILL_AREA group defines the cut area used by the CONTOUR_AREA_NON_STEEP,
CONTOUR_FOLLOW, ZLEVEL_PROFILE_STEEP, and FLOWCUT_SINGLE operations.
Double-click on the MILL_AREA icon to edit the group.
485
Machining a Cavity
Visualizing Material Removal for the Program
You will graphically simulate material removal for the program.
In the Program Order View of the Operation Navigator, fully expand the objects.
Notice the sequence of operations. The ZLEVEL_FOLLOW_CAVITY operation first roughs
out the cavity. The CONTOUR_AREA_NON_STEEP and ZLEVEL_PROFILE_STEEP
operations then semi-finish the cavity. The CONTOUR_FOLLOW and FLOWCUT_SINGLE
operations finish the cavity.
Highlight the PROGRAM group.
in the toolbar.
486
In the following section, you will create a Single Pass Flow Cut operation similar to the one in
this program.
OK to complete the tool path visualization.
Close the part file.
Manufacturing.
487
This subtype defines most of the operation parameters you will need to create a Single Pass
Flow Cut operation.
The system automatically names the operation FLOWCUT_SINGLE.
Specify the following groups in the Create Operation dialog.
488
The operation will inherit the parameters defined by these groups.
OK to begin creating the operation.
Notice that the Select/Reselect option is blanked for defining the cut area. The cut area cannot
be defined within the operation because it is inherited from the MILL_AREA group.
The cut area has been defined as all the interior faces of the cavity.
Refresh the display.
489
490
491
Notice that some of the flow cuts have been eliminated. The angles formed between part
surfaces in these areas exceeds the Maximum Concavity of 100.0000 degrees. The areas of
the cylindrical intersections that have a concavity less that 120 are not cut because the length
of the cut is less than 0.80.
492
You will now increase the Maximum Concavity so that the tool cuts as much of the flat area
on the top of the part as possible. The value you enter must be positive and must be less than
or equal to 179.0000 degrees.
Key in 179 for the Maximum Concavity.
A closer look reveals that the tool path still does not cut all the way across the top of the part.
This is an area where the angle between part surfaces is very large (between 179 and 180
degrees) and is nearly flat.
You cannot specify a Maximum Concavity greater than 179.0000 degrees. You can, however,
increase the Hookup Distance to eliminate unwanted gaps in the tool path.
493
The tool no longer retracts and now continues cutting across the top of the part.
494
In your part, the fillet that surrounds the cavity on three sides has a radius of 0.5000 inch. The
tool you have been using (MILL_2) has a diameter of only 0.2000 inch. This is why flow
cutting has not occurred along the fillet.
You will change to a larger tool and observe how flow cutting is generated along the fillets as
a result bi-tangency contact points between two surfaces.
Choose the Groups tab.
Choose Tool: MILL_2 and Reselect.
495
496
Choose Application
Manufacturing.
This subtype defines most of the operation parameters you will need to create a Multiple Pass
Flow Cut operation.
The system automatically names the operation FLOWCUT_MULTIPLE.
Specify the following groups in the Create Operation dialog.
497
You will now make some changes to improve the tool path.
498
499
Unidirection causes the cutter to move from one outside cut to the other, traversing through
the center.
500
Choose the More tab.
Set the Cut Direction to High to Low.
Notice that the short cutting moves at the intersections of the fillets have been eliminated.
OK to complete the operation.
501
Reference Tool Diameter enables you to specify the width of the finishing cut region based on
the diameter of the roughing (reference) tool. The reference tool is typically the tool used to
previously rough out the area. The system calculates the bi-tangency contact points from the
502
specified Reference Tool Diameter and then uses these points to define the cut region for the
finishing operation.
1.
2.
3.
4.
Because the reference tool determines the bi-tangency contact points rather than the actual
cutting tool, this type of flow cut operation can finish large fillets using multiple passes of a
small tool.
Choose Application
Manufacturing.
503
Choose mill_contour as the Type.
Choose FLOWCUT_REF_TOOL as the subtype.
This subtype defines most of the operation parameters you will need to create a Reference
Tool Flow Cut operation.
The system automatically names the operation FLOWCUT_REF_TOOL.
Specify the following groups in the Create Operation dialog.
504
Because the reference tool has the same radius as the fillet (.5000), it contacts the surfaces on
each side of the fillet, establishing the necessary bi-tangency contact points.
Overlap Distance enables you to extend the width of the area defined by the Reference Tool
Diameter along the tangent surfaces.
505
506
Radial cuts allow hand finishing of concave corners and valleys across scallops rather than
along scallops. It is often used as a follow-up to flow cutting.
In this lesson, you will create a fixed axis surface contouring operation that uses the Radial
Cut drive method to finish the concave corner the part.
507
Choose Application
Manufacturing.
in the toolbar.
508
The WORKPIECE geometry group defines the part geometry and the blank geometry. Blank
geometry is required by the Verify function to graphically simulate material removal.
The operation will inherit the parameters defined by these groups.
OK to begin creating the operation.
A Warning dialog is displayed, cautioning you that previously defined drive parameters will
be deleted.
OK the warning.
509
The % of Tool option allows you to define the stepover in terms of a percentage the effective
tool diameter. This distance is measured at the boundary (between points C and D).
Turn the Stepover option on.
% of Tool should already be specified as the Stepover.
Key in 20 for the Percent.
510
If multiple boundaries are defined, a lift is applied allowing the tool to traverse from one
boundary to the next.
OK to complete the Radial Cut drive method.
Notice how far apart the stepovers are at the corners. You may control this by specifying a
maximum stepover value.
511
512
Notice how the tool path crosses over itself at the corners and how it cuts all the way to the
outside edge of the part. This can be corrected by adjusting the Bandwidth.
513
Key in .25 for Material Side and .74 for Opposite Side.
The tool path no longer crosses over itself at the corners and no longer cuts all the way to the
outside edge of the part.
OK to complete the operation.
514
In the Program Order View of the Operation Navigator, highlight the PROGRAM icon.
515
The drive path is generated from points and curves and projected onto the part surfaces where
the tool path is created. The curves may be open or closed, contiguous or noncontiguous,
planar or nonplanar.
In this lesson, you will create a fixed axis surface contouring operation that uses the
Curve/Point drive method.
516
Manufacturing.
in the toolbar.
517
The WORKPIECE geometry group defines the part geometry and the blank geometry. Blank
geometry is required by the Verify function to graphically simulate material removal.
The operation will inherit the parameters defined by these groups.
Key in engrave for the operation name.
OK the warning.
The Curve/Point Drive Method dialog displays.
518
2. Projection Direction
3. Tool Path
4. Part Surface
519
Select the second curve at the upper end so the cut direction vector displays as illustrated
below.
You may choose Back at any time to deselect the curves one at a time if you make a mistake.
520
521
The tool should not retract at the end of the fifth curve, but should cut continuously to the end
of the sixth curve.
Turn the Local Lift at End option off.
Select the fifth curve so the vector displays as illustrated below.
Turn the Local Lift at End option on and select the sixth and seventh curves.
522
Turn the Local Lift at End option off and select curves eight through eleven at the
positions indicated below so they are cut in a counterclockwise direction.
523
Choose Cutting.
Key in -.035 for the Part Stock.
524
This section describes the non-cutting moves that apply to this particular operation. Refer to
the non-cutting moves lesson at the end of this course for a complete discussion.
You will first define non-cutting moves for engages. You will then define non-cutting moves
for retracts by specifying that they will use the same non-cutting moves as defined for
engages.
525
The Case options determine whether the motion parameters will apply to all engages or only
to specific types of engages. By specifying Default as the Case, all types of engages will use
the same motion parameters.
Be sure the Case is specified as Default.
The Status option determines the available motion parameters. For this operation, all engages
will move a specified distance to the part along the tool axis.
Be sure the Status is specified as Manual.
Here is how you would read the Non-Cutting Moves dialog; "Unless otherwise specified, all
engages will move .25 inches in a linear direction defined by the orientation of the current
tool axis".
526
Next, you will define retracts by specifying that they will use the same motion parameters as
defined for engages.
Notice that the Case is set to Default and the Status is set to Use Engage. All retracts (by
default) will use the same parameters as defined for engages. In other words, all retracts (by
default) will move from the part to the clearance plane in a linear path along the tool axis.
527
Blank
Blank.
Set the Rectangle/Polygon Method to Inside and drag a rectangle around the drive
geometry.
528
in the toolbar.
529
Unlike other drive methods which require an abrupt change in direction to Stepover to the
next cutting pass, the Spiral drive method Stepovers are a smooth, constant transition
outward. Because this drive method maintains a constant cutting speed and smooth motion, it
is useful for high speed machining applications.
530
In this lesson, you will create a fixed axis surface contouring operation that uses the Spiral
drive method to finish the part. You will then Animate the operation to graphically simulate
material removal.
Manufacturing.
in the toolbar.
531
The WORKPIECE geometry group defines the blank geometry required by the Verify
function to graphically simulate material removal.
The operation will inherit the parameters defined by these groups.
Key in spiral for the operation name.
and Select.
532
OK the warning.
The Spiral Drive Method dialog is displayed.
533
Spiral drive method stepovers are a smooth, constant transition outward and do not require an
abrupt change of direction.
Tool Diameter allows you to define the stepover in terms of a percentage of the effective tool
diameter.
Choose Tool Diameter as the Stepover.
534
535
The Vector Constructor dialog displays and the current projection vector displays on the part.
OK to accept this projection vector.
OK to complete the Spiral drive method.
536
in the toolbar.
537
OK to complete the tool path visualization.
Close the part file.
The Surface Area drive method creates an array of drive points on the drive surface and then
projects them to the part surface along a specified projection vector. The tool path is created
as the tool moves across the part surface from one contact point to the next. A tool path may
also be created directly on the drive surface when there is no part geometry defined.
In this lesson, you will create variable axis surface contouring operations using the Surface
Area drive method and a variety of tool axis controls.
Examining a Program
You will first examine a program consisting of operations that rough and semi-finish a part.
You will then add a variable axis surface contouring operation that finishes the contoured
surfaces.
538
Examining a Program
Opening the Part
Open part file srf_srf_area_1.prt from the srf subdirectory.
Examining a Program
Entering the Manufacturing Application
Choose Application
Manufacturing.
In the Geometry View of the Operation Navigator, fully expand the objects as illustrated
below.
539
These operations rough and semi-finish the part. They inherit parameters from the MCS and
WORKPIECE groups.
Examining a Program
Examining the Workpiece Group
The WORKPIECE group defines the part geometry.
Highlight WORKPIECE.
Examining a Program
540
in the toolbar.
541
542
This option is the most generic of the multi-axis subtypes and will allow you to create a wide
variety of operations.
The system automatically names the operation VARIABLE_CONTOUR.
Specify the following groups in the Create Operation dialog.
and Select.
543
Surface Regions (Tools Prepare Geometry Surface Region) are CAM features that
contain faces on a single solid body or sheet. The ability to select a single entity makes the
specification of Part and Blank geometry very easy. Surface Regions are also easy to identify
and select as features using the Model Navigation Tool.
Surface Regions are associative to the solid. That is, when you modify the solid, the
associated Surface Regions update automatically to match the solid.
Surface Regions are created by selecting faces of a body. All faces of a Surface Region
Feature must be on the same body. Three methods of defining Surface Regions (Seed, All
Faces, and Selected Faces) are available in the Surface Regions dialog box under Region
Type.
To summarize, the purpose of creating Surface Regions is to organize the areas to be
machined, to make the selection of Part and Blank Geometry easier by enabling you to use the
Surface Region selection method, and to establish associativity with bodies.
OK to accept the surface region as the part geometry.
and Select.
544
Choose Faces as the Filter Method.
Warning causes the system to issue only a warning message and does not alter the tool path
545
Skip causes the tool to omit the tool positions which gouge the Check Geometry.
Retract causes the tool to avoid gouging the Check Geometry by using the Check Engage and
Retract parameters defined in Non-Cutting moves.
Check Safe Clearance defines an extended safety zone for check geometry which cannot be
violated by the tool or the tool holder.
OK the warning.
The Surface Drive Method dialog displays.
546
Select the planar face on the bottom of the part.
When machining part surfaces as in this example, the Projection Vector (which you have not
yet defined) determines which side of the surface the tool contacts and the Material Side
vector has no effect.
547
Choose Cut Direction.
Select the vector illustrated below.
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
548
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.
Stepover controls the distance between successive Cut Passes. You may specify the Stepover
in terms of the scallop size or the total number of Stepovers. The Stepover options vary
depending on the Cut Type used.
549
Scallop allows you to specify the maximum allowable size of Scallops by specifying values
for height, horizontal, and vertical distances. This method is useful for good Scallop Height
Control when the Drive Surface is also used as the Part Surface. The system limits the size of
the stepover to roughly less than two-thirds of the tool diameter regardless of what you
specify as the scallop size.
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
Horizontal Limit allows you to restrict the distance a tool may move in a direction normal to
the Projection Vector. This option helps you avoid leaving wide ridges on near vertical
surfaces by limiting the horizontal distance of the Stepover.
Vertical Limit allows you to restrict the distance a tool may move in a direction parallel to the
Projection Vector. This option helps you avoid leaving wide ridges on near vertical surfaces
by limiting the vertical distance of the Stepover.
Horizontal Limit and Vertical Limit may be used together, separately, or not at all. If the
values are set to zero, then they are not used.
Number allows you to specify the total number of Stepovers for the Tool Path.
If the Cut Type you select is Follow Pocket, enter the Number of Stepovers for the First
Direction (i.e., cut direction) and for the Second Direction (i.e., Stepover direction).
550
Drive points always project from the drive geometry to the part geometry. The angle of the
vector determines the path along which the drive points project. For this part, the drive points
project upward from the drive geometry (bottom face of the part) to the part geometry along
the ZM axis. The positive vs. negative direction of the arrowhead does not matter.
The side of the part geometry the tool contacts is determined by the direction of the projection
vector. The tool always positions to the part geometry on the side the Projection Vector
approaches. For this part, the arrowhead must point downward (as it currently does) so that
the tool approaches and positions on the part geometry from the top.
Projection Vector enables you to define how the Drive Points project to the Part Surface, and
the side of the Part Surface the tool contacts.
The Drive Points project along the Projection Vector to the Part Surface. Sometimes, as
illustrated below, Drive Point project in the opposite direction of the Projection Vector (but
still along the vector axis) as they move from the Drive Surface to the Part Surface.
The direction of the Projection Vector determines the side of the Part Surface the tool
contacts. The tool always positions to the Part Surface from the side the Projection Vector
551
approaches. In the following figure, drive point p1 projects to the Part Surface in the opposite
direction of the Projection Vector to create p2.
1. Projection Vector
2. Part Surface
3. Drive Surface
The types of Projection Vectors available depend upon the Drive Method. The Projection
Vector option is common to all Drive Methods except Flow Cut.
The following figure illustrates another example of how the Drive Points project to the Part
Surface. In this example, the Projection Vector is defined as Fixed. The vector is parallel to
the ZM axis at any given point on the Part Surface. To reach the Part Surface, the Drive
Points must project from the Boundary Plane in the same direction as the Projection Vector
arrowhead.
1.
2.
3.
4.
Drive Boundary
Projection Vector
Part Surface
Drive Path Projection
The direction of the Projection Vector determines the side of the Part Surfaces the tool
contacts.
1. Projection Vector
2. Part Surface
552
3. Drive Surface
4. Tool Side of Part Surface
The following figures illustrate how the direction of the Projection Vector determines which
side of the Part Surfaces the tool contacts. In each figure, the tool contacts the same Part
Surface (inside the cylinder), but the contact side differs depending on the direction of the
Projection Vector.
The Projection Vector illustrated below, Towards Line, yields undesirable results. The tool
follows the direction of the Projection Vector and approaches the Part Surface from the
outside of the cylinder and gouges the part.
1.
2.
3.
4.
Part Surface
Drive Surface
Projection Vector
Tool Gouges Part
The Projection Vector illustrated below, Away From Line, yields the desired results. The tool
follows the direction of the Projection Vector and approaches the Part Surface from the inside
of the cylinder and does not gouge the part.
1.
2.
3.
4.
Part Surface
Drive Surface
Projection Vector
Tool Does Not Gouge Part
553
When using Away From Point or Away From Line as the Projection vector, the minimum
distance from the Part Surface to the vector focal point or line must be greater than the radius
of the tool as illustrated below. The tool end must be allowed to position to the projection
vector focal point or anywhere along the projection vector focal line without gouging the Part
Surface.
1.
2.
3.
4.
5.
6.
Tool Path
Part Surface
Drive Surface
Distance Greater than Tool Radius
Projection Vector Away from Line
Projection Vector Focal Line
If the tool gouges the Part Surface when the tool end is positioned at the focal point or
anywhere along the focal line as illustrated below, the system cannot guarantee a good tool
path.
1.
2.
3.
4.
5.
6.
Gouge
Part Surface
Drive Surface
Distance Less than Tool Radius
Projection Vector Away from Line
Projection Vector Focal Line
554
A variable tool axis constantly changes orientation as it moves along the tool path. The
method you use to control the orientation of the tool axis depends to a large extent on the
shape of the part you are machining.
For this part, a fixed tool axis would cause the tool to plunge straight down along the vertical
sides.
By contrast, a tool axis that is normal to the part surface would cause excessive tool
undulations.
555
This part requires a tool axis that follows the general convex shape of the part geometry while
not undulating excessively. Away From Line defines a variable tool axis that diverges away
from a focal line. The tool axis hinges on the line as it travels along the length and remains
normal to the line.
Choose Away From Line under Tool Axis. You might need to scroll up in the dialog to
see this option.
556
The Toolpath Visualization dialog displays with the Replay tab chosen.
557
Choose the Play Forward icon.
558
This part is the same as the one used in the previous section with the addition of a surface that
will be used as drive geometry.
Choose Application
Manufacturing.
559
and Select.
OK the warning.
560
The drive geometry will define the drive points and will control the tool axis.
Choose Select under Drive Geometry.
Select the curved surface above the part.
561
Choose Normal to Drive under Projection Vector.
Normal to Drive allows you to define the projection vector relative to the drive surface
normals.
The side of the part geometry the tool contacts is determined by the direction of the projection
vector. The tool always positions to the part geometry on the side of the part geometry the
projection vector approaches. For this part, the projection vector must point inward toward the
part geometry as illustrated below for the tool to position correctly.
When using Normal to Drive, the projection vector is calculated as the inverse of the material
side vector. This means that the projection vector currently points outward away from the part
geometry and not inward as it should.
Refresh the graphics display to remove the vectors.
Choose Flip Material.
This reverses the direction of the material side vector.
The projection vector, calculated as the inverse of the material side vector, now points inward
toward the part geometry as it should. The tool will therefore position to the part geometry
along the projection vector.
562
Number of Steps defines the total number of stepovers for the tool path.
563
Key in 50 for the Number of Steps.
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.
564
Choose Normal to Drive under Tool Axis.
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
If the drive geometry does not appear translucent as illustrated below, choose
Preferences Visualization Visual (tab) and turn on Translucency.
Choose the Play Forward icon.
565
It is difficult to tell by looking at the tool path whether or not the tool gouges the part.
Defining check geometry can help.
OK to complete the tool path visualization.
and Select.
566
567
Normal to Drive defines a tool axis perpendicular to the drive geometry. In this operation, you
will define only the drive geometry. You will not define part geometry. As a result, the tool
path will be created directly on the drive geometry and definition of a projection vector will
not be necessary.
Manufacturing.
568
Choose the Create Operation icon in the toolbar.
In the Create Operation dialog, choose mill_multi-axis as the Type.
Choose VARIABLE_CONTOUR as the subtype.
The system automatically names the operation VARIABLE_CONTOUR.
Specify the following groups in the Create Operation dialog.
OK the warning.
The Surface Drive Method dialog displays.
569
Select the face illustrated below.
The material side vector determines the side the tool will contact when cutting directly on the
drive surface. This vector should point towards the material to be removed (away from the
part). It currently points away from the material to be removed and must be reversed.
Choose Flip Material.
This reverses the direction of the material side vector.
570
571
Choose Scallop as the Stepover.
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
Key in 0.0100 for the Scallop Height.
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.
572
573
The When Gouging option allows you to specify how the system will respond when the tool
gouges the Drive Surface during cutting moves. These options only apply when you are
cutting to Drive Surfaces and not when you are cutting to Part Surfaces.
None causes the system to ignore Drive Surface gouging. It will generate the same unaltered
tool path as the Warning option, but will not issue a warning message to the tool path or
CLSF.
Skip causes the system to alter the tool path by removing only the Drive Points that cause
gouging to occur. The result is a straight tool movement from the last position before gouging
to the first position which is no longer gouging.
When generating tool paths directly from Drive Surface, the tool does not violate the Drive
Surface at convex corners, and does not gouge concave regions when using Skip as illustrated
below.
In some cases where the drive surface is smoothly concave, the Skip option may not clean up
the tool path as well as illustrated in the concave corner case above.
Retract causes the tool to avoid gouging the Drive Surface by using the parameters defined in
Non-Cutting Moves.
574
Check geometry will prevent the tool from gouging the blades. You will define the check
geometry by selecting the three faces on each blade.
Choose the Check icon
and Select.
Select the three faces that define the first blade as illustrated below.
Select the three faces that define the second blade as illustrated below.
575
The Variable Contour dialog displays.
Retract causes the tool to avoid gouging the check geometry by using the Check, Engage, and
Retract parameters defined in Non-Cutting moves.
Check Safe Clearance defines an extended safety zone for check geometry which cannot be
violated by the tool or the tool holder.
576
This section describes the non-cutting moves that apply to this particular operation. Refer to
the non-cutting moves lesson at the end of this course for a complete discussion.
Choose Non-Cutting.
You will first define non-cutting moves for engages. You will then define non-cutting moves
for retracts by specifying that they will use the same non-cutting moves as defined for
engages.
The Case options determine whether the motion parameters will apply to all engages or only
to specific types of engages. By specifying Default as the Case, all types of engages will use
the same motion parameters.
Be sure the Case is specified as Default.
The Status option determines the available motion parameters. For this operation, all engages
will move a specified distance to the part along the tool axis.
Choose Manual for the Status.
577
Here is how you would read the Non-Cutting Moves dialog; "Unless otherwise specified, all
engages will move 1.5 inches in a linear direction defined by the orientation of the current
tool axis".
Next, you will define retracts by specifying that they will use the same motion parameters as
defined for engages.
Notice that the Case is set to Default and the Status is set to Use Engage. All retracts (by
default) will use the same parameters as defined for engages. In other words, all retracts (by
default) will move from the part to the clearance plane in a linear path along the tool axis.
OK to accept the Non-Cutting Moves.
578
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
579
You will create the first operation by specifying all the necessary parameters to finish the first
blade.
You will create the second operation by copying the first operation and then respecifying the
drive geometry to finish the second blade.
Swarf Drive defines a tool axis that follows the swarf rulings of drive surfaces. The side of the
tool cuts along the drive surfaces and the tip of the tool cuts along the part surfaces.
Manufacturing.
580
Specify the following groups in the Create Operation dialog.
OK the warning.
The Surface Drive Method dialog displays.
581
Drive surfaces must be selected in order and must be edge-to-edge.
The material side vector determines the side the tool will contact when cutting directly on the
drive surface. This vector should point towards the material to be removed (away from the
part) as it currently does.
The currently displayed drive direction vector will cause the tool to cut along the drive
surfaces in the direction indicated below.
582
583
Four directional vectors appear relative to the first drive surface you selected. The vector you
select defines the swarf ruling direction that the tool axis will follow. The vector you select
should point toward the tool holder.
Rotate the view so you can see these vectors clearly.
Choose the vector illustrated below.
584
The When Gouging option allows you to specify how the system will respond when the tool
gouges the Drive Surface during cutting moves. These options only apply when you are
cutting to Drive Surfaces and not when you are cutting to Part Surfaces.
585
None causes the system to ignore Drive Surface gouging. It will generate the same unaltered
tool path as the Warning option, but will not issue a warning message to the tool path or
CLSF.
Skip causes the system to alter the tool path by removing only the Drive Points that cause
gouging to occur. The result is a straight tool movement from the last position before gouging
to the first position which is no longer gouging.
When generating tool paths directly from Drive Surface, the tool does not violate the Drive
Surface at convex corners, and does not gouge concave regions when using Skip as illustrated
below.
In some cases where the drive surface is smoothly concave, the Skip option may not clean up
the tool path as well as illustrated in the concave corner case above.
Retract causes the tool to avoid gouging the Drive Surface by using the parameters defined in
Non-Cutting Moves.
and Select.
586
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
Choose the Play Forward icon.
587
MB3
SWARF_COPY now appears as the last operation in the Program Order View.
588
589
Generate the tool path.
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
Instancing an Operation
Instancing allows you to make multiple copies of the tool path while maintaining a link to the
original operation. Editing one instance automatically updates all instances.
590
This is especially useful when the part has not been fully modeled and uses a callout to
specify that certain features are repeated.
Instancing an Operation
Opening the Part
You will create five instances of an operation that finishes one of the blades.
Open part file srf_srf_area_5.prt from the srf subdirectory.
Choose Application
Manufacturing.
Instancing an Operation
Replaying the Tool Path
You will replay the tool path and observe how the SWARF operation finishes the blade.
591
In the Program Order View of the Operation Navigator, highlight the SWARF operation
and MB3 Replay.
Instancing an Operation
Creating Instances
You will create five instances of the operation by rotating it about the centerline in 60 degree
increments.
In the Program Order View of the Operation Navigator, highlight the SWARF operation
icon and MB3 Object Transform.
Choose Rotate About Line.
Choose Existing Line.
Select the centerline of the part.
592
The instances display temporarily for visual verification.
Each instance is linked to the original operation. Unlike copies, modifying any instance will
automatically update all associated instances.
Instancing an Operation
Editing an Instance
You will edit one of the instances and observe how all five associated instances automatically
update.
Double-click on the SWARF_INSTANCE_2 icon to edit the operation.
A warning displays informing you that all associated instances will be edited.
OK the warning.
593
Choose Method:MILL_FINISH and Reselect.
Instancing an Operation
Generating the Tool Path
You will generate the sequence of operations and then visualize the tool paths.
Highlight the Program icon and MB3
Generate.
594
595
Choose Application
Manufacturing.
and Display.
Part surfaces (unlike drive surfaces) do not need to be arranged in an orderly grid of rows and
columns.
596
OK the warning.
597
The material side vector determines which side of the surface the tool contacts only when
machining directly on drive surfaces. When machining on part surfaces as in this example, the
projection vector (not the material side vector) determines the side of the surface the tool
contacts. The material side vector therefore has no effect on this operation.
598
Choose Specify Vector under Projection Vector.
The side of the part geometry the tool contacts is determined by the direction of the projection
vector. The tool always positions to the part geometry on the side that the projection vector
approaches. For this part, the projection vector must point in a downward direction so that the
tool positions to the part geometry from the top.
Be sure that the I,J,K values in the Vector Constructor dialog are 0,0,-1.
Drive points always project along the vector to the part geometry. In this case, the points
project along the vertical vector but up from the bottom of the part in the opposite direction of
the arrowhead.
OK to accept the projection vector.
599
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
Be sure the Scallop Height is 0.0050.
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.
600
601
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
602
Manufacturing.
This operation uses Normal to Part as the tool axis and is similar to the operation you created
in the previous section.
603
Lead Angle defines the angle of the tool forward or backward along the tool path. Tilt Angle
defines the angle of the tool side to side.
1.
2.
3.
4.
Negative Tilt
Positive Tilt
Lead (positive)
Lag (negative)
604
Key in the following values for Lead, Minimum Lead, and Maximum Lead.
605
Orient View
Front).
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
A positive lead angle leans the tool forward based on the direction of the cutting pass. This is
why the lead flips direction as the tool alternates between zig and zag cuts.
606
axis. Unlike a lead angle, a rotation angle leans the tool to the same side of the normal tool
axis regardless of the zig or zag cut direction.
1. Rotation Angle
2. Tilt
Manufacturing.
This operation uses Normal to Part as the tool axis. You will change this to a 4-Axis Normal
to Part tool axis.
607
3. Plane Normal to Rotation Axis
4. Axis Parallel to Plane
Select line end points 1 and 2 as illustrated below to define the Rotation Axis.
608
Orient View
Front).
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
609
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
The tool consistently leans to the right (by 15 degrees) of a tool axis that is otherwise normal
to the part surface during both zig and zag moves.
610
Manufacturing.
611
This operation uses 4-Axis Normal to Part as the tool axis. You will change this to a 4-Axis
Relative to Part tool axis.
The rotation axis defines the plane that the tilt is referenced from.
A tilt angle defines the angle of the tool axis from side to side and is referenced from the
plane normal to the rotation axis. A positive value tilts the tool to the right as you look in the
direction of cut. A negative value tilts the tool to the left.
1. Plane Normal to Rotation Axis
2. Rotation Axis
3. Axis Parallel to Plane. Tilt of 0 Degrees
612
The 4-Axis Relative to Part dialog displays. The Rotation Angle and Rotation Axis are
retained from the 4-Axis Normal to Part tool axis.
Key in 5.0 degrees for the Lead.
613
Orient View
Front).
614
615
In this operation, you will define only the drive geometry. You will not define part geometry.
As a result, the tool path will be created directly on the drive geometry and definition of a
projection vector will not be necessary.
Choose Application
Manufacturing.
in the toolbar.
616
OK to begin creating the operation.
OK the warning.
The Surface Drive Method dialog displays.
617
Faces must be selected in an orderly sequence. They may not be selected randomly. The
sequence in which you select the first adjacent faces defines a row. When you finish selecting
the first row, you must specify that you wish to begin selecting the second row. Each
subsequent row must then contain the same number of adjacent faces.
Select the second face. You may need to rotate the model.
618
You must now specify that you wish to begin the next row.
619
By choosing this option, you have specified that every row will contain four faces. You will
no longer need to choose Select Next Row when beginning a new row.
Select the fifth through eighth faces.
Continue selecting faces in the same orderly sequence until all twenty-eight faces have
been selected.
620
OK to complete the drive geometry.
The Surface Drive Method dialog displays.
The material side vector determines which side the tool contacts when cutting on the drive
surfaces. The material side vector should point towards the material to be removed (away
from the part) as illustrated above. If it does not, Flip Material can be used to reverse the
direction.
Choose Display under Drive Geometry to verify that the drive geometry has been correctly
defined.
621
622
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
Key in 0.01 for the Scallop Height.
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.
623
You may define as many vectors extending from specified positions on the drive geometry as
needed to create a smooth tool axis movement. The more vectors you specify, the more
control you have over the tool axis.
624
Choose Interpolate under Tool Axis.
An array of default tool axis vectors displays. These vectors are normal to the drive surfaces
and define the current Interpolate tool axis. Using all of these vectors would cause excessive
change in the tool axis.
You may remove, add, and edit vectors to achieve the necessary tool axis control. To edit or
remove a vector, you must first highlight the desired vector by using the Previous or Next
arrow options or by selecting the desired vector directly from the screen and then choose Edit
or Remove. Display refreshes the screen and updates the currently defined vectors for visual
reference.
625
Choose the Next arrow until the vector illustrated below highlights.
626
Continue using Next and choosing Remove to delete vectors until only the vectors
illustrated below remain. remember, you can choose Display at any time to update the
currently defined vectors for visual reference.
627
Orient View
Front).
The tool axis rotates 180 degrees as the tool zig-zags from one side of the part to the other.
You can reduce the change in the tool axis by editing the tool axis vectors.
OK to complete the tool path visualization.
628
629
Choose the upper end of the angled line as illustrated below.
630
Choose Display to refresh the screen.
The currently defined tool axis vectors are displayed.
Continue using Previous or Next, choosing Edit, choosing the Inferred Vector icon, and
selecting the top end of the appropriate angled line to edit the remaining five vectors at the
bottom of the part.
631
Orient View
Front).
632
The tool axis rotates 180 degrees as the tool zig-zags from one side of the part to the other.
You can reduce the change in the tool axis by editing the tool axis vectors.
OK to complete the tool path visualization.
OK to complete the operation.
Close the part file.
633
In this operation, you will define only the drive geometry. You will not define part geometry.
As a result, the tool path will be created directly on the drive geometry and definition of a
projection vector will not be necessary.
Choose Application
Manufacturing.
634
OK the warning.
The Surface Drive Method dialog displays.
635
636
You must now specify that you wish to begin the next row.
Choose Select Next Row.
By choosing this option, you have specified that you will begin a new row and that every row
will contain three surfaces.
Select the fourth, fifth, and sixth surfaces.
637
638
surfaces have been selected. You may need to rotate the model.
639
The material side vector determines which side the tool contacts when cutting on the drive
surfaces. The material side vector should point towards the material to be removed (away
from the part) as illustrated above. If it does not, Flip Material can be used to reverse the
direction.
Refresh the graphics display.
640
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
Key in 0.10 for the Scallop Height.
Choose Display Drive Path to verify that drive points and zig drive path are defined on the
drive geometry.
641
642
The When Gouging option allows you to specify how the system will respond when the tool
gouges the Drive Surface during cutting moves. These options only apply when you are
cutting to Drive Surfaces and not when you are cutting to Part Surfaces.
643
None causes the system to ignore Drive Surface gouging. It will generate the same unaltered
tool path as the Warning option, but will not issue a warning message to the tool path or
CLSF.
Skip causes the system to alter the tool path by removing only the Drive Points that cause
gouging to occur. The result is a straight tool movement from the last position before gouging
to the first position which is no longer gouging.
When generating tool paths directly from Drive Surface, the tool does not violate the Drive
Surface at convex corners, and does not gouge concave regions when using Skip as illustrated
below.
In some cases where the drive surface is smoothly concave, the Skip option may not clean up
the tool path as well as illustrated in the concave corner case above.
Retract causes the tool to avoid gouging the Drive Surface by using the parameters defined in
Non-Cutting Moves.
644
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
645
In this operation, you will define only the drive geometry. You will not define part geometry.
As a result, the tool path will be created directly on the drive geometry and definition of a
projection vector will not be necessary.
646
Choose Application
Manufacturing.
OK the warning.
647
The Surface Drive Method dialog displays.
648
649
650
and Select.
651
652
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
Choose the Verify icon at the bottom of the dialog.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Play Forward icon.
653
654
To complete this project, you should be familiar with the following types of operations.
CONTOUR_AREA_NON-STEEP
CONTOUR_ZIGZAG
CONTOUR_AREA_DIR_STEEP
In addition, you should know how to create a Mill Area parent group and how to define a
Trim Boundary and a Cut Area.
You will also Animate the tool path and use Show Excess to graphically display the excess
material left by the roughing operations.
655
656
Create a CONTOUR_ZIGZAG operation using the MILL_AREA geometry group to
finish the part.
Create a CONTOUR_ZIGZAG operation using a Cut Area to finish the core with a
very small stepover.
Use Verify Toolpath to graphically simulate material removal for the entire program.
657
658
Open part file srf_proj_1.prt from the srf subdirectory.
Enter the Manufacturing Application.
Fully expand the objects in the Geometry View of the Operation Navigator.
Choose the Geometry View icon in the Toolbar.
In the Operation Navigator, select the plus (+) signs next to the MCS_MILL and
WORKPIECE groups.
Replay the two operations.
In the Operation Navigator, highlight the WORKPIECE icon and MB3
Replay.
These two Z-Level Milling operations perform the initial rough cuts. You will create four
Fixed Axis Surface Contouring operations that use the Area Mill drive method to semi-finish
and finish the part.
659
660
OK to complete the operation.
661
662
663
Under Drive Method, choose Area Milling.
Choose User Defined as the Cut Angle and OK to accept 0.0000 degrees.
Key 25.0000 for the Stepover Percent.
OK to accept the parameters.
Generate the tool path.
664
665
666
667
668
To complete this project, you should be familiar with the following types of operations.
FLOWCUT_SINGLE
FLOWCUT_REF_TOOL
You will also Animate the tool paths to graphically simulate material removal.
669
Create a FLOWCUT_SINGLE operation to finish the corners using a single pass and a
small tool.
Use Verify Toolpath to graphically simulate material removal for the entire program.
670
671
The white areas indicate that further finishing is required to machine to the specified Outtol.
Cancel to dismiss the Toolpath Visualization dialog.
You will create two Flow Cut operations to finish the corners and fillets.
672
Create a FLOWCUT_REF_TOOL operation using the following parent groups:
Choose the Create Operation icon.
Choose mill_contour as the Type
Choose the FLOWCUT_REF_TOOL icon as the subtype.
Specify the parent groups as indicated below.
673
674
675