NC 5X Advanced

CimatronE 8.5 Tutorial

Table of Contents
5X Advanced....................................................................................................................... 1
5X Advanced - Pro .......................................................................................................... 2
Basic ............................................................................................................................. 2
Advanced.................................................................................................................... 44
Applications................................................................................................................... 69

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5X Advanced
Create finishing toolpaths on multiple surfaces for 5-axis machining.
This procedure supports 3 - 5 axis machining with a wide variety of machining strategies and cutters (including
Lollipop and Slot Mill). You have full control over the cutter orientation and over the behavior between cutting
motions. Up to four sets of check faces can be used, each with a different offset and a different response when a
theoretical path gouges it. Defining machine limits and other machine properties are also available.
Multiple layers (based on 3D offsets) can be used, combined with gouge check and control and the use of drive
surfaces allows roughing in 4 / 5X machining for special cases such as turbine blades machining.
Note: To use all the features of the 5X Advanced procedure, a license is required. This license includes the use
of Slot Mill and Lollipop cutters. Please contact your Cimatron Provider. If you do not have a license, you will not
be able to create, edit or execute a 5X Aerospace procedure.
5X Advanced - Pro: This is the full package of the 5X Advanced technology with full control over the process.

5X Advanced Applications: All other subselection options under the 5X Advanced display a minimum number
of parameters to accomplish a specific task. Select the appropriate subselection option and set the parameters.

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5X Advanced - Pro
Basic

Basic tutorial
5X Advanced Pro Introduction
This exercise explains the 5X Advanced Pro concept, basic features and methods of definition. It is conducted
step by step using simple geometry.

When dealing with surface geometry and not a solid model, prior to any 5X Advanced Pro work it is
recommended to check the object direction and make sure all the normals of all the faces are in the right
direction to prevent strange results.

Terminology

CC (Contact Point): the point where the tool touches the material.
CL Point: The point that is represented by the coordinates of the machine program (Control Point in
Cimatron terminology).
I, J, K: Values that represent the orientation of the tool axis.

When the tool tilts it rotates around the CC point. Note that the point on the material is fixed and the point on
the tool itself changes according to the orientation (except for sharp corner tools).

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5X Advanced Pro Procedure

There are four logical steps for the definition of a 5X Aerospace procedure, as follows:

Step 1- Surfaces Paths: Definition of machining strategy, geometry and other behavior control
parameters based on which the system will calculate the CC points and the TP that passes through
them.
Step 2 - Tool Axis Control: Definition of the tool axis orientation options and limits.
Step 3- Collision Control: Definition for collision checking and various solutions that can be applied.
Step 4 - Link: Control the link options between the motions.

Step 1 Surfaces Paths

Step 1 Surfaces Paths

Geometry and Cutter
Open the AS_Ex1.elt file.

In the first step you will create motions as shown in the picture above. Unidir motions are motions that proceed
around the cylinder with 10mm space between each other.
Create a new 5X Advanced Pro procedure.

Note that under Geometry there is a Drive Surfaces parameter. Do not select any geometry
The look of the geometry selection screen changes according to the machining strategy that will be chosen in
the next step. Since you do not know what is required yet, it is better not to select any geometry at this stage.

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The relevant selection options will be available later on. This screen will be useful for editing the geometry
selection, if required.

Select the Ball20 cutter.

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Motion Parameters - Access

Click the Motion Parameters icon and select the Access tab to access the 5X Advanced Pro Control
Panel dialog

Note that the first tab in the dialog, is the Surface Paths. This is the first logical step in the definition as
described in the Introduction step.

Select Parallel Cuts pattern (1) as the machining strategy.

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Set the angle in X, Y to 0 (2) and the angle in Z to -90 (3).

Note that angle on the XY plane (0 deg) in 5X Advanced Pro is in the Y+ direction.
The measuring angle in Z in this case is the angle on the ZX plane, and is set to -90. This means motions will
start from the right side and advance to the left. Generally this angle will be performed on a plane normal to the
above set XY plane.

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Placing the cursor on each value field to display an explanation picture.

Selecting Geometry and Motion Parameters

Click Drive surfaces to select the relevant geometry.

Select the entire geometry.

Select the geometry by dragging a box, or by using the Select all button.

In the Sorting Area, change the Cutting method to One Way.

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In the Surface Quality area, change the Maximum step over to 10mm

The One Way cutting method is similar to Unidir in other procedures and Maximum Step Over is similar to
either Side Step or Down Step depending on the Angle in Z.
When the Z Angle causes the motions to proceed from top to bottom, the Maximum Step Over value resembles
Down Step.
Select OK.

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In the Procedure Parameter Table click the Save and Calculate icon.

Cuts Along Curve

Display the axis set.

Click the sets icon

Display the axis set.

Double click the procedure to edit its parameters.

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Click the Motion Parameters icon. Click the Access tab. Change the strategy to Cuts along curve.

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Click the Lead button, pick the center axis and exit.

Select OK.

In the Procedure Parameter Table click the Save and Calculate icon

This is another way to obtain the required motions without having to calculate the angles required as in the
previous definition.
The cuts are performed normal to the leading curve. They begin at the side which is closer to the pick point on
the leading curve.

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Notice the gaps between the first and last lane and the cylinder edges as indicated by the arrows in the
picture below. The size of the gap is half of the step over. The cuts are performed normal to the leading curve.
They start at the side that is closer to the pick point on the leading curve

Full Start and End at Exact

Edit the procedure.
Select the Full start and end at exact option as the area type.

Check the Start Point option and press its button.

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Define the start point and set the Y = -100.

Execute the procedure.

Notice the difference between the start points before and after execution.

Note that the definition of a start point is only a hint for the system, (it does not need to be exact) as it tries to
locate the nearest possible position next to your point.

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Note that the tool path will be generated on the whole surface, exactly up to the surface edge or close to the
nearest possible position.

Limit by One or Two Points

Edit the procedure.
Select the Limit cuts by one or two points option as the area type and press the Advanced button.

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Enter the parameters as indicated in the picture below.

Execute the procedure. Notice the gaps between the motion and the surface edge. Zoom into the areas
marked in red circles as shown in the picture below:

Note that the distance between the passes is equally spaced (less than the 10mm specified) to ensure
smooth result!

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Step 2 Tool Axis Control

Step 2 Tool Axis Control
Tool Axis Control
Duplicate the procedure and edit the new procedure.
Select the Tool axis control tab and change the tool axis to the Be tilted relative to cutting direction
option, as shown below:

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Set the lead angle to 15.

Execute the procedure.

Note that the original setting of the tool axis was fixed and normal to the faces. (Tool axis direction = face
normal at touch point).
Positive value = lead angle (tool leans to the movement direction).
Negative value = lag angle (tool leans away from the movement direction).

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Save and Calculate the procedure. Switch to a side view and simulate (WireFrame Simulation) the two
procedures to see the results.

Tilted with Fix Angle to Axis

Edit the procedure.
Change the tool axis to the Tilted with fix angle to axis option.
Set the tilt angle to 45 and make sure it is set to X-Axis.

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With this option the tool axis will be tilted at a fixed angle relative to the chosen axis. The tilt axis can be towards
the X, Y and Z axis or to any line created in the geometry. Tilt axis and surface normal build a plane in which the
tool tilts.
Execute, switch to front view and enter the Navigator to view the results.

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The tool is now tilted towards X+ in a constant angle of 45 degrees all along the TP. Notice that the CC
(touch) point on the surface is maintained while the CL point is moved due to the tilt.

Step 3 Collision Control

Step 3 Collision Control

Gouge Check
Display the Box set.

Edit the procedure and set the tool axis to the original position, by selecting the Not to be tilted and stays
normal to surface option.

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Select the Gouge check tab.

Check the status check-box on the left hand side of the 1st check set.
Set the strategy to Retracting tool along tool axis.
Uncheck the Drive surfaces from the geometry.

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Notes:
You have now activated the 1st set of the available gouge check sets. The gouge will be checked only for the tip
and shaft of the tool (in Cimatron terminology it would mean the whole cut length).
This setting is defined by a check box under each one of the tool components. Notice that there is a different
clearance that can be set for each of them.
Arbor means Shank in Cimatron terminology.
There are different strategies to choose from, each of them will cause a different behavior if a gouge is detected.
In this case the tool will retract along its axis to a position where it will not gouge anymore.
Un-checking the Drive surfaces from geometry tells the system to check only against the Check surfaces,
notice that in this case a different stock to leave (offset) and tolerance can be set. Otherwise the system uses the
procedure tolerance and offset that are defined in the Cimatron parameter grid.

Hit the browse button ( ) near the Check surfaces #1.

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Select all the red box faces and exit.

Select the Advanced button.

Uncheck the Check gouge between positions.

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Select OK and Save and Calculate the procedure.

Notice the look of the Geometry dialog It includes all the geometry components needed according to the
settings you have previously defined.

Enter the Navigator to simulate the procedure to view the results.

Notice that check faces were machined as well! At all times the tool orientation is kept normal to the drive
face (cylinder).
Unlike in other procedures, the check faces in 5X Aerospace can be machined as well. This behavior is defined
in the strategy setting.
The drive surface in 5X Aerospace behaves similar to Aiming face in other procedures.

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Check Gouge Between Positions

Duplicate the procedure and edit the new procedure.
Ensure that the Check gouge between positions at the bottom of the Gouge check tab page (under the
Advanced option) is checked.

Execute the procedure.

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Switch to side view and perform navigation on the 2 procedures to view the difference between them

Notice the difference. The previous procedures movement is done through less TP nodes than the new one.
There might be a possibility for small gouge in that movement.
Checking this option causes the gouge check to be more accurate. The system adds some checking TP nodes
between the ones that are normally created, causing the motion to be smooth and move more accurately around
the geometry to prevent even smaller gouges.

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Leaving Out Gouging Points

Edit the procedure.
Change the gouge check strategy to Leaving out gouging points.
In the Stock to leave enter 2mm.

The target of this setting is to prevent the machining over the check faces and only to proceed as far as 2 mm
close to them.
Execute and view results.

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Notice that the check surfaces are bypassed with some rectangular motions. The highest Z point is at
150mm. The distance in the Y+ direction is even larger.
In the side view you will be able to view the offset distance from the check faces by zooming into the area
marked in blue circle.

Notice the offset from the check faces.

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Step 4 Link
Link
Edit the procedure.
Select the Link tab. Press the Clearance area button.

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Set the clearance Type to Cylindrical parallel to X and define the Radius at 120.

Press the Distances button.

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Set Rapid distance to 5 and the Feed distance to 3.

Execute and view the results.

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There are different options to define the clearance shape. In this case it will be a cylinder of 120mm radius
with the center passing through the UCS origin point (Through X=0 Y=0 Z-0). The options are described, as
follows:

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Feed distance: Last approach motion towards the material. In Cimatron this motion would be the
Delta_Z_Up or Surface Normal motions.
Rapid distance: Last rapid motion before the first feed motion. Performed in the same direction.

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The rapid motions bypassing the check surfaces have a cylindrical shape.

Notice that the created cylindrical motions are performed in a radius of 210mm and not 120 as defined. The
system will calculate the minimal safe distance needed in order not to gouge any geometry. The search for a
new safe height is performed in steps of 10mm as defined in the Air move safety distance parameter.

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Use Macro
Hide the cylinder set and show the cylinder2 set.
Edit the procedure and replace the drive surface with the new cylinder.

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In surface paths tab change the cutting method to One Way. Click the Start Point button and change the
Rotate by (Deg) value to 2.

Press the Link tab.

On the top of the dialog change the First Entry and Last Exit to Use .. macro.
Use macro means to do some other kind of motion than straight approach or retract. The type of macro is
defined in the lower part of the dialog. There is a special macro for entry (approach) and one for exit (retract),
described as follows:

First Entry: First approach motion of a procedure.

Last Exit: Last retract motion of a procedure.

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Press the Entry/Exit macro button

Select the Vertical Tang. Arc option for both macros:

Execute and view results.

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Notice the tangent approach and retract as a result of using the macro. There are a few entry/exit types of
motions to choose from in the macro
combo-boxes.
The shifted start point is the result of the Rotate by (Deg) 2 that was set in the Start Point dialog.
Near the triangular hole two kinds of connection motions can be seen. One goes directly over the hole and the
other jumps to clear. These motions can be controlled.

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Control the Motion Behavior

Edit the procedure and press to the link tab.
In the Gaps along cut group change the Small gap size in % of tool diameter to 300.
In the Links between slice group change the Small Moves type to Blend Spines.

There are 3 dialog groups:

Gaps along cut: To control the motion behavior when interference along a cutting lane.
Links between slice: To control the motion behavior between lanes/layers.
Links between passes: To control the motion behavior between regions.

In the first two groups there is a difference between small and large. The definition of what is small and what is
big can be defined by the user as a percentage of the tool diameter or exact value:

Different motion behaviors can be set for the small gaps or large ones:

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Execute and view results.

Notice that the connections are now direct over the triangle gap. By setting the along cut to 300 % (of tool
diameter) the system was told that up to 60mm (tool diameter 20mm) the gap should be considered as small and
the connection type will be direct. The Blend spline setting resulted with smooth S-connections between the
slices.

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Advanced options
Flip Step Over
Edit the procedure.
Check the Flip step over option in the Surface paths tab.

In the Tool axis control tab select the Tilt with fixed 45 deg to X option.

In the Gouge check tab select the Moving tool away and the retract in YZ plane options.

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Execute and view results.

Notice that since the to Flip step over option is selected, the machining starts from the other side. In order
to prevent the gouging of the check faces (box) the tool moves away from the geometry, and all these
movements are performed on the YZ plane, maintaining a constant X value.

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Tilt From Point Away

Show the SET center point.
Edit the procedure. Set the tool axis will option to Tilt from point away
Click the Browse () button,
In the point dialog Click the Browse () button, and select the point at the center of the cylinder axis.

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Select the Retract tool along tool axis option in the Gouge check tab.

Execute and view the results.

Notice that at all positions of the tool axis are pointing to the point picked.

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Advanced
5X Advanced Pro- advanced
In this tutorial, you will perform the following tasks:
Learn how to start 5x Advanced Pro and create a real multi surface toolpath perpendicular to surface
Change the 5x Advanced Pro toolpath from perpendicular to surface into a Swarf toolpath
Deal with improper surfaces using 5x Advanced Pro gap handling mechanisms.
Learn the 5x Advanced Pro ability to avoid collisions by tilting the tool intelligently.
Combine more than one collision strategies on more than one set of surface models.
Use advanced collision controls to avoid gouging of vertical walls and sharp corners.
Use more sophisticated options to apply different offsets to different sets of surfaces.
Study 5x Advanced Pro holder collision.

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Step1
Object direction
Open the SIMPLE_NC.elt file.

Check the object direction of the faces.

From the Analyze menu, select the Object direction option or click the

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icon.

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Select the face and apply the direction as indicated in the picture below and then select the other black
faces:

Note that after performing the operation, if entering the Object direction option, all faces are in the right
direction.

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Create Part and Stock

Create a 5X TP. Set the Z (Clearance) to be 70.

Create a Part procedure from all displayed the faces.

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Create a Stock procedure from the faces set criteria with 1 mm offset.

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Create a simple 5X Advanced Pro procedure

Create a new 5X Aerospace procedure.

Load a cutter from another elt ,from the file: Simple_NC_Complete.elt

the three cutters.

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Use the existing F12 cutter.

Set the procedure parameters as shown in the picture below:

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Parallel to Curve
Press the Access button to access the 5X Aerospace dialog. (Do not select any geometry)
In the Surface Paths page select the Parallel to Curve pattern.

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Use the Single Edge and Drive Surfaces buttons in the dialog and select the geometry as shown in the
picture below:

Select the curve from the Curves set as the single edge.

Switch to the Link page and change the First entry and Last Exit to use Rapid Distance.

Select OK and Save & Calculate' the procedure.

Use the Navigator to simulate to examine results.

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Notice that the cutter is normal to the faces at each point

Step 2 Create a Single Pass Swarf Milling Procedure

Duplicate the procedure and edit it.
Open the 5X Advanced Pro dialog.
In the Type area, select the Determine by number of cuts option and set the Number of cuts to 1.
Change the Cutting Method to One Way.

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Switch to the Tool Axis Control page and select Be tilted relative to cutting direction as the Tool Axis
option.
Set the Tilt Side Angle option to 90.

Select OK and Save & Calculate the procedure. Perform Wireframe Simulation to examine result.

Notice that the cutter is tangent to the faces at each touch point.
By the above setting you have caused the cutter to Swarf mill the faces, cutting with the cutter side.
Notice that the motion is interrupted at one point and the cutter retracts to clear height.

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The retract motion is caused by the gap in the geometry. The cut along the lower edge is interrupted.

Step 3 Handle gaps along cut

Duplicate the procedure and edit it.
Open the dialog. Change to the Link page and set the Small Gap size to 300.
Make sure that the Small Gaps behavior is set to Follow Surfaces.

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Select OK and Save & Calculate the procedure.

Enter the Navigator to examine the results.

The retract to clear option no longer exists and the motions are following the faces as much as possible.
Notice that the Drive Surfaces are being gouged by the cutter all along the motion.

Step 4 Avoid collision with Drive Surfaces

Duplicate the procedure and edit it.
Open the dialog and select the Gouge Check tab. Check the 1st check group, set the strategy to Tilt tool
away with max angle and select only the Drive surfaces option.

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Only one of the gouge check options is activated. The checking is done with the cutting length of the cutter (Tool
Tip and Tool Shaft) against the drive surfaces. The strategy in case of gouge, will be to tilt the cutter sideways.
Select OK and Save & Calculate the procedure.
Perform a Wireframe simulation to examine the results.

Notice that the cutter is tilted away just enough to touch the upper side of the drive faces without gouging
them.

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Step 5 Avoid Collision with Horizontal Center Bar

Show the 1st Gouge set.
Duplicate the procedure and edit it. Open the dialog and select the Gouge Check tab. Uncheck the tool tip
in the 1st check group. .

Check the 2nd check group, set the strategy to Retract tool along tool axis. Select only check surfaces,
set 0.5mm as Stock to leave and 0.05 for Tolerance.

Uncheck the Check gouge between positions (under the Advanced option).

With this setting the tool will retract along its axis whenever a gouge is detected, within 0.5 mm from some check
surfaces. The retract will be done until a point where there is no longer a gouge.

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Select the Check Surfaces (Set: 1st gouge) as shown in the picture below:

Select OK and Save & Calculate the procedure. Examine the results

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The tool is retracting along its axis just enough to go over the check faces. When it passes the check faces it
goes back to the original motion location.

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Step 6 Advanced Collision Checking

Regular collision checking is calculated on surface points (TP-Nodes), this may lead to minor gouges with the
check surfaces.
The pictures above shows what may happen while the cutter is moving from the bottom point to the ones above.
In some situations it can gouge the corner. (this picture is performed with Check Surface Offset = 0)
Duplicate the procedure and edit it. Open the dialog and change to the Gouge Check tab. Ensure that the
Check gouge between positions is checked.

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Select OK and Save & Calculate the procedure.

Examine results. Compared to the previous procedure.

The system added TP-Nodes between the original one in order to better move around the check faces obstacle,
to create a gouge free motion.

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Step 7: Avoid strange tool movements at sharp inner edges

Zoom in to the area close to the connection between the two drive faces.

At sharp inner edges you are facing the so called dove tail problem (see picture). This causes a damage of the
drive surfaces. It is caused by the Tilt the Tool Away collision check strategy.

The dove tail problem is a very common thing with 5X machining based on surfaces. This will appear with all
inner surfaces which have a fillet radius smaller than the tool radius.

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Duplicate the procedure and edit it. Open the dialog and check the Round Corner checkbox.

Select OK and Save & Calculate the procedure. Examine the results.

The result is smoother. The loop is no longer gouging the part.

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Step 8 Conic cutter and holder collision check

Shaw the 2nd Gouge set.

Duplicate the procedure. Change the cutter to FLAT6TP3.

Open the dialog and select the Gouge Check tab. Check the Tooltip option in the 1st check group.

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Save & Calculate and examine the results.

Notice that the cutter doesnt gouge the faces (as before) but the holder gouges the vertical box on the side.
Lets assume that this is a clamping device that we want to avoid gouging.

Edit the procedure. In the 1st gouge check group select the check surfaces (#1).

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Select all faces of the vertical box as check surfaces (#1).

Select OK and Save & Calculate the procedure. Examine results.

As a result of your new definitions the cutter tilts away more to make sure that the holder does not gouge.
Because of the extra tilt the motions are changed, notice the difference between the old and new TP.

The result can be seen in SIMPLE_NC_Complete.elt.

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Applications
To help the users to cope with the many options available in the 5X Advanced Pro package, a number of
applications have been created. Each one is specially designed for common 5X tasks. The control over the
parameters is limited, but the ease of use is greatly increased.
Impeller
Open the Impeller.elt file.
Milling impellers can be particularly complicated. The tool must be tilted constantly to avoid gouging. Four
application modules are now available to help the user get the best toolpath possible.

Create a new procedure. In 5X Advanced, choose the Impeller / Roughing Sub-selection.

Note: Applications are available only under 5X TP. Several applications can with appropriate settings create
a 4X TP.

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Choose the B3 cutter.

Click on the Access button, notice the simplified Control Panel that opens.

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Behind the scenes, the Morph Between 2 Surfaces option (within the "Pro" package) has been selected.
The number of sub-options has been greatly reduced, such that you need to set only the most relevant ones to
get the best results.

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Impeller1
First we will select the geometry. It is clear which Right, Left and Floor faces need to be selected.

Set the Cut Control parameters; Cutting method to Zigzag and Cut order to From center away".

Set the Maximum Step-over to 2 and leave 0.5 mm for the Finishing operations.

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For Clearance we will choose a Sphere larger than the radius of the part (which is about 70 mm) situated
approximately at the center of the bottom.
Set the Rapid, Feed and Safety Distances.

Impeller2
Note that the Entry/Exit Macros can be either set to ON or OFF for all situations.
Turn them ON and set them to Vertical Tang. Arc.

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Select OK.
Click on the Collision Control button and switch it from OFF to ON.

Now, check the 'Check Surfaces' check button, and press the Check Surfaces' button. Select the walls and
floor as Check Surfaces.

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Impeller3
Finally (for now) we will set the Generate tool path only at front side option in the Advanced menu.

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Execute the procedure. (Select OK, and Save & Calculate).

Enter the Navigator.

Note that the results are good. But for Roughing, we do not want all the material removed in one pass. We would
prefer layers.

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Impeller4
Edit the procedure.
Measuring the blade at its deepest point, we see that it is more than 28 mm.

Press the Access tab menu.

Check the Depth Cuts option and click on the button to open the menu.

Set the Roughing Passes for 8 and the passes of 4 mm.

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Sort them by Passes. This will result in layers.

Execute the procedure.

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Viewing from the side we can see that there are quite a lot of air motions. This is the price paid for using the
simplified interface of the application. Our toolpath is not 100% efficient. But we need not settle for good
enough. We can switch to the 5X Pro interface at this point and refine the parameters so that we get the perfect
result.

Impeller5
Edit the procedure and change the sub-selection to Pro.

Access the 5X Pro menu.

We can see that it opens with all of the parameters set to those that we set in the Roughing Application, along
with its own defaults.
We have a Morph Between 2 Surfaces procedure set to our needs

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Open the Roughing tab

Activate the Stock Definition & Click on the button

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Select:'By Criteria'.

Select the Set called Stock.

Execute the procedure and view the results. Note that the layers have been trimmed to the stock limits.

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Impeller6
Now lets Finish Mill the floor of the impeller.
There are 2 applications for this; first we will use the Auto Tilt"

The geometry selection is retained from the previous procedure. But even without it, it is clear what needs
to be selected.

Set the parameters for the finishing procedure.

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Check Surfaces are the same as we used in the Rough procedure. As is the Clearance Area and Entry/Exit
Macros. Use a smaller Maximum Step-Over and change the Stock Remain to 0.

Execute the procedure.

Examine the results.

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The results are good (depending on the geometry, the Auto-Tilt option can sometimes give wavy results) but the
tool is swarf milling the wall at some points and not at other points.

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Impeller7
Edit the last procedure.
Change the Sub-Selection to Floor Finish.

Set the parameters to the same as we had with the Auto-Tilt and add the Tilt Curve to guide the tool.
Select OK, and execute the procedure.

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(Tilt curves like this can easily be created by building a Blend Face between the wings, and using Curve: From
Face and creating a Section Line through the mid point of the edge.)

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Impeller8
We will Finish Mill the walls now with the side of the tool.
Create a new procedure with the Blade Swarf Finishing Sub-Selection.

Again, it is clear what the surface selection should be. (Be sure to Reset selection before selecting the
floor and wall surfaces.)

Turn on the Advanced Generate tool path only at front side option.

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Set the other options as they were set in the previous procedures.
Since the walls are vertical, we want Tangential or Horizontal Tangential Arcs for Entry/Exit Macros.
Execute the procedure and examine the results.

Repeat the method to mill the other wall.

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