Mt11065 - NX6 9 2008 Fixed Axis Techniques Student Guide PDF

Fixed Axis Techniques
Student Guide
Sept 2008
MT11065 NX 6
Publication Number
mt11065_s NX 6
Proprietary and restricted rights notice
This software and related documentation are proprietary to Siemens Product

Lifecycle Management Software Inc.
2008 Siemens Product Lifecycle Management Software Inc. All Rights
Reserved.
All trademarks belong to their respective holders.
2 Fixed Axis Techniques Student Guide mt11065_s NX 6

Contents
Course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Course description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Course objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intended audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Student responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Class standards for NX part files . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Class part file naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Layers and categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Activity format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Workbook overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Classroom system information . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WAVE Geometry Linker in Manufacturing . . . . . . . . . . . . . . . . . . . . 1-1

The WAVE Geometry Linker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Geometry types used by the Geometry Linker . . . . . . . . . . . . . . . 1-3
Edit links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Broken links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Delete parent geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Delete linked geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Activity: Create an assembly for WAVE . . . . . . . . . . . . . . . . . . . . 1-9
Link procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Activity: Create WAVE geometry . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Delete Face procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
Activity: Delete Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Activity: Other modeling techniques . . . . . . . . . . . . . . . . . . . . . 1-18
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
Advanced Cavity Milling topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cut Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Activity: Cut Levels parameters . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Cut patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Activity: Zig-Zag cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
In-Process Work Piece for Cavity Milling . . . . . . . . . . . . . . . . . . . . . . . 2-13
Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Activity: Level Based In-process Workpiece (IPW) . . . . . . . . . . . 2-16
Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-21
Fixed Axis Techniques Student Guide 3

Contents
Activity: Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . . . . . . . 2-22

Cavity Milling stock options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
Activity: Blank Distance option . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Plunge Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Plunge milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Activity: Create a Plunge Milling operation . . . . . . . . . . . . . . . . . . . . . . 3-5
Plunge Milling Step Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Activity: Plunge Milling Step Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Activity: Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Steep Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Activity: ZLEVEL_PROFILE_STEEP Operations . . . . . . . . . . . . . . . . . . 4-8
Activity: Z-Level Profile Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Z-Level Cutting Between Levels (aka Gap Machining) . . . . . . . . . . . . . 4-14
Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview of the NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Activity: The NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Machining options that require change for High Speed
Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Activity: Create a High Speed Machining operation . . . . . . . . . . . 6-4
Mixed Cut Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Activity: Mixed Cut Directions . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Trochoidal Cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Activity: Trochoidal cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

Contents
Flow Cut Reference Tool Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Activity: Create Fixed Contour operations . . . . . . . . . . . . . . . . . . . . . . 7-10
Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Activity: Mill Area geometry groups . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Trim Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Activity: Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Flow and Cross curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Activity: Create an Automatic Streamline operation . . . . . . . . . . 8-5
Activity: Create a Manual Streamline operation . . . . . . . . . . . . 8-10
Activity: Add additional curves for more control . . . . . . . . . . . . . . . . . . 8-15
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

Course overview
Course description
The Fixed Axis Techniques course teaches the use of the NX Manufacturing
application for creating 21/2 and 3axis tool paths.
Course objectives
After successfully completing this course, you should be able to perform the
following activities in NX:
Create group objects that supply information to operations
Utilize options and parameters that are common to various operation

types
Create Associative Machining Geometry, Advanced Roughing operations

and Finishing operations.

Course overview
Intended audience
This course is designed for Manufacturing Engineers, Process Planners and
NC/CNC Programmers that have the basic knowledge of NC/CNC manual
programming of 3-axis positioning and contouring equipment.
Prerequisites
Essentials for NX Designers or self-paced course equivalent
Basic understanding of the Master Model concept
Working knowledge of the following:

NX user interface
Part file saving conventions
Experience as an NC/CNC programmer
Student responsibilities
Be on time
Participate in class
Listen attentively and take notes
Practice what you have learned
Enjoy the class

Course overview
Class standards for NX part files

The following standards will be used in this class. Standardization allows
users to work with other parts while being able to predict the organization
of the part file. All work should be performed in accordance with these
standards.
Class part file naming

This class utilizes the following file naming standard:
Where the student is requested to save a part file for later use, the initials
of the students given name, middle name, and surname replace the course
identifier "***" in the new filename with the remainder of the filename
matching the original. These files should reside in the students personal
directory.
Currently up to 128 characters are valid for file names. A four character
extension (.prt) is automatically added to define the file type. This
means the maximum number of user defined characters for the file
name is actually 124.
Layers and categories

Parts used in this course were creating using layer categories the same as or
very similar to those found in the Model template parts.
Layers provide an advanced alternative to display management (Show and
Hide) to organize data
Layers Categories Description
110 SOLIDS solid bodies
1120 SHEETS sheet bodies
2140 SKETCHES all external sketches
4160 CURVES non-sketch curves
6180 DATUMS planes, axes, coordinate systems
91255 no category assigned
Activity format
Activities have the following format:

Course overview
Step 1: This is an example of a step. Steps specify what will be

accomplished.
This is an example of an action bullet.
Action bullets detail how to complete the step.
Workbook overview
The workbook contains a project that requires you to apply the knowledge
that you learned in the class and in the student activities. The projects do not
contain detailed instructions as do the student activities.
It is the intent of this project to allow you to apply the skills taught in this
course. However, the time constraint of this course is also a factor, at any
point when progress is not being made, enlist the help of your instructor.
Classroom system information
Your instructor will provide you with the following items for working in the
classroom:
Student Login:
User name:
Password:
Work Directory:
Parts Directory:
Instructor:
Date:

1
Lesson
1 WAVE Geometry Linker in

Manufacturing
Purpose
In this lesson, you will learn different methods available for creating
machining geometry, using the WAVE (What If Alternative Value
Engineering) Geometry Linker, that is associated to the designers original
geometry.
Objective
Upon completion of this lesson, you will be able to:
Use the WAVE Geometry Linker to create associative, linked geometry.
Make modifications to linked geometry.
Use a "base part" to control the manufacturing setup.
Build a simulated casting solid body using the Wave Geometry Linker.
Fixed Axis Techniques Student Guide 1-1

WAVE Geometry Linker in Manufacturing
1
The WAVE Geometry Linker
The WAVE Geometry Linker is used to associatively copy geometry from a
component part in an assembly into the work part. The resulting linked
geometry is associated to the parent geometry. Modifying the parent geometry
will cause the linked geometry in the other parts to update.
The WAVE Geometry Linker is available with a Manufacturing Bundle
license. It does not require a NX WAVE license.
Different types of objects can be selected for linking, including points, curves,
sketches, datums, faces, and bodies. The linked geometry can be used for
creating and positioning new features in the work part.
The Wave Geometry linker is accessed by choosing InsertAssociative
CopyWAVE Geometry Linker from the menu bar, or from the WAVE
Geometry Linker button on the Assemblies toolbar.
The Fix at Current Timestamp determines weather or not features added

to parent body after linked body is created will propagate to liked body.
When turned off, any new features added altering the parent geometry
will be reflected in the linked geometry. When turned on, new features
added after the link was created will not be affected.
Hide Original lets you blank the original geometry so that the linked
geometry in the work part will be easier to work with while the assembly
is displayed.
Associative determines weather or not linked body will update to reflect

changes in parent..
1-2 Fixed Axis Techniques Student Guide mt11065_s NX 6

1
Geometry types used by the Geometry Linker
Several different types of geometry can be used in the WAVE application.

Composite Curve
Point
Datum
Face
Region of Faces
Body
Mirror Body
Routing Object
When selecting geometry to copy, you should consider how permanent the
geometry will be. If you copy as little geometry as possible to do the job,
performance will be improved but updates will be less robust when the parent
geometry is altered.
For example, if you copy individual curves to another part, the link may not
update correctly if one of the curves is deleted. Conversely, if you copy an
entire sketch, curves may be removed or added and the link will update.

1
Edit links
Links may be edited by choosing EditFeatureEdit Parameters in the Part

Navigator and selecting a linked feature. Linked features have an dialog
box similar to the one below.
When this dialog box is displayed, the cursor is active in the graphic window
allowing new parent geometry selection for the link being edited. The new
parent geometry must be the same type as the old geometry (curve, datum,
solid body, etc.)
Parent indicates the parent geometry type, work part or other part.
Wave Information shows the name of the part where the parent geometry
is located, parent feature, and link status. If the parent geometry is
located in the current work part, the part name given is Work Part. If the

1
feature was linked, but the link has been broken, the parent is shown as
a Broken Link.
The dialog box information updates when you select new parent
geometry, which you can do at any time.
The Fix at Current Timestamp determines weather or not features added

to parent body after linked body is created will propagate to liked body.
When turned off, any new features added altering the parent geometry
will be reflected in the linked geometry. When turned on, new features
added after the link was created will not be affected.
Associative lets you break the association between the linked feature and
its parent. This means that the linked feature will no longer update if its
parent changes. You can later define a new parent by selecting geometry
with the cursor.
Replacement Assistant allows replacement of one linked object with

another (cannot be used on linked sketches or strings). Objects must
be of the same type.
Reverse Direction reverses the normal of the face selected.
Depending on the geometry type of the feature being edited, other options
may appear on the dialog box.
When editing links and selecting new parent geometry, it may be easier
to temporarily work in an exploded view to distinguish between the
existing linked geometry and the new parent geometry.

1
Broken links
A link may become broken for several of the following reasons:

The parent geometry is deleted.
The path from the linked geometry to the parent part is broken. This can
occur if the component part containing the parent geometry is deleted
or substituted.
If the parent is removed from the start part reference set that defines
the linked part.
If you deliberately break the link (e.g., using Edit Feature or the Break
option on the WAVE Geometry Navigator dialog box).

1
Delete parent geometry
To prevent unintentional deletion of the parents of linked geometry, a message

will warn you if a delete operation would cause inter-part links to break.
The Information option provides details about the links that will be
broken in an Information window.

1
Delete linked geometry
Linked geometry is created as a feature and can be deleted by choosing

EditFeatureDelete (or choosing the Delete Feature icon).
Linked bodies may also be deleted by choosing EditDelete. If you choose
this method, you will not have an opportunity to verify child features before
they are removed.
Assemblies and WAVE

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

1
Activity: Create an assembly for WAVE
In this activity, you will create an assembly structure for later use with the
WAVE Geometry Linker. Remember that WAVE only works in the context
of an assembly.
Using WAVE, you will create a simulated casting model that is associated
with the original geometry.
For the casting body, it will be necessary to remove the seven drilled holes,
and add .250" machining stock on the inlet, outlet and mixer tube faces. Also
note that the ring groove will not exist on the casting body.
All machined faces have 1/4" of added stock. Once the modeling changes
are made, you will drill all holes and machine the ring groove into the
mixer outlet face, since the casting process was not accurate enough for the
tolerances required.
Step 1: Create a new part.
On the Standard toolbar, click New .
Notice that the dialog box has several tabbed pages.
Click the Model tab. Expand the Units list and select Inches.
On the Model page, select the Assembly template.
This template will provide the standard Layer settings and

Category Names as defined for this class.
In the New File Name group, in the Name box, type

***_mixer_mfg , where *** represents your initials. Make sure
Folder is set to your home folder.

1
Saving parts to your home is standard practice for this class.
Parts that you create must be saved in a folder to which you
have read and write permissions.
Click OK.
Step 2: The Add Component dialog box appears. This will allow you to
add the part you are going to work on.
In the Part group, click Open .
Select mixer_body from the parts folder.
Click OK.
From the Positioning list select Absolute Origin.
Expand Settings.
Type mixer in the Name box.
From the Reference Set list select SOLID
Click OK.
Step 3: Examine the current assembly structure.

In the Resource bar, click the Assembly Navigator tab.
There are currently two parts in this assembly. The top level part
is ***_mixer_mfg, while mixer_body is the single component.
Currently, only the component contains any geometry.
The next step will be to create a new component that will contain
the WAVE casting body.
Step 4: Create an empty component.

Choose AssembliesComponentsCreate New Component
from the menu bar.
Expand the Units list and select Inches.
On the Model page, select the Model template.
In the File Name group, in the Name box, type

***_mixer_casting.
Ensure Folder is set to your home folder.

1
Click OK.
In the Create New Component dialog box expand the Settings

group and change the component name to casting.
Click OK.
A new component, named CASTING, is displayed in the

Component Name column of the Assembly Navigator. The name
of the part is ***_mixer_casting. To display the Component Name
column, right-click and choose ColumnsComponent Name.
Step 5: Save the assembly.
Click Save on the toolbar.
When you save an assembly, all modified components below

the work part are saved as well.

1
Link procedure
You use the InsertAssociative CopyWAVE Geometry Linker dialog

box to create associated objects between parts. The linker allows you to
copy geometry downward into component parts, upward into higher level
assemblies, or sideways between components within an assembly. As you
build your Mixer assembly you will use the sideways functionality.
To create linked geometry:
Arrange your assembly display so that the part containing the geometry
to be copied is visible, and the geometry of interest is selectable.
Change Work Part to the part that is to receive the linked copies.
Choose Insert Associative Copy WAVE Geometry Linker.
Use the linker dialog box to filter the type of object(s). You may select
several objects of different types.
Choose Apply to make copies and remain in the Selection dialog box, or
OK to copy objects and exit the dialog box.

1
Activity: Create WAVE geometry
In this activity, you will practice using the geometry linker. You will create
a WAVE linked copy of the mixer body, then perform modifications to that
copy to simulate a casting.
Step 1: Prepare the assembly.
If necessary, open the ***_mixer_mfg assembly part and then
the Assembly Navigator.
Choose StartModeling.
In the Assembly Navigator, right-click ***_mixer_casting and

choose Make Work Part.
The mixer body changes color. This is a visual clue that geometry
is no longer in the current modeling hierarchy.
Step 2: Change the Role.

Select the Roles tab and click Essentials with full menus icon.
Step 3: Choose InsertAssociative CopyWave Geometry Linker.

It is possible to link types of geometry other than solid bodies.
Curves, Sketches, and Datum Planes are also commonly linked.
Set Type to BODY in the WAVE Geometry Linker dialog

box.
Select the mixer body.
Click OK.
Step 4: Modify the display of the linked casting.

There are now two identical bodies, lying in the same model space;
the component body and the linked copy. It can be difficult to
determine one from the other, it will be necessary to clarify the
differences. First, you will remove the original body from the
display. Then, you will change the display of the linked body.
In the Assembly Navigator, right-click the ***_mixer_casting

component and choose Make Displayed Part.
In the graphics window change the view orientation and shade

status if required.
Choose EditObject Display.

1
Select the linked body and choose OK.
Using Edit Object Display is a powerful method of

differentiating between bodies that are similar in
appearance.
In the Basic group, change Color to Yellow.
Choose OK in the Edit Object Display dialog box.
Step 5: Make the top-level part the displayed part, then save the work
in progress.
At this point no physical difference exists between the mixer body
and the mixer casting. They do have a visual difference. In the next
activity, you will perform modeling changes to the mixer casting.
In the Assembly Navigator, right-click the ***_mixer_casting

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

choose Make Work Part, if necessary.
Click the red check mark in front of Mixer_body and the yellow
casting will remain on the screen.
Click the red check mark in front of ***_mixer_casting and

it will leave the screen.
Click the grey check mark in front of mixer_body and the

original model will appear.
Click on the grey check mark in front of ***_mixer_casting

and it will appear, but will blend completely with the original
model. This will be changed in the next activity.
Click Save .
Delete Face
Use the Delete Face command to delete faces. You can:

Automatically heal the open area left in the model by the deleted faces, by
extending adjacent faces.
Preserve adjacent blends

1
Delete Face procedure
You will use the Delete Face function to remove holes from your mixer casting
body.
To use Delete Face:
Click Synchronous Modeling Delete Face on the Direct

Modeling toolbar.
Click Select Face
Click Apply or OK.
The selected faces are deleted and the open area is healed

1
Activity: Delete Face
In this activity, you will practice using Delete Face as a tool to reduce the
complexity of a linked solid body.
Step 1: Make the CASTING component the work and displayed part.
If necessary, open your ***_mixer_mfg assembly part and then
open the Assembly Navigator.
Right-click the ***_mixer_casting component and choose Make

Displayed Part.
Step 2: Perform a Delete Face operation on the seven bolt holes on the
outlet face and mixer tubes.
Choose StartModeling if required.
Choose InsertSynchronous ModelingDelete Face.
The cue line reads: Select faces to delete.
Select the five holes on the mounting face. Select the cylindrical
faces of the holes.
Select the two cylindrical faces of the inlet tubes.

Click OK in the Delete Face dialog box.
Click Save .

1
Activity: Other modeling techniques
Previously Delete Face was used to remove unwanted geometry from the
Linked casting body. Now, you will explore other ways to modify a linked
body. The first option explored is Make Coplanar.
Step 1: Make the CASTING component the work and displayed part, if
necessary.
If necessary, open your ***_mixer_mfg assembly part and then
open the Assembly Navigator.
Click on the ***_mixer_casting component, choose Make

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

Choose StartModeling.
Choose InsertSynchronous ModelingConstrainMake

Coplanar.
The Make Coplanar dialog box is displayed.
Select the bottom face of the ring groove, as shown below. This
is the Motion Face.

1
Select the Stationary Face, select the outlet
face.
Click OK.
Step 3: Use the Offset Face option to add machining stock.

In this step, you will add machining stock to the inlet and outlet
faces, as well as the mixer tube faces.
From the menu bar, choose InsertOffset/ScaleOffset Face.
In the Offset Faces dialog box, type 0.250 for the Offset value.
Select the inlet and outlet faces, and the two mixer tube faces.
Click OK.
The modeling changes are complete. It will be difficult to visualize

those changes in shaded mode, without a further display change
to the casting.
Step 4: Change the translucency of the casting.

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

1
If necessary, turn on Shaded mode.
From the menu bar, choose EditObject Display.
Select the body and choose OK.
Slide the Translucency bar to 50% and choose OK.
If the solid body does not become semi-transparent, choose

PreferencesVisualization Performance, and turn off
Disable Translucency, located on the General Settings tab
under Session Settings.
Step 5: Make ***_mixer_mfg the work part, and compare the two solid
bodies.
To fully realize the extent of the changes made, you will display
both the original and the linked body together.
Open the Assembly Navigator.
Right-click the CASTING component and choose Display

Parent***_mixer_mfg.
In the Assembly Navigator, double-click ***_mixer_mfg to

make it the work part.
Examine the two models.
The CASTING component has stock added on the machined faces.

All drilled holes have been removed, as well as the ring groove.

1
This is only one potential method for creating a simulated casting
body. Other methods and techniques could also have been used.
However, this method is fully associated to the original, so that if
the original body changes, the casting body will update also.
At this stage, NC/CNC programming, using the CASTING
component as the BLANK, could now begin.
Choose FileClose Save All and Close.

1
Summary
The WAVE Geometry Linker provides an efficient method to associatively
copy geometry used for machining from a component part in an assembly into
a work part. The machining geometry is modifiable for manufacturing needs
but does not change the original design intent.
In this lesson you:
Used Assemblies to enable "Best Practices" for modeling in manufacturing.
Created a WAVE solid body that is associatively linked to the original.
Modified the WAVE geometry to simulate a casting for machining.

Lesson
2 Advanced Cavity Milling topics

2
Purpose
This lesson teaches you how to use additional Cavity Milling options to create
tool paths. You will also use Geometry Parent Groups to machine Cavity
Milling geometry.
Objective
Utilize advanced Cavity Milling options
Create and modify Geometry parent groups for Cavity Milling
Create and modify Cut Levels
Utilize the In-Process Work Piece

Advanced Cavity Milling topics
Cut Levels
Cavity Milling cuts geometry in planes or levels.
The advantage to this approach is that tool paths remain relatively short, due
2 to minimum tool path movement, which is performed in layers.
The disadvantage is that when machining geometry that is close to horizontal
more stock may remain than desired. See the diagram below.
The closer the geometry approaches horizontal, the more stock that remains.
Through the use of Cut Level parameters, you can reduce the amount of stock
that remains by reducing the depth of cut in these near level areas.
Use Cut Levels in the Cavity Mill dialog box to access the Cut Levels
dialog box.
The Cut Levels dialog box serves these primary functions:
Create, delete or modify Ranges
Modify Cut Levels within Ranges
To reduce the amount of additional stock, a new range can be added. The
Depth per Cut in that Range only is modified.
In the next activity, you will use various Cut Level parameters.

Activity: Cut Levels parameters
In this activity, you will replay an operation and review the various Cut
Levels. You will then modify the range to allow the tool to cut without any
warning messages. 2
Step 1: Open, rename the part, and start the Manufacturing application.
Open base_mfg_2_setup_1.
Choose StartManufacturing.
Step 2: Display the Operation Navigator.

In the Operation Navigator, verify the Program Order view is
active.
In the Resource bar, click the Operation Navigator tab and

expand the BASE_MALE_DIE parent group.
Step 3: Generate the operation.

In the Operation Navigator, double-click CAVITY_MILL to edit
the operation.
Click Generate .
Refresh or hit F5 to remove the path display.
Step 4: Edit the Bottom of Range #1.
Click Cut Levels from the Path Settings group in the

Cavity Mill dialog box.

Large and small plane symbols appear. The large plane represents
the Range, and the small planes are the Levels within the Range.
Some Ranges do not have any additional levels.
At the very top of the dialog box, there are three buttons for
defining ranges. The Auto Generate (1) button defines ranges
that will align with planar horizontal faces. The User Defined (2)
button defines ranges by selection of the bottom plane for each
new range. The Single (3) button defines the cut range based on
part and blank geometry.
In the Cut Levels dialog box, click (beneath Range 1,

Level 1) once.
The color changes for the active planes, and the Range number and
Level numbers change to Range 2, Levels 2-7.
Click until Range 4, Levels 12-14 is highlighted, and the

Range Depth value is 3.25.
This is where we want to stop machining at, but there is one more
Range left.

Click one more time and Range 5, Levels 15-16 are

highlighted, and the Range Depth value will read 3.75. Now
click Delete Current Range and delete Range 5.

2
OK the Cut Levels dialog box.
Click Generate .
The path now stops at the desired level.
OK to the Cavity Mill dialog box.
Close the part.

Cut patterns
In the Path Settings Group, Cut Pattern determines the pattern the cutter
will use when machining the part.
2 The Cut Patterns are as follows:
Zig-Zag machines in a series of parallel straight line passes. Climb

or conventional cut directions are not maintained since the cut direction
changes from one pass to the next.
Zig always cuts in one direction. The tool retracts at the end of each cut,
then positions to the start of the next cut.

Zig with Contour also machines with cuts going in one direction.
However, contouring of the boundary is added between passes, before and
after the cut motion. The tool then retracts and re-engages at the start of
the contouring move for the next cut. 2
Follow Periphery offsets the tool from the outermost edge that is defined
by Part or Blank geometry. Internal islands and cavities will require Island
Cleanup or a clean up Profile pass.
Follow Part

creates concentric offsets from all specified Part geometry. The outermost
edge and all interior islands and cavities are used to compute the tool path.
Climb (or Conventional) cutting is maintained.
2
Trochoidial cut pattern uses small loops along a path (resembles a

stretched-out spring). This is a useful cut pattern in high speed machining
applications when constant volume removal needs to be maintained.

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

Activity: Zig-Zag cut pattern
In this activity, you will use the Zig-Zag cut pattern to cut the part.
Step 1: Open the part and start the Manufacturing application.
2
Open base_mfg_2_setup_1.
If necessary, choose Start Manufacturing.
Step 2: Edit an existing operation to change the Cut Pattern.

In the Operation Navigator, double-click the CAVITY_MILL
operation.
In the Cavity Mill dialog box, in the Path Settings group, select
Zig-Zag for the Cut Pattern.

Click Generate .
The tool path is generated. 2

Step 4: Change the Cutting options.
In the Path Setting group in the Cavity Mill dialog box, click
Cutting Parameters .
The Cut Parameters dialog box is displayed. Options available are

based on the selected Cut Pattern.
Click the Strategy tab.
In the Degrees box, type 45.
Click Display Cut Direction .
An arrow indicates the applied Cut Angle.

You may need to refresh the screen in order to see the Cut
Direction Arrow.
OK the Cutting Parameters dialog box.
Click Generate to generate the operation.
Click on the Assembly Navigator tab.
Expand the base_mfg_2 part.
Right click on the base_stock and select Hide.
Click Verify .
Use 3D Dynamic verification to analyze the results.
The Zig-Zag cut pattern does not have a stepover on every pass,
resulting in a less than desirable tool path.
Cancel the Tool Path Visualization dialog box.
Change the Cut Pattern to Zig with Contour.


Choose Generate to generate the operation.
Verify the tool path, using 3D Dynamic.

2
This time the tool path is more efficient in the method of cleaning
up the corners.
Close the part..

In-Process Work Piece for Cavity Milling

To make the various Cavity Milling operations as efficient as possible,
you must determine what has been machined in each previous operation.
Variables such as cutting tool lengths and diameters, draft angles and
undercuts, fixture and tool clearances, will affect the amount of material
2
that each operation may leave.
The material that remains after each operation is executed is referred to
as the In Process work piece or IPW.
The remaining material (IPW) can be used for input into a subsequent
operation which may be used for additional roughing. To use the previous
IPW, tool path generation must be done sequentially, from the first operation
to the last, within a certain geometry group.
Two methods for creating the In Process work piece are available:
1. 3D IPW
2. Level Based IPW

Level Based IPW
Level Based IPW uses the 2D cut regions from the previous Cavity Milling
and/or Z-Level operation to identify and machine the remaining (Rest)
2 material.
Must be Cavity Mill or Z-Level operations.
Must be under the same Geometry Group.
Must have the same Tool Axis.

Use 3D
Use 3D uses a 3D internal definition to represent the remaining material.

All milling operations can produce a 3D IPW. Using 3D is the correct IPW
option if you are also using other types of operations to remove material from
the blank. For example, if your cavity milling operation follows a surface
2
contouring operation, then you must use the 3D IPW.

Activity: Level Based In-process Workpiece (IPW)
In this activity, you will machine the part using three different cutter sizes.
You will start with a cavity mill operation and activate the use of the Level
2 Based IPW by using the REST_MILLING operation type and generate the
multiple operations.
You will make three operations, all using the same WORKPIECE and
MILL_AREA. Planning ahead when programming will lead you to make and
use Geometry groups
Step 1: Open level_based_mfg_setup_2 and start the Manufacturing
application.
Rename the part ***_level_based_mfg_setup_2 using
FileSave As on the menu bar.
Step 2: Display the Operation Navigator.

Click the Operation Navigator tab in the Resource bar.

Step 3: Display the Geometry View in the Operation Navigator and

expand the objects.
On the Operation Navigator toolbar, click Geometry View ,

then expand the MCS_MILL and WORKPIECE parent groups. 2
In this case, Cavity Mill will use only the MILL_AREA to contain
the tool to inside of the pockets, rather than the entire part.
Step 4: Create the first operation.
Click Create Operation .
Select mill_contour from the Type list.
Click CAVITY_MILL .

Set the following location specifications:

Program PROGRAM
Tool EM-1.00
Geometry INSIDE_MILL_AREA
2 Method MILL_ROUGH
For Name type RM_ROUGH_1 and click OK.
No additional parameters are going to be changed in this operation.
Click Generate to generate the tool path.
Click OK to accept the path.
Step 5: Create the second operation.

On the Manufacturing Create toolbar, click Create Operation
Make sure Type is set to mill_contour and click CAVITY_MILL
Set the following location options:

Program PROGRAM
Tool EM-.75
Method MILL_ROUGH
Name the operation RM_ROUGH_2 and click OK.
Click Cutting Parameters .
Click the Containment tab.
From the In Process Workpiece list select Use Level Based.
Click OK.
Click Generate .
A Tool Path generate message is displayed.

Click OK.

The Information Window appears because the tool cannot fit into
some of the areas of the part, namely the square corners.
Dismiss the Information Window, and click OK to accept the

path
2
Step 6: Create the third operation.
Click CAVITY_MILL .
Set the following location options:

Program PROGRAM
Tool EM-.5
Method MILL_ROUGH
Name the operation RM_ROUGH_3 and click OK
Click the Containment tab.
From the In Process Workpiece list select Use Level Based.
Click OK.
Click Generate .
Click OK to accept the path.
Step 7: Verify the Tool Path.

Display the Program View in the Operation Navigator and expand
the objects.
From the operation navigator right-click PROGRAM and select

Tool PathVerify.
Select the 3D Dynamic tab.
Click Play.

Close the part.

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

Non Cutting Moves Start/Drill
2
Cavity Mill
Points
Corner Rough
Points
Rest Milling
Points
Z-Level Processors
Points
Profile 3D
Points
Face Milling Processors
Points
Planar Mill Processors
Points
Plunge Mill Points in Path Settings
Pre-Drill Engage Points

Operations normally determine where they start.
You can use the Pre-Drill Engage Points option to specify where you want
the tool to start cutting. With this option, the tool moves to the pre-drilled
engage point you specify, then to the specified cut level. It then moves to the
processor generated start point and generates the remainder of the tool path.
Region Start Points

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

Activity: Pre-Drill Engage Point

In this activity, you will edit the current operation to use a Pre-drilled Engage
Point to start your tool path and to use a Region Start Point. The Pre-drill
Engage Point is a hole that has been previously drilled and is represented
2 by a modeled hole in the BLANK. The Cut Region Start point will be an
Inferred Point on the model.
Step 1: Open the form_mold_mfg_setup_3 part and start the
Manufacturing application.
Choose FileOpen.
Select form_mold_mfg_setup_3, then click OK.
Choose Start Manufacturing.
Step 2: Activate the Operation Navigator.

In the Resource bar, click the Operation Navigator tab.

active.
Step 3: Edit an existing operation.

Double-click the CAVITY_MILL operation.
The Cavity Mill dialog box is displayed. You will now define a point
that represents a hole which has been previously drilled.
Step 4: Define a Pre-drill Engage Point for this operation.
In the Path Settings group, click Non Cutting Moves .
Click the Start/Drill Points tab and expand the Pre-Drill Points
group.
Verify the Selection Scope is set to Within Work Part and

Components.
Click the Point Constructor and select the arc center of the
drilled hole in the Blank that we are going to engage into.
Click OK in the Point dialog box.
Expand the List and verify that a value of 5.2500, 2.5000, and
3.1250 is present.
Expand the Region Start Points group.

Click Point Constructor and select the Mid Point of the

edge shown here.
OK the Point dialog box.
Expand the List and verify that a value of 4.4575, 2.5000, and
.2000 is present.
Click the Engage tab.
In the Closed Area group, select Plunge for the Engage Type.
Click OK in the Non-Cutting Moves dialog box.

Step 5: Generate the tool path.
Click Generate to create the tool path.
2 Notice that all levels start at the Pre-Drill Engage Point in the
center of the part, then move to the start point which is determined
by the processor.
Click Verify .
In the Tool Path Visualization dialog box, set Display (under

Motion Display) to Current Level.
Click Play .
You may want to slow the animation speed down.
OK the Tool Path Visualization dialog box.
OK to accept the operation.
Close all pars without savingt.

Cavity Milling stock options
Stock options for Cavity Milling are found on the Cut Parameters dialog box.
This dialog box is activated by selecting the Cutting button found on the
Cavity Mill operation dialogs. 2
Some of the stock options are as follows:
Part Side Stock adds stock to the individual walls of the part.
Part Floor Stock adds stock to the floor.
Blank Stock is stock applied to Blank geometry.
Check Stock is the distance that the tool will stay away from the check
geometry.
Trim Stock is the distance that the tool will stay away from the trim boundary.
Blank Distance applies to Part geometry. This is an offset distance which
can be used for a casting or forging. Blank Distance can be found under the
Strategy tab.

Activity: Blank Distance option
In this activity, you will learn how to set the Blank Distance for a core type
part. The MCS, Part geometry and Program Name have already been created
2 for you.
Step 1: Open a new part, rename and start the Manufacturing application.
Open the horn_mfg_setup_1 part.

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

The Create Operation dialog box is displayed.
Click CAVITY_MILL .

Set the following:

Program ROUGH_WITHOUT_CASTING
Tool EM-.375-.06
Geometry WORKPIECE
Method MILL_FINISH
2
Name the operation CM_.20_BLANKDISTANCE.
Click OK.
The Cavity Mill dialog box is displayed.
Step 3: Verify the Part Geometry selection.
For Specify Part click Display .
Note that the Part geometry is displayed.

Note that no Blank geometry has been selected and cannot be
displayed.
Step 4: Specify Operation settings.

In the Path Settings group, select Follow Part from the Cut
Pattern list.
In the Global Depth per Cut type .125.
The Cut Parameters dialog box is displayed.

Click the Strategy tab if required.
In the Cutting group, select Depth First from the Cut Order list.
In the Blank group type .20 in the Blank Distance box.
Click OK.
Click Generate .
Click OK.

The tool path cuts all of the core geometry.

Notice that the tool path follows the part contour since you used
the Blank Distance option.
2 In this case, you specified that the Blank was near-net-shape with
.200" stock overall.
Click OK to accept the tool path.
Close the part.

Summary
The Cavity Milling module provides efficient and robust capabilities
of removing large amounts of stock, primarily in cavity and core type
applications.
2
The following functions are available in Cavity Milling:
Use of the In-Process work piece for accurate removal of material using
different size cutting tools
Cut levels to precisely control depths of cut
Cut patterns to control direction and method of removing stock

2
Lesson
3 Plunge Milling
Purpose 3
In this lesson you will use Plunge Milling for roughing with multiple
operations. You will also utilize the 3D IPW to limit cut areas between
operations.
Objective
Create Plunge Milling operations.
Specify Pre-Drill Engage Points to safely enter the material.
Utilize 3D IPW geometry used to limit the cut area.

Plunge Milling
Plunge milling
Plunge Milling will provide for material removal using vertical motion, the
strongest cut direction of the machine tool and cutter.
Plunge milling cuts to the deepest part of the cut region and then steps
upward toward the shallower cut levels.
Pre-drilled Points are needed when non center cutting tools are used. You can
specify where the pre-drilled hole is located in the operation, then you create
the required operation to drill that hole.
3
There are three methods available for specifying pre-drilled engage points:
1. Point/Arc by using existing points or arcs. The arcs are associative to the
geometry. They must be explicit or sketch curves.
2. Cursor by using the cursor position.
3. Generic Point by using the option on the generic point dialog box.
Plunge Mill
Description
Parameter
Zig-Zag, Zig, Zig with Contour. Follow Periphery, and Follow
Part are for roughing, Profile is for finishing. Follow Part
Cut Method
has specific enhancements for plunge roughing. Profile has
specific enhancements for plunge finishing.

Plunge Milling
Parameter Description
Max Cut Max Cut Width is the maximum width, looking down the tool
Width axis, that the tool can cut. This is usually supplied by the
tool manufacturer, based on the size of the inserts. If this is
smaller than the tool radius, then the bottom of the tool has a
non-cutting portion in the center. This parameter determines
the tool type for Plunge Milling operations. Max Cut Width may
limit the step over and step ahead to prevent the non-cutting
portion of the tool from plunging into solid material.
Set Max Cut Width to 50% or more for center cutting tools to 3
maximize the amount of cutting.
NX now assumes that this is a center cutting tool and
doesnt check to see if there is a non-cutting portion of
the tool that violates the in-process workpiece.
Set Max Cut Width to less than 50% for non-center cutting tools.
NX now assumes this is a non-center cutting tool, and
uses Max Cut Width to determine if a non-cutting portion
of the tool violates the in-process workpiece.
If it isnt possible to cut a closed cavity without violating

the Max Cut Width, the operation will output pre-drill
points and a warning for you to add the required drilling
operation
In the figure below, A = tool insert, B= workpiece, C = Max

Cut Width.

Plunge Milling
Stepover specifies the distance between adjacent cut

Stepover
passes.
Step ahead specifies the forward step from one plunge
to the next. When necessary, the system reduces the
Step Ahead
applied
Step ahead to stay within the Max Cut Width value.
For non-center cutting cases, either the step-over
distance or the step-ahead distance must be less than
the specified Max Cut Width value. The software reduces
the applied Step ahead to stay within the Max Cut
3 Width value.
Step Ahead and

Stepover
Figure. Step Ahead (A) and Stepover (B)

Plunge Levels Use Plunge Levels to define the plunge depth.

Plunge Milling
Activity: Create a Plunge Milling operation

In this activity, you will create a new Plunge Milling operation. The 3D IPW
will be activated. The 3D IPW will be used in the next activity limiting the
tool path to the remaining material. Pre-Drill Engage Points will be added to
allow take advantage of a hole that has been previously drilled in the part.
Step 1: Open the part,and enter the Manufacturing application.
Open the plunge_mill_mfg_setup_1 part.
Choose StartManufacturing if necessary.
Step 2: Create a new operation.

On the Manufacturing Create toolbar, click Create Operation.
The Create Operation dialog box displays.

From the Type list select mill_contour.
In the Operation Subtype group, click PLUNGE_MILLING .
In the Location group, set the following parameters:

Program PROGRAM
Tool EM-1.25
Geometry MILL_AREA
Method MILL_ROUGH
Name the operation PLUNGE_1.25
Click OK.

Plunge Milling
Review the Geometry selection in the Plunge Milling dialog box.
Step 3: You will set a Pre Drilled Point as a safe starting position for the
tool path.
In the Plunge Milling dialog box, in the Path Settings group,
click next to Points.
In the Pre-Drill Engage Points group click Edit

3
Click the Generic Point button and select the arc center of the
hole in the part.
Click OK until you return to the Plunge Milling dialog box.
Step 4: Generate and Verify the operation.
Generate the tool path.
Click Verify on the Plunge Milling dialog box.
In the Tool Path Visualization dialog box, choose the 2D

Dynamic tab.
Click Play .
The operation removes the part material from the deepest pocket
working upward towards the top of the part.
Click OK in the Tool Path Visualization dialog box.

Plunge Milling
Click OK to save the operation.
Step 5: You will copy the previous operation, replace the tool with a
smaller tool and use the 3D IPW from the original operation to
maximize tool motion.
Change the Operation Navigator to the Machine Tool View.
In the background of the navigator, right-click and choose

Expand All.
3
Right-click the PLUNGE_1.25 operation found under the
EM-1.25 in the Operation Navigator and choose Copy.
Right-click EM.75 and choose Paste Inside.
Right-click the new operation and choose Rename change

the operation name to PLUNGE_.75.
Right-click the new operation and choose Edit.
You will now turn on 3D IPW option to avoid unnecessary tool

motion in the next tool path.
In the Plunge Milling dialog box, click Cutting Parameters .
Select the Containment tab and set In-process Workpiece to

Use 3D.
Click OK.
Click Generate .
Notice that the tool only cut the areas that were not accessible to
the previous tool.
You will use the Verify option to replay the operation.
Click Verify .

Dynamic property tab.
Click Play .
The operation removes the part material from the deepest pocket
working upward towards the top of the part.

Plunge Milling
3
Click OK in the Tool Path Visualization dialog box.
Click OK to save the operation.
Step 6: Close the part.

Plunge Milling
Plunge Milling Step Up

In this activity, you will change Plunge Milling Step Up. The Step up feature
allows for improved material control on steep or shallow walls.
The Step Up option lets you control the distance between two or more cut
levels.

Plunge Milling
Activity: Plunge Milling Step Up

1. Open base_2_setup_3 and start Manufacturing
2. Create a PLUNGE_MILLING operation.
Click Create Operation .
From the Type list, select mill_contour.
From the Operation Subtype list, select PLUNGE_MILLING .
Set the Location as follows;

Program 1234
Tool EM-1_.125
Geometry WORKPIECE
Method MILL_FINISH
Click OK.
3. Generate and Verify the tool path.

Click Generate.
The tool path utilizes the Step Up distance. The Step Up distance is 25%
of the tool diameter.
4. Change the Step Up distance.

In the Step Up box type 50.
5. Generate and Verify the tool path.

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

Plunge Milling
The Step Up is the minimum distance allowed. This is to eliminate plunge

cuts that remove small amounts of material.
Click OK.
6. Close the part.

Plunge Milling
Summary
The Plunge Milling module provides efficient and robust capabilities of
removing large amounts of stock using a plunge mill approach.
You examined the following in Plunge Milling:
Used the In-Process work piece for accurate removal of material using
different size cutting tools
Added Pre-Drilled Engage points to safely enter the material.

3
Used the Step Ahead and Max Cut Width parameters

Lesson
4 Z-Level Milling
Purpose
This lesson is an introduction to the Z-Level operation type, which is useful

when profiling steep areas. You can also isolate specific areas that you want
to cut or avoid cutting within a Z-Level operation.
Objective
4
Understand the uses of Z-Level milling.
Create milling operations using the Z-Level operation type.
Understand the meaning and use of steep and non-steep areas of geometry.

Z-Level Milling
Z-Level Milling
Z-Level Milling is designed to profile bodies or faces at multiple depths. It
will cut steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face) or the entire part.
The following Z-Level operation types are available:
CORNER ROUGH Cavity milling with a reference tool that can be

used with or without the In Process Work piece; uses existing reference
tool
ZLEVEL_PROFILE Uses the Profile Cut Method without the Steep

Angle being set
4
ZLEVEL_CORNER Z-Level milling that uses an existing reference
tool; and compliments flowcut machining
Part geometry and Cut Area geometry can be specified to limit the area to
be cut. If cut area geometry is not defined, then the entire part is used as
the cut area.
1. Create new Geometry
2. Select or Edit the Part Geometry
3. Select or Edit the Check Geometry
4. Select or Edit the Cut Area Geometry
5. Select or Edit the Trim Boundaries Geometry
Many of the option settings found in Z-Level Milling are the same as in other
operation types. A description of some of these options are as follows:

Z-Level Milling
Geometry
Part geometry consists of bodies and faces which represents the Part after
cutting.
Check geometry consists of bodies and faces which represent clamps or

obstructions that are not to be machined.
Cut Area geometry represents the areas on the Part to be machined; it

can be some or all of the part.
Trim geometry consists of closed boundaries which indicate where material

will be left or removed; all Trim boundaries have tool positions on only.
During tool path generation, the geometry is traced, steep areas and trace
shapes are determined, cut areas are identified and a tool path is generated 4
for all cut depths specified.

Z-Level Milling
Activity: Z-Level Milling

In this activity, you will generate tool paths using Z-Level Milling. Z-Level
is designed to profile an entire part or steep areas that were previously left
by the roughing operations.
Open the part base_mfg_3_setup_1.
Start the Manufacturing application if necessary.

In the Resource bar, click the Operation Navigator tab, and
then change to the Program Order View.
Expand the BASE_MALE_DIE group.
Step 3: Create a Z-Level operation.
Click Create Operation on the Manufacturing Create tool

bar.
From the Type list select mill_contour.
In the Operation Subtype group, click ZLEVEL_PROFILE .
In the Location group set the following parameters:

Program BASE_MALE_DIE
Tool EM_1.25_.25
Geometry WORKPIECE
Method MILL_FINISH
Click OK.

Z-Level Milling
The Zlevel Profile dialog box is displayed.
Step 4: Change the Depth of Cut.

For ease of viewing turn model shading off.
In the Path Settings group, type 0.100 in the Global Depth

per Cut box.
You will now change the cut levels. You will stop cutting material
at the top of the bottom face. The default is the bottom face of
the part.
Click Cut Levels .
The Cut Levels dialog box is displayed, and plane symbols appear
4
on our part which represent Ranges and Levels.
Select the Downward icon and observe the Range change and
the highlighted area move down on the model.
Index to the 4th range and click Delete Current Range .
Choose OK.

Z-Level Milling
Step 6: Verify the Program that you have created.
Click Verify to examine the tool path results.

Dynamic property tab.
Click Play .
Click OK twice to complete the operation.
Close the part.

Z-Level Milling
Steep Angle
The steepness of the part at any given area is defined by the angle between
the tool axis and the normal of the face. The steep area is the area where the
steepness of the part is greater than the specified Steep Angle. When the
Steep Anglecheck box is selected, areas of the part with a steepness greater
than or equal to the specified Steep Angle are cut. When Steep Angle check
box is cleared, the part, as defined by the part geometry and any limiting cut
area geometry, is cut.

Z-Level Milling
Activity: ZLEVEL_PROFILE_STEEP Operations

In this activity, you will create a ZLEVEL_PROFILE_STEEP operation to
machine all of the steep geometry located within the cavity. You will use the
Geometry Parent Group, WORKPIECE that contains all of the Part geometry.
The tool path will cut only within the Steep areas specified.
Open the part cap_2_setup_1.
Start the Manufacturing application.

In the Resource bar, click the Operation Navigator tab, and
then change to Geometry View.
The MCS_MILL Parent Group is displayed in the Operation

Navigator.
Expand the MCS_MILL and WORKPIECE Geometry Parent
Groups.
The CAVITY_MILL operation is listed in the Operation Navigator

along with a MILL_AREA that will be used in our activity.
Change the view of the Operation Navigator to the Program

Order View.
Step 3: Create the ZLEVEL_PROFILE operation.

The Create Operation dialog box is displayed.

Z-Level Milling
In the Operation Subtype group, select ZLEVEL_PROFILE
Set the following:

Program INTERIOR
Tool EM_1.00_.25
Geometry MILL_AREA
Method MILL_FINISH
Click OK.
Click Display next to Specify Part.

4
The entire part highlights, then refresh the graphics area.
Click Display next to Specify Cut Area.
Only the inside faces highlight.
Step 4: Set the Steep Parameter and Depth of Cut.

In the Path Settings group, from the Steep Containment list,
select Steep Only.
The Angle option defaults to 65 Degrees.
Set Global Depth per Cut to .05.
Click Generate and generate the tool path.
Choose OK to save the operation.
Step 6: Verify the tool path

With Program Order View on in the Operation Navigator,
right-click INTERIOR program and choose Tool PathVerify.
The Tool Path Visualization dialog box is displayed.

Click the 3D Dynamic tab.
Select Suppress Animation near the bottom of the dialog box.

Z-Level Milling
Click Forward to Next Operation .
The system prepares a display of what our stock looks like after
the two operations, but we do not need to watch the step by step
material removal.
Notice the areas cut by the tool paths. Many of the areas
near the blends were not machined. A contour area operation
may be a better choice for finishing less steep areas.
Step 7: Set the Steep Parameter and Depth of Cut.

4 The Angle option appears and is defaulted to 65 Degree.
Right-click ZLEVEL_PROFILE and choose Edit.
Set Steep Angle to 45.
Step 9: Verify the tool path comparing the results with the initial path.
With Program Order View on in the Operation Navigator,

right-click INTERIOR program and choose Tool PathVerify.
The Tool Path Visualization dialog box is displayed.
Click the 3D Dynamic tab.
Select Suppress Animation near the bottom of the dialog box.
The tool path is adjusted to the new Steep Angle.
Close the part.

Z-Level Milling
Activity: Z-Level Profile Milling

In this activity, you will create a Z-Level Profile operation to machine the
geometry of the island within the cavity. You will create a Mill Area Geometry
Group that contains the geometry necessary for machining the island. The
tool path will cut only within the area that has been specified.
Step 1: Create the Geometry Parent Group.
Open the steep_form_mfg_setup_1 part and start
Manufacturing.
Select Create Geometry from the Manufacturing Create

tool bar.
The Create Geometry dialog box is displayed. 4

In the Geometry Subtype group, click Mill_Area .
If necessary, set the Geometry Location to WORKPIECE.
Enter ZLEVEL_AREA as the Name.
Click OK.
The Mill Area dialog box is displayed.
Click Specify Cut Area .
The Cut Area dialog box is displayed.

Z-Level Milling
Select the interior island geometry as shown. Having the

model in a top view will aid in the selection process.
Make sure that the system you are using has the Preference
Selection Multi-Selection set to Rectangle for the Mouse
Gesture, and Inside for the Selection rule.
Click OK.
To briefly review you have created a Geometry Parent Group,

named ZLEVEL_AREA which contains the geometry of the island.
This Geometry Group will be used in the ZLEVEL_PROFILE
operation.
Click OK.
You will now create the operation.
Step 2: Create the ZLEVEL_PROFILE Operation.

On the Manufacturing Workpiece toolbar, select Create
Operation .
In the Operation Subtype group, click ZLEVEL_PROFILE .
Set the following:

Program INTERIOR-PROGRAM
Tool EM-.500-.06
Geometry ZLEVEL_AREA

Z-Level Milling
Method MILL_FINISH
Click OK.
The ZLEVEL_PROFILE dialog box is displayed.

The Part geometry is displayed. It was specified in the
WORKPIECE Parent Group.
In the Geometry group, select Cut Area and choose Display
The Cut Area geometry is displayed. It was specified in the

ZLEVEL_AREA Parent under the WORKPIECE Parent Group.
Change the Global Depth per Cut to .15.

4
Close the part.

Z-Level Milling
Z-Level Cutting Between Levels (aka Gap Machining)

Z-Level cutting between levels, commonly referred to as Gap Machining,
creates extra cut levels (2) when gaps occur due to the occurrence of non-steep
(1) areas. This avoids the creation of separate Area Milling operations or,
in some cases, the use of extremely small depths of cut to control excessive
scallop heights in non-steep areas.
Resultant tool paths from Gap Machining produce uniform scallops,

regardless of the angle of steepness, incorporating fewer engages and retracts,
producing a more consistent surface finish.
Stepover option
Stepover pertains to machining the gap areas.
When used with the default Use Depth of Cut parameter, the stepover
matches the depth of cut of the current cut range.
Max Cut Traverse option

Max Cut Traverse defines the longest distance that the cutting tool feeds
along the part when not cutting.
Sequencing of Gap and Z-Level tool paths

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

Z-Level Milling
Z-Level tool path is machined from the top-down and uses the same
connection methods as it would without the Cut Between Levels option
When a gap is discovered, the gap is cut, cutting continues until another
gap is found or the cut is complete at that level.
Z-Level Gap machining is activated from the Cut Parameters dialog box by
clicking the Connections tab and selecting Cut Between Levels. Modify the
parameters on that dialog box as needed.
Additional information on Z-Level Gap Machining can be found in the
online documentation from the NX Help menu.

Z-Level Milling
Activity: Z-Level Gap Machining

In this activity, you will activate Gap Machining option in an existing Z-Level
operation.
Open the part male_cover_mfg_setup_1.
Rename the part ***_male_cover_mfg_setup_1 using

If necessary, display the Operation Navigator in the Program

Order view.
Step 2: Replay an existing Z-Level operation.

Double-click the ZLEVEL_PROFILE operation for editing
purposes.
Click Replay .
Clear the Pause After Display and Refresh Before Display

check boxes and click OK.

Z-Level Milling
The tool path is displayed. Note the non-steep areas and the
numerous engage retracts that occur.
The operation does a fairly good job of machining the steep

geometry but does not machine the non-steep area very well. You
will now turn on the Cut Between Levels (Gap Machining) option
to completely finish machine the part in one complete operation.
The Cut Parameters dialog box is displayed.
Click the Connections tab.
Select the Cut Between Levels check box..
Select Constant from the Stepover list.
In the Distance box, type 0.15.
ClickOK.

Z-Level Milling
Click Generate.
Clear the Pause After Display and Display Cut Regions check
boxes and click OK.
The non-steep areas are now machined as well as the steep areas
of the part.
Close the part.

Z-Level Milling
Summary
This lesson was an introduction to Z-Level milling, which is used when
profiling steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face). This operation
type is useful in minimizing the amount of scallop or cusps that remains
on the part.
In this lesson you:
Created an operation using Z-Level Profile operation types.
Reviewed and generated operations using Z-Level operations

incorporating Steep options.
Reviewed and generated operations using Z-Level operations

incorporating Cut Between Levels (Gap machining). 4

4
Lesson
5 NC Assistant
Purpose
This lesson will familiarize you with the functionality of the NC Assistant.
The NC Assistant is a very useful tool used to analyze corner and fillet radii,
draft angles and cutting depths. Analyzing these features will aid you in the
determination of the tool configuration needed to cut the part.
Objective
Use the NC Assistant 5
Determine cutter geometry based on information feedback from the NC
Assistant

NC Assistant
Overview of the NC Assistant

The NC Assistant is only available inside of the Manufacturing applications,
and assists you in analyzing the geometry and determining the proper tooling.
The Assistant is found in the main menu bar by choosing AnalysisNC
Assistant and provides you the following four options:
1. Depths of floors and faces
2. Corner radii
3. Fillet radii
4. Draft angles
The information provided is color coded on the shaded model along with a
listing giving data on the geometry being analyzed.
You select the geometry to be analyzed by selecting individual faces or by

rectangular selection and then set the various parameters. .
When analyzing Levels, information is provided on the distance of planar
levels from a reference plane. This information can be used as an aid in
determining the length of the tool(s) that is needed.

NC Assistant
Analysis of Corner Radius provides information on the minimum corner radii

of the faces selected. This information will aid you in determining proper
tool diameter(s).
Analysis of Fillet Radius displays the minimum fillet radius of the selected
faces with reference to a vector. This information will help you to determine
the tool nose radius, required, if any.
Analysis of Draft Angle will determine the slopes of the faces selected with
reference to a specified vector. This information will help you to determine
the taper of the tool (also can be a quick aid in determining various areas of
draft on a casting or injection mold).
When analyzing the various types, limits can be set. For example, if you
wanted to check for all corner radii that were greater than .500 inches
and less than .750 inches, values can be set for the minimum of .500 and
maximum of .750.

NC Assistant
Activity: The NC Assistant

In this activity, you will become familiar with the various features of the NC
Assistant. You will use the NC Assistant to determine the length, cutting
diameter and corner radius of the tool(s) necessary to finish all pockets of the
part. Since you will only be analyzing this part, there is no need to rename or
save it.
Step 1: Open the part file and enter the Manufacturing Application.
Open the part analyzing_part_mfg_setup_1.
Rename the part ***_ analyzing_part_mfg_setup_1 using

Step 2: Activate the NC Assistant.

You will need to determine the tool configuration(s) necessary to
finish machine this part. Visually, it is sometimes difficult to detect
draft, if any, on parts. You will use the NC Assistant, to analyze
the geometry configuration.
Choose Analysis NC Assistant.
The NC Assistant dialog box is displayed.
Step 3: Use the NC Assistant to determine cutter length.

If you look at the cue line, you will see that you are being asked to
set parameters or select faces. You will accept the defaults for all
parameters and select the entire part for face selection.
First you will analyze the Levels (height or depth) of various
features to determine tool length requirements.

NC Assistant
The cue line ask you to set parameters or select faces. You will set
the Reference Plane to the top of the stock.
Click the Reference Plane button and select the top face of
the stock block.
Click OK to return to the NC Assistant dialog box.
Drag a rectangle around the entire part.
Click Apply.
An Information Window listing the colors, the number of faces, and

their depth is shown. These colors are displayed on your model in
the graphics window. The deepest face is 3.25, thereby requiring a
tool length of 3.25 for the roughing operation.
Step 4: Use the NC Assistant to determine cutter diameter.

The second item for consideration is to determine the diameter of
cutters that will be required. For this determination you will use
the NC Assistant to determine the various corner radii of the part. 5
Choose Corner Radii from the Analysis Type pull-down menu.
The dialog box for Corner Radii analysis is displayed.

Notice the limits for Minimum and Maximum Radius. These can
be used to isolate different sized geometry.
Click and drag a rectangle around the entire part.
Click Apply.
Corner Radii analysis results are displayed, only one .188 radius is
found. The rest of the blends are tapered.
Step 5: Use the NC Assistant to determine cutter corner radius.

Now we will determine the fillets on the model which will control
the corner radius of our tools.
Choose Fillet Radii from the Analysis Type pull-down menu.
The dialog box for Fillet Radii analysis is displayed.

The cue line asked you to set parameters or select faces.
Accept the defaults and click and drag a rectangle around the
entire part.
Click Apply.

NC Assistant
Fillet Radii analysis results are displayed with colors, number of

faces and their sizes in the information window.
Step 6: Use the NC Assistant to determine draft angle on walls.

The fourth item for consideration is to determine any draft angles
on the part that are machinable through the use of a tapered cutter.
Choose Draft Angles from the Analysis Type pull-down menu
in the NC Assistant.
The dialog box for Draft Angles analysis is displayed and the cue
line asked you to set parameters or select faces.
Under Tolerances, change Angle to 1.0.
Click and drag a rectangle around the entire part.
Draft Angle analysis results are displayed with colors, number of

faces and their angle values in the information window.
5 Click Apply.
Cancel the NC Assistant dialog box and dismiss the

Information window
Save and Close the part.

NC Assistant
Summary
The NC Assistant is an efficient tool to use for analyzing part geometry
for various corner radii, fillet radii, floor depths and draft angles. This
information is beneficial in the determination of cutter parameters used for
cutting your part.
In this lesson you:
Became familiar with the functionality of NC Assistant.
Performed various analysis functions which were used to determine cutter

length, diameter, corner radius and draft angle

5
Lesson
6 High Speed Machining
Purpose
This lesson will introduce you to some of the parameters and settings that
will assist in the creation of High Speed Machining (HSM) operations. These
operations will allow for constant material removal and smooth cutter motion.
Objective
Generate High Speed Machining operations.

High Speed Machining

HSM technology has shown increases in productivity and improved part
quality. Characteristics of HSM are high spindle speeds, fast feed rates, light
cuts, smooth tool movement and constant volume removal. Due to the rapid
changes in dynamics of chip removal at these very high speeds, cut methods
and characteristics of the tool path are critical factors in the success of the
cutting process. Factors such as sudden stops, sharp corners, reversal of
cut direction and erratic tool movements will directly affect the speed at
which cuts are made.
There are two basic goals for HSM. They are:
Maintain constant material volume removal
Generate smooth tool moves throughout the entire cutting path
Applications abound in the aerospace and mold and die industry for HSM
technology. Cutting thin wall parts in the aerospace industry is a typical
application. In the mold and die industry, contoured surface cutting can
be accomplished at high spindle speed and feed rates. Incorporating very
small step overs results in very fine finishes that generally require no hand
finishing work. Since tool deflection is at a minimum, greater accuracies
can be achieved.

Machining options that require change for High Speed Machining
Stepover allows you to control the distance between cut passes, smaller
stopover for lighter cutter loads.
Helical Engage with shallow ramps controlled by cutter manufacturer

specifications.
Cut Levels can be adjusted for shallower cut depths.
Feedrates and Spindle Speeds need to be adjusted for high speed

machining.
Mixed Cut Directions in Z-Level Profile can be used to help maintain

contact with the part material.
Level to Level Direct on Part can help maintain contact with the part in
Z-Level Profile when changing cut levels.
Intol/Outol between 0.001 and 0.0005 will increase the size of the program
but will greatly decrease the amount of hand work to finish the part that
must be done.
Cut Order can be set to cut the level first in all multiple features before
progressing to the next level. This should be done in both roughing and
finishing to maintain rigidity in the thin walls 6
Trochoidal cut patterns reduce slotting on the initial pass of pocketing
paths.

Activity: Create a High Speed Machining operation

In this activity, you will edit a conventional pocketing operation, changing
parameters that will make the operation ideal for High Speed Machining.
Step 1: Open, then rename the part file and review an existing operation.
Open the part center_rib_mfg_setup_1.
Save as ***_ center_rib_mfg_setup_1 where *** represents

your initials.
6
This part file contains three operations that rough the part with
default template settings. Normally one operation would work, but
for training purpose there are three operations. You will edit these
operations and change numerous parameters that will make these
operations more applicable to High Speed Machining.
If necessary, change the view of the Operation Navigator to
the Program Order view.
Expand Program.
Right-click the cm_rough_2 operation and choose

ToolpathVerify.
In the Tool Path Visualization dialog box, in the Motion Display

group, set Display to Current Level.
The tool path is displayed. Review the method of engagement, the

sharp corners generated within the tool path, the depth of cut, etc.

You will now edit the operation and modify parameters that are
applicable for High Speed Machining.
Cancel the Tool Path Visualization dialog box.
Step 2: Edit the existing operation and modify parameters suitable for
High Speed Machining.
Double-click on the operation cm_rough_2.

Currently, all parameters set are default parameters. You will now
change parameters for High Speed Machining.
From the Stepover list select Constant.
Type 0.10 in the Distance box.
In the Global Depth per Cut box type .10.
Currently all of the engage and retract parameters are still at

the default settings. We are going to set a few to show different
results. Some of these values will vary at your shop due to cutter
configuration, center cutting versus non-center cutting.
Click Non Cutting Moves and set the following parameters 6

in the Closed Area of this dialog box:
Diameter 50.0
Ramp Angle 4.0
Height .02
Minimum Ramp Angle 40.0
Diameter and Ramp Angle make a smaller tighter helical engage,

Height value controls how far above the stock the helix starts.
Minimum Ramp Length controls the material under non-center
cutting tools.
Click OK.
Cutter geometry determines specific ramp angles and

overlap distance requirements.
Select Cutting Parameters .
Click the Stock tab.

The Intol and Outtol values shown are inherited from the
MILL_ROUGH Method that was chosen when the operation was
made. There should be no need for making these any tighter for
roughing.
Select the Corners tab..
This option will add a fillet at all corners (corner roll) which
eliminates sharp moves.
Select All Passes from the Smoothing list.
From the Slowdown Distance list select Current Tool.
Slowdown is used to slow the feed rates as you approach corners

or obstructions in the tool path. Slowdown can be controlled by
length, starting location and the rate of slowdown.
Number Of Steps allows you to set the abruptness of slowdown.
The greater the number, the more even the slowdown.
Set the Number of Steps to 4.
Click OK.
Select Feeds and Speeds .

6
The Feeds and Speeds dialog box is displayed.
Click Set Machining Data .
There are now values in the various windows that came from the
Machining Data Base that is provided with the software. This part
is made from P20 Prehardened steel, and we are using a Bullnose
Inserted endmill and we are using a HSM Rough Milling method.
Expand More under the Feed Rates group.
Various values are listed for the cutting of this part.
Click OK.
Step 3: Create the tool path.
Click Verify .

In the Tool Path Visualization dialog box, in the Motion Display

group, set Display to Current Level.
Check the corners on all the passes for the fillets.
Another change could be the decreasing of the helical engage

diameter. All of these settings should be customized for individual
shop and programmer preferences.
Click OK to accept the operation.
Save but do not close as we will continue to use this file.

Mixed Cut Directions
Cut patterns for high speed machining must allow constant volume removal
and eliminate burying the cutter into material. They must also provide
a smooth transition from level to level, eliminating constant retracting,
traversing and engaging.
Mixed cut directions are useful when large open areas are cut and you want
the cutter to cut back and forth instead of beginning each cut at the same end
of the part. This will minimize the time that is spent traversing between the
various cut levels and from the end of one cut to the beginning of the next.
The next activity will familiarize you with using mixed cut directions
and making direct moves when cutting between levels in a Zlevel cutting
operation.

Activity: Mixed Cut Directions

In this activity, you will use the part file from the previous activity and
explore the use of the Mixed Cut Direction option in Z-Level Profile.
Step 1: Edit the existing operation and modify parameters so that the tool
is in constant contact with the part.
Continue with the part file ***_ center_rib_mfg_setup_1.
Double-click on the operation ZL_PRO_POCKET.
Click Verify , then Play to view the tool path.

You may want to slow down the display speed.
Notice that the tool retracts and engages for each cut level.
Click OK to dismiss the Tool Path Visualization dialog.
You will now change the cut parameters to allow the cutter to
move directly from one cut level to the next without engaging,
traversing and retracting.
If necessary choose the Strategy tab.
From the Cut Direction list select Mixed.
Click the Connections tab, and select Direct on Part from the
Level to Level list.
Click OK to accept the Cut Parameters.

Step 2: Create the tool path.
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
6 cut from one level to the next.
Click OK to complete the operation.
Save the part file, but do not close as it will be used for the
next activity.

Trochoidal Cut pattern
The Trochoidal Cut pattern is used when there is a need to control or prevent
tool embedding, as when the operation needs to rough out a closed area
(pocket) and the first pass will have the cutter machining with the whole
diameter. This is also an issue in tight (<90) corners or between islands.
This Trochoidal pattern (Moving circular loop) opens up a slot in the excess
material and then steps away from that initial slot with normal smooth
pattern step over to finish the material removal. This pattern is controlled
by a stepover and path width values that provide maximum and minimum
settings.
(1) Step Over
(2) Path Width
The following figure illustrates the Trochoidal Cut pattern. Note the looping
pattern. The cutter machines the material in small looping motions.

Activity: Trochoidal cut pattern

In this activity, you will first examine an existing planar milling operation
that uses the Follow Part cut method. You will then change the cut method
to Trochoidal, select a different cutting tool and regenerate the operation to
observe the changes in the corresponding tool paths.
Step 1: Continue using the ***_ center_rib_mfg_setup_1 part from the
previous activity.
Step 2: If necessary, enter the Manufacturing application and display the

Operation Navigator.
If necessary, change to the Program Order view of the
Operation Navigator and expand the group objects.
We are going to use CM_ROUGH_1 for this activity.

This operation will be replayed and then modified by applying the
Trochoidal Cut method.
Step 3: Replay and then modify the CM_ROUGH_1 operation to utilize

the Trochoidal Cut method.
Double-click the CM_ROUGH_1 operation.
Click Replay .

The tool path is displayed.

You will now modify the operation by changing the Cut Method
to Trochoidal.
From the Cut Pattern list select Trochoidal.
Type 30 in the Percent of Flat Diameter box.
In the Trochoidal Width box type 50..
In the Min Trochoidal Width box type 15.
In the Stepover Limit % box type 120.
In the Trochoidal Step Ahead box type 20.
Click OK.
Generate the tool path.
Step 4: Examine in detail, the tool path created using the Trochoidal Cut
method. 6
Click Verify .
From the Display list select Current Level.
Zoom in on the various cut areas and examine the tool path in
detail.
Click OK twice.
Save and Close the part file.

Summary
High Speed Machining technology has shown dramatic increases in
productivity and improved part quality. The characteristics of HSM such as
high spindle speeds, fast feed rates, light cuts, smooth tool movement and
constant volume removal are obtainable through various parameter settings.
In this lesson you:
Explored various parameters within operations that lend themselves to
High Speed Machining concepts.
Generated operations, using parameters that were conducive to HSM.
Used the Trochoidal Cut method to generate tool paths that avoids
embedding the tool in material and limits the amount of step over.

Lesson
7 Fixed Contour operation types
Purpose
This lesson will show you how to create a Fixed Contour operation using
several of the options and concepts that are unique to Fixed Contour
machining. You will also review the steps necessary to create various Parent
Groups that will aid you in the selection of geometry and cutting tools. Fixed
Contour operations are generally used for creation of tool paths used to finish
the contoured areas of a part.
Objective
Use the Fixed Contour Area Milling and Flow Cut Drive methods to
create tool paths
Create Geometry Groups used for Fixed Contouring operations
Choose the most appropriate drive method for a Fixed Contour operation
Apply the more advanced concepts of Fixed Contour operations for

creating tool paths
7

Fixed Contour operation types
Fixed Contour overview

Fixed Contour operations are used to finish areas formed by contoured
geometry. Fixed Contour tool paths are able to follow complex contours by
the control of tool axis, projection vector and drive methods. Tool paths are
created in two steps. The first step generates drive points from the drive
geometry. The second step projects the drive points along a projection vector
to the part geometry.
The drive points are created from some or all of the part geometry, or can be
created from other geometry that is not associated with the part. The points
are then projected to the part geometry.
The tool path is created on the selected part surfaces by projecting points
from the drive surface in the direction of a specified projection vector. If part
surfaces are not defined, the tool path can be created directly on the drive
surface.
Terminology used in Fixed Contour operations

Part Geometry - Geometry selected to cut.
Check Geometry - Geometry selected that is used to stop tool movement.
Drive Geometry - Geometry used to generate drive points.
Drive Points - Generated from the drive geometry and projected onto the
part geometry.
Drive Method - Method of defining drive points required to create a tool

path. Some drive methods allow the creation of a string of drive points
7 along a curve while others allow the creation of an array of drive points
within an area.
Projection Vector - Used to describe how the drive points project to the
part surface and which side of the part surface the tool contacts. The
selected drive method determines which projection vectors are available.
The projection vector does not need to coincide with the tool axis
vector.

Drive methods for Fixed Contouring

The Drive method defines the method of creating drive points.
Each drive method contains a series of dialogs that are displayed upon
selection.
Curve/Point drive method

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

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

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

The Area Milling drive method allows you to specify a cut area for tool path
generation.
Cut Area(s) may be defined by selecting surface regions, sheet bodies, or
faces. They can be selected in any order.
If you do not specify a Cut Area, the processor will use the selected part
7
geometry (excluding areas not accessible by the tool) as the cut area.
Surface drive method

The Surface Area drive method allows you to create an array of drive
points that lie on an orderly grid of faces, and must share a common edge;
they must not contain gaps that exceed the Chaining Tolerance defined
under Preferences (PreferencesSelectionChaining Tolerance). Trimmed
surfaces can be used to define drive surfaces as long as the trimmed surface
has four sides.
Tool Path drive method

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

Radial Cut drive method

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

Flow Cut drive methods allows you to generate drive points along concave
corners and valleys formed by part surfaces. The direction and order of the
flow cuts are determined using rules based on machining best practices.
Text drive method
Text drive methods allows you to generate drive paths based on text created
from drafting notes.
User Function drive method

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

Geometry groups associated with Fixed Contour operations

There are three different Geometry groups available for use in Fixed Contour
operations. They are:
The MILL_GEOM group which allows part, blank and check geometry.
The MILL_BND group which also allows part, blank, check and trim
and floor boundary geometry.
The MILL_AREA group allows part and check but not blank geometry. It
also allows for the specification of Cut Areas ,Wall and Trim geometry.
Fixed Contour operations are generally used to finish contoured types of

geometry.


The Fixed Contour operation types are:
FIXED_CONTOUR Generic Fixed Contour operation type. Allows

selection of various drive methods and cut types. Use when other Fixed
Contour operation types are not applicable.
CONTOUR_AREA Uses Area Milling drive method. Ideal for

cutting specific areas of part geometry for semi finish or finishing cuts.
CONTOUR_AREA_NON_STEEP Controls how steep you can cut up

and down due to cutter issues.
CONTOUR_AREA_DIR_STEEP Allows steep areas to be cut with

respect to the direction of cut.
CONTOUR_SURFACE_AREA Uses Surface Area drive method

where orderly rows and columns of faces (grids) are available.
STREAMLINE The Streamline drive method builds an implied

drive surface from the selected geometry. Streamline enables completely
flexible tool path creation. A well ordered grid of regular faces is not
required.
FLOWCUT_REF_TOOL Operations have 4 main operations: 1)

7 Flowcut Single Pass, one pass down a groove. 2) Flowcut Multiple Pass,
Multiple passes down a groove. 3) Flowcut Multiple Pass Reference Tool,
uses previous tool to control ares to be cut. 4) Flowcut Smooth, uses
smooth loops to exit and engage.
PROFILE_3D Generates a profile pass utilizing three dimensional

curves, edges, faces, existing boundaries or points. Machines at a given
Z-depth offset with respect to the geometry type selected.

More on Flow Cut drive methods

The Flow Cut drive method allows the specification of Climb, Conventional,
or Mixed cut directions for single pass operations.
The Climb and Conventional options allow the climb or conventional method
for all cutting passes in the operation. If a steep side can be determined, the
steep side is used to calculate the Climb or Conventional cut direction. If a
steep side cannot be determined, the cut direction is determined internally.
The Mixed option allows for the internal calculation of the cut direction.

Flow Cut drive method using Cut Area and Trim Boundary Geometry
The Flow Cut drive method allows Cut Area geometry to be defined the same
way as the Area Milling drive method. Concave valleys are analyzed within
the cut area as well as concave valleys formed by the cut area and part
geometry. Valleys formed by the cut area and check geometry are excluded.

Flow Cut Reference Tool Drive Method

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

Activity: Create Fixed Contour operations

The following activity creates simple Fixed Contour rough and finish
operations. You will first review a Cavity Milling operation that was used to
rough the majority of the part. You will then create Contour Area operations
that will semi-finish and finish the part. Finally, you will use Flow Cut
operations, using a Reference Tool, to remove stock that remained from
previous operations.
Step 1: Open the part, rename and start the Manufacturing application.
Open the part male_cover_mfg_3_setup_1.
Save As ***_male_cover_mfg_3_setup_1 .
Start the Manufacturing application and display the Operation

Navigator in the Program Order.
Step 2: Hide the stock for clarity

7 Click the Assembly Navigator tab.
Expand male_cover_mfg_3.
Right-click male_cover_stock and choose Hide.
Step 3: Review the Cavity Milling roughing operation.

This part has been rough cut using a Cavity Mill operation.
Click the Operation Navigator tab.
Right-click the ROUGH_CM operation and choose Tool

PathVerify.
Click the 3D Dynamics tab
Select the Suppress Animation check box.

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

display
Note that a number of .250 steps were left in the material as a
result of the specified Cut Level. Also, .050 Floor and Side Stock
were specified in the operation.
You will create a Fixed Contour operation to semi-finish machine

the part.
Step 4: Create a Fixed Contour operation to semi-finish the part.
On the Manufacturing toolbar, select Create Operation .
In the Operation Subtype group, click CONTOUR_AREA .
In the Location group, set:

Program MALE_COVER
Tool BALLMILL-1.00
Geometry WORKPIECE
Method MILL_SEMI_FINISH
Enter the Name as semi_rough_fc.
Choose OK.
7
The Contour Area dialog box is displayed.
In the Geometry group, next to Specify Part click Display .
In the Drive Method group, click Edit .
The Area Milling Drive Method dialog box is displayed.

In the Drive Settings group set or verify the following options:
Select Zig Zag from the Cut Pattern list.
From the Stepover list select % Tool Flat
Type 25 in the Percent box.
From the Cut Angle list select Automatic.
Click OK.
Click Generate .
OK to accept the operation.
Step 5: Create a Fixed Contour finishing operation using the Contour

Area operation type.
On the Manufacturing Workpiece toolbar, click Create
Operation .
In the Operation Subtype group, click CONTOUR_AREA .
In the Create Operation dialog box, set the following:

Program MALE_COVER
Tool BALLMILL-1.00
7 Geometry WORKPIECE
Method MILL_FINISH
Type finish_fc in the name box.
Click OK.
The Contour Area dialog box is displayed.
The Area Milling Method dialog box is displayed.

From the Cut Pattern select Follow Periphery.
From the Pattern Direction select Outward.
From the Stepover list select Scallop
Type .002 in the Scallop Height box.
From the Stepover Applied list select On Plane.
Choose OK.
Click Generate .
Step 6: Create a Flow Cut finishing operation. 7

The tool could not fit into some areas of the part geometry because
of tool size. You will use a Flow Cut operation and a smaller tool
to remove uncut areas.
On the Manufacturing toolbar, select Create Operation .
The Create Operation dialog box appears.

In the Operation Subtype group, click FLOWCUT_REF_TOOL
In the Location group, set:

Program MALE_COVER
Tool BALLMILL-.500

Geometry WORKPIECE
Method MILL_FINISH
Enter the Name as flow_fc.
Click OK.
The Flowcut Reference Tool dialog box is displayed.

Note that on the dialog box there is no Drive Method label since
Flow Cut is the Drive Method.
Step 7: Change the Reference Tool setting.

You will change the Reference Tool setting. The previous tool used
was a 1.00 diameter tool.
Expand Reference Tool.
Enter 1.00 in the Ref. Tool Diameter value field.
Leave the Overlap distance set to .03. The amount of overlap with
the previous operation may change due to size of cutters and your
company preferences.
Click Generate .
Note that the area being cut is in reference to the 1.000 Reference
Tool diameter.
Choose OK.
Save and Close the part.

Cut Area
In the previous activity, youmachined the entire part with our operations
for semi-finish and finishing. Now you are going to break our part down
into smaller pieces.
If an area of our part requires numerous machining operation on any given
area, then a separate Geometry Group should be made under the Create
Geometry group. You are going to create our Cut Area as a Geometry Group.
You will break our part down to an even smaller machining area by using a
Trim Boundary in the next activity.

Activity: Mill Area geometry groups

This activity will demonstrate how to create and use a MILL_AREA geometry
group in an operation. You will Replay and examine the results of an existing
operation. You will then create a MILL_AREA geometry group consisting of
faces and will modify the inheritance of the operation to use the MILL_AREA
parent.
Step 1: Open the part, rename it, and start the Manufacturing application.
Open the part male_cover_mfg_2_setup_1.
Rename the part ***_male_cover_mfg_2_setup_1 using

7
Change the Operation Navigator to the Geometry View.
Expand the MCS_MILL and WORKPIECE geometry groups.
Step 2: Replay the current operation.

Right-click the FC_FINISH_RIBS operation and choose Replay.

This Fixed Contour operation machines the entire part.

In the next steps, you will create a MILL_AREA geometry group to
limit the machining to just the two ribs protruding from the part.
Refresh the graphics screen.
Step 3: Create the MILL_AREA geometry group.

On the Manufacturing Create toolbar, click Create Geometry
Set the Geometry Subtype to MILL_AREA .
In the Location group, set Geometry to WORKPIECE.

7
In the Name field, type two_ribs.
Click OK.
The MILL_AREA dialog box is displayed.
Step 4: Define the Cut Area geometry.
Click Specify Cut Area .
At this time, it will make it easier to select the rib faces by

clicking the Assembly Navigator tab and unchecking the red
check mark in front of the male_cover_stock, bolt_5 and the
male_cover_mach_plate components. This will prevent the
selection of faces that are not part of the Workpiece.

Rotating the model to a top view would let you do a

rectangular box selection of the faces in the two areas.
Choose the faces of the ribs, as shown.
When finished selecting the faces, choose OK.
When using the rectangular selection method, you may

accidentally select some of the faces in the bottom face. They
will not be machined so they can be left in the Geometry
group, or they can be de-selected by holding down the Shift
key and pick them again.
Choose OK again to accept the dialog box.
Step 5: Change the inheritance of the operation.

7 You will move the FC_FINISH_RIBS operation, so that the
operation will machine only the faces specified.
Drag the FC_FINISH_RIBS operation so that it resides under
the TWO_RIBS Parent Group, then release the mouse button.
Right-click the FC_FINISH_RIBS operation and choose Edit.
The tool path is generated and cuts the faces selected in the
MILL_AREA group.
Click Edit next to Area Milling.
From the Cut Pattern list select Zig Zag.
Click Generate .

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

Trim Boundary
A Trim Boundary is like any other boundary except it can control the tool
path and prevent the generation either inside or outside of the boundary.
A Trim Boundary can be part of the Mill Area Geometry group, or as an
addition to the operation. Does the area in question require multiple
machining will determine where it should be placed.

Activity: Trim Boundaries

In this activity, you will create a trim boundary inside of a MILL_AREA
Parent Group and will then generate the corresponding operation.
Step 1: Continue using the part.
Continue using ***_male_cover_mfg_2_setup_1.
Step 2: Create a Trim Boundary.
Change the view to TOP.
Change the Operation Navigator to the Geometry View.
You will now edit the operation.
Double-click on the TWO_RIBS geometry.
Click TRIM . 7
The boundary you will create will be developed using cursor
location points.
For Filter Type click Point Boundary .
Change the Point Method to Cursor Location.
Notice that the Trim Side setting is defaulted to Inside. This

means that the area inside of the Trim Boundary will not be
machined. Changing to Outside would allow for machining only
inside of the Trim Boundary.
Using four screen position points create a trim boundary

similar to the one shown below.

Only four points are needed, as the boundary processor will close
the shape for you.
Choose OK to return to the main dialog box.
Generate the tool path for the FC_FINISH_RIBS operation and

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

Save and close the part.

Summary
This lesson introduced you to Fixed Contour operations that gives you the
ability to machine complex contour geometry with numerous options.
In this lesson you:
Created Area Milling and Flow Cut operations.
Made extensive use of the MILL_AREA parent group.
Created Trim Boundaries

Lesson
8 Streamline drive method
Purpose
In this lesson you will use Streamline Milling operations to create tool paths
on contoured faces. The Streamline drive method builds an implied drive
surface from the selected geometry. Streamline enables completely flexible
tool path creation.
Objective
Create Streamline milling operations
Create Streamline operations using Automatic Flow and Cross Curves
Create Streamline operations by defining Specified Flow and Cross Curves
Add cross curves to further define the tool path

Streamline drive method

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

Flow and Cross curves

Flow and cross curves create:
Intermediate cross curve Intermediate flow curve

Typical 4sided selected to give more selected to give more
configuration. shape control for the pattern control for the
drive surface. drive surface.
Foursided drive surface

with one intermediate
flow (for better pattern Threesided with two
control) and one flows and two cross curve
Threesided with two
intermediate cross (for sets. The second flow
flows and one cross.
better shape control) curve set contains a
added. You can add single point.
as many intermediate
curves as needed.
Two sided drive surface Two closed loops

Two sided drive surface. with a cross curve added selected. A cross curve

gives shape to the drive

to better define the
surface and defines the
shape.
start points.
Automatic
selection only
identifies the two
exterior loops of
the cut area. With
Specify you can
Two closed loops manually select
selected. (The point any number of
at top is technically the closed loops to
second closed loop.) Two create flow curve
cross curves give more sets.
control over the shape of
the drive surface.

Activity: Create an Automatic Streamline operation
In this activity, you will create a new Streamline drive method operation.
You will use the predefined WORKPIECE along with the new Cut Area
geometry and use Automatic Flow and Cross curves.
Step 1: Open, rename the part, and enter the Manufacturing application.
Open the cap_setup_1 part.
Rename the part ***_cap_setup_1 using FileSave As on the

menu bar.
Step 2: Select the geometry for the operation.

On the Manufacturing Create toolbar, click Create Geometry
The Create Geometry toolbar appears.

Select mill_contour from the Type list.
In the Geometry Subtype group, click Mill Area .

8
In the Location group select WORKPIECE from the Geometry
list.
Type MILL_AREA in the Name box (if necessary).
Click OK.
In the Geometry group, click Specify Cut Area and select

the faces as shown.

Click OK to return to the MILL_AREA dialog box.
Click OK to return to the Operation Navigator.
Step 3: Create a new Streamline operation.

In the Manufacturing Create toolbar click Create Operation
Select mill_contour from the Type list (if needed).
Click STREAMLINE .
Set the Location groups as shown:

Program 1234
Tool BMILL_.75
Geometry MILL_AREA
Method MILL_FINISH
Name the operation SCOOP_END.

8 Click OK to create the operation.
Step 4: Edit the Drive Parameters to preview the tool path.

In the Streamline dialog box, in the Drive Method group, click
Edit .
The Streamline Drive Method dialog box is displayed.

The Flow and Cross curves are displayed. The Drive Path Preview
is also displayed.

Click OK.
Click Generate .
Click OK to complete the operation.
The Flow and Cross curves were selected using the Automatic
setting. The curves were selected as shown below.
Step 5: Edit the Streamline path to examine the Flow and Cross curves.
8
Double-click the SCOOP_END operation in the Program View
of the Operation Navigator.
Expand the Preview group
Clear the Preview check box.

Refresh the graphics screen.
In the Flow Curves group, expand the List.
Click Flow 1 in the list to see the first flow curve.
Click Flow 2 in the list to see the second flow curve.
In the Cross Curves group, expand the List again.
Click Cross 1 in the list to see the first cross curve.
Click Cross 2 in the list to see the second cross curve.
In the Preview group, select the Preview check box.
The drive path is displayed on the graphics screen.
In the Drive Settings group, set the Number of Stepovers to 20.
In the Preview group, click Display .
Click OK.
Click Generate .
Review the tool path.

Click OK.
Save the part, but do not close.

Activity: Create a Manual Streamline operation

In this activity, you will create a new Streamline drive method operation
using the pre-defined WORKPIECE and the MILL_AREA from the last
activity. You will Specify the Flow and Cross curves.
Step 1: Continue to use the ***_cap_setup_1 part.
If necessary, open the ***_cap_setup_1 part.
Choose Start Manufacturing if necessary.

In the Manufacturing Create toolbar click Create Operation
In the Operation Subtype group, click STREAMLINE .
Set the Location parameters as shown:

Program 1234
Tool BMILL_.75
Geometry MILL_AREA
Method MILL_FINISH
8
Click OK to create the operation.
The Streamline dialog box appears.
Step 3: Edit the Drive Parameters to remove the Automatic Flow and
Cross curves.
In the Drive Method group click Edit next to Method.

is also displayed.
In the Drive Curve Selection group, select Specify from the

Selection Method list.
In the Flow Curves group expand the List.
Highlight Flow 1 and click Remove .
Highlight Flow 2 and click Remove .
In the Cross Curves group expand the List.
Highlight Cross 1 and click Remove .
Highlight Cross 2 and click Remove .
Step 4: You will select the new Flow and Cross curves to generate a
different path.
In the Flow Curves group click Curve .

8
Select the following curves.

In the Flow Curves group, click Add New Set .
Select the curves as shown below.
The Flow Curves direction vectors should point in the direction

shown.
If the vectors do not match, highlight the appropriate Flow

Curve and select Reverse Direction .

The Flow curves are complete. You will now select the Cross
curves.
In the Cross Curves group click Select Curve .
Choose Single Curve from the Curve Rule list.
In the Cross Curves group click Add New Set .
When finished, the Flow and Cross must align correctly. Each set
of curves should point in the same direction.
If the direction vectors are not correct, highlight one of the

curves in the list and click Reverse Direction .
In the Drive Settings group, select Contact from the Tool

Position list.
Click OK.

Click Generate .
The same curves are used in the Automatic and Specify operations.
The selection of Flow and Cross curves has changed the resulting
tool path.
Compare the results from the Automatic and Specified paths.
Click OK.
Save the part, but do not close as you will use it in the next
activity.

Activity: Add additional curves for more control

In this activity, you will create a new Streamline drive method operation. You
will use the predefined WORKPIECE along with a new Cut Area geometry
and use Automatic Flow and Cross curves, then add additional Cross curves.
Step 1: Continue using ***_cap_setup_1 from the previous activity.
Step 2: Select the geometry for the operation.

In the Manufacturing Create toolbar, click Create Geometry
The Create Geometry dialog box appears.
In the Geometry Subtype group click Mill Area .
In the Location group, set Geometry to WORKPIECE.
Type MILL_AREA_1 in the Name box.
Click OK.
8
In the Geometry group, click Specify Cut Area and select
the faces as shown.

Click OK to return to the MILL_AREA dialog box.
Click OK to return to the Operation Navigator.
In the Operation Subtype group, click STREAMLINE .
Set the Location groups as shown:
Program 1234
Tool BMILL_.75
Geometry MILL_AREA_1
Method MILL_FINISH
Click OK to create the operation.

8
Step 4: Edit the Drive Parameters to preview the tool path.
In the Drive Method group click Edit .

is also displayed.
Click OK and Generate the tool path.

The tool path could be smoother with the addition of more cross
curves.
Step 5: Add more Cross curves to control the drive path.
In the Drive Method group click Edit .

In the Cross Curves group expand the List and click Add New
Set.
Select the first set of curves as shown.
In the Cross Curve group, click Add New Set.
You will select the same curves on the opposite side of the part.
Select the first set of curves as shown.

8
Click OK.


Click Generate.
The tool path is more smooth.
Step 7: Modify the Projection Vector to improve the path.

The projection vector determines how the drive points are projected
onto the part geometry. This part has steep walls to projecting
along the tool axis is not the best option.
Expand Projection Vector.
Select Toward Drive from the Vector list.

Click Generate.
The tool path is improved.
Step 9: Change the tool position to further control the tool path.
The current tool path is rolling over the top of the part geometry.
In the Drive Settings section of the dialog box choose Contact

from the Tool Position list.


Click Generate.
The tool path is complete.

Summary
The Streamline drive method simplifies geometry selection and provides
additional drive path control.
You examined the following in Streamline:
Used Automatic Flow and Cross curves to create a tool path.
Selected user defined Flow and Cross curves to create a tool path.
Added additional cross curves to control the drive path.

Index
C H
Cavity Mill High Speed Machining
Cut Levels . . . . . . . . . . . . . . . . . . 2-2 application of . . . . . . . . . . . . . . . . 6-2
Cut Patterns characteristics . . . . . . . . . . . . . . . 6-2
Cut Pattern . . . . . . . . . . . . . . 2-6 mixed cut directions . . . . . . . . . . . 6-8
Cavity Milling specific goals . . . . . . . . . . . . . . . . . 6-2
cut region start points . . . . . . . . . 2-21
Cut Area Geometry N
Z-Level Milling . . . . . . . . . . . . . . . 4-3
NC Assistant
Cut Levels . . . . . . . . . . . . . . . . . . . . 2-2
analysis types available . . . . . . . . 5-2
Cut Patterns . . . . . . . . . . . . . . . . . . 2-6
draft angle . . . . . . . . . . . . . . . 5-3
fillet radius . . . . . . . . . . . . . . 5-3
F levels . . . . . . . . . . . . . . . . . . . 5-2
Fixed Contour
drive geometry . . . . . . . . . . . . . . . 7-2 P
drive methods
Part Geometry
flow cut . . . . . . . . . . . . . . 7-4, 7-7
Check Geometry
radial cut . . . . . . . . . . . . . . . . 7-4
Z-Level Milling . . . . . . . . . . . 4-3
tool path . . . . . . . . . . . . . . . . 7-3
User Function . . . . . . . . . . . . 7-4
drive points . . . . . . . . . . . . . . . . . 7-2 T
operation types . . . . . . . . . . . . . . . 7-6 Trim Geometry
contour_area . . . . . . . . . . . . . 7-6 Steep Angle
contour_surface_area . . . . . . . 7-6 Z-Level Milling . . . . . . . . 4-3, 4-7
fixed_contour . . . . . . . . . . . . . 7-6
terminology . . . . . . . . . . . . . . . . . 7-2 W
check geometry . . . . . . . . . . . 7-2
WAVE Geometry Linker . . . . . . . 1-2, 1-5
drive geometry . . . . . . . . . . . . 7-2
Assemblies and Wave . . . . . . . . . . 1-8
drive method . . . . . . . . . . . . . 7-2
Create Associative . . . . . . . . . . . . 1-2
drive points . . . . . . . . . . . . . . 7-2
definition of . . . . . . . . . . . . . . . . . 1-2
part geometry . . . . . . . . . . . . 7-2
deleting parent geometry . . . . . . . 1-7
projection vector . . . . . . . . . . . 7-2
editing links . . . . . . . . . . . . . . . . . 1-4
use of . . . . . . . . . . . . . . . . . . . . . . 7-2
Hide Original . . . . . . . . . . . . . . . . 1-2
linking procedure . . . . . . . . . . . . 1-12
G Links
Geometry Types Associative . . . . . . . . . . . . . . . 1-5
Z-Level Milling . . . . . . . . . . . . . . . 4-3 broken . . . . . . . . . . . . . . . . . . 1-6
Fixed Axis Techniques Student Guide Index-1

Index
deleting of . . . . . . . . . . . . . . . 1-8 Cut Area Geometry . . . . . . . . . . . . 4-3

simplify Geometry Types . . . . . . . . . . . . . . 4-3
Simplify Body . . . . . . . . . . . 1-15 Part Geometry . . . . . . . . . . . . . . . 4-3
Steep Angle . . . . . . . . . . . . . . . . . 4-7
Z Trim Geometry . . . . . . . . . . . . . . . 4-3
Z-Level Milling Types . . . . . . . . . . . . . . . . . . . . . . 4-2
Check Geometry . . . . . . . . . . . . . . 4-3
Index-2 Fixed Axis Techniques Student Guide mt11065_s NX 6

UGS Education Services offers a blend of training L
solutions for all of our product lifecycle management E
products. A
Our Online Store Learning Advantage was R
developed to provide our customers with just in time N
training for the latest in application developments. I
N
Here are some of the Learning Advantages: G
Customers have direct access
Self-paced course layout
A
Online Assessments
D
Just in time training for the latest release
V
A
N
T
To learn more about the Learning Advantage visit A
our website http://training.ugs.com or email us at G
training @ugs.com E
This page left blank intentionally.
STUDENT PROFILE
In order to stay in tune with our customers we ask for some background information. This information will be kept
confidential and will not be shared with anyone outside of Education Services.
Please Print
Your Name U.S. citizen Yes No
Course Title/Dates NX6 Fixed Axis Techniques / thru
Hotel/motel you are staying at during your training
Planned departure time on last day of class
Employer Location
Your title and job responsibilities /
Industry: Auto Aero Consumer products Machining Tooling Medical Other
Types of products/parts/data that you work with
Reason for training

Please verify/add to this list of training for Unigraphics, I-deas, Imageware, Teamcenter Mfg., Teamcenter Eng. (I-Man), Teamcenter
Enterprise (Metaphase), or Dimensional Mgmt./Visualization. Medium means Instructor-lead (IL), On-line (OL), or Self-paced (SP)
Software From Whom When Course Name Medium
Other CAD/CAM/CAE /PDM software you have used

Please check! your ability/knowledge in the following
Subject None Novice Intermediate Advanced
CAD modeling
CAD assemblies
CAD drafting
CAM
CAE
PDM data management
PDM system management
Platform (operating system)
Thank you for your participation and we hope your training experience will be an outstanding one.
Course Agenda
Fixed Axis Techniques - Course Agenda

Day One
Course Overview
Lesson 1. WAVE Geometry Linker in Manufacturing
Workbook Machining Preparation
Lesson 2. Advanced Cavity Milling Topics
Afternoon
Lesson 2. Advanced Cavity Milling Topics
Lesson 3. Plunge Milling
Day Two
Lesson 4. Z-Level Milling
Lesson 5. NC Assistant
Afternoon
Lesson 6. High Speed Machining
Workbook Plunge and Cavity Milling
Day Three
Lesson 7 Fixed Contour Operation Types
Lesson 8 Streamline drive method
Afternoon
Workbook Fixed Contour Finishing Operations
Accelerators
The following Accelerators can be listed from within an NX session by choosing
InformationCustom MenubarAccelerators.
Function Accelerator
FileNew... Ctrl+N
FileOpen... Ctrl+O
FileSave Ctrl+S
FileSave As... Ctrl+Shift+A
FilePlot... Ctrl+P
FileExecuteGrip... Ctrl+G
FileExecuteDebug Grip... Ctrl+Shift+G
FileExecuteNX Open... Ctrl+U
EditUndo Ctrl+Z
EditRedo Ctrl+Y
EditCut Ctrl+X
EditCopy Ctrl+C
Edit-Paste Ctrl+V
EditDelete... Ctrl+D or Delete
EditSelectionTop Selection Priority - Feature F
EditSelectionTop Selection Priority - Face G
EditSelectionTop Selection Priority - Body B
EditSelectionTop Selection Priority - Edge E
EditSelectionTop Selection Priority - Component C
EditSelection-Select All Ctrl+A
EditShow and HideShow and Hide... (by type) Ctrl+W
EditShow and HideHide... Ctrl+B
EditShow and HideInvert Shown and Hidden Ctrl+Shift+B
EditShow and HideImmediate Hide Ctrl+Shift+I
EditShow and HideShow... Ctrl+Shift+K
EditShow and HideShow All Ctrl+Shift+U
EditTransform... Ctrl+T
EditMove Object Ctrl+Shift+M
EditObject Display... Ctrl+J
ViewOperationZoom... Ctrl+Shift+Z
ViewOperationRotate... Ctrl+R
ViewOperationSection... Ctrl+H
ViewLayoutNew... Ctrl+Shift+N
ViewLayoutOpen... Ctrl+Shift+O
ViewLayoutFit All Views (only with multiple views) Ctrl+Shift+F
ViewLayoutFit Ctrl+F
ViewVisualizationHigh Quality Image... Ctrl+Shift+H
ViewInformation Window F4
Hide or show the current dialog box F3
ViewReset Orientation Ctrl+F8
InsertSketch... S
InsertDesign FeatureExtrude... X
InsertDesign FeatureRevolve... R
InsertTrimTrimmed Sheet... T
InsertSweepVariational Sweep... V
FormatLayer Settings... Ctrl+L
FormatVisible in View... Ctrl+Shift+V
FormatWCSDisplay W
ToolsExpression... Ctrl+E
ToolsUpdateMake First Feature Current Ctrl+Shift+Home
ToolsUpdateMake Previous Feature Current Ctrl+Shift+Left Arrow
ToolsUpdateMake Next Feature Current Ctrl+Shift+Right Arrow
ToolsUpdateMake Last Feature Current Ctrl+Shift+End
ToolsJournalPlay... Alt+F8
ToolsJournalEdit Alt+F11
ToolsMacroStart Record... Ctrl+Shift+R
ToolsMacroPlayback... Ctrl+Shift+P
ToolsMacroStep... Ctrl+Shift+S
ToolsMovieRecord Alt+F5
ToolsMovieStop Alt+F7
InformationObject... Ctrl+I
AnalysisCurveRefresh Curvature Graphs Ctrl+Shift+C
PreferencesObject... Ctrl+Shift+J
PreferencesSelection... Ctrl+Shift+T
StartModeling... M or Ctrl+M
StartAll ApplicationsShape Studio... Ctrl+Alt+S
StartDrafting... Ctrl+Shift+D
StartManufacturing... Ctrl+Alt+M
StartNX Sheet Metal... Ctrl+Alt+N
StartAssemblies A
HelpOn Context... F1
Refresh F5
Fit Ctrl+F
Zoom F6
Rotate F7
Orient View-Trimetric Home
Orient View-Isometric End
Orient View-Top Ctrl+Alt+T
Orient View-Front Ctrl+Alt+F
Orient View-Right Ctrl+Alt+R
Orient View-Left Ctrl+Alt+L
Snap View F8
Evaluation Delivery
NX 6 Sheet Metal Design, Course # TR16020
Dates thru
Please share your opinion in all of the following sections with a check in the appropriate box:
Instructor: 5
SOMEWHAT
SOMEWHAT
STRONGLY
STRONGLY
DISAGREE
DISAGREE
DISAGREE
AGREE
AGREE
AGREE
If there were 2 instructors, please evaluate the 2nd instructor with Xs
Instructor: 7
1. clearly explained the course objectives
2. was knowledgeable about the subject
3. answered my questions appropriately
4. encouraged questions in class
5. was well spoken and a good communicator
6. was well prepared to deliver the course
7. made good use of the training time
8. conducted themselves professionally
9. used examples relevant to the course and audience
10. provided enough time to complete the exercises
11. used review and summary to emphasize important information
12. did all they could to help the class meet the course objectives
Comments on overall impression of instructor(s):

Overall impression of instructor(s) Poor Excellent
Suggestions for improvement of course delivery:
What you liked best about the course delivery:
Class Logistics:
1. The training facilities were comfortable, clean, and provided a good learning
environment
2. The computer equipment was reliable
3. The software performed properly
4. The overhead projection unit was clear and working properly
5. The registration and confirmation process was efficient
Hotels: (We try to leverage this information to better accommodate our customers)
1. Name of the hotel Best hotel Ive stayed at
2. Was this hotel recommended during your registration process? YES NO
3. Problem? (brief description)
SEE BACK
Evaluation - Courseware
NX 6 Sheet Metal Design, Course # TR16020
SOMEWHAT
SOMEWHAT
STRONGLY
STRONGLY
DISAGREE
DISAGREE
DISAGREE
Please share your opinion for all of the following sections with a check in the appropriate box:
AGREE
AGREE
AGREE
Material:
1. The training material supported the course and lesson objectives
2. The training material contained all topics needed to complete the projects
3. The training material provided clear and descriptive directions
4. The training material was easy to read and understand
5. The course flowed in a logical and meaningful manner
6. How appropriate was the length of the course relative to the material? Too short Too long Just right
Comments on Course and Material:
Overall impression of course Poor Excellent
Student:
1. I met the prerequisites for the class (I had the skills I needed)
2. My objectives were consistent with the course objectives
3. I will be able to use the skills I have learned on my job
4. My expectations for this course were met
5. I am confident that with practice I will become proficient
Name (optional): Location/room
Please check this box if you would like your comments featured in our training publications.
(Your name is required at the bottom of this form)
Please check this box if you would like to receive more information on our other courses and services.
(Your name is required at the bottom of this form)
Thank you for your business. We hope to continue to provide your training
and personal development for the future.

Mt11065 - NX6 9 2008 Fixed Axis Techniques Student Guide PDF

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Mt11065 - NX6 9 2008 Fixed Axis Techniques Student Guide PDF

Загружено:

Авторское право:

Доступные форматы

Fixed Axis Techniques

This software and related documentation are proprietary to Siemens Product

2 Fixed Axis Techniques Student Guide mt11065_s NX 6

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

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

Fixed Axis Techniques Student Guide 3

Activity: Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . . . . . . . 2-22

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

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

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

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

4 Fixed Axis Techniques Student Guide mt11065_s NX 6

Flow Cut Reference Tool Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

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

Fixed Axis Techniques Student Guide 5

Utilize options and parameters that are common to various operation

Create Associative Machining Geometry, Advanced Roughing operations

Fixed Axis Techniques Student Guide 7

Basic understanding of the Master Model concept

Working knowledge of the following:

Part file saving conventions

Experience as an NC/CNC programmer

Listen attentively and take notes

Practice what you have learned

Enjoy the class

8 Fixed Axis Techniques Student Guide mt11065_s NX 6

Class standards for NX part files

Class part file naming

Layers and categories

Fixed Axis Techniques Student Guide 9

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

Action bullets detail how to complete the step.

Classroom system information

10 Fixed Axis Techniques Student Guide mt11065_s NX 6

1 WAVE Geometry Linker in

Make modifications to linked geometry.

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

Fixed Axis Techniques Student Guide 1-1

The Fix at Current Timestamp determines weather or not features added

Associative determines weather or not linked body will update to reflect

1-2 Fixed Axis Techniques Student Guide mt11065_s NX 6

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

Fixed Axis Techniques Student Guide 1-3

Links may be edited by choosing EditFeatureEdit Parameters in the Part

1-4 Fixed Axis Techniques Student Guide mt11065_s NX 6

The Fix at Current Timestamp determines weather or not features added

Replacement Assistant allows replacement of one linked object with

Reverse Direction reverses the normal of the face selected.

Fixed Axis Techniques Student Guide 1-5

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

1-6 Fixed Axis Techniques Student Guide mt11065_s NX 6

To prevent unintentional deletion of the parents of linked geometry, a message

Fixed Axis Techniques Student Guide 1-7

Linked geometry is created as a feature and can be deleted by choosing

Assemblies and WAVE

1-8 Fixed Axis Techniques Student Guide mt11065_s NX 6

On the Standard toolbar, click New .

Notice that the dialog box has several tabbed pages.

On the Model page, select the Assembly template.

This template will provide the standard Layer settings and

In the New File Name group, in the Name box, type

Fixed Axis Techniques Student Guide 1-9

In the Part group, click Open .