UGS-NX-4

The Manufacturing module allows you to interactively program and postprocess milling,
drilling, turning, and wire edm tool paths. Customizable configuration files define the
available machining processors, tool libraries, postprocessors, and other high level
parameters which can be targeted to specific market segments such as Mold and Die and
Machinery. Templates allow you to customize the user interface and specify machining
Setups which can include machine tools, cutting tools, machining methods, shared
geometry, and sequences of operations.

The Operation Navigator allows you to view and manage relationships between
operations, geometry, machining methods, and tools. It allows groups of parameters to be
shared among many operations, eliminating the repetitious, tedious task of re-specifying
parameters for each operation, and provides separate views to manage these relationships.

Because of the highly customizable nature of the Manufacturing module, the available
options and general appearance of dialog boxes on your system may differ from those
described in this document. The organization and contents of this documentation is based
on the Mach Kit (default set of configuration files, templates, and libraries) delivered
with each release by NX.
Upon entering the Manufacturing module for the first time with a part, you are required
to choose an Application Package (configuration.dat file) and a Machining Discipline.
This determines the Machining Applications (templates) available in the Create
Operation dialog box. The chosen Machining Discipline may be changed at any time in
the Create Operation dialog box by choosing another Type option.

n NX the NC machining environment is referred to as the setup. The first time you open a
part in the Manufacturing application you select the setup from the Machining
Environment dialog and then select initialize. For more information on the setup options
go to the Initializing the CAM Setup section. With the setup you can input and save the
full machining environment; this includes the tool paths and their parameters.

The tool paths and their parameters are saved inside what is called an operation. Each
operation contains its own tool path and parameters. NX allows you to separate the
operations into sections called groups. These groups become parents when operations are
placed underneath them in the Operation Navigator. Therefore, the documentation often
refers to them as parent groups, when talking about an issue that relates to the group both
before and after it contains operations. The relation between the operations and these
parent groups is displayed through the different views of the Operation Navigator.

The Operation Navigator contains four views: Geometry View, Tool View, Method
View, and Program Order View. Each operation has four parent groups: geometry, tools,
methods, and the program order. As you would assume, to view the geometry parent
groups look in the Geometry View. To view the tool parent groups, look in the Tool
View.

Within these views you can plan, edit, view, and manipulate your data. To create an
operation or parent group however, you must click the appropriate Create icon and create
the operation or parent group in the appropriate dialog. Once you have created the
operation or parent group, it displays in the Operation Navigator where you can then edit,
view and manipulate it along with the other operations and parent groups already in your
NC program.

INITIALIZING CAM SETUP

There are three ways to create the setup for your part: through the Machining
Environment dialog, through the NX Library, and through Palettes.

If you are using the Machining Environment dialog select the configuration and the
setup from the Machining Environment dialog and then select initialize. The tables
below explain the options in the Machining Environment dialog.

If you are in a Teamcenter environment, or if your configuration includes

LIBRARY_SETUP_TEMPLATE, such as cam_library, then the software classifies and
retrieves the setups through NX Library. See Data Management for more information.
If you select your setup by using Palettes, select the palettes tab in the Resource bar, and
select your setup from the graphical list of setups.

To create a Palette enter Manufacturing and select Preferences-→ Manufacturing-→

Configuration-→ Add Palette. The software displays the Library Class Selection
Dialog. From this dialog select either Inch or Metric, depending on the units of your part.
As you create more Palettes we suggest you don't mix units on a single Palette, but
instead create separate Palettes for inch and metric.

To remove a Palette enter Manufacturing and select Preferences-→ User Interface-→

Resource Bar.

Do not switch between Teamcenter and native environments during a session

It is recommended that users start NX in either Teamcenter or native, with the
correct CAM configuration specified to match. If a user needs to work in CAM in
both environments, they should have two ways to start NX, so that the CAM
configuration is set before NX is started. This can be done with batch files, or using
multiple .env files.
Configurations Setups
cam_general mill_planar, mill_contour, mill_mulit-axis, drill, hole_making, turning
and wire_edm
cam_iman_library all in the Teamcenter Manufacturing library
cam_library all in the ascii library
hole_making hole_making, mill_planar, mill_contour and drill
lathe turning and legacy_lathe
lathe_mill turning, mill_planar, drill and hole_making
mill_contour mill_contour, mill_planar, drill, hole_making, die_sequences and
mold_sequences
mill_multi-axis mill_multi_axis, mill_contour, mill_planar, drill and hole_making
mill_planar mill_planar, drill and hole_making
mill_planar_hsm mill_planar_hsm, drill and hole_making
shops_diemold shops_mill_contour, shops_mill_planar, shops_drill, shops_control,
shops_die_sequences and shops_mold_sequences
shops_machinery shops_mill_planar, shops_drill and shops_control
wire_edm wire_edm
Setups What Is In The Initial Setup What Can Be Created
mill_planar This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and methods for drilling, for drilling and planar milling.
rough milling, semi-finish milling
and finish milling.
mill_contour This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and methods for drilling, for drilling, planar milling, and
rough milling, semi-finish milling, fixed axis contouring.
and finish milling.
mill_multi-axis This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and methods for drilling for drilling, planar milling, fixed
and rough, semi-finish, and finish axis contouring, and variable axis
milling. contouring.
drill This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and methods for drilling, for drilling.
rough milling, semi-finish milling
and finish milling.
hole_making This contains an MCS, Workpiece, Operations, tools, and groups used
several Programs for holemaking for drilling, including optimized
operations, and methods for drilling program groups, and feature cut
and hole milling. method geometry groups.
turning This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and six methods for for turning.
turning.
legacy_lathe This contains an MCS, Workpiece, Legacy Lathe operations, tools, and
Program, and methods for program groups. Methods can be
centerline (drilling), rough, finish, created but are not used by the
groove, thread, and auxillary Legacy Lathe operations. MCS
Geometry Groups can be created
and used, but the Legacy Lathe
operations ignores the data in
Workpiece geometry groups (PART
and BLANK geometry).
wire_edm This contains an MCS, Workpiece, Operations, tools, and groups used
Program, and methods for wire for wire EDM, including geometry
EDM. groups for internal and external trim
sequences.
die_sequences This contains everything in Geometry groups for special
mill_contour plus several tools and machining sequences for die
methods commonly used for die machining. A process assistant takes
machining. A process assistant you through several steps each time
takes you through several steps you create a sequence. This ensures
when you create the setup. This the system stores the required
ensures the system stores the selections in the correct groups.
required selections in the correct
groups.
mold_sequences This contains everything in Geometry groups for special
mill_contour, plus several tools and machining sequences for mold
methods commonly used for mold machining. A process assistant takes
machining. A process assistant you through several steps each time
takes you through several steps you create a sequence. This ensures
when you create the setup. This the system stores the required
ensures the system stores the selections in the correct groups.
required selections in the correct
groups.
mill_planar_ Same setup environment as Operations, tools, and groups used
hsm mill_planar. The difference is for drilling and high speed
within the operation templates, machining planar milling.
some of the parameters for cutting
are set to different values to favor
high speed machining (HSM).

OPERATIONS

The main unit of NX CAM is the setup. The setup consists of all the operations and the
environment in which the operations were created. An operation contains a uniquely
generated tool path and the information within the tool path: geometry, tool, and
machining parameters. An operation is different from an NC program in that one
operation generates one tool path and the NC program may generate numerous tool paths.
You post process the NC program to create the actual commands that are sent to the CNC
controller.

Four Parents of an Operation

Each operation has four parents. The operations inherit information from each parent and
the system uses it to calculate the tool path. The four types of parent groups are given
below:

• The geometry for the specific operation.

• The tooling to be used.
• The machining parameters for the operation.
• The program that contains the operation.

These are the four parents that supply information to an operation. For each new
operation you need to select these four parent groups. The previous selections remain
modal as you create operations so you only need to select what changes. Below is a short
description of each of these four Parents.

The geometry for the specific operation

For each operation you must choose the orientation and the geometry. The orientation is
defined by a coordinate system and the geometry is defined in various ways, depending
on what type of operation you are creating.

The coordinate system, fixture offset, clearance plane and tool axis can all be stored in an
orientation group.

The geometry to be machined in each operation needs to be defined either in the

geometry parent or within each individual operation. It is usually more convenient to
define the geometry in a geometry parent group. If the geometry is specified here it can
be used by all the subsequent operations of the parent. For example, if you are going to
repeat similar operations on two cavities, you can put the cavity geometry in two groups,
and then create or copy the same operations under each group. This saves you from
duplicating your efforts.

The geometry also defines the part material, which is used to calculate machining data.

The tooling to be used

Each operation needs a tool to cut the tool path. Tools can be retrieved from a library
with hundreds of standard tools, or created as needed. Tools are placed in holders,
carriers, and turrets, on a machine tool.

Tools have a tool material that is used to calculate machining data.

The machining parameters for the operation

Each operation contains numerous parameters. The most specific parameters such as
engage, retract, and stepover, are stored in the operation. Some parameters are shared by
many operations and are stored in the Method parent group. These shared parameters can
include the stock, tolerance, feedrates, and display colors.

The method also defines the cut method used to calculate machining data.

The Program that contains the operation

You create programs to help you organize your operations and the order in which the
system runs them. If you need two programs (or tape files) for this job, you create a
program group for each one, such as tape_1 and tape_2. When you create an operation,
you select whether it machines in the program tape_1 or tape_2. Before you postprocess,
you can reorder the operations in each program, or move them from one program to the
other.

MOLD AND DIE SETUP OVER VIEW

The system offers special setups for mold and die projects containing groups and tools
that are common for a particular type of part, such as a mold cavity. The special setups
include templates for sequences. These sequences are geometry groups that contain a
series of operations working together to produce a part. The system includes several
examples for the mold and die industry. These setups and sequences show what you can
do with group templates. You can learn from them, develop your own templates, and
customize to your shop practices.

When creating these setups and sequences, a process assistant asks you several questions,
leading you step by step through all the information required to generate the tool paths.
You can turn off the process assistants, edit the groups created by the template, and select
the correct geometry independent of the process assistants.
 For a very detailed step by step example of using the mold and die setups see CAST.
In CAST select Manufacturing -→ Manufacturing Essentials -→ Creating Operation
Sequences.

CREATE MOLD SETUP

Mold sequences and die sequences are available within the Mill_Contour configuration
setups. When you select a setup for a mold or die sequence, a process assistant asks you
for required information through a progression of dialogs. Each dialog prompts for
information that is common for the whole setup, such as the coordinate system or
geometry. Select OK to continue to the next dialog, or Back to return to the last dialog.
All the setup and process assistants work in a manner similar to that described in the
following example:

Example

Open a part without a setup and select the Manufacturing application. To create the setup,
select the Mill_Contour configuration, then select the mold_sequences setup and
Initialize.

The system displays a welcome dialog, and the process assistant leads you through the
following steps:

This image displays the parts of the setup you will define this example.

1. Select the machine coordinate system.

2. In the dialog, select an MCS icon and define the machine coordinate system for
this program. The system stores this information in the MCS group.
3. Select the clearance plane.
4. Define a safe clearance above the part where the system can use rapid motion.
 5. Select the Clearance checkbox and then select Specify.
6. Select or display the part geometry.

If Display is active, select it to see what part geometry the system has selected.
The system automatically selects all the geometry named PART. If this is what
you want, select OK.

If Display is not active, click Select and select your part geometry. This is usually
a solid body of the entire core or cavity. The system needs this information even if
you only cut some of the faces. This is to keep the tool from gouging or colliding
with the rest of the part body. This is also used by Visualize and the Gouge
Checker.

7. Select or display the blank geometry.

If Display is active, select it to see what blank geometry the system has selected.
The system automatically selects all geometry named BLANK. If this is what you
want, select OK.

If Display is not active, click Select and select your blank geometry. Select a solid
body or use the auto block or auto distance options. This represents what your
part looks like at the beginning of the setup, before being machined.

8. Select OK. The system displays an information window and a message that you
have completed the setup. The setup contains the MCS and workpiece as well as
several tools and methods that are common in mold machining. The information
window gives you two choices: either change templates and create operations as
you normally do, or select the Create Geometry icon to create predefined
sequences.

The next section explains how to create predefined sequences:

CREATING MACHINING SEQUENCES

1. Select the Create Geometry icon. The system displays the Create Geometry
dialog. Be sure the type is set to mold_sequences. If mold_sequences is not
available, go to Preferences-→ Manufacturing-→ Configuration and select the
Mill_Contour configuration.

2. In the Create Geometry dialog, select the sequence_zlevel icon .

3. Set the Parent Group to Workpiece and select OK. This tells the system that you
want to use the zlevel sequence to machine the workpiece that you already
selected in the setup.
4. The system displays a dialog that begins another process assistant. This process
assistant leads you through creating a machining sequence as shown in the
example below.
Example

This image displays the parts of the sequence you will define in the following example.

1. To machine the entire part, select OK without selecting a cut area. The system
then tries to cut all the faces on the part. If you only want to machine some of the
part, click Select. This option selects the faces or surface region that you want to
machine with this sequence.

The system stores the faces or surface regions selected here in a Mill_Area group.
For example, use this if you want to cut the faces in the molding area, without
cutting the parting line or other faces.

2. Select the contour cut area.

3. Select the contour trim area.

To use trim boundaries, click Select and select the trim boundaries. You can
select the outside edges of the part with trim set to outside. This will prevent the
tool from making any extra motion outside the part.

4. Trim boundaries allow you to contain the tool path, inside or outside of selected
areas. Use this to limit cutting to just specific areas of the cut area or part, or to
avoid some areas. If you don't select trim boundaries, the system tries to cut the
entire cut area or part.
5. Select optional operations.

This dialog contains a list of optional operations. For example, there is a flowcut
operation that you should select if your part has blends with less than a radius of .
125 inch (3 mm). If your part doesn't have small corners like these, you don't need
to select the checkbox for this operation.

For very fine finishing, there is a zigzag fine operation that cuts with very small
stepovers. If you want a finishing operation like this, select the checkbox for this
operation.
 To view all the operations you created in this group, display the Geometry View
in the Operation Navigator and expand the ZLEVEL_SEQUENCE group. Look at
the operations and make any changes before generating.

For example, if you need smaller tolerances for roughing, display the Method
View and edit the MOLD_ROUGH method. If you want to use a different tool for
the pre-roughing, display the Tool View and move that operation to a new tool.

To generate the tool paths without examining the operations first, select the
Generate Tool Paths checkbox and click OK.

6. Generate.

Additional Sequences

You have now created one machining sequence for some or all of the workpiece. If
needed, you can create more sequences for other cut areas on this workpiece, or for
another workpiece.

Customizing
The process assistant is an aid to help you create a setup and the sequences of operations.
Once you use the process assistant you can edit these operations to fit them to your needs.
You can also delete or add operations to change the process. If you are making the same
edits and changes to the same operations after using the process assistant, you should
consider customizing the operations in the template, or creating your own template.
Remember that these templates are updated with each release, so make a copy of your .

The User Defined Mill Tool dialog lets you create corner-rounding tools and chamfering
tools, as well as other custom shapes. You define multiple tracking points on the tool
then, from the operation, select an appropriate tracking point to drive the cutter along the
part boundary. Since the most common application for this type of tool is simple
profiling, user defined tools are currently only available within the PLANAR_PROFILE
operation.

Where Do I Find It?

Create Tool → mill_planar → MILL_USER_DEFINED

To create a user-defined tool:

1. Pick Create Tooll.

2. Set the type to mill_planar.

3. Pick MILL_USER_DEFINED.
4. Define the line and arc segments.

To define a new segment:

a. Enter values forLine Length, Line/Arc Start Angle, Arc Radius, and
Arc Sweep.
b. Select Add to append the new segment to the end of the list.

New segments are always added to the end of the list.

To modify a segment, select it in the list, change the values, and pick Modify.

To delete a segment, select it in the list, and pick Delete.

The tool shape must move progressively upwards, from the tip of the tool (A),
towards the shank without crossing over the center-line. The shape on the left
in the figure below is invalid.

5. Pick Display Tool at any time to view the tool's shape.

When you select Display Tool, the tool is closed off with a horizontal line to
the tool center-line.

You must be in the front view to see the tracking points accurately.
 6. Define each tracking point of the tool to coincide with the ‘setup gauge length’
and the intended operations' Adjust Register offset (PLANAR_PROFILE main
dialog → Machine.)

For more information on creating tracking points, see Tracking Point.

7. Assign other values as required. For information on common tool parameters, see
Milling Tool Parameters

Currently, user defined mill tools are only available in the PLANAR_PROFILE
operation.

TOOL HOLDER OVERVIEW

The system defines the holder in the tool definition dialog as one or more cylinders or
tapered cylinders. The Area Milling and Flow Cut Drive methods of Fixed Axis Surface
Contouring and Z Level Profile can use this definition of the tool holder to ensure a
collision-free tool path.

• When the system displays the tool from the tool dialog or MB3, it displays the
holder with the tool.
• During tool path replay from the Operation dialog or MB3, the system displays
the holder when you select 3D tool in the operation display options.
• In Visualize, the system can display the holder during replay and dynamic
material removal. To use this option in the Area Milling and Flow Cut Drive
methods of Fixed Axis Surface Contouring, select the Use Tool Holder check box
so the operation recognizes the tool holder.

By default, when you create milling and drilling tools, a page labeled Holder contains the
holder parameters. You can also access the holder on tools created in previous releases,
through an action button labeled Holder. If you do not see holder parameters in the tool
dialog, you can add them by selecting the tool and using MB3 -→ object -→ customize,
and then adding the Holder item for the button, or by adding the holder bitmap and
parameter items.

Even though the holder can be defined on any milling or drilling tool, it can only be
used by some processors, such as Area Milling and Flow Cut Drive methods of Fixed
Axis Surface Contouring and Z Level Profile.
 1. Engage
2. Part Safe Clearance
3. Part Stock Offset
4. Part Stock
5. Cut Area
6. Holder will never violate Part Safe Clearance
7. Part Geometry

The image above shows how the holder is used in fixed axis surface contouring.

BARREL CUTTER

When Type is set to Barrel Cutter, New allows you to create a barrel shaped cutter tool
for milling operations. For limitations on allowable cutter shapes, see Tool Type
Parameters.

Barrel Cutters should only be used for planar milling and surface contouring
operations.

You may choose or define the following when creating a Barrel Cutter:

(D) Diameter Diameter is the diameter of the Barrel Cutter.

(R) Barrel Barrel Radius is the radius of the arc defining the profile shape of the
Radius sides of the cutter. See the previous diagram. Also see the discussion on Y
Center.
(R1) Lower Lower Radius is the lower corner radius of the profile of the tool.
Radius
(R2) Upper Upper Radius is the upper corner radius of the profile of the tool.
Radius
(L) Length Length is the length of the cutter including the shank.
(FL) Flute Flute Length is the height of the cutting surface on the cutter.
Length
(Y) Y Center Y Center is the height of the center of the arc defining the profile of the
outside edge of the cutter. See discussion on Barrel Radius and the
previous diagram.
(SD) Shank Shank Diameter is the diameter of the shank at the top of the Barrel
Diameter Cutter. See the previous diagram.
Number Flutes Number Flutes is the number of flutes in the Barrel Cutter.
Direction Direction is the spindle direction of the tool. Choose either CLW or
CCLW.
ZOFF ZOFF allows you to correct the positioning of the tool due to variations in
tool length.
ADJUST ADJUST Register allows you to correct the positioning of the tool due to
Register variations in the milling machine. This option is similar for all tool types.
CUTCOM CUTCOM Register allows you to correct the positioning of the tool due to
Register the variations in tool diameter caused by wear. This option is similar for
all tool types.
Tool Number Tool Number provides a way to reference the tool for the LOAD/TOOl
command in the CLSF. This options works the same for all milling tools.
Catalog Catalog Number provides a method to track the tool. This option is similar
Number for all tool types.
Display Tool Display Tool allows you to display a profile of the tool in the graphics
window. This option is similar for all tool types.

T-CUTTER

When Type is set to T-Cutter, New allows you to create a "T" shaped cutter tools for
milling operations.

T-Cutters should only be used for planar milling and surface contouring operations.

You may choose or define the following when creating a T-Cutter:

(D) Diameter Diameter is the diameter of the T-Cutter.

(R1) Lower Lower Radius is the lower corner radius of the profile of the tool.
Radius
(R2) Upper Upper Radius is the upper corner radius of the profile of the tool.
Radius
(L) Length Length is the length of the cutter including the shank.
(FL) Flute Flute Length is the height of the cutting surface on the cutter.
Length
(SD) Shank Shank Diameter is the diameter of the shank at the top of the T-Cutter.
Diameter
Number Flutes Number Flutes is the number of flutes in the T-Cutter.
Direction Direction is the spindle direction of the tool. Choose either CLW or
CCLW.
ZOFF ZOFF allows you to correct the positioning of the tool due to variations in
tool length.
ADJUST ADJUST Register allows you to correct the positioning of the tool due to
Register variations in the milling machine. This option is similar for all tool types.
CUTCOM CUTCOM Register allows you to correct the positioning of the tool due to
Register the variations in tool diameter caused by wear. This option is similar for
all tool types.
Tool Number Tool Number provides a way to reference the tool for the LOAD/TOOl
command in the CLSF. This options works the same for all milling tools.
Catalog Catalog Number provides a method to track the tool. This option is similar
Number for all tool types.
Display Tool Display Tool allows you to display a profile of the tool in the graphics
window. This option is similar for all tool types.

BALL—MILL

This option allows you to define a true ball mill in natural manner by supplying the
diameter of the ball and taper angle along with other common tool definition parameters.
The Ball Mill is available for all manufacturing modules.

TRACKING-POINT

The default tracking point for all milling tools is on the centerline at the end of the tool.
You can define additional tracking points for any milling tool. For each additional
tracking point, supply the following information:

• Diameter- the output diameter of the tracking point.

 • Distance- the distance along the tool axis measured up from the tool tip.
• Adjust register.
• Cutcom register.
• Z Offset value for the postprocessor.
• A name.

Where do I Find it?

To enter the User Defined Tracking Points dialog go to any Milling Tool dialog-→ More-
→ Tracking Points.

To select a tracking point in an operation dialog go to the Cutter Compensation dialog:

Operation dialog-→ Machine-→ Cutter Compensation.

Tracking Point Dialog

The User Defined Tracking Points dialog allows you to add new tracking points, modify
tracking points, and delete tracking points.

If tracking points currently exist, the system selects the last one and displays the data in
the fields below the table.

If no current tracking points exist, the system sets all the data fields to zero and displays a
default name in the Name field.

Tracking Point Procedures

The following are procedures to create and select user defined tracking points:

To Create a New Tracking Point

1. In the User Defined Tracking Points dialog, enter a name in the Name field if you
don't want the default name. If you enter a name that the system already uses, the
system appends a sequence number to ensure uniqueness.
2. Enter values in the Diameter and Distance data fields.
3. If you want to define values for Z Offset, Adjust, and Cutcom, select the check
boxes and add values in their respective fields.
4. Select Add.

To Modify an Existing Tracking Point

1. In the User Defined Tracking Points dialog, select the tracking point in the
Defined Trackpoints field. The system displays the data in the data fields.
2. Modify any of the data values of this point in the data fields and select Modify to
save the changes.
If you enter or modify data values in the dialog and select OK, the following occurs:

• If no Tracking Points are defined, the system adds a new point to the current
cutter using the values displayed in the dialog.
• If Tracking Points are defined, the system modifies the selected point using the
values displayed in the dialog.

To Delete a Tracking Point

1. Select Delete Point to delete the point

2. Select OK or Cancel to exit the dialog.

Selecting the Tracking Point in the Operation

You can only use user defined tracking points in Planar Profile operations.

1. In the Operation Dialog select Machine-→ Cutter Compensation. The system

displays the Cutter Compensation dialog.
2. In the Cutcom drop down menu select Engage/Retract.
3. Select the Output Contact/Tracking Data check box.
4. Select a name of a tracking point from the Tracking Point drop down menu.
5. Select OK.

The system uses the selected tracking point for the tool path output and the Z Offset,
Adjust register or Cutcom register if defined.

REAMER

A reamer is a rotary cutting tool generally of cylindrical or conical shape designed to

enlarge and finish holes to accurate dimensions. It usually has two or more peripheral
flutes either parallel to its axis or in a right or left hand helix as required.

Tool Parameters Description

(SD) Shank Diameter Reduced diameter of the tool shank.
(D) Diameter This diameter represents the diameter of the flutes of the
reamer.
(L) Length Maximum length that can be used for machining.
(FL) Flute Length The Reamer can drill beyond the flute length of the tool, unlike
 most other drilling tools.
(B) Taper Angle Some reamers are tapered. Especially those used to form the
inside diameter.
(TDD) Taper Diameter This is the distance from the tip of the tool to the point where
Distance the diameter is measured.
(TL) Tip Length This represents the length of the chamfer at the tip of the tool.

Boring tools are used for enlarging or finishing internal cylindrical forms by removing
metal with single point or tools with multiple cutting edges.

Tool Parameters Description

(SD) Shank Diameter of the shank.
Diameter
(D) Diameter Many boring bars have adjustable diameter settings and so the diameter
of these tools should be specified exactly.
(L) Length Maximum length that can be used for machining.
(CR) Corner This parameter indicates the corner radius of the tool tip (see the too
Radius shape).

Counter bore are rotary, often pilot guided, end cutting tools having one or more cutting
tips and usually having straight or helical flutes. They are used for enlarging holes for a
limited depth.

Tool Description
Parameters
(D) Diameter This parameter represents the diameter of the counterboring tool.
(L) Length Maximum length that can be used for machining.
(CR) Corner Radius between the body of the tool and the tip.
Radius
(PD) Pilot This parameter is the Diameter of the pilot.
Diameter
(PL) Pilot This parameter is the length of the pilot.
Length
Number of This parameter should be included so that the feed rate can be calculated
Flutes and may range from two flutes to more.

METHOD-GROUPS

Method Groups define the type of cut method (Rough, Finish, Semi Finish).
Parameters such as Intol, Outol, and Part Stock are defined. The various parameters used
to define Mill, Drill, Lathe, and Wire EDM Method Groups are described in the
following sections:

Feed Rates, Specify Colors, Additional Passes, Part Stock, Intol/Outol, Display Options,
Inheritance.

For more information on viewing, creating, and using Method Groups, see the Method
View.

Feed rates values can differ for the several types of tool movement during the progress
of the tool path. Also, you can express feed rate values in inches per minute or inches per
revolution (IPM, IPR) - or millimeter per minute or millimeter per revolution (MMPM,
MMPR) for metric parts. The default feed rates are 10 IPM (English Units) and 10
MMPM (metric units).

When you select the Feed Rates option (the actual option name will vary depending on
the machining module you are in), a feed rates dialog box is displayed. The Feed Rate
dialog box displayed will vary depending upon the machining module you use. This
section describes the Feed Rate options common to all machining modules except Wire
EDM. For Wire EDM Feed Rate options refer to Feed Rates in Wire EDM.

The order of the following feed rates is intended to follow a typical programming
feed rate sequence. This order is not yet implemented in all machining cut types.

The feed rate dialog box displays the current feed rate unit (e.g., IPR) and the current
feed rate value for each type of tool movement.

Feed rates may also be defined at the boundary level and at the boundary member level.
See Custom Boundary Data.

Rapid

Rapid applies only to the next GOTO point in the tool path and CLSF. Subsequent moves
use the last specified feed rate.
 A Rapid feed rate of zero causes the postprocessor command RAPID to be written
into the CLSF causing either a machine dependent rapid code (e.g., G00) or the
machine tool maximum feed rate to be output by the postprocessor.

Engage is the feed rate given for the tool movement from the Engage position to the
initial cutting position. This feed rate also applies to the return feed rate when the tool
returns to the workpiece after lifts. An Engage feed rate of zero causes the tool to engage
at the Cut feed rate.

Cut

Cut is the feed rate given for the tool movement while the cutter is in contact with part
geometry.

Retract

Retract is the feed rate given for the tool movement to the Retract position from the final
tool path cutting position. A Retract feed rate of zero causes the tool to retract at the
Rapid feed rate for linear moves and at the Cut feed rate for circular moves.

First Cut

First Cut is the feed rate given for the initial cutting pass. (Subsequent passes feed at the
Cut feed rate value.)

Approach is the Feed Rate given for the tool movement from the Start Point to the
Engage position. In Planar and Cavity Milling operations that use multiple levels, the
Approach feedrate is used to control the feed from one level to another.

In Surface Contouring, Approach is the feed rate given to the move prior to the engage
move. This move may come from either a Start move or a Traversal move.

In Drill and Lathe Groove modules, an Approach feed rate of zero causes the tool to
move at the Cut feed rate if specified minimum clearance is zero; otherwise, the Rapid
feed rate is used.

In the other modules, an Approach feed rate of zero causes the tool to move at the Rapid
feed rate if the engage method is specified; otherwise, the Engage feed rate is used.

Departure

Departure represents the feed rate for the moves out of the hole (or groove) used to clear
out the chips in Lathe Groove and Lathe Drill.

In Surface Contouring, Departure is the feed rate given to the move after a retract move.
This move may go to a Traversal move or may be a return move.
Thread

Thread is currently unavailable for all processors and is permanently greyed out.

Step over

Step over is the feed rate for the cutter as it moves to the next parallel pass. This does not
apply if the tool lifts from the work surface. Therefore, the Step over feed rate applies
only to modules allowing Zigzag tool paths.

Return is the feed rate for the tool move to the Return Point. A Return feed rate of zero
causes the tool to move at the Rapid feed rate.

Side Cut

The Side Cut option applies only to the Lathe Groove module. It controls the sideways
cutting movements for By Level Zig-Zag, Left to Right, and Right to Left cut methods. It
does not control the plunging and contouring movements. The Side Cut feedrate does not
apply to Plunge cut methods.

Traversal

Traversal (Planar Milling and Cavity Milling) is the feed rate used for fast horizontal
non-cutting tool motion when the Transfer Method option on the Engage/Retract dialog
box has a status of Previous Plane (instead of Clearance Plane).

Traversal feed rate is used only when the tool is the Vertical Clearance distance above the
uncut surface and the Horizontal Clearance distance away from any cavity islands or
walls. This protects part surfaces during tool transit and the tool may move without lifting
to the Clearance Plane.

Change Feed Rate Units allows you to specify tool motion in terms of inches per
minute, inches per revolution, or None. When you select this option you can specify Feed
Rate Units for:

• Each type of tool movement

• All non cutting tool movements
• All cutting tool movements

Or you may use Set All to None to set all feed rate units to None.

The Change Feed Rate Units option only appears in the older style menu boxes.

Feed Rates and Engage/Retract parameter interaction are illustrated in the following Feed
Rates figure.
Set Non-Cut Units

Set Non-Cut Units allows you to set all non-cutting feed rate units to IPM, IPR, or None
(or MMPM, MMPR, or None for metric parts).

Set Cut Units allows you to set all cutting feed rate units to IPM, IPR, or None (or
MMPM, MMPR, or None for metric parts).

In the older style menus Set Non-Cut Units and Set Cut Units are accessed for
modification through the Change Feed Rate Units option described below.

Feed Rates
This figure does not apply to Surface Contouring. For Surface Contouring, see Non-
Cutting.

Part stock is the amount of material to be left on the part after machining. This value will
be inherited by operations that are created under the method parent. You can override the
inherited value by entering a new value in the operation. Each of the processors have
specific ways in which they apply the part stock. For documentation on how part stock
works in each processor go to the documentation on the specific processor.

Procedure

1. Go to the Machining Method View.

2. Edit a method, such as MILL_ROUGH, with a double-click or MB3→Edit.
3. The system displays a MILL_METHOD dialog containing the part stock.
4. Enter a new value for the part stock.
5. Click OK.

Any operation that inherits their stock from this method now inherits the new stock and
needs to be regenerated.
Some parameters are passed down from group to group and from group to operation. For
example, an operation or a Method group inherits display and tolerance parameters from
another Method group. Not all operations can be placed in all Method groups. Different
operations can inherit different parameters.

Method inheritance can be overridden in an operation. For example, if an operation

inherits into from a method group and you change the into in the operation, the
inheritance of the into parameter is turned off.

The graphic below explains this in greater detail. From this graphic you can see the
following:

• The MILL_FINISH parent contains the stock and tolerance information.

• The BLUE parent contains the display color and feed rate information for the two
operations listed below it.
• The GREEN parent contains the display color and feed rate information for the
three operations listed below it.
• The operations listed below the BLUE parent inherit the stock and tolerance
information from MILL_FINISH and the display color and feed rate information
from BLUE.
• The operations listed below the GREEN parent Inherit the stock and tolerance
information from MILL_FINISH and the display color and feed rate information
from GREEN.

There are two methods to see the status of a parameter:

• The Inheritance Status icon .

• The inheritance list

The Inheritance Status Icon

The Inheritance Status icon beside many parameters tells you at a glance if the
parameter is inherited or locally set in the operation. This icon has two states:

Local The value is locally defined in the current dialog (for example, the operation
dialog).
Inherited The parameter is inherited from a parent object. When you modify this
parameter, you see that the icon changes to the Local mode, meaning that it is
no longer inherited.
• Hover with the mouse over the input field to see the origin of the inherited
value.
• Hover with the mouse over the icon to see if the parameter is local or
inherited.

• Double-click on the icon to easily switch between local and inherited status.
The Inheritance List

You can also use the inheritance list to see where an operation is getting its method.
There are two ways to access the inheritance list:

• Choose Details in the Operation Navigator. The system displays the Details
Panel containing the inheritance list.
• MB3 on the operation → Object → Inheritance List.

Templates are operations and groups within CAM Part files which contain predefined
parameters that enable you to quickly and easily define new operations and groups
tailored to your specific needs. They eliminate the tedious task of redefining parameters
from a set of standard system defaults each time you define a new operation or group.

Templates appear as subtype icons available in the Create Operation and Create Program,
Tool, Geometry, and Method group dialog boxes (object dialog boxes). Templates define
operation parameters which include numeric values (Part Intol, Part Outol, Feed Rates,
Stepover Distance, etc.), and can display customized object editing dialog boxes
("Create" dialogs). In addition, templates determine the groups and operations that
initially appear in the Operation Navigation Tool when you first enter Manufacturing
with a new part.
A Template Part File is a CAM part file containing a collection of Templates (predefined
operations and groups) from which you may choose. Template Part files appear in the
CAM Setup portion of the Machining Environment dialog box and are listed as Type
options in the operation and group creation dialog boxes. A Template Set is a collection
of Template Part Files from which you may choose. Template Sets are specified within
the Configuration files.
Template Sets may be created and maintained by end-users or by system managers,
depending on your work environment. Templates Sets are also provided and maintained
by NX for each release. The Template Sets you create may use any valid naming
convention and may be stored in any directory. Template Sets must, however, use an .opt
extension. The standard NX supplied Operation Template Sets use a specific naming
convention and reside in a specific directory (refer to the Configuration Files section)
when initially installed on your system.
You may re-specify the current Template Set by selecting Preferences>CAM
General>Specify Template Set and then specifying the Template Set directory and name.
Whenever you re-specify a Template Set, the available Type options in the object dialog
boxes change to reflect the new Template Part Files. You may also select a Template Part
File with the Browse option in the Type option list.

When you create a new Operation, you specify the desired Template Part by choosing a
Type and specify the desired template by choosing a machining application (subtype
icon) in the Create Operation dialog box. The template parameters are copied into the
new operation. When you create a new Group, you specify the desired Template Part by
choosing a Type and specify the desired group template by choosing a subtype icon in the
Create Program, Tool, Geometry, or Method group dialog.

Wizard Builder needs to know which template parts are available to the NX session, and
which objects in those template parts it can use to create new objects. This information is
customer-specific. If you have customized templates, you must export them to an XML
file, manufacturing_template.xml, as described below, prior to using the Manufacturing
Wizard Builder. Manufacturing Wizard Builder reads this XML file when creating a
wizard.

NX exports all template part files to $UGII_CAM_TEMPLATE_PART_DIR. The

software exports the subdirectory associated with the unit of the part that is active at the
time you start the export (inch or metric). Any additional template parts that have been
loaded using the Browse... feature are not written to the XML file.

To export the template part files to XML, proceed as follows:

1. In NX, enter the Manufacturing application.

2. Select File → Export →Wizard Template Data. The system opens a file
selection dialog.
3. Select the Simulation Process Studio installation directory, ...\NX installation
files\PSSTUDIO. This is where the Manufacturing Wizard Builder looks for the
XML file containing the template information.

The system creates the XML file, manufacturing_template.xml, and stores it in the
directory you specified.

PLANNER-MILLING
Planar Milling operations create tool paths that remove volumes of material in planar
layers. This type of operation is most commonly used to rough out material in preparation
for a finishing operation.

Cavity Milling and Planar Milling are similar in that they both remove material in cut
levels that are perpendicular to the Tool Axis. However, the two operation types differ in
the method used to define the material.
 • Planar Milling uses boundaries to define the Part material.
• Cavity Milling uses boundaries, faces, curves, and bodies to define the Part
material.

Planar Milling is intended to cut parts with vertical walls, and planar islands and floors
normal to the tool axis. Cavity Milling is intended for parts with tapered walls and
contoured floors as illustrated below.

Planar and Cavity Mill Parts

The Cut Volume is the material to be removed. You can specify the material to be
removed as the Blank material (stock piece, forging, casting, etc.), minus the Part
material as illustrated below. You can define the Blank and Part geometry with
boundaries in Planar Milling, or by selecting faces, curves, or bodies in Cavity Milling.

Part and Blank Geometry

In Planar Milling, boundaries are used to define the Part, Blank, Check, and Trim
geometry. The boundaries are swept along the tool axis to the Floor Plane to define the
Part and Blank volumes.
Blank and Part Boundaries

In the above figure, a Blank boundary defines the Blank volume and multiple Part
boundaries define the Part volume. The cut volume (material to be removed) is defined
by the Blank volume minus the Part volume.

It is not always necessary to specify a Blank boundary. A Part boundary may serve as a
peripheral loop (main containment boundary) by enclosing the other Part boundaries as
illustrated below.

Part Boundaries

In the above figure, a Part boundary serves as a main containment boundary, essentially
defining the Blank volume. Multiple Part boundaries within the main containment
boundary define the Part volume. The cut volume (material to be removed) is defined by
the difference between the Blank volume and the Part Volume.

Boundaries can be defined by selecting curves or edges, permanent boundaries, or faces.

To correctly identify the Part and Blank volumes, boundaries should be placed at the top
of the material.

Although a Blank boundary may be specified as Tanto, the tool does not actually cut
tangent to a Blank boundary. If it did, the tool would cut through empty space for the first
pass and no material would be removed until the first stepover. Instead, the first cutting
pass is offset into the Blank material the distance of one stepover as illustrated below.

Tanto on a Blank Boundary

The above figure illustrates the first Tanto pass of a Follow Periphery cut pattern on a
Blank boundary.

With the Follow Periphery pattern, some narrow regions may not be cut, and may
leave excess material for the next cut level. For this reason, wall cleanup and island
cleanup should both be turned on in the cutting parameters. These assure that the
cutter takes a pass along each part and island wall, and does not leave any excess
material.

Part allows you to specify geometry that will represent the finished Part.
 Blank allows you to specify geometry that will represent the raw material you wish to
cut away. A Blank boundary does not represent the final part and can be cut through or
engaged into directly.

Check enables you to define geometry you do not wish to violate such as clamps that
hold the part. The areas where the Check Geometry overlaps the volume of material to be
removed will not be cut You may specify a Check Stock value (Cutting>Check Stock)
which defines the distance the tool will be positioned from the Check Geometry. A Tanto
tool position is applied to Check Boundaries.

Check Boundary

When the tool encounters Check Geometry, it will either cut around the Check geometry
(as illustrated above) or it will retract depending on the status of Follow Check in the Cut
Parameters dialog box.

Trim allows you to specify boundaries that will further constrain the cut regions at each
cut level. You may define the area of the cut region to exclude from the operation by
specifying the Side Trimmed as Inside or Outside for Closed boundaries, or Left or Right
for Open boundaries.
Side Trimmed Outside

You may specify a Trim Stock value (Cutting>Trim Stock) as illustrated below to define
the distance the tool will be positioned from the Trim Geometry.

Trim Boundary

An On tool position is always applied to Trim Boundaries. You do not have the option of
specifying a Tanto condition.

Floor defines the lowest (last) cut level. All cut levels are generated parallel to the Floor
plane. Only one Floor can be defined per operation. Redefining the Floor automatically
replaces the existing Floor.

The following figure illustrates an example of how the Floor correctly defines the lowest
cut level when a Blank boundary is used.
Floor Defining Lowest Level of Blank Geometry

The following figure illustrates an example of how the Floor correctly defines the lowest
cut level when only Part boundaries are used.

Floor Defining Lowest Level of Part Geometry

The cutter must be able to reach the Floor without gouging the part. If the Floor defines a
cut level that is inaccessible as illustrated below, an error message is displayed.

Inaccessible Floor Plane

If you do not specify a Floor, the system uses the X-Y plane of the Machine Coordinate
System (MCS).

2D-CONTACT-CONTOUR

The 2D Contact Contour functionality is available only in the operation type, Planar
Profile.

When you use Contact Contour, the path starts at the centerline, moves to the contact
points, and then moves back to the centerline. The traversal moves at the start of the path
are all at the tool centerline. On the engage move where Cutcom is automatically turned
on, the path starts at the tool centerline, and ends at the contact point. The path stays at
the contact points until the tool reaches the retract move where Cutcom is automatically
turned off. This move starts at the contact point, and ends at the centerline point. Further
moves to retract and traverse are output at the centerline.
When the output path follows the contact path (contact points), the software calculates
the corresponding tool center path and positions the tool appropriately.

Benefits of Using 2D Contact Contour

• Basing the output data on the geometry shape that controls the side of the tool
allows you to compensate for tool wear without having to regenerate the tool path.

• This also allows for variation in tool size. You have flexibility with the size of
tool that can be used. For example, if you don't have a 1.000 inch (24mm)
diameter cutter, but have one that is smaller, you can compensate by simply
adjusting the cutter diameter right on the shop floor. Time is saved because you
don't have to rework the program. You can compensate for variation in the tool
diameter right at the machine.
• The numbers in the tool path can reflect the dimensions of the part so that you can
compare the tool path data in the program with part geometry dimensions.

The figure below illustrates a part machined with Planar Profile, but it does not use 2D
Contact Contour. Note that the tool path (in blue) is output at the center of the cutter.

Part Machined Without Using 2D Contact Contour

When using 2D Contact Contour Machining, the Planar Profile processor can output the
tool path to representing the contact locations at the perimeter of the cutter or at any user-
defined tracking position on the cutter. The figure below shows the tool path being
output at the periphery of the cutter (with ADD ARCS active).
Part Machined Using 2D Contact Contour with Add Arcs

When you use Cutter Compensation (Cutcom) with 2D Contact Contour Output, the
Cutter Compensation is activated during a straight line move (yellow line in the figure
above) that is the Automatic Linear Engage or that precedes the Automatic Circular
Engage (yellow curve in the figure above). During that linear move, the tool path is
output from the center of the tool end at the start of the move to the first Contact Contour
position at the end of the move.

Engage and Retract

For the figure below, the dotted line represents the centerline path, and the solid line
represents the contact contour path. Note that the tool motion is the same for both paths.
The solid yellow arrow represents the engage move where CutCom starts. The tool
starts at the centerline path (dotted line) and then moves to the contact point (perimeter of
the tool). The dark blue solid line indicates the retract move where CutCom is turned off.
Just as the engage move starts at the centerline path, the retract move ends at the
centerline path.

Engage and Retract

Using 2D Contact Contour

• In a Planar Profile operation, press the Machine button.

• The Machine Control dialog appears.
 • Press the Cutter Compensation button
• Set CutCom to Engage/Retract.
• Select the check box for Output Contact/Tracking Data.

Make sure you set all Engage/Retract options to Automatic.

Programmed Cutter Size

The programmer is responsible for telling the operator the allowable range for cutter size.

Because the true size of the cutter is not known until the part is machined, the graphical
display of the part shape may not truly represent the shape that is actually cut, depending
on the capabilities of the machine tool controller. The tool size that the system displays
is the cutter size that you program.

Some problems with cutter compensation in the CNC controller can occur if the actual
cutter size is much larger than the programmed cutter size, and may cause the part to be
gouged. The figure below illustrates the correct programmed cutter size. Notice that
with this size, there is enough room to engage the cutter without violating the part.

Programmed Cutter Size

If the actual tool is so much larger that it exceeds the length of the engage move, the tool
may gouge the part, or not have enough room to activate Cutter Compensation. The
figure below illustrates this.
Cutter Larger Than Programmed Size
Corner Control

There are two distinct forms of the output when the 2D Contact Contour option is active.
These two options for Corner Control are designed to match the distinct capabilities
available on various controllers.

• Add Arcs - The system adds arcs to the output geometry path, preventing the
cutter from entering restricted areas where the cutter may gouge the part (refer
again to the figure below).

Tool Contacts at Vertex with Add Arc Corner Control

• Extend Tangents - The system outputs a tool path that is determined by the
movement of the cutter and the active tracking point. In many internal corner
cases, the tool path is extended to a sharp corner (refer to the corners of the right
portion of the figure below) to accommodate the Cutter Compensation
functionality of the controller. It is up to the machine tool controller to calculate
the tool positioning along that shape and make decisions about where the cutter
can fit and where it cannot.

Tool Contacts at Vertex with Ext Tan Corner Control

 If the actual cutter size is smaller than the programmed cutter size, and Corner
Control is set to Extend Tangents, the fillets generated in the corners of the actual
part may be smaller than the programmed part. Setting Corner Control to Add Arcs
prevents this situation.
Add Arcs Special Cases

Even when Corner Control is set to Add Arcs, there are some cases where Extend
Tangents is still used:

• When two adjacent segments touch the tool at the same time, arcs aren't added.
The corner is treated like Extend Tangents. This is shown in the three corners on
the left side of the figure below.
• When two segments that aren't adjacent touch the tool at the same time, the corner
is considered complex, and arcs are added. This is shown in three places on the
right side of the figure below.

CUT-DEPTH-IN-PLANNER-MILLING

Cut Depths allows you to determine the cut levels of a multi-depth operation. Cut Depths
may be defined by island tops, the floor plane, and by keying in values. The Cut Depths
parameters only apply if the tool axis is normal to the floor, or the part boundary is
parallel to the floor. If the tool axis is not normal to the floor, or the part boundary is not
parallel to the floor, then the tool path will be generated on the floor only (as if the Type
had been set to Floor Only). Cut Depths displays a dialog box containing the following
options:

Type Specifies the method used to define the cut depths

 Maximum Defines the largest allowable cut depth for each cut level occurring after
the Initial level and before the Final level
Minimum Defines the smallest allowable cut depth for each cut level occurring
after the Initial level and before the Final level
Initial Defines the cut depth for the first cut level of a multi-level Planar
Milling operation
Final Defines the cut depth for the last cut level of a multi-level Planar
Milling operation
Increment Side Adds a side stock value to each succeeding cut level in a multi-level
Stock roughing tool path
Top Off Islands Generates a separate path on the top of each island that the processor
could not initially clean with one of the cut levels
Type

Type allows you to specify the method used to define the cut depths. The method you
select determines which numeric values may be input in the above dialog box. A cut level
is always generated at the floor regardless of which method you select.

The option you select here is displayed in the Planar Milling dialog box under Cut Depths
for easy visual reference. Each of the above Type options are described on the following
pages.

User Defined

User Defined allows you to specify cut depths exclusively by entering numeric values.
This option activates the Maximum, Minimum, Initial, Final, and Increment Side Stock
fields. The Top Off Islands button also becomes available. Each of these options are
described on the following pages.
User Defined
Floor Only

Floor Only generates a single cut level at the Floor plane as illustrated below.

Floor Only
Floor & Island Tops

Floor & Island Tops generates a single cut level at the Floor Plane followed by a cleanup
path at the top of each island. Cleanup paths are restricted to the top face of each island
and do not cut outside the island boundaries. Notice in the following figure how the tool
paths do not superimpose on top of one another in the top view.

Floor & Island Tops

Notice in the above figure that planar "levels" are not created as they would be if using
Levels At Island Tops.

It is important when using this option to understand what NX regards as an island. In the
above figure, for example, cleanup paths are created in what appear to be pockets.

Levels At Island Tops

Levels At Island Tops generates a planar cut level at the top of each island followed by a
single cut level at the Floor Plane. Unlike cleanup paths which do not cut outside the
island boundaries, cut levels generate tool paths that completely remove all blank
material within each planar level. Notice in the following figure how the tool paths
superimpose on top of one another in the top view. This option activates the Initial, Final,
and Increment Side Stock fields.

Levels At Island Tops

It is important when using this option to understand what NX regards as an island. In the
above figure, for example, cut levels are created in what appear to be pockets.

Fixed Depth

Fixed Depth generates multiple cut levels at a constant depth. Maximum is used to
specify the cut depth. You can also specify an Increment Side Stock value. Top Off
Islands may be used to define additional cleanup paths for island tops that do not coincide
with the cut levels.
Fixed Depth
Maximum and Minimum

Maximum defines the largest allowable cut depth for each cut level occurring after the
Initial level and before the Final level. Minimum defines the smallest allowable cut depth
for each cut level occurring after the Initial level and before the Final level. These two
options work together to define an allowable range in which cut depths can be defined.
The system creates equal depths as close to the specified Maximum depth as possible.
Island tops falling within this range will define cut levels. Island tops not falling within
this range will not define cut levels, but may be machined with a cleanup path using the
Top Off Islands option.

Maximum and Minimum

NOTE: If Maximum equals 0.000, the system will generate a single cut level at the
Floor plane regardless of the other Depth of Cut parameters. Top Off Islands and
Final, for example, will not affect the operation if Maximum equals 0.000. This
feature allows the system to accommodate operations that were generated with a prior
release that only allowed single level planar milling.

The specified Maximum cutting depth is displayed directly on the Planar Milling dialog
box easy visual reference.

Initial

Initial allows you to define the cut depth for the first cut level of a multi-level Planar
Milling operation. This value is measured from the Blank Boundary plane (or if a Blank
Boundary has not been defined from the highest Part Boundary plane) and is independent
of the Maximum and Minimum values. See the Maximum and Minimum figure.

Final

Final allows you to define the cut depth for the last cut level of a multi-level Planar
Milling operation. This value is measured from the Floor Plane. See the Maximum and
Minimum figure.

If Final is greater than 0.000, the system generates at least two cut levels; one at the Final
distance above the Floor plane and the other on the Floor plane. Maximum must be a
value greater than Zero when using User Defined Type to generate more than one cut
level.
Increment Side Stock

Increment Side Stock adds a side stock value to each succeeding cut level in a multi-level
roughing tool path. Adding Increment Side Stock maintains side clearance between the
cutter and the wall, and relieves stress on the cutter as it cuts deeper cut levels. Cut level
1 will apply the Part Stock value. Cut level 2 will begin to apply side stock value equal to
one time the specified Increment Side Stock value. Cut level 3 will have a side stock
equal to two times the specified Increment Side Stock, and so on. The following figure
shows how the Increment Side Stock will be applied.

Incremental Side Stock Application

Top Off Islands

Top Off Islands - toggles between ON and OFF. If Top Off Islands is set to ON, the
system will generate a separate path on the top of each island that the processor could
initially not clean with one of the cut levels. This case can occur when the Minimum
depth of cut value is greater than the distance between the top of island and previous cut
level, causing the subsequent cut level to cut below the island top.

When using Top Off Islands, if the machining method is Follow Periphery or Follow
Part, the system will always generate the Follow Periphery cutter path with region
connection. If the machining method is Zig, Zig Zag, or Zig With Contour, the tops of the
islands will always be cleaned up with a Zig Zag cutter path. Profile or Standard Drive
type cuts will not generate such a clean up pass.

The processor will find a safe point for the tool to engage from outside of the island to the
island's top surface without gouging any of the part's walls without regard for any engage
methods that can be set.

In the event that the top surface of the island was finished off by one of the cut levels, this
parameter will have no influence on the resulting tool path. Even if Top Off Islands is set
to ON, the system will only generate a separate cleanup path to top off an island if it is
necessary. The following figure shows how the processor determines the cut level planes.

Top Off Islands in Planar Milling

Final Floor Stock is a cut parameter specific to Planar Milling.

Final Floor Stock enables you to specify the amount of material to remain on the floor of
the pocket (Floor plane and the top of the islands) after the completion of the tool path
generated by the current operation.

Blank Distance is a cut parameter specific to Planar Milling in its behavior. Instead of
a blank boundary, the blank can be specified as a constant distance larger than the part.
This is useful when working on a casting or a part that has a constant thickness of
material to be removed.

Cavity Milling operations create tool paths that remove volumes of material in
planar layers. This type of operation is most commonly used to rough out material in
preparation for a finishing operation.

Cavity Milling and Planar Milling are similar in that they both remove material in cut
levels that are perpendicular to the Tool Axis. However, the two operation types differ in
the method used to define the material.

• Planar Milling uses boundaries to define the Part material.

 • Cavity Milling uses boundaries, faces, curves, and bodies to define the Part
material.

Planar Milling is intended to cut parts with vertical walls, and planar islands and floors
normal to the tool axis. Cavity Milling is intended for parts with tapered walls and
contoured floors as illustrated below.

Planar and Cavity Mill Parts

The Cut Volume is the material to be removed. You can specify the material to be
removed as the Blank material (stock piece, forging, casting, etc.), minus the Part
material as illustrated below. You can define the Blank and Part geometry with
boundaries in Planar Milling, or by selecting faces, curves, or bodies in Cavity Milling.

Part and Blank Geometry

In Planar Milling, boundaries are used to define the Part, Blank, Check, and Trim
geometry. The boundaries are swept along the tool axis to the Floor Plane to define the
Part and Blank volumes.
Blank and Part Boundaries

In the above figure, a Blank boundary defines the Blank volume and multiple Part
boundaries define the Part volume. The cut volume (material to be removed) is defined
by the Blank volume minus the Part volume.

It is not always necessary to specify a Blank boundary. A Part boundary may serve as a
peripheral loop (main containment boundary) by enclosing the other Part boundaries as
illustrated below.

Part Boundaries

In the above figure, a Part boundary serves as a main containment boundary, essentially
defining the Blank volume. Multiple Part boundaries within the main containment
boundary define the Part volume. The cut volume (material to be removed) is defined by
the difference between the Blank volume and the Part Volume.

Boundaries can be defined by selecting curves or edges, permanent boundaries, or faces.

To correctly identify the Part and Blank volumes, boundaries should be placed at the top
of the material.

Although a Blank boundary may be specified as Tanto, the tool does not actually cut
tangent to a Blank boundary. If it did, the tool would cut through empty space for the first
pass and no material would be removed until the first stepover. Instead, the first cutting
pass is offset into the Blank material the distance of one stepover as illustrated below.
Tanto on a Blank Boundary

The above figure illustrates the first Tanto pass of a Follow Periphery cut pattern on a
Blank boundary.

With the Follow Periphery pattern, some narrow regions may not be cut, and
may leave excess material for the next cut level. For this reason, wall cleanup
and island cleanup should both be turned on in the cutting parameters. These
assure that the cutter takes a pass along each part and island wall, and does not
leave any excess material.
Overview Options Related Topics

Plunge Milling is a unique milling operation that is best used in deep

areas that require a long tool. Successive plunge motions take advantage of the increased
rigidity when a tool moves along the z-axis to efficiently rough out large volumes of
blank. The reduced radial force makes it possible to use long slender tools and maintain a
high rate of material removal. Plunge Milling is attractive for finishing hard-to-reach
deep walls using long slender tool assemblies.

Using Plunge Milling to rough contoured shapes usually leaves large scallops and steps.
Use an in-process workpiece in the following operations to get a more consistent
remaining stock.

Plunge Regions

Most ZLevel operations cut from the top down. Plunge Milling starts at the deepest
plunge depth. Each successive region then ignores the previous region.

When a cavity has multiple regions, they are grouped and cut in order (bottom-up). The
figure below shows a sample cutting order for multiple regions.

Multiple Plunge Regions

Cutting From the Top Down

Because Plunge Milling is a bottom-up operation, to cut from the top down you must
create multiple operations, each with a range below the previous one. The first operation
range would be from the top of the part to some midway level, the next below that, etc.
Within each operation, the cutting remains bottom up.

Operation Parameters

Plunge Milling operations have similar roughing options to Cavity Mill. Plunge Milling
uses the Profile cut method for finishing, and the options are similar to ZLevel profile
operations. A few additional parameters, such as Step Ahead and Max Cut Width, are
supported.

Where Do I Find It?

To use Plunge Milling:

Create Operation→ Type = mill_contour→ Subtype = PLUNGE_MILLING

Z-Level Milling is a fixed axis milling module designed to profile the part
modeled from solid bodies/faces at multiple levels. It allows you to cut only steep areas
of the part or the entire part. In addition to the Part geometry, you may also specify the
cut area geometry as a subset of the Part geometry to limit the areas to be cut. If no cut
area geometry is defined, then the entire Part geometry is considered the cut area. During
the tool path generation, the processor will trace the geometry, detect the steep areas of
the part geometry if requested, order the traced shapes, identify the cut areas to be
machined, and cut those areas without gouging the part for all cut levels.

One key feature of Z-Level Milling is the ability to specify a Steep Angle to distinguish
steep from non-steep areas. When Steep Angle is toggled ON, only areas with a steepness
greater than the specified Steep Angle are profiled. When Steep Angle is toggled OFF,
the entire part is profiled as illustrated below.
Many of the parameters defined in Z-Level Milling are the same as those require for a
Cavity Mill operation. Refer to the section on Cavity Milling for additional details on
options not fully described in this section.

Note that Z-Level cutting can be especially effective for High Speed Machining:

• You can maintain scallop height on steep walls.

• You can cut multiple levels in one operation.
• You can cut multiple features (regions) in one operation.
• You can cut by level (waterline) for thin-walled parts.
• There is wide availability of linear, circular, helical engages at each level.
• You can maintain the tool in constant contact with the material.
• You can finish by using Z-Level for steep walls.

Advantages to Using Zlevel Instead of Cavity Milling

In some cases, Cavity Milling with a Profile cut method can produce a similar tool path.
Because Zlevel is designed for semi-finishing and finishing, there are several advantages
to using Zlevel instead of Cavity Milling:
 • Zlevel does not require blank geometry.
• Zlevel will use cut area--either selected in the operation or inherited from a
mill_area.
• Zlevel can inherit trim boundaries from a mill_area group.
• Zlevel has steep containment.
• When cutting depth first, Zlevel orders by shape, where Cavity Milling orders by
region. This means that all levels on an island part shape are cut before moving to
the next island.
• On closed shapes, Zlevel can move from level to level by ramping directly on the
part, to create a helical-like path.
• On open shapes, Zlevel can cut in alternating directions, creating a zig-zag motion
down a wall.

Face Milling Overview

Face Milling is best at cutting planar faces on solid bodies such as pads on a casting. By
picking the faces, the system automatically knows not to gouge the rest of the part.

There are three templates provided for creating face milling operations. Create Operation
→ Mill_Planar → and then selecting one of the following:

• Face Milling Area Face Milling Area has part geometry, cut area, wall
geometry, check geometry, and automatic wall selection.

• Face Milling Face Milling has part geometry, faces (blank boundaries),
check boundaries, and check geometry.

• Face Milling Manual Face Milling Manual contains all the geometry types,
and the cut pattern is set to mixed.

Specify Face Geometry

• With Face Milling, you can specify the face geometry simply by selecting the
faces to be machined.
• You also can define face geometry by selecting existing curves and edges or by
specifying a sequence of points in much the same way as in Planar Milling.
• You can easily create boundaries from a face and its chamfers using an option
called Ignore Chamfers.
• Face Milling automatically combines regions that are within close proximity and
need to be cut to the same height.
• Additionally, with Face Milling you can program the cutting and traversing of
voids.

Specify the amount of material to be removed

 • With Face Milling, you can specify the amount of material to be removed and the
surrounding part and check geometry to avoid gouging. The selected faces define
the floors to be faced off. By selecting the solid body as part geometry, the system
can avoid gouging the part.
• The thickness of the material to be removed is measured upward from the level of
a face boundary plane and along the tool axis. All boundaries of the Face
Geometry can be defined at different levels. The tool axis is automatically defined
as the normal of the first selected face boundary plane. Since Face Milling
removes material in planar levels with respect to the tool axis, the normal of a
face boundary plane must be parallel with the tool axis. If it is not, the face will be
ignored during tool path generation.

Although Planar Mill can be used to perform Face Milling, the Face Milling Module
greatly simplifies the process. In Planar Mill, you can create the boundary geometry by
picking the desired face, lifting the boundary to the desired height, and selecting the floor
at the plane of the planar face. Several operations may be needed when planar faces to be
machined are at different levels.

A Face Milling operation is created from a template, and requires geometry, a tool, and
parameters to generate a tool path. The face geometry is required as an input for tool path
generation. For each selected face, the processor traces the geometry, identifies regions to
be machined, and cuts these regions without gouging the part.

The Face Milling dialog box enables you to specify whether you wish to define Part,
Face, or Check geometry. It contains many parameters common to Planar Milling. Each
is described in the following sections.

Engages and Retracts

For Face Milling automatic engages/retracts, the system always attempts to generate safe
moves. For engage moves, this means engaging from an open air position whenever
possible.
Fixed and Variable Contour
Fixed and Variable Contour are machining methods used to finish areas formed by
contoured surfaces. They enable the tool path to follow intricate contours of very
complex surfaces by allowing you to carefully control the Tool Axis and Projection
Vector.

Variable Contour Using Drive Surfaces

Tool paths are created by projecting Drive Points to Part Geometry. Drive points are
generated from Drive Geometry, such as curves, boundaries, faces, or surfaces, and
projected along a specified projection vector to the Part Geometry. The tool then
positions to the Part Geometry to generate the tool path.

The following figure illustrates how an operation is created by projecting Drive Points
from a bounded plane to a Part Surface. An array of Drive Points is first created within
the boundary and then projected along a specified Projection Vector to the Part Surface.

Projection of Drive Points

The tool positions to contact points on the Part Surface. As the tool moves across the part
from one contact point to the next, the tool path is created using the Output Cutter
Location Point at the tip of the tool.
Boundary Drive Method

The Surface Area Drive Method provides additional control over both the Tool Axis and
the Projection Vector. The following figure illustrates how an operation is created by
projecting Drive Points from a Drive Surface to Part Surfaces. An array of Drive Points is
first created on the selected Drive Surface and then projected along the specified
Projection Vector to the Part Surfaces. The tool positions to the Part Surfaces at Contact
Points. As the tool moves from one Contact Point to the next, the Tool Path is created
using the Output Cutter Location Point at the tip of the tool. In this example, both the
Projection Vector and the Tool Axis are variable and are defined as normal to the Drive
Surface.

Surface Area Drive Method

The following figure illustrates how a Tool Path is created directly from the Drive Points
when there is no defined Part Geometry. An array of Drive Points is created on the
selected Drive Surface. The tool positions directly on the Drive Points which become the
Contact Points. In this example, the Tool Axis is variable and is defined as normal to the
Drive Surfaces.
Tool Path on Drive Surfaces

A Fixed Tool Axis remains parallel to a specified vector. A Variable Tool Axis
constantly changes orientation as it moves along the Tool Path. If you specify Fixed
Contour, only the Fixed Tool Axis options are available. If you specify Variable Contour,
all Tool Axis options (except Fixed) are available.

The Drive Method enables you to define the Drive Points required to create a Tool Path.
Some Drive Methods allow you to create a string of Drive Points along a curve while
others allow you to create an array of Drive Points within an area. Once defined, the
Drive Points are used to create a Tool Path. If no Part geometry is selected, the Tool Path
is created directly from the Drive Points. Otherwise, the Tool Path is created by
projecting Drive Points to the Part Surfaces along the Projection Vector.

The Projection Vector enables you to define how the Drive Points project to the Part
Surface and the side of the Part Surface the tool contacts. The selected Drive Method
determines which Projection Vectors are available. Projection Vectors can be defined for
all Drive Methods except Flow Cut, which does not utilize Projection Vector. When
machining directly on the Drive Geometry (Part Geometry is not defined), the Projection
Vector is not used.

In Surface Contouring, all Part Geometry is processed as bounded entities. Accordingly,

since Surface Contouring entities are finite, the tool can position only to existing
locations on the Part Geometry (and that includes the edge of an entity.) The tool cannot
position to an extension of the Part Geometry. Drive Geometry, however, can be
extended.

Zig-Zag Surface is a processor that was used in the 1980's and 1990's. It is now obsolete
and should not be used for new work. Because it is obsolete the documentation will no
longer be updated or maintained in any way. Area Milling should be used for work
originally done with Zig-Zag Surface.

Zig-Zag Surface machining is designed for contour machining a single trimmed surface.
Zig-Zag Surface also provides the capability to offset the tool from holes trimmed in the
surface (by the radius of the tool plus any specified stock). You can specify a tool path
direction or accept a system-generated tool path direction. Both Zig and Zig-Zag cut
types are available.

Zig-Zag Surface tool paths are generated in parallel passes, using a chordal
approximation of the surface to be machined. You can control the number of input points
by a chordal deviation in the direction of cut. This is the allowable deviation from the
surface. Scallop Height controls the distance between parallel passes according to the
maximum height of material (scallop) you specify to be left between passes. This is
affected by the cutter definition and the curvature of the surface.
Zig-Zag Surface also provides gouge check so that the system can check for violation of
the surface. You have the following options available:

Surface Selection Specify Edge Tolerance, Stock, and Gouge Check Area
Methods
Modify Hole Selection Edit Hole List, specify Tolerance and Stock
Part Geometry Reselects the surface to be machined and to respecifies the hole
data
Avoidance Geometry Specifies, activates (or cancels) geometry used for non-cutting
moves
Display Options Determines how the tool and tool path are displayed on the
screen
Machine Control Redefines the cutting tool and enters post processor commands
in the tool path
Feeds Specifies feedrate values for different types of tool movements
Engage Retract Secifies tool motion to bring the tool safely into or away from
the part
Fl Stck/Min Clr Specifies a value by which the tool or tool path is offset
Tool Axis Specifies a value by which the tool or tool path is offset
Material Side Determines which side of the part surface machined
Step Tolerances Sets two variables that determine sur face roughness
Cut Type Zig or Zig-Zag
Step Type/Dir Specifies the cut direction method
Offset/Gouge Different methods of surface checking
Verify Points Displays contact points the system uses in calculating the cutter
path

Avoidance Geometry, Display Options, Machine Control, and Feeds are common to all
cutting options and are discussed in the Common Options section.

Zig-Zag Surface Machining

Interactive Sequence

The following are the general interactive steps involved in the Zig-Zag Surface operation:

• Describe the cutter.

• Select the surface to be machined.
• Select holes.
 • Set the remaining operation parameter values and status (e.g., tool path direction
and type, tool axis, start point, clearance plane, feed rates).
• Generate, and either accept or reject the tool path.

Specify the output path name and enter any desired Edge Tol, Stock, and/or Gouge Check
Area values before you select the surface.

Interactive Input also can be defined at the boundary level, at the boundary member level,
and the group level, using Custom Boundary Data.

The following pages provide a description of the surface selection methods available.

Name Definition Where

Additional Material on Part as permanent definition Geometry
Part Offset
(Contour only) Group
Remaining material on Part by a given operation, should be
Part Stock Operation
0 for the last finishing operation
Difference between the Part Stock from the previous
Part Stock
operation and the Part Stock of the current operation Operation
Offset
(Contour only)
Safe
Additional safety zone on Part/Check for collision checking Operation
Clearance
Operation

Any stock amount that you specify at the operation level is added to Part Offset value.

Stock Types
1 Check Safe Clearance
2 Part Safe Clearance
3 Part Stock Offset
4 Part Stock (Custom Part Stock)
5 Part Offset (Custom Part Offset)
 Part Stock Offset and Part Offset are for Contour only.
Custom Data Offset

Every operation defaults to the same offset for that particular geometry group. However,
you can override this default by customizing an offset for that particular operation. In the
figure above, Custom Part Stock can override Part Stock (4), and Custom Part Offset can
override Part Offset (5).

1. While in Geometry view, click on Work piece.

The MILL_GEOM dialog appears

2. Highlight the Part icon , and press Select.

3. Press the Custom Data button.

The Part Geometry dialog appears.

4. In the Custom Data section, if you select the checkbox for Offset, you can enter a
Part Offset amount.

The Cut Feed text field allows you to specify the Feed Rate for tool movement while the
cutter is in contact with the Part Geometry.

Cut Depth and Maximum (Planar Milling)

Cut Depth allows you to define the method for determining the cut levels of a multi-depth
Planar Mill operation.

The following options are available for defining Cut Depth:

User Defined and Fixed Depth activate the Maximum field. Maximum allows you to
define the maximum cutting depth that the system should use in calculating the cut levels
of a multi-level Planar Milling operation.

The selected Cut Depth option and Maximum value are displayed in this section of the
Planar Milling dialog box for easy visual reference. They may also be defined (along
with additional parameters) using the Cut Depths button in the Machining Parameters
section of this same dialog box.

The current Cut Depth method and Maximum value are always displayed here regardless
of where they have been defined.

Follow Periphery creates a cut pattern that produces a sequence of concentric passes
following the contours of the cut region. The cut pattern will be generated by offsetting
the peripheral loop of the region. When passes are overlapped with the inner shapes of
the region, they will be merged to form one pass which then will be offset again to form
the next pass. All passes within the machinable region will be closed shapes.

Like Zig-Zag, Follow Periphery maximizes cutting moves by allowing the tool to remain
continually engaged during stepovers. In addition to specifying the cut direction as Climb
or Conventional, the Pocket Direction must be specified as Inward or Outward.

The following figure illustrates the basic sequence of Follow Periphery tool movements
using a Climb cut and an Outward pocket direction.

Follow Periphery - Climb, Outward

When using an Inward pocket direction, the side of the tool nearest the center of the cut
pattern determines Climb or Conventional. When using an Outward pocket direction, the
side of the tool nearest the edge of the cut region determines Climb or Conventional.

Follow Periphery
The above figure illustrates how a Climb cut when used in combination with an Inward
pocket direction produces a Conventional cut along the wall on the first pass. To avoid
this, you can add Part Stock to move the first pass away from the wall and then specify a
Finish Pass. The Finish Pass will produce a final profile cut along the wall to remove the
Part Stock and maintain the specified Climb cut.

Tool Paths do not cross one another. In cases where one area requires more pocketing
passes than another area, the tool traverses between the subregions to complete the larger
area as illustrated below. If many traversals are required, Region Connection can be used
to optimize the tool motion.

Subregions
CAUTION: Whenever the stepover is very large (stepover>50% of the tool diameter,
but <100% of the tool diameter) some areas may not be cut between consecutive
passes. For these areas, the processor will generate additional cleanup moves to
remove the material.

Diagonal tool movements called tusks are generated at the corners of inner passes to
remove material from corners. Tusks become necessary when the stepover is large in
relation to the tool diameter and there is no overlap between passes at the corners.

Tusks
Skinny Regions
The system recognizes that Follow Periphery cut pattern does not fit in skinny regions.
Therefore, when you use Follow Periphery with skinny regions, the system automatically
adjusts the cut pattern to allow for a profile pass along the skinny region. Notice in the
figure below that the Follow Periphery cut pattern (number 4) is placed further down on
the part; it does not follow the entire part. This is because the final profile pass (number
2) machines the remaining material. This eliminates wasted movements as a result of
cutting air (material already cut by the previous Follow Periphery pattern).

Follow Periphery with Skinny Regions

1 The part is represented by the green area.
Final Profile pass to cut skinny region, as well as area not cut by Follow Periphery path,
2
represented by straight blue line.
3 Cut Region represented by dashed pink line.
4 Follow Periphery represented by light blue path.
5 Area not cut by Follow Periphery path represented by the brown area.
Cut Order

For inward progression, the system cuts all the open passes first, and then cuts all the
closed inner passes. For outward progression, the system cuts all the closed inner passes
first, and then cuts all the open passes. When cutting the open passes, the tool engages to
an open pass, cuts, retracts and transfers to another open pass.

Follow Periphery with skinny regions is new behavior. Prior to NX2, when using
Follow Periphery pattern, you had to turn on Wall Cleanup and Island Cleanup to
machine narrow regions that may not have been cut.

Follow Part creates a cut pattern by forming an equal number of offsets (where
possible) from all specified Part geometry. Unlike Follow Periphery which offsets only
from the peripheral loop (defined by Part or Blank geometry), Follow Part creates the cut
pattern by offsetting from all Part geometry whether it defines the peripheral loop,
islands, or cavities. It therefore guarantees the tool will cut along all Part geometry and
eliminates the need for an Island Cleanup Pass. Follow Part offsets from Blank geometry
only when there is no defined Part geometry to offset from (as in the case of facing
regions). Part geometry defining cavities and islands is offset as illustrated below to
create a Follow Part cut pattern.

Follow Part Cut Pattern

CAUTION: Whenever the stepover is very large (stepover>50% of the tool diameter,
but <100% of the tool diameter) some areas may not be cut between consecutive
passes. For these areas, the processor will generate additional cleanup moves to
remove the material.

We recommend that you use Follow Part for cavity regions with islands. This will
eliminate the need to use Follow Periphery with Island Cleanup. Follow Part will ensure
that all Part geometry will be cut completely without setting any toggles.

The system attempts to create an equal number of offsets from all Part geometry.
Intersecting offsets do not cross, but trim to one another as illustrated below.

Trimmed Offsets

Follow Part rigorously maintains a Climb or Conventional cut as illustrated below.

Maintaining Climb Cuts

Unlike Follow Periphery, Follow Part does not allow you to specify a Pocket Direction of
Inward or Outward. Instead, the system determines the Pocket Direction (stepover
direction) as always cutting toward the Part geometry. In other words, for each set of
offsets, the offset closest to the Part geometry is the last cutting pass. For cavities, the
stepover direction is outward (cutting passes get continually larger as they progress
toward the Part), while for islands the stepover direction is inward (cutting passes get
continually smaller as they progress toward the Part).

Facing Regions

For facing regions (regions where the peripheral loop is defined by Blank geometry and
there is no Part geometry), the offsets follow the peripheral shape defined by the Blank
geometry and the stepover direction is inward.

Facing Region
Core Regions

For core regions (regions where the peripheral loop is defined by Blank geometry and
islands are defined by Part geometry), the offsets follow the shape of the Part geometry
and the stepover direction is inward toward the Part geometry defining each island.
Core Region
Cavity Regions

For cavity regions (regions where the peripheral loop is defined by Part geometry), the
stepover direction is outward toward the Part geometry defining the peripheral of the
cavity, and inward toward the Part geometry defining each island.

Cavity Region
Open Sided Regions

For open sided regions (regions where Part geometry offsets do not create a closed
peripheral shape due to the intersection of Part and Blank geometry), the stepover
direction is outward toward the Part geometry defining the periphery, and inward toward
the Part geometry defining the islands.
Open Sided Region
Cut Levels

For Planar and Cavity Milling operations with multiple cut levels, Follow Part evaluates
the type of cut region at each level and applies the appropriate offsets. The following
figure illustrates the various offsets that are generated for a multi-level Planar Milling
operation with different region types at each level.

Multi-Level Planar Milling Operation

Profile creates a single or specified number of cutting passes to finish part walls. It
can machine both open and closed regions.

For machinable regions with closed shapes, the profile pass will be built and traversed in
the same way as the Follow Part cut pattern.
Profile Cut Type

Small areas of the part geometry can be finished as illustrated below by defining blank
geometry only in the area of the part you want to finish.

Finishing a Small Area

You may create additional passes that allow the tool to step toward the part geometry to
remove material along the wall in successive concentric cuts by specifying a value in the
Additional Passes field.

Additional Passes
CAUTION: Whenever the stepover is very large (stepover>50% of the tool diameter,
but <100% of the tool diameter) some areas may not be cut between consecutive
passes. For these areas, the processor will generate additional cleanup moves to
remove the material.

More than one Open region can be cut at a time. If the open regions are close enough that
the cutter passes cross, the system will adjust the tool path. If an Open Shape and an
Island are close, the cutter passes will be built outward from the Open Shape only and
will be adjusted to not gouge the Island. If multiple Islands are close, the cutter passes
will be built outward from the Islands and combined where they cross.
Overlapping Cutter Passes

If the first (last) segment of the boundary is a line or an arc, the first (last) segment of the
tool path is normally a parallel line or concentric arc. In certain circumstances, however,
the first (last) segment of the boundary will "disappear" from the tool path, in which case
the first (last) segment of the tool path is "parallel" to the second (next to last) segment of
the boundary.

This happens, for example, when the first (last) segment of the boundary is a concave arc
(one whose center lies on the same side of the arc as the tool) and the tool radius plus the
side stock exceeds the arc radius.

Stock parameters vary by operation, and include:

Stock Parameters
Part Stock An envelope of material surrounding the Part Geometry which
remains on the part after machining

Planar, Face, Contour Milling

Wall Stock Face Milling
Blank Stock Planar, Cavity, Face
Blank Distance Planar, Cavity
Check Stock Planar, Cavity, Z-level, Face, Contour
Final Floor Stock Planar, Face, Planar Profile
Finish Stock Planar
Part Floor Stock Cavity Milling, ZLevel, Corner Rough, Planar Milling, Face Milling
Part Side Stock ZLevel, Cavity Milling
Use Floor Same as Cavity Milling, ZLevel
Side
Use Floor Same as Fixed and Variable Contour, Contour Profile method
Wall
Trim Stock Planar, Cavity, ZLevel milling
Boundary Stock Surface Contouring - Fixed with Boundary Drive Method, Contour
Milling, Fixed and Variable Contour
Tolerance Parameters
Intol Use Intol to specify the maximum amount by which the tool may
 penetrate through the surface.

(Planar Milling, Cavity Milling, ZLevell Milling, Face milling,

Contour Milling)
Outol Use Outol to specify the maximum amount by which the tool may
avoid contacting the surface.

(Planar Milling, Cavity Milling, ZLevel Milling, Face milling,

Contour Milling)
Part Intol/Part Allowable range the tool may deviate from the actual Part Surfaces.
Outol
(Contour Milling)
Boundary Maximum allowable violation of the inside (left) or outside (right) of
Intol/Outol a boundary.

(Contour Milling)

TOOL-AXIS
Tangent to Curve allows you to define a Fixed Tool Axis Vector tangent to a selected
curve. You will specify a vector origin point, select an existing curve, and select one of
two displayed vectors. The Tool Axis remains parallel to this vector as it moves along the
Tool Path.

Toward Point allows you to define a Variable Tool Axis that converges toward a focal
point. The point is specified using the Point Subfunction. The Tool Axis Vector points
toward the defined focal point and toward the tool holder as illustrated below.
Toward Point Tool Axis Using a Zig-Zag Cut Type

Normal To Part allows you to define a Tool Axis perpendicular to the Part Surfaces at
each contact point.

Tool Axis Normal to Part Surface

4-Axis Normal To Part allows you to define a tool axis that uses a 4-Axis Rotation
Angle. The 4-Axis orientation causes the tool to rotate about the defined rotation axis
while always remaining normal to the rotation axis.

The rotation angle causes the Tool Axis to lean forward or back in relation to an
otherwise normal axis relative to the Part Surface. Unlike a Lead angle, a 4-Axis rotation
angle always leans to the same side of the normal axis. It is independent of the direction
of the tool movement.
4-Axis, Norm to Part

Notice in the left view illustrated above, that the rotation angle causes the tool axis to
lean to the right of the Part Surface normal axis in both the Zig and Zag moves. The tool
moves within parallel planes normal to the defined rotation axis.

Example of 4-Axis Normal to Part

Here is an example of how 4-Axis Normal to Part works:

• Select 4-Axis Normal to Part as the Tool Axis.

• Select Two Points from the Vector Subfunction dialog.
• Define two points (a & b above) for the rotation axis using the Point Subfunction.
• Key in the 4-Axis Rotation Angle.

4-Axis Relative To Part works in much the same way as 4-Axis Normal To Part. In
addition, however, you may define a Lead and a Tilt angle. Because this is a 4-Axis
machining method, the Tilt angle is generally left at the default value of zero degrees.

If a Rotation Angle is specified in conjunction with a Lead and/or Tilt angle, then the
final tool axis is determined by the following steps:

1. The Lead Angle and/or Tilt Angle are applied according to the part surface
normal and the direction of motion of the cutter.
2. Because the tool axis in Step 1 may not lie in a valid 4-axis tool movement plane,
that tool axis is then projected on to the valid 4-axis plane.
3. The Rotation Angle is applied directly within the 4-axis plane.

Lead Angle defines the angle of the Tool Axis forward or backward along the Tool Path.
A positive Lead Angle value leans the tool forward based on the direction of the Tool
Path. A negative Lead Angle value leans the tool backward based on the direction of the
tool path.
4-Axis Relative to Part

Tilt Angle defines the angle of the Tool Axis from side to side. A positive value tilts the
tool to the right as you look in the direction of cut. A negative value tilts the tool to the
left.

4-Axis Relative to Part

Example of 4-Axis Relative to Part

Here is an example of how 4-Axis Relative to Part works:

• Choose 4-Axis Relative to Part as the Tool Axis.

• Choose 2 Points as the Rotation Axis.
• Define two points (a & b above
• Key in the desired 4-Axis rotation angle, Lead, and Tilt angles.
• Choose OK.

Planar and Cavity Milling can be especially effective for High Speed Machining:

• Planar and Cavity Milling are used when you want to remove the material in
many shallow depth, planar layers.
• Planar and Cavity Milling also can be used with a deeper depth of cut, and a very
small stepover.