Mt11050 - Nx4 2 2006 - Multi Axis Techniques Student Guide February 2006 MT11050 NX 4 PDF

Multi-Axis Techniques
Student Guide
February 2006
MT11050 NX 4
Publication Number
mt11050_g NX 4
Manual History
Manual Unigraphics Publication

Revision Version Date
Version 16 August 2000
Version 17.1.1 February 2001
Version 18.0 November 2001
Unigraphics NX November 2002
Unigraphics NX 2 January 2004
NX 3 May 2005
NX 4 February 2006
This edition obsoletes all previous editions.
Proprietary & Restricted Rights Notice
This software and related documentation are proprietary to UGS Corp.

2006 UGS Corp. All Rights Reserved.
All trademarks belong to their respective holders.
2006 UGS Corporation

All Rights Reserved.
Produced in the United States of America.
2 Multi-Axis Techniques Student Guide mt11050_g NX 4

Contents
Course Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Course Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Student Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Class Standard for NX Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Class Part Naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Colors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Seed Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Workbook Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Classroom System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Student and Workbook Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
WAVE Geometry Linker in Manufacturing . . . . . . . . . . . . . . . . . . . . 1-1

The WAVE Geometry Linker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Geometry Types Used by the Geometry Linker . . . . . . . . . . . . . . 1-4
Editing Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Broken Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Newly Broken Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Deleting Parent Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Deleting Linked Geometry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Activity: Creating an Assembly for WAVE . . . . . . . . . . . . . . . . . 1-11
Linking Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16
Activity: Creating WAVE Geometry . . . . . . . . . . . . . . . . . . . . . . 1-17
Simplify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
Simplify Body Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
Activity: Using Simplify Body . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21
Activity: Other Modeling Techniques . . . . . . . . . . . . . . . . . . . . . 1-23
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
Advanced Cavity Milling Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Cut Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Activity: Using Cut Levels Parameters . . . . . . . . . . . . . . . . . . . . 2-4
Cut Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Activity: Zig-Zag Cut Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
In-Process work piece for Cavity Milling . . . . . . . . . . . . . . . . . . . . . 2-16
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 3

Contents
Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Activity: Using the Level Based In-process Workpiece (IPW) . . . 2-19
Activity: Using the 3D In-Process Work Piece (IPW) . . . . . . . . . 2-25
Pre-Drill Engage and Cut Region Start Points . . . . . . . . . . . . . . 2-32
Activity: Using a Pre-Drill Engage Point . . . . . . . . . . . . . . . . . . 2-35
Cavity Milling Stock Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
Activity: Using the Blank Distance Option . . . . . . . . . . . . . . . . . 2-40
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Activity: Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Steep Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Activity: ZLEVEL_PROFILE_STEEP Operations . . . . . . . . . . . . . . . 3-9
Activity: Z-Level Profile Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Z-Level Cutting Between Levels (aka Gap Machining) . . . . . . . . . . . 3-21
Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
MILL_AREA Geometry Parent Groups . . . . . . . . . . . . . . . . . . . . . . . 4-1
MILL_AREA Geometry Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Activity: MILL_AREA Geometry Parent Groups . . . . . . . . . . . . . 4-4
Trim Boundary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Activity: Using Trim Boundaries . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Fixed Contour Operation Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fixed Contour Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

More on Flow Cut Drive Methods . . . . . . . . . . . . . . . . . . . . . . . 5-12
Activity: Creating Fixed Contour Operations . . . . . . . . . . . . . . . 5-17
Non-Cutting Moves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Activity: Using Non-Cutting Moves . . . . . . . . . . . . . . . . . . . . . . 5-35
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Introduction to Four and Five Axis Machining . . . . . . . . . . . . . . . . 6-1
Multi-Axis Machining Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Activity: Operations at Other Than 0,0,1 Tool Axis . . . . . . . . . . . 6-3
Defining the Center of Rotation for a Rotary Axis . . . . . . . . . . . . . . 6-16
Activity: Main and Local MCS in Multi-Axis Applications . . . . . 6-18
Activity: Main and Local MCS in Multi-Axis Applications . . . . . 6-27
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
4 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
Contents
Sequential Mill Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Sequential Milling Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Sequential Milling Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Defining the Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Multiple Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Activity: Basic Sequential Milling Techniques . . . . . . . . . . . . . . 7-13
More on Check Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Activity: Sequential Milling of a Multi-Surfaced Floor . . . . . . . . 7-38
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Sequential Mill Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Tool Axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Activity: Sequential Mill Five-Axis Fan Motion . . . . . . . . . . . . . . 8-7
Standard and Nested Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-19
Activity: Sequential Mill Using Loops . . . . . . . . . . . . . . . . . . . 8-23
Activity: Removing Excess Stock from a Closed Wall . . . . . . . . . 8-27
Activity: Using Looping to Remove Excess Stock . . . . . . . . . . . . 8-34
Additional Sequential Mill Options . . . . . . . . . . . . . . . . . . . . . . 8-36
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
Variable Contour Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Terminology used in Variable Contour . . . . . . . . . . . . . . . . . . . . . 9-4
Variable Contour vs Fixed Contour . . . . . . . . . . . . . . . . . . . . . . . 9-5
Drive Methods for Variable Contouring . . . . . . . . . . . . . . . . . . . . 9-6
Activity: Overview of Variable Contour Options . . . . . . . . . . . . . 9-18
Tool Axis Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-21
Activity: Point and Line Tool Axis Types . . . . . . . . . . . . . . . . . . 9-25
Activity: Normal to Part and Relative to Part . . . . . . . . . . . . . . . . . 9-32
Activity: Using Special Tool Axis and non Part Geometry . . . . . . 9-37
Activity: Swarf Drive Tool Axis . . . . . . . . . . . . . . . . . . . . . . . . . 9-45
Activity: Using the Interpolated Tool Axis . . . . . . . . . . . . . . . . . 9-61
A Comparison of Variable Contour vs. Sequential Milling . . . . . . . . 9-68
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-71
Variable Contour Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Advanced Variable Contour Machining . . . . . . . . . . . . . . . . . . . . . . 10-2
Activity: Examining the Part and Part Objects . . . . . . . . . . . . . . 10-3
Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-12
Activity: Contour Profile Drive Method . . . . . . . . . . . . . . . . . . . . . 10-13
Geometry Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-21
Automatic Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-22
Activity: Floor selection and Automatic Wall . . . . . . . . . . . . . . . . . 10-23
Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Activity: Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

Contents
Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

Activity: Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . 10-33
Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-41
Activity: Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . . . . . . . . 10-48
Activity: Auxiliary Floor and Automatic Auxiliary Floor . . . . . . . . 10-49
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-55
Projection Vectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Zig-Zag Surface Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Advanced Surface Contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
Course Overview
Course Description
The Multi-Axis Machining course teaches the use of the Manufacturing
application for creating 4 and 5-axis milling tool paths. You will learn about
the Variable Contour and Sequential Mill operation types that are designed
for multi-axis machining. You will also learn about the tool axes that are
available within Variable Contour and Sequential Mill operations.
Intended Audience
This course is intended for Manufacturing Engineers, NC/CNC programmers
and anyone with the desire to learn how to create four and five axis tool paths.
Prerequisites
The required prerequisites for the course are NX Manufacturing
Fundamentals with Basic Design or the CAST equivalent. Any additional
experience in creating multi-axis tool paths is an asset in taking this course.

Objectives
Objectives
After successfully completing this course, you will be able to perform the
following activities in NX:
choose between Variable Contour and Sequential Mill operation types
choose the best type of tool axis for creating various multi-axis tool paths
develop multi-axis machining practices
develop NX multi-axis programming practices
Student Responsibilities
Be on time.
Participate in class.
Focus on the subject matter.
Listen attentively and take notes.
Enjoy the class.
Course Overview
Class Standard for NX Parts

The following standards are used in this class. Standardization allows users
to work with others parts while being able to predict the organization of the
part file. All work should be performed in accordance with these standards.
Class Part Naming
This class uses the following file naming standard:
Where the student is requested to save a part file for later use, the initials
of the students given name, middle name, and surname replace the course
identifier "***" in the new file name with the remainder of the file name
matching the original. These files should reside in the students personal
directory.
The Arrow Symbol
The arrow symbol ( ), represents that you choose an option, then

immediately choose another option. For example, ToolsOperation
NavigatorTool pathReplay means:
put the cursor on Tools on the main menu bar
press mouse button #1 to display the pull-down menu.
slide the cursor down to Operation Navigator (continuing to press mouse

button # 1)
slide the cursor down to Tool path
slide the cursor down to Replay
release mouse button #1

Class Standard for NX Parts
Layers and Categories
There are standard layer assignments and category names in each of the
part files. They are as follows:
Layers 1-100, Model Geometry (Category: MODEL)
Layers 1-14, Solid Geometry (Category: SOLIDS)
Layers 15-20, Linked Objects (Category: LINKED OBJECTS)
Layers 21-40, Sketch Geometry (Category: SKETCHES)
Layers 41-60, Curve Geometry (Category: CURVES)
Layers 61-80, Reference Geometry (Category: DATUMS)
Layers 81-100, Sheet Bodies (Category: SHEETS)
Layers 101 - 120, Drafting Objects (Category: DRAFT)
Layers 101 - 110, Drawing Borders (Category: FORMATS)
Layers 121 - 130, Mechanism Tools (Category: MECH)
Layers 131 - 150, Finite Element Meshes and Engr. Tools (Category: CAE)
Layers 151 - 180, Manufacturing (Category: MFG)
Layers 181 - 190, Quality Tools (Category: QA)
Colors
The following colors are preset to indicate different object types.
Object Color Used

Solid Bodies Green
Sheet Bodies Yellow
Lines and Arc Green
(non-sketch curves)
Conics and Splines Blue
(non-sketch curves)
Sketch Curves Cyan
Reference Curves Gray
(in sketches)
Datum Features Aquamarine
Points and Coordinate Systems White
System Display Color Red
Course Overview
Seed Part
Seed parts are an effective tool for establishing customer defaults or any
settings that are part dependent (saved with the part file). This may include
non-geometric data such as:
sketch preferences
commonly used expressions
layer categories
user-defined views and layouts
part attributes
How to Use This Manual

It is important that you use the Student Guide in the sequence presented
since later lessons assume you have learned concepts and techniques taught
in an earlier lesson. If necessary, you can always refer to any previous activity
where a method or technique was originally taught.
The format of the activities is consistent throughout this manual. Steps are
labeled and specify what will be accomplished at any given point in the
activity. Below each step are action boxes which emphasize the individual
actions that must be taken to accomplish the step. As your knowledge of NX
increases, the action boxes may seem redundant as the step text becomes all
that is needed to accomplish a given task.
Step 1: This is an example of a step.
This is an example of an action box.
Choose Edge Lengths, Corner for the creation method.
The general format for lesson content is:

Presentation
Activity
Summary
While working through lesson activities, you will experience a higher degree
of comprehension if you read the Cue and Status lines.
At the start of each class day you will be expected to log onto your terminal
and start NX, being ready to follow the instructors curriculum. At the end of
the days class you should always exit NX and log off the terminal.

Workbook Overview
Workbook Overview
The workbook contains a project that requires you to apply the knowledge
that you learned in the class and in the Student Activities. The projects do
not contain detailed instructions as do the Student Activities.
The intent of the projects is to allow you to apply the skills taught in this
course. At any point when you are not making progress, ask your instructor
for help.
Course Overview
Classroom System Information

Your instructor will provide you with the following items for working
in the classroom:
Student Login:
User name:
Password:
Work Directory:
Parts Directory:
Instructor:
Date:
Student and Workbook Parts
The parts for this class are stored in the class Parts directory. There are two
directories located in the Parts directory, the Student_parts and workbook.
The Student_parts directory contains the parts that you will use when
working on activities in the Student Manual.
The workbook directory contains the parts that you will use when working
on the project within the workbook.
System Privileges
You do not have the system privilege to modify any of the part files. If you
attempt to do so, you will get a message saying that the file is Read Only.
However, this does not restrict you from working with these files.

1
Lesson
1 WAVE Geometry Linker in

Manufacturing
Purpose
In this lesson, you will learn different methods available for creating
machining geometry, using the WAVE (What If Alternative Value
Engineering) Geometry Linker, that is associated to the designers original
geometry.
Objective
Upon completion of this lesson, you will be able to:

Use the WAVE Geometry Linker to create associative, linked geometry.
Make modifications to linked geometry.
Use a "base part" to control the manufacturing setup.
Build a simulated casting solid body using the Wave Geometry Linker.
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 1-1
WAVE Geometry Linker in Manufacturing
1
The WAVE Geometry Linker
The WAVE Geometry Linker is used to associatively copy geometry from a
component part in an assembly into the work part. The resulting linked
geometry is associated to the parent geometry. Modifying the parent geometry
will cause the linked geometry in the other parts to update.
The WAVE Geometry Linker is available with an Assemblies license.
It does not require a NX WAVE license.
Different types of objects can be selected for linking, including points, curves,
sketches, datums, faces, and bodies. The linked geometry can be used for
creating and positioning new features in the work part.
The Wave Geometry linker is accessed by choosing InsertAssociative
CopyWAVE Geometry Linker from the menu bar.
1-2 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
1
The At Timestamp option lets you specify where the linked object is placed
in the feature list. When turned off, any new features added altering the
parent geometry will be reflected in the linked geometry. When turned on,
new features added after the link was created will not be affected.
Blank Original lets you blank the original geometry so that the linked
geometry in the work part will be easier to work with while the assembly
is displayed.
Create Non-Associative option will create a broken link. The geometry

will be created in the work part but will not be associated to the parent
geometry.
1
Geometry Types Used by the Geometry Linker
Several different types of geometry can be used in the WAVE application.

Points
Curves/Strings
Sketches
Datums
Faces
Regions of Faces
Bodies and Mirrored Bodies
When selecting geometry to copy, you should consider how permanent the
geometry will be. If you copy as little geometry as possible to do the job,
performance will be improved but updates will be less robust when the parent
geometry is altered.
For example, if you copy individual curves to another part, the link may not
update correctly if one of the curves is deleted. Conversely, if you copy an
entire sketch, curves may be removed or added and the link will update.
1
Editing Links
Links may be edited by choosing EditFeature Parameters in the Model

Navigator and selecting a linked feature. Linked features have an Edit dialog
similar to the one below.
When this dialog is displayed, the cursor is active in the graphic window
allowing new parent geometry selection for the link being edited. The new
parent geometry must be the same type as the old geometry (curve, datum,
solid body, etc.)
Parent indicates the parent geometry type. If the feature was linked, but
the link has been broken, the parent is shown as a Broken Link.
Part shows the name of the part where the parent geometry is located. If
the parent geometry is located in the current work part, the part name
given is Work Part.
The dialog information updates when you select new parent
geometry, which you can do at any time.
1
At Timestamp allows you to specify the timestamp at which the linked
feature is placed. If toggled on, the list box will display the features in the
parent part. One of these features may be selected from the list to specify
a new timestamp location for the linked feature being edited. If toggled
off, all features in the parent part will be reflected in the linked feature.
Break Link lets you break the association between the linked feature and
its parent. This means that the linked feature will no longer update if its
parent changes. You can later define a new parent by selecting geometry
with the cursor.
Replacement Assistant allows replacement of one linked object with

another (cannot be used on linked sketches or strings).
Flip Face Normal reverses the normal of the face selected.
An Extracted feature (intra-part) can be converted to a Linked feature

(inter-part) by selecting the appropriate option and selecting new parent
geometry from another component in the assembly.
Depending on the geometry type of the feature being edited, other options
may appear on the dialog.
When editing links and selecting new parent geometry, it may be
easier to temporarily work in an exploded view to distinguish between
the existing linked geometry and the new parent geometry.
1
Broken Links
A link may become broken for several of the following reasons:

The parent geometry is deleted.
The path from the linked geometry to the parent part is broken. This can
occur if the component part containing the parent geometry is deleted
or substituted.
If the parent is removed from the start part reference set that defines
the linked part.
If you deliberately break the link (e.g., using Edit Feature or the Break
option on the WAVE Geometry Navigator dialog).
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Newly Broken Links
When a link breaks for an indirect reason (i.e., any reason except the last one
listed above), the link is identified as newly broken until you accept it. You
can accept newly broken links from the WAVE Geometry Navigator dialog or
the Edit during Update dialog.
After a link is accepted, its status is changed to broken until a new parent is
defined.
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Deleting Parent Geometry
To prevent unintentional deletion of the parents of linked geometry, a message

will warn you if a delete operation would cause inter-part links to break. This
applies to operations using EditFeatureDelete, EditDelete, and Model
NavigatorDelete while the parts containing the linked geometry are loaded.
The Information option provides details about the links that will be
broken in an Information window.
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Deleting Linked Geometry
Linked geometry is created as a feature and can be deleted by choosing

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

assembly link must exist between two part files before a WAVE link can be
established.
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Activity: Creating an Assembly for WAVE
In this activity, you will create an assembly structure for later use with the
WAVE Geometry Linker. Remember that WAVE only works in the context
of an assembly.
This activity uses a hypothetical company that has been awarded a contract
to machine a mixer housing.
The customer has supplied a NX solid model of the designed part. Since
high-production quantities are needed, the customer has decided to make the
part as an aluminum casting. This will reduce significantly, the amount of
time spent machining. Unfortunately, the customer has not supplied a solid
model of the casting which we will need to create. Using WAVE, you will
create a simulated casting model that is associated with the original geometry.
For the casting body, it will be necessary to remove the seven drilled holes,
and add .250" machining stock on the inlet, outlet and mixer tube faces. Also
note that the ring groove will not exist on the casting body.
All machined faces have 1/4" of added stock. Once the modeling changes
are made, you will drill all holes and machine the ring groove into the
mixer outlet face, since the casting process was not accurate enough for the
tolerances required.
Step 1: Open the seed part, seedpart_in, and save it with a new name.
If necessary, start NX.
Use FileOpen.
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Navigate to your parts folder and open the file seedpart_in .
Choose FileSave As ***_mixer_mfg where *** represents

your initials.
Step 2: Add the existing designed part as an assembly component.

Your first objective will be to add the existing mixer housing as the
first component of the mixer_mfg assembly. All assembly links
will be on layer 11.
If necessary, from the main menu, choose StartAssemblies.
Change the Work Layer to 11.
From the main menu, choose AssembliesComponentsAdd

Existing.
In the Select Part dialog, select the Choose Part File button.
Select mixer_body, then choose OK.
In the Add Existing Part dialog, change the component name

to mixer. It can be typed in upper or lower case.
If necessary, while still in the Add Existing Part dialog, choose

SOLID from the Reference Set pull-down menu.
The Add Existing Part dialog is still displayed.
Verify that the Positioning pull-down menu is set to Absolute.
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Choose OK in the Add Existing Part dialog.
The Point Constructor dialog is displayed.
Choose the Reset button in the Point Constructor dialog, then

choose OK.
The mixer body part is now a component of ***_mixer_mfg.
Cancel the Select Part dialog.
Step 3: Examine the current assembly structure.

Display the Assembly Navigator by choosing the Assembly
Navigator tab in the resource bar.
Clicking once on the tab temporarily displays the
Assembly Navigator by sliding it to the left over the
graphics display.
Double-clicking on the tab displays the Assembly
Navigator in a separate window which can then be
moved and docked.
There are currently two parts in this assembly. The top-level

control part is ***_mixer_mfg, while mixer_body is the single
component. Currently, only the component contains any
geometry.
The next step will be to create a new component that will
contain the WAVE casting body.
Step 4: Create an empty component, then apply the seed part preferences.
Choose AssembliesComponentsCreate New from the
menu bar.
Choose OK
In the File Name field, of the Select Part Name dialog, type in
***_mixer_casting, then choose OK.
The Create New Component dialog is displayed.
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In the Component Name field, type CASTING, then choose OK.
A new component, named CASTING, is displayed in the
Component Name column of the Assembly Navigator.
The name of the part file is ***_mixer_casting. You may
need to display the Component Name column by selecting
MB3,ColumnsComponent Name.
Next, apply the layer and color standards from the seed part
file. In NX, all operations apply to the work part, which is
currently ***_mixer_mfg. To apply the seed part defaults, the
CASTING component should be the work part. For clarity, we
will also make it the displayed part.
In the Assembly Navigator, highlight the CASTING component,

***_mixer_casting, and using MB3 choose Make Displayed Part
from the pop-up menu.
To illustrate the lack of user-defined defaults, choose

FormatLayer Settings.
Notice the category field is blank.
Choose Cancel in the Layer Settings dialog.
Choose FileImport Part.
If necessary, in the Import Part dialog, uncheck Create Named

Group, then choose OK.
Browse to the seedpart_in.prt, and double-click on it.

Choose OK in the Point Constructor dialog. Since no geometry

is being imported, position is not relevant.
Also, there is no interaction on the screen.
Choose Cancel in the Point Constructor dialog.
Choose FormatLayer Settings.

Notice the several different layer categories defined.
Choose Cancel in the Layer Settings dialog.
Step 5: Make the top-level part the displayed part, and save the work
created thus far.
In the Assembly Navigator, highlight ***_mixer_casting, and
using MB3, choose Display Parent ***_mixer_mfg.
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In the Assembly Navigator, highlight ***_mixer_mfg, and using
MB3, choose Make Work Part.
Choose the Save icon on the toolbar.

When you save an assembly, all modified components
below the work part are saved as well.
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Linking Procedure
You use the AssembliesWAVE Geometry Linker dialog to create associated

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

to copy objects and exit the dialog.
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Activity: Creating WAVE Geometry
In this activity, you will practice using the geometry linker. You will create
a WAVE linked copy of the mixer body, then perform modifications to that
copy to simulate a casting.
Step 1: Prepare the assembly.
If necessary, open the ***_mixer_mfg assembly part and then
the Assembly Navigator.
Choose Start Modeling.
Highlight the component ***_mixer_casting in the Assembly

Navigator, and make it the Work Part by using MB3, and
selecting Make Work Part.
The mixer body, in the graphics window, fades to green. This is
a visual clue that geometry is no longer in the current modeling
hierarchy.
The work layer is where linked geometry will be created.
Choose FormatLayer Settings.
Make Layer 1 the work layer.
Choose OK in the Layer Settings dialog.
Step 2: Select the Role Essentials with full menus and create a Linked
Body. The simplify option does not appear on the Essentials role.
Select the Roles tab and drag the Essentials with full menus
icon to the graphics screen.
Choose InsertAssociative CopyWave Geometry Linker.

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

dialog.
Select the mixer body.
Choose OK.
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Step 3: Modify the display of the linked casting.
There are now two identical bodies, lying in the same model space;
the component body and the linked copy. It can be difficult to
determine one from the other, it will be necessary to clarify the
differences. First, you will remove the original body from the
display. Then, you will change the display of the linked body.
In the Assembly Navigator use MB3 over the ***_mixer_casting

component, and choose Make Displayed Part.
In the graphics window, use MB3Replace ViewTFR-TRI

from the pull-down menu.
Choose the Shaded icon from the main menu bar.
Choose EditObject Display.
Select the linked body and choose OK(green check mark) .

Using Edit Object Display is a powerful method of
differentiating between bodies that are similar in
appearance.
Change the Color to Yellow.
Choose OK in the Edit Object Display dialog.
Step 4: Make the top-level part the displayed part, then save the work
in progress.
At this point no physical difference exists between the mixer body
and the mixer casting. They do have a visual difference. In the next
activity, you will perform modeling changes to the mixer casting.
In the Assembly Navigator, using MB3 on the ***_mixer_casting

component, choose Display Parent***_mixer_mfg.
In the Assembly Navigator, using MB3 on ***_mixer_mfg,

choose Make Work Part.
Choose the Save icon on the toolbar.
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Simplify
Simplify is a powerful modeling tool that can be used to satisfy a wide range
of needs in developing models that are associative, but somewhat different.
Simplify provides a method of removing faces. This process must be able to
extend surrounding faces to "heal the wound" where the faces have been
removed.
Uses of Simplify:
Remove "machined" features for preparing an as cast part from a body
that is not appropriately constructed for link At Timestamp, or from a
body whose features are not accessible.
Remove details such as holes and blends for finite element analysis.
In casting tooling work, core and pattern preparation in parts where the
regions were not modeled separately. Simplify can often be used both
to remove interior faces, for patterns, and to remove exterior faces, for
cores (if the system cannot heal wounds left by core removal, the pattern
designer must extract regions and sew core-print faces to obtain a core
body).
Preparing a body for export to a supplier who need only be concerned with
the exterior envelope. Interior faces are removed using simplify, then the
simplified part is linked into a new part for export to the supplier. The
linked part has no "knowledge" of interior features in the original, but it
can still be updated by the owning company if the parent body changes.
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Simplify Body Procedure
You will use the Simplify Body function to remove holes from your mixer
casting body.
To simplify geometry:
Choose as a retained face, one that will not be simplified away.
Select Automatic Hole Removal.
Set the size for the Hole Dia Less Than parameter.
Choose Apply to perform simplification.
Acknowledge the simplify notice.
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Activity: Using Simplify Body
In this activity, you will practice using Simplify Body as a tool to reduce the
complexity of a linked solid body.
Step 1: Make the CASTING component the work and displayed part.
If necessary, open your ***_mixer_mfg assembly part and then

open the Assembly Navigator.
In the Assembly Navigator, use MB3 on the ***_mixer_casting

component and choose Make Displayed Part.
Step 2: Perform a Simplify Body operation on the seven bolt holes on the
outlet face and mixer tubes.
Choose StartModeling.
Choose InsertDirect ModelingSimplify.

The Simplify Body dialog is displayed.
The cue line reads Select retained faces.
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Select any face on the body that will not be removed when the
holes are removed.
Select Automatic Hole Removal.
Specify .500 in the Hole Dia Lless Than field and press the
Return key.
Choose Apply and then press OK in the Simplify Body dialog.
The Simplify Body information window gives the number of faces

removed and retained (in this case 7 faces are removed, 108 faces
remain).
Dismiss the Simplify Body information dialog by choosing OK.
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Activity: Other Modeling Techniques
Previously, Simplify Body was used to remove unwanted geometry from the
Linked casting body. Now, you will explore other ways to modify a linked
body. The first option explored is Extrude.
Step 1: Make the CASTING component the work and displayed part.
If necessary, open your ***_mixer_mfg assembly part and then
open the Assembly Navigator.
If necessary, in the Assembly Navigator, using MB3 on the

***_mixer_casting component, choose Make Displayed Part.
Step 2: Use Extrude to fill in the ring groove.

Choose StartModeling.
Choose Insert Design FeatureExtrude.

The Extrude Widget is displayed.
On the Selection Intent toolbar change the type filter from Any
to Face Edges.
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Choose the bottom face of the ring groove, as shown below.
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Choose the Unite icon from the Boolean pull-down menu.
Under Limits, End, change from Value to Until Extended.
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Select the outlet face, then choose OK on the Extrude dialog.
The O-ring groove has been removed from the outlet face.
Step 3: Use the Offset Face option to add machining stock.

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

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

To make it easier to visually distinguish between the original
designed part and the casting, you will make the casting model
translucent.
If necessary, use the Shaded icon to turn on shaded mode.
From the menu bar choose EditObject Display.
Select the body and choose OK.
Slide the Translucency bar to 50% and choose OK.

If the solid body does not become semi-transparent,
choose PreferencesVisualization Performance, and
turn off Disable Translucency, located on the General
Settings tab under Session Settings.
Step 5: Make ***_mixer_mfg the work part, and compare the two solid
bodies.
To fully realize the extent of the changes made, you will display
both the original and the linked body together.
1
Find and depress the Assembly Navigator button to activate
the Assembly Navigator.
Use MB3 on the CASTING component and choose Display

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

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

faces. All drilled holes have been removed, as well as the ring
groove.
This is only one potential method for creating a simulated
casting body. Other methods and techniques could also have
been used. However, this method is fully associated to the
original, so that if the original body changes, the casting body
will update also.
At this stage, NC/CNC programming, using the CASTING
component as the BLANK, could now begin.
Choose FileClose Save All and Close.
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Summary
The WAVE Geometry Linker provides an efficient method to associatively
copy geometry used for machining from a component part in an assembly into
a work part. The machining geometry is modifiable for manufacturing needs
but does not change the original design intent.
In this lesson you:
Used Assemblies to enable "Best Practices" for modeling in manufacturing.
Created a WAVE solid body that is associatively linked to the original.
Modified the WAVE geometry to simulate a casting for machining.
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Lesson
2 Advanced Cavity Milling Topics

2
Purpose
This lesson teaches you how to use additional Cavity Milling options to create
tool paths. You will also use Geometry Parent Groups to machine Cavity
Milling geometry.
Objective

Utilize advanced Cavity Milling options
Create and modify Geometry parent groups for Cavity Milling
Create and modify Cut Levels
Utilize the In-Process Work Piece
Advanced Cavity Milling Topics
Cut Levels
Cavity Milling cuts geometry in planes or levels.
The advantage to this approach is that tool paths remain relatively short, due
2 to minimum tool path movement, which is performed in layers.
The disadvantage is that when machining geometry that is close to horizontal
more stock may remain than desired. See the diagram below.
The closer the geometry approaches horizontal, the more stock that remains.
Through the use of Cut Level parameters, you can reduce the amount of
stock that remains.
The Cut Levels dialog is located under the Cut Levels button in the Cavity
Mill dialog.
The Cut Levels dialog serves two primary functions:

Create and modify Ranges
Modify Cut Levels within Ranges
To reduce the amount of additional stock, a new range can be added. The
Depth per Cut in that Range only is modified.
In the next activity, you will use various Cut Level parameters.
Activity: Using Cut Levels Parameters

In this activity, you will replay an operation and review the various Cut
Levels. You will then modify the range to allow the tool to cut without any
2 warning messages.
Step 1: Open, rename the part file, and enter the Manufacturing
application.
Open the part file base_mfg_2.
Rename the part ***_base_mfg_2 using the File Save As

option on the menu bar.
Choose Start Manufacturing.
Step 2: Activate the Operation Navigator.

Choose the Operation Navigator tab from the resource bar and
expand the BASE_MALE_DIE parent group.
In the Operation Navigator, verify the Program Order view is

active.
Step 3: Use Verify to examine the operation.

You will use the Verify option to replay an existing operation.
To speed up the Dynamic Replay mode, make the image
smaller. In the graphics window, choose MB3 Zoom 2
In/Out and zoom the object out. This option is unavailable
when the Tool path Visualization dialog is active.
Highlight the CAVITY_MILL operation, using MB3, choose

Toolpath Verify.
In the Tool path Visualization dialog, choose the 2D Dynamic

property page (tab).
As shown, choose the Play icon.
This operation, in the current state, machines too low on the

part.
You will perform the steps necessary to correct this deficiency.
Choose Cancel in the Tool path Visualization dialog.
Step 4: Edit the Bottom of Range #1.

The first step is to remove the warning from this operation by
changing the cut range.
Double-click on the CAVITY_MILL operation.
Generate the operation.
At this level, the part and blank geometry are identical, the
trace generated for the part and blank geometry are the same;
therefore no geometry is available for machining. You will now
alter the cut levels to eliminate the warning message.
Choose OK to the Warning message.
Choose Cut Levels from the CAVITY_MILL dialog.

At the very top of the dialog, there are three buttons for
defining ranges. The Auto Generate (1) button defines ranges
that will align with planar horizontal faces. The User Defined
(2) button defines ranges by selection of the bottom plane for
each new range. The Single (3) button defines the cut range
based on part and blank geometry.
Examining the status line, you will find that there are currently
15 Cut Levels within one range in this operation.
In the Cut Levels dialog, choose the Edit current range icon.
Choosing a face will modify the bottom of Range #1.
Select the face of the part as shown.
The status line shows 13 cut levels and the range depth
changes to 3.25.
Choose OK on the Cut Levels dialog.

The operation successfully generates without warning
messages.
Save the part file.
Cut Patterns
The Cut Method (1) determines the cut pattern used for cutting.
The Cut Patterns are as follows:
Zig-Zag machines in a series of parallel straight line passes. Climb

or conventional cut directions are not maintained since the cut direction
2 changes from one pass to the next.
Zig always cuts in one direction. The tool retracts at the end of each
cut, then positions to the start of the next cut.
Zig with Contour also machines with cuts going in one direction.
However, contouring of the boundary is added between passes, before and
after the cut motion. The tool then retracts and re-engages at the start of
the contouring move for the next cut.
Follow Periphery offsets the tool from the outermost edge that is
defined by Part or Blank geometry. Internal islands and cavities will require
Island Cleanup or a clean up Profile pass.
Follow Part creates concentric offsets from all specified Part geometry.
The outermost edge and all interior islands and cavities are used to compute
the tool path. Climb (or Conventional) cutting is maintained.
2
Trochoidial cut pattern uses small loops along a path (resembles a

stretched-out spring). This is a useful cut pattern in high speed machining
applications when constant volume removal needs to be maintained.
Profile follows a boundary using the side of the tool. For this method,
the tool follows the direction of the boundary.
Activity: Zig-Zag Cut Pattern
In this activity, you will use the Zig-Zag cut pattern to cut the part.
Step 1: Open the part file and enter the Manufacturing application.
2
Continue using the part from the previous activity,
***_base_mfg_2.
If necessary, choose Start Manufacturing.
Step 2: Edit an existing operation to change the Cut Pattern.

Double-click on the CAVITY_MILL operation.
From the CAVITY_MILL dialog, choose the Zig-Zag Cut Method.
Step 3: Generate the operation.

Choose the Generate icon to generate the operation.
The tool path is generated.
2
Step 4: Change the Cutting options.
Choose the Cutting button from the CAVITY_MILL dialog.
The Cut Parameters dialog is displayed. Options available are
based on the selected Cut Method.
Key -45.0 in the Degrees field of the Cut Parameters dialog.
Choose the Display Cut Direction button.
An arrow indicates the applied Cut Angle.
Choose OK on the Cut Parameters dialog.

Use 3D Dynamic verification to analyze the results.

The Zig-Zag cut pattern does not have a stepover on every
pass, resulting in a less than desirable tool path.
Cancel the Tool path Visualization dialog.
Change the Cut Method to Zig with Contour.

Verify the tool path, using the 3D Dynamic option.

2
This time the tool path is more efficient in the method of
cleaning up the corners.
Save the part.
In-Process work piece for Cavity Milling

To make the various Cavity Milling operations as efficient as possible, you
must determine what has been machined in each operation. Variables such
2 as cutting tool lengths and diameters, draft angles and undercuts, fixture and
tool clearances, will affect the amount of material that each operation may
leave. The material that remains after each operation is executed is referred
to as the In-Process work piece or IPW.
Generally speaking, the remaining material (IPW) can be used for input into
a subsequent operation which may be used for additional roughing. The end
result is a semi-finished part that has most of the rough material or stock
completely removed.
To use the IPW, certain conditions must be adhered to. Tool path generation
must be done sequentially, from the first operation to the last, within a certain
geometry group. The tool path must be successfully generated and accepted
in all previous operations in the sequence before the IPW can be used for
the next operation of the sequence.
Two methods for creating the In-Process work piece are available. The
options available are 3D IPW and Level Based IPW.
Level Based IPW
Level-Based IPW uses the 2D cut regions from the previous Cavity Milling
and/or ZLevel operations to identify and machine rest material. These
previous operations are referred to as reference operations. Level-Based IPW
is limited to Cavity Milling or ZLevel milling operations with the same tool
2
axis as the previous operation. The rest milling and reference operations
must belong to the same geometry group
Use 3D
Use 3D uses a 3D internal definition to represent the remaining material.

All milling operations can produce a 3D IPW. Use 3D is the correct IPW
2 option if you are also using other types of operations to remove material from
the blank. For example, if your cavity milling operation follows a surface
contouring operation, then you must use the 3D IPW. If you must use 3D
IPW for cavity milling operations.
Activity: Using the Level Based In-process Workpiece (IPW)
In this activity, you will machine the part using three different cutter sizes.
You will activate the use of the Level Based IPW and generate the operation.
You will edit subsequent operations, each using smaller tools utilizing the
Level Based IPW.
2
Step 1: Open the part level_based_mfg and enter the Manufacturing
application.
From the menu bar, select File.
Choose Open.
Select the file level_based_mfg, then choose OK.

Choose the Operation Navigator tab from the resource bar.
Step 3: Display the Geometry View in the Operation Navigator and

expand the objects.
2 Choose the Geometry View button from the Operation

Navigator tool bar, then expand the MCS_MILL , WORKPIECE
, and MILL_AREA parent groups.
Step 4: Edit the operation CVM1and use the Level Based IPW.
Double-click the CVM1 operation in the Operation Navigator.
Choose Cutting from the CAVITY_MILL dialog.
Choose the Containment tab from the Cut Parameters dialog.
Select Use Level Based for the In-process Workpiece.
Choose OK to accept the Cut Parameters.
Choose Generate to generate the tool path.

A warning Message appears The preference to enable Level
Based IPW is not turned on appears.
Choose NO to turn the preference on and continue.
Choose OK to accept the operation.
Choose OK to accept the operation
Verify the tool path, using the 3D Dynamic option.

This time the tool path is more efficient in the method of
cleaning up the corners.
Close the part file.
Activity: Using the 3D In-Process Work Piece (IPW)
In this activity, you will machine the core block for an ATM key pad using
three different cutter sizes. You will define the BLANK in the MILL_GEOM
parent group, activate the use of the 3D IPW and generate the operation. You
will then use the subsequent IPW as the blank for the next operation and then
2
use the IPW created from that operation to finish the keypad.
Step 1: Open the part ipw and enter the Manufacturing application.
Choose Open.
Select the file ipw, then choose OK.

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

expand the objects.
2 Choose the Geometry View button from the Operation

Navigator tool bar, then expand the MCS_MILL and
WORKPIECE parent groups.
Step 4: Edit the operations and use the IPW.

Choose the Containment tab from the Cut Parameters dialog.
Select Use 3D for the In Process Workpiece.

The first Cavity Milling tool path is displayed. You will want
to display the amount of stock that remains that becomes the
blank for the next operation.
Choose the Display Resulting IPW icon.
The resultant IPW is displayed.
This IPW will be used as the Blank for the next operation,
CVM2.
The initial IPW was defined as the Blank in the WORKPIECE
geometry parent group. You generated the operation, using
the initial IPW, and set options needed to create the IPW for a
subsequent operation. You will use this IPW as the Blank for
the operation, CVM2.
Choose OK to accept the previous operation.
Choose Cutting from the CAVITY_MILL dialog. 2

The second Cavity Milling tool path is displayed. You will now
display the IPW to show the remaining material.
Choose the Display Output IPW icon.
The resultant IPW is displayed.
This IPW will be used as the Blank for the next operation.
You will use the current IPW for the final Cavity Milling
operation.
Choose OK to accept the previous operation.
Pre-Drill Engage and Cut Region Start Points
Pre-Drill Engage and Cut Region Start Points are found in the Points/Control
Geometry section of the Cavity Milling dialog. These two options provide
2 control over the cutting start point within single and multiple regions of
Cavity Milling. They also determine the direction that the tool moves towards
the cavity or core walls.
Pre-Drill Engage Points
Cavity Milling determines the tool path start point.

You can use the Pre-Drill Engage Points option to specify where you want
the tool to start cutting. With this option, the tool moves to the pre-drilled
engage point you specify, then to the specified cut level. It then moves to the
processor generated start point and generates the remainder of the tool path.
To use this option, specify a pre-drilled engage point and an optional depth
value. If you are going to specify a depth value, it must be done prior to
specifying the start point.
There are three methods available for specifying pre-drilled engage points:
Point/Arc - by using existing points or arcs. The arcs are associative to the
geometry. They must be explicit or sketch curves.
Cursor - by using the cursor position.
Generic Point - by using the option on the generic point dialog.
The depth value for a start cut point is optional. If you do not specify a value,
the pre-drilled engage point is used at every cut level.
As shown , cut level 1 uses the pre-drilled engage point that falls within the
specified depth. Cut levels 2 and 3 do not use the specified pre-drilled engage
point since the cut levels are not within the specified depth. The processor
will use the internally defined cut start point to cut the remaining cut levels
(2 and 3).
All specified depths are measured from the top plane.
You can define Pre-drilled points using either the Engage/Retract

dialog or the Pre-drill Start Points option located under the Control
Geometry button. The Engage/Retract Pre-drill points and settings
override the points defined under the Control Geometry Option. If
2 you specify multiple Pre-drill points you can optimize the order in
which they are drilled by customizing the Engage/Retract options
which are available.
Cut Region Start Points
Cut Region Start Points allows you to specify cut start points for each region
in a multi-region cavity. When you use circular engages, this option can avoid
engages into pocket corners by using the Automatic or User Defined method
of engagement.
The Cut Region Start Points defaults are as follows:

Automatic establishes the Cut Region Start Point at the "flattest" convex
corner of the cut region. If there are no convex corners, the midpoint of the
longest boundary segment of the cut region is used. This option assures that
the tool will step over or engage the part at a location which is least likely to
cause the tool to become buried in the material.
Standard establishes the Cut Region Start Point as close as possible to the
start point of the boundary region. The shape of the boundary, cut type,
and position of islands and pockets will influence how closely the processor
positions the Cut Region Start Point to the Boundary Start Point. Moving the
Boundary Start Point affects the location of the Cut Region Start Point.
Activity: Using a Pre-Drill Engage Point
In this activity, you will edit the current operation to use a Pre-drilled Engage
Point to start your tool path. The Pre-drill Engage Point is a hole that has
been previously drilled. 2
Step 1: Open the part form_mold_mfg and choose the manufacturing
application.
Choose Open.
Select the file form_mold_mfg, then choose OK.

Choose the Operation navigator tab from the resource bar.
Step 3: Edit an existing operation.

Double-click on the CM_ROUGH operation in the Operation
Navigator.
The Cavity Milling dialog is displayed. You will now define a
point that represents a hole which has been previously drilled.
This will be the engage point for the tool that is used to start
each cut level.
Step 4: Define a Pre-drill Engage Point for this operation.
Choose Points in the Control Geometry section.
2
The Control Geometry dialog is displayed. Notice that there
are two sections to this dialog, Pre-Drill Engage and Cut
Region Start Points.
Choose Edit in the Pre-Drill Engage Points section.
The Pre-Drill Engage Points dialog is displayed.
You can use the Depth parameter when you want a particular
Pre-Drill Engage Point to be used only for certain cut levels.
If you do not specify a depth parameter, the point will be used
at all cut levels. If you use the parameter it must be defined
before specifying the point.
For this activity, you will not specify a depth parameter. This
particular Pre-Drill Engage Point will be used at all cut levels.
Choose Generic Point.

Key in the following values: XC=5 YC=2.5 ZC=0
Choose OK.
The point just created is displayed (this point is at the bottom
of the part, if your display setting is solid, set to wire frame
to see the point).
2
Choose OK until you return to the Cavity Milling dialog.
Step 5: Generate the tool path.

Choose the Generate icon to create the tool path.
Notice that all levels start at the Pre-Drill Engage Point in
the center of the part, then move to the start point which is
determined by the processor.
Save your Part.
Cavity Milling Stock Options
Stock options for Cavity Milling are found on the Cut Parameters dialog.
This dialog is activated by selecting the Cutting button found on the Cavity
Mill operation dialogs. 2
Some of the stock options are as follows:

-Part Side Stock adds stock to the individual walls of the part.
-Part Floor Stock adds stock to the floor.
-Check Stock is the distance that the tool will stay away from the check
geometry.
-Trim Stock is the distance that the tool will stay away from the trim
boundary.
-Blank Stock is stock applied to Blank geometry.
-Blank Distance applies to Part geometry. This is an offset distance which
can be used for a casting or forging.
Activity: Using the Blank Distance Option
In this activity, you will learn how to set the Blank Distance for a core type
part. The MCS, Part geometry and Program Name have already been created
2 for you.
Step 1: Open a new part file, rename and enter the Manufacturing
Application.
Open the part file horn_mfg.
Rename the part ***_horn_mfg using the Save As option on

the menu bar, where *** represents your initials.
Choose Start Manufacturing .

The Operation Navigator is displayed.
Step 2: Create an operation utilizing Blank Distance as a part offset.

As shown below, select the Create Operation icon from the
Create toolbar.
2
The Create Operation dialog is displayed.
Select the Cavity Milling icon.
Set the following:

Program: ROUGH_WITHOUT_CASTING
Use Geometry: WORKPIECE
Use Tool: EM-.375-.06
Use Method: MILL_FINISH
On the Create Operation dialog, name the operation

CM_.20_BLANKDISTANCE.
Choose OK.
The CAVITY_MILLING dialog is displayed.
Step 3: Verify the Part Geometry selection.
Under the Geometry label, select the Part icon.
Choose Display.
Note that the Part geometry is displayed.
Under the Geometry label, select the Blank icon.

Note that no Blank geometry has been selected.
Step 4: Specify Operation settings.

Set the Cut Method to Follow Part.
Set Depth Per Cut to .125.
Choose Cutting.
The Cut Parameters dialog is displayed.
Change the Cut Order to Depth First.
Change the Blank Distance to .20.
Choose OK.
The CAVITY_MILL dialog is displayed.
Choose the Generate icon to generate the tool path.
Choose OK after viewing each Cut Level.
The tool path cuts all of the core geometry.
Notice that the tool path follows the part contour since you used
the Blank Distance option rather than selecting other geometry
(such as a solid block) to represent the Blank shape.
In this case, you specified that the Blank was near-net-shape with
.250" stock overall.
Choose OK to accept the tool path.
Save the part file.
Cut Parameters - Trim by

Trim by enables the Blank geometry to be recognized on core parts when
the Blank geometry has not been explicitly defined. The Trim by method
2 provides a Silhouette option to clean up the material which surrounds the
Part geometry. It is available only when Tolerant Machining is toggled to on.
This option positions the tool to the outer most edge periphery (silhouette) of
the part geometry and then offsets it outside by the tool radius. The silhouette
can be consider as a shadow of the part projected along the tool axis.
When using Trim by Silhouette, the processor uses the traces at the bottom of
the defined part geometry as trim shapes. These shapes are then projected
along the tool axis to each cut level and are used to generate machinable
regions as trim shapes.
Cut Parameters - Tolerant Machining

The Tolerant Machining ON option is the preferred method for Cavity Milling
operations. Tolerant Machining will find all machinable regions without
gouging the part.
Tolerant Machining algorithms digitize a model on a rectangular grid that is
determined by the defined cutting tolerance and the tool size. In most parts,
the grid size range between 1-2 millimeters (.04 - .08").
When you specify a Blank distance that is an offset from the Part, the
tolerance used to trace the Blank is larger than the tolerance used to trace
the Part. This is due to dimensions of Blank geometry not being as accurate
as those of the Part geometry. When you specify Blank geometry that is close
to the size of Part geometry, the Blank and Part traces will overlap and result
in an undesirable cut region(s). In this case it would be better to cut a profile
pass along the Part without specifying the Blank. The resultant tool path will 2
be along the Part geometry.
When the processor encounters geometry that contains gaps or that is not
perfectly matched, it will move the tool using an approximation within the
specified tolerances.
The processing time is longer when Tolerant Machining is on. Tolerant
Machining SHOULD ALWAYS be turned on.
Cut Parameters - Undercut Handling
Undercut Handling is used with geometry features containing undercuts. It

is applied only to non-tolerant machining.
If Tolerant Machining is turned on, Undercut Handling is automatically

turned off.
When using the Undercut Handling option Horizontal Clearance (specified
under the Engage/Retract Method) applies to the shank of the tool (the
portion above the flutes) unless the Horizontal Clearance is greater than the
tool radius. In this case the tool radius is used.
As the tool progresses deeper through the various cut levels, Horizontal
Clearance will keep the shank from contacting the part geometry which
forms the undercut.
In the following example the Horizontal Clearance uses the default of .100.
2 The tool radius is .120. The tool will be offset from the undercut face by .100.
Part, Blank, Check Geometry - Topology

Topology provides options for surface analysis that allow checking for
material side inconsistency, gaps and missing and duplicate surfaces.
This option is available when you are editing geometry and aids in the
correction of model geometry errors that occur when models from other CAD
systems are converted into NX models or from within a model created using
NX.
The topology processor inspects the model for missing, duplicated and
non-tangent faces which can create multiple shells and an erratic tool path.
It is suggested that the Topology option be used only if tool path
generation fails.
The following are common causes of tool path generation failures.

Duplicate faces
Missing fillets and faces
Smaller than tolerance faces (usually fillets)
The following is a summary of the options on the Topology dialog:
Tolerances - Distance is the tolerance used for connecting faces and curves.
The distance value represents the maximum value that two objects can be
apart and still be considered connected. Angle is the tolerance used for
determining the type of each edge (convex, concave or tangent). The Angle
value represents the maximum angle that the normals of two adjacent faces
or curves can vary at an edge to determine if the edge is convex, concave or
tangent.
Rebuild Topology - After editing tolerances or material side, you can choose
Rebuild Topology to create the shell. Surfaces are considered adjacent if the
gaps are less than the tolerance specified and one or more shells are created.
Model geometry is not modified.
Material Side- allows you to change the material side of any object that is
used to define the cutting operation. Material Side is represented by a vector
arrow that points away from the material.
Unify All - allows Material Side to be located on the same side for all objects.
Reverse All - allows Material Side to be reversed for all objects.
Inspect or Edit Shell - allows the inspection of the classification of edge types
2 and Material Side for individual objects.
Faces - allows the inspection of Material Side defined for each face. Faces can
be set to undefined, same or opposite.
Undefined allows you to highlight all faces where the Material Side is
not defined
Same allows you to highlight all of the faces where the Material Side is
the same as that of the majority of faces
Opposite allows you to highlight all of the faces where the Material Side
is different than that of the majority of faces
Edges - allows the review of the classification of various edges. Edges can
be set to the following:
Undefined allows the highlight of any edge which is not classified by the
system
Non-manifold allows the highlight of any unresolved edge where more

than two faces meet along the same portion of the edge
Exterior allows the highlight of all of the outside edges that define the
cutting region
Interior allows the highlight of all of the inside edges that define the
cutting region
Inconsistent allows the highlight of edges where the adjacent faces have
material sides on opposite sides
Complex allows the highlight of edges that are neither completely

tangent, concave or convex
Tangent allows the highlight of all edges that are classified as being
tangent
Concave allows the highlight of all edges that are classified as being
concave
Convex allows the highlight of all edges that are classified as being convex
Display Material Side - this option results in the display of the Material Side
indicator whenever one of the face options is chosen.
The Material Side indicator is a vector that points towards the material to
be removed which is away from the Material Side.
Refresh Before Display - the system will refresh the screen every time you
choose one of the Face or Edge options.
2
Arrow Buttons - allows you to cycle through the different shells as you inspect
and edit the topology.
Summary
The Cavity Milling module provides efficient and robust capabilities
of removing large amounts of stock, primarily in cavity and core type
2 applications.
The following functions are available in Cavity Milling:
Use of the In-Process work piece for accurate removal of material using
different size cutting tools
Cut levels to precisely control depths of cut
Cut patterns to control direction and method of removing stock
Lesson
3 Z-Level Milling
Purpose 3
This lesson is an introduction to the Z-Level operation type, which is useful
when profiling steep areas. You can also isolate specific areas that you want
to cut or avoid cutting within a Z-Level operation.
Objective

Understand the uses of Z-Level milling.
Create milling operations using the Z-Level operation type.
Understand the meaning and use of steep and non-steep areas of geometry.
Z-Level Milling
Z-Level Milling
Z-Level Milling is designed to profile bodies or faces at multiple depths. It
will cut steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face) or the entire part.
The following Z-Level operation types are available:
ZLEVEL_FOLLOW_CAVITY - uses the Follow Part Cut Method;

3 ideal for "cavity" type parts
ZLEVEL_FOLLOW_CORE - uses the Follow Part Cut Method; ideal

for "core" type parts
CORNER ROUGH - Cavity milling with a reference tool that can be

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

Angle being set
ZLEVEL_PROFILE_STEEP - uses the Profile Cut Method with the

Steep Angle set to 65 degrees
ZLEVEL_CORNER - Z-Level milling that uses an existing reference

tool; compliments flowcut machining
Part geometry and Cut Area geometry can be specified to limit the area to
be cut. If cut area geometry is not defined, then the entire part is used as
the cut area.
Z-Level Milling
1. Part
2. Check
3. Cut Area
4. Trim
Many of the option settings found in Z-Level Milling are the same as in Cavity
Milling. A description of some of these options are as follows:
Geometry
Part geometry consists of bodies and faces which represents the Part
after cutting
Check geometry consists of bodies and faces which represent clamps or
obstructions that are not to be machined
Cut Area geometry represents the areas on the Part to be machined; it
can be some or all of the part
Trim geometry consists of closed boundaries which indicate where

material will be left or removed; all Trim boundaries have tool positions
on only
During tool path generation, the geometry is traced, steep areas and trace
shapes are determined, cut areas are identified and a tool path is generated
for all cut depths specified.
Z-Level Milling
Activity: Z-Level Milling
In this activity, you will generate tool paths using Z-Level Milling. Z-Level
is designed to profile an entire part or steep areas that were previously left
by the Area Milling Drive Method.
Open the part base_mfg_3.
Enter the Manufacturing application.

Change the view of the Operation Navigator to the Geometry

View.
The MCS_MILL Parent Group is displayed in the Operation
Navigator.
Expand the MCS_MILL and WORKPIECE Geometry Parent

Groups.
The ROUGHING_1 operation is listed in the Operation
Navigator.
Step 2: Create a Z-Level operation.

Choose the Create Operation icon on the Manufacturing Create
tool bar.
Make sure the Type is set to mill_contour.
Z-Level Milling
Choose the ZLEVEL_PROFILE icon.
Set the Program to BASE_MALE_DIE.
Set Use Geometry to WORKPIECE.
Set Use Tool to EM_1.25_.25.
Set Use Method to MILL_FINISH. 3

Name the operation zlevel_finish.
Choose OK.
The ZLEVEL_PROFILE dialog is displayed.
Step 3: Change the Depth of Cut.

You will change the depth of cut.
For ease of viewing turn model shading off.
Next to the Global Depth Per Cut label, enter 0.100.

You will now change the cut levels. You will stop cutting
material at the top of the bottom face. The default is the
bottom face.
Z-Level Milling
Choose the Cut Levels button.

The Cut Levels dialog is displayed.
Select the Down Arrow button.
Index to the 4th range and select the delete icon.
Choose OK.

Choose the Generate icon and generate the tool path.
Z-Level Milling
Choose OK in the Display Parameters dialog to continue

generating the tool path.
Step 5: Verify the Program that you have created.

Use Toolpath Verification to examine the tool path results.
Z-Level Milling
Steep Angle
The steepness of the part at any given area is defined by the angle between
the tool axis and the normal of the face. The steep area is the area where the
steepness of the part is greater than the specified Steep Angle. When the
Steep Angle is toggled on, areas of the part with a steepness greater than or
equal to the specified Steep Angle are cut. When the Steep Angle is toggled
off, the part, as defined by the part geometry and any limiting cut area
geometry, is cut.
3
Z-Level Milling
Activity: ZLEVEL_PROFILE_STEEP Operations

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

3


View.
The MCS_MILL Parent Group is displayed in the Operation
Navigator.
Z-Level Milling

Groups.
The CM_ROUGH operation is listed in the Operation Navigator.
Step 2: Create the ZLEVEL_PROFILE_STEEP operation.

Select the Create Operation icon from the Create toolbar.
3
Select the ZLEVEL_PROFILE_STEEP icon.
Set the following:

Program: INTERIOR
Z-Level Milling
Choose OK.
The ZLEVEL_PROFILE_STEEP dialog is displayed.
Under the Geometry label, select the Part icon and choose
Display.
The Part geometry is displayed. Note that the Part geometry
was specified in the Parent Group named WORKPIECE.
Under the Geometry label, select the Cut Area icon and notice
that only the Select button is available.
Since the Cut Area was not specified, by default, the entire
part will be used for cutting.
Also note the Steep Angle and the other default option settings.
Z-Level Milling

Choose the Generate icon and generate the tool path.
Choose OK to save the operation.

Notice the areas cut by the tool path. Remember that the Steep
Angle was set to 65 degrees.
Do not save the part, you will be using it in the next activity.
3
Minimum Cut Length
Minimum Cut Length enables the elimination of short tool path segments
that may occur in isolated areas of the part. Moves shorter than this value
are not generated.
Depth Per Cut
Depth Per Cut allows the specification of the maximum depth per cut in
a range. Cut depths are calculated that are equal and do not exceed the
specified Depth Per Cut value.
Z-Level Milling
Z-Level Milling
Cut Order
Z-Level Milling determines cut traces by shape. Shapes can be profiled by
Depth First in which each shape is completely profiled before beginning to
profile the next shape. Shapes can also be profiled by Level First in which all
shapes are profiled at a particular level before cutting each shape at the
next level.
Control Geometry
Control Geometry allows the specification of Control Points to determine
where the tool engages the part and the floor plane.
Z-Level Milling
Trim by
Trim by is used to prevent the tool from rolling around corners.

The Silhouette option uses the outline of the part geometry, as viewed down
the tool axis, to generate a trace. The tool is positioned along the silhouette of
the part geometry. The trace is then offset to the outside by the tool radius
distance. The silhouette can be thought of as the shadow of the part projected
along the tool axis.
When using Trim by Silhouette, the traces at the bottom of the part geometry
are used as trim shapes. These shapes will be projected along the tool axis to
3
each cut level and will be used in the process of generating the machinable
regions as trim shapes.
Remove Edge Traces
Edge tracing (edge roll) is usually an undesirable condition that can occur
when the Drive Path extends beyond the edge of the part geometry. The
tool rolls over the edge of the part geometry potentially gouging the part.
The Remove Edge Traces option allows the control of whether or not edge
tracing occurs.
Z-Level Milling
Activity: Z-Level Profile Milling

In this activity, you will create a Z-Level Profile operation to machine the
geometry of the island within the cavity. You will create a Geometry Parent
Group (MILL_AREA) that contains the geometry necessary for machining.
The tool path will cut only within the area that has been specified.
Step 1: Create the Geometry Parent Group.
Continue using form_mold_mfg.
3
Select the Create Geometry icon from the Create tool bar.
The Create Geometry dialog is displayed (make sure Type is

mill_contour).
In the Create Geometry dialog select the Mill_Area icon.
If necessary, select the WORKPIECE as the Parent Group.
Enter ZLEVEL_AREA as the Name.
Z-Level Milling
Choose OK.
The MILL_AREA dialog is displayed.
Choose the Cut Area icon.
Choose Select.
The Cut Area dialog is displayed.
Z-Level Milling
Select the interior island geometry as shown.
Make sure that when selecting with a rectangle,

selection criteria should be inside only.
Choose OK, twice to return to the Create Geometry dialog.

Note that you do not need to specify Blank Geometry.
To briefly review you have created a Geometry Parent
Group, named ZLEVEL_AREA which contains the geometry
of the island. This Parent Group will be used in the
ZLEVEL_PROFILE operation.
You will now create the operation.
Step 2: Create the ZLEVEL_PROFILE Operation.

Choose the Create Operation icon.
Select the ZLEVEL_PROFILE icon.
Set the following:
Program: INTERIOR
Use Geometry: ZLEVEL_AREA
Z-Level Milling
Choose OK.
Under the Geometry label, select the Part icon and choose
Display.
The Part geometry is displayed. It was specified in the
WORKPIECE Parent Group. 3
Under the Geometry label, select the Cut Area icon and choose
Display.
The Cut Area geometry is displayed. It was specified in the
ZLEVEL_AREA Parent under the WORKPIECE Parent Group.
Change the Global Depth Per Cut to .15.
Change Cut Order to Depth First.
Z-Level Milling
Do not Save the part file.
Z-Level Milling
Z-Level Cutting Between Levels (aka Gap Machining)

Z-Level cutting between levels, commonly referred to as Gap Machining,
creates extra cut levels (2) when gaps occur due to the occurrence of non-steep
(1) areas. This avoids the creation of separate Area Milling operations or,
in some cases, the use of extremely small depths of cut to control excessive
scallop heights in non-steep areas.
Gap Machining minimizes excessive tool wear and breakage caused by the
removal of large amounts of scallop stock left from previous operations.
Resultant tool paths from Gap Machining produce uniform scallops,
regardless of the angle of steepness, incorporating fewer engages and retracts,
producing a more consistent surface finish.
Stepover option
Stepover pertains to machining the gap areas.
When used with the default Use Depth of Cut parameter, the stepover
matches the depth of cut of the current cut range. To further enhance the
Z-Level Milling
control of the scallop height in these areas, you can also specify the stepover
distance. Since each cut level range can have a different depth of cut, if you
specify Use Depth of Cut, then the range it lies in determines the stepover
for that gap region. If a gap region spans several ranges that do not have cut
levels defined, the gap region will use the minimum depth of cut of the ranges.
Max Cut Traverse option
Max Cut Traverse defines the longest distance that the cutting tool feeds
3 along the part when not cutting. When connecting cutting areas, if the total
distance is less than the Max Cut Traverse parameter, the tool will feed along
the part. If the distance is larger then the current transfer method is used to
retract, traverse, and engage to the next location. This value is a length or a
percent of the tool diameter.
Sequencing of Gap and Z-Level tool paths
Z-Level and gap tool paths are sequenced and ordered as follows:
Z-Level tool path is machined from the top-down and uses the same
connection methods as it would without the Cut Between Levels option
1. After each Z-level cut is completed, the tool begins to cut the level below it
2. When cutting the lower level, gaps between the lower level and the
previous level above it are determined
3. When a gap is discovered, the gap is cut, cutting continues until another
gap is found or the cut is complete at that level
4. Gap level at the lower level is cut based on Max Cut Traverse parameter;
if Max Cut Traverse is exceeded, a traverse move to the next level takes
places; if the move to the next level is within the Max Cut Traverse
distance, the tool makes a direct on-part move to the next level without
traversing
Level-to-level connections violating a gap region are removed and replaced

with a traversal move
Engage and retract moves are kept to a minimum along the tool axis
Connections are made from the Z-Level cut to the gap area; after cutting
the gap area, the tool returns to the lower level
Z-Level Milling
Z-Level Gap machining is activated from the Cut Parameters dialog by

selecting the Connections tab and selection of Cut Between Levels. Modify the
parameters on that dialog as needed.
Z-Level Milling
Activity: Z-Level Gap Machining

In this activity, you will activate Gap Machining option in an existing Z-Level
operation.
Choose File Open male_cover_mfg.
ChooseStart Manufacturing.
If necessary, display the Operation Navigator in the Program

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

Double-click on the ZLEVEL_PROFILE operation for editing
purposes.
Z-Level Milling
Choose the Replay button.
3
The tool path is displayed. Note the non-steep areas and the
numerous engage retracts that occur.
The operation does a fairly good job of machining the steep

geometry but does not machine the non-steep area very well.
You will now turn on the Cut Between Levels (Gap Machining)
option to completely finish machine the part in one complete
operation.
Z-Level Milling
Choose the Cutting button.
The Cut Parameters dialog is displayed.
Choose the Connections to tab.

3
Turn On the Cut Between Levels option.
Z-Level Milling
Set the Stepover to Constant.
Change the Distance to 0.15.
ChooseOK.
Z-Level Milling

The non-steep areas are now machined as well as the steep

areas of the part.
Do not Save the part file.
Z-Level Milling
Summary
This lesson was an introduction to Z-Level milling, which is used when
profiling steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face). This operation
type is useful in minimizing the amount of scallop or cusps that remains
on the part.
In this lesson you:
3 Created an operation using Z-Level Profile operation types.
Reviewed and generated operations using Z-Level operations

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

incorporating Cut Between Levels (Gap machining).
Lesson
4 MILL_AREA Geometry
Parent Groups
Purpose
This lesson introduces you to the MILL_AREA Geometry Parent Groups,

which are used in limiting cut areas.
4
Objective
Create and use MILL_AREA Geometry Parent Groups.
Create and modify Trim Boundaries.
Recognize the type of geometry MILL_AREA Parent Groups use.
MILL_AREA Geometry Overview
Occasionally, when machining large or complex parts, it is desirable to limit

the area that an operation machines. The MILL_AREA Geometry Parent
Group is designed for that purpose.
The MILL_AREA Geometry Parent Group allows the user to select a small
portion of a part to machine. This area is based on the faces of the part which
you select. This group of faces to machine is called a Cut Area.
The area to machine can be further limited by use of a Trim Boundary.
Below is the MILL_AREA Geometry Parent Group dialog.
MILL_AREA Geometry Parent Groups
Part Geometry - is typically specified in the WORKPIECE

Geometry Parent Group and represent the material to be cut
Check Geometry - represents clamps, vises, locator pins, and other

items that are not cut
Cut Area - represents the specific geometry to be machined
Wall Geometry - represents walls or sides of a part
Trim Boundary - allows you to define trim boundaries that limit

the cutting area
Cut Area
When choosing the Cut Area icon, the Cut Area dialog is displayed.
Only faces and sheet bodies can be selected for Cut Area geometry. The
Features option allows surface regions (groups of faces or sheet bodies) for
selection purposes.
Activity: MILL_AREA Geometry Parent Groups
This activity will demonstrate how to create and use a MILL_AREA geometry
Parent Group in an operation. You will Replay and examine the results of
an existing operation. You will then create a MILL_AREA geometry Parent
Group consisting of faces and will modify the inheritance of the operation to
use the MILL_AREA parent.
Step 1: Open the part file, rename it, and enter the Manufacturing
application.
Open the part male_cover_mfg_2.
Rename the part ***_male_cover_mfg_2 using the File Save

As option on the menu bar.
Choose Start Manufacturing .
Change the Operation Navigator to the Geometry View.

Groups.
Step 2: Replay the current operation. 4

Highlight the FC_FINISH_RIBS operation, use MB3 and select
Replay.
This Fixed Contour operation machines the entire part. This is

not the desired result.
In the next steps, you will create a MILL_AREA geometry
Parent Group to limit the machining to just the two ribs
protruding from the part.
Refresh the graphics screen.

There are at least three ways to refresh the screen:
1. MB3 Refresh
2. Press the F5 button
3. From the top menu bar, choose View Refresh
Step 3: Create the MILL_AREA Geometry Parent Group.

Choose the Create Geometry icon.
If necessary, change the Type to mill_contour.

4 Choose the Subtype MILL_AREA.
Change the Parent Group to WORKPIECE.
In the Name field, enter two_ribs.
Choose OK.
The MILL_AREA dialog is displayed.
Step 4: Define the Cut Area geometry.

Choose the Cut Area icon.
Choose the Select button.
Choose the faces of the ribs, as shown.
When finished selecting the faces, choose OK.
Choose OK again to accept the dialog.
Step 5: Change the inheritance of the operation.

You will move the FC_FINISH_RIBS operation, so that the
operation will machine only the faces specified.
Currently, the Geometry View of the Operation Navigator looks
as follows:
4
Using MB1, click and drag the FC_FINISH_RIBS operation
so that it resides under the TWO_RIBS Parent Group, then
release MB1.
Highlight the FC_FINISH_RIBS operation, using MB3, select

Generate from the pop-up menu.
The tool path is generated and cuts the faces selected in the
MILL_AREA Parent Group.
Save the part file.
Trim Boundary
A Trim Boundary is the same as any other boundary except that any tool path
that falls within the area described by the boundary will be trimmed away.
When you choose the Trim Boundary icon, the standard boundary dialog
is displayed.
Activity: Using Trim Boundaries
In this activity, you will create a trim boundary inside of a MILL_AREA

Parent Group and will then generate the corresponding operation.
Step 1: Continue using the part file.
Continue using ***_male_cover_mfg_2.
Step 2: Create a Trim Boundary.

Change the view to TOP.
Change the Operation Navigator to the Geometry View.

You will now edit the operation.
Double-click on the TWO_RIBS operation.
Choose the TRIM icon, and then choose Select.
The boundary you will create will be developed using cursor

location points.
4 Choose the Point Boundary icon.
Change the Point Method to Cursor Location.
Using four screen position points create a trim boundary

similar to the one shown below.
Choose OK to return to the main dialog.
Generate the tool path for the FC_FINISH_RIBS operation and

examine the results.
Any tool path that falls within the Trim boundary is removed.
Save the part file.
Summary
The MILL_AREA geometry group allows flexibility in determining exact
areas for cutting purposes. The use of this geometry group and Trim
Boundaries gives you the ability of isolating specific areas of geometry used in
the machining process.
In this lesson you:
Created MILL_AREA geometry to machine specific areas.
4
Lesson
5 Fixed Contour Operation Types
Purpose
This lesson will show you how to create a Fixed Contour operation using
several of the options and concepts that are unique to Fixed Contour
machining. You will also review the steps necessary to create various Parent
Groups that will aid you in the selection of geometry and cutting tools. Fixed
Contour operations are generally used for creation of tool paths used to finish
the contoured areas of a part.
Objective
Upon completion of this lesson, you will be able to: 5

Use the Fixed Contour Area Milling and Flow Cut Drive methods to
create tool paths
Use Non-cutting moves in Fixed Contour operations
Create Parent Groups used for Fixed Contouring operations
Choose the most appropriate drive method for a Fixed Contour operation
Apply the more advanced concepts of Fixed Contour operations for

creating tool paths
Fixed Contour Operation Types
Fixed Contour Overview

Fixed Contour operations are used to finish areas formed by contoured
geometry. Fixed Contour tool paths are able to follow complex contours by
the control of tool axis, projection vector and drive methods. Tool paths are
created in two steps. The first step generates drive points from the drive
geometry. The second step projects the drive points along a projection vector
to the part geometry.
The drive points are created from some or all of the part geometry, or can be
created from other geometry that is not associated with the part. The points
are then projected to the part geometry.
The tool path output is created by internal processing which moves the tool
from the drive point along the projection vector until contact is made with the
part geometry. The position may coincide with the projected drive point or, if
other part geometry prevents the tool from reaching the projected drive point,
a new output point is generated and the unusable drive point is ignored.
Fixed Contour operations use a fixed tool axis for finishing contoured
geometry and can effectively clean up ridges and scallops left by other tool
paths.
Fixed Contour is the better choice for finish machining for several other
reasons:
In addition to Part geometry, Drive geometry can control tool movement
Numerous Drive Methods are available for specialized machining
Uncut areas left after semi-finishing or finishing passes can be easily

removed
Fixed Contour Tool Path Accuracy
Fixed Contour provides several options that help insure the accuracy of the
tool path. Included are:
Check Geometry to stop tool movement
Gouge Checking to prevent gouging of the part
Collision Checking to prevent unintended tool contact with other geometry

5
Various tolerance options
Fixed Contour operations can position to existing locations on the part

geometry (which includes the edge of an object), but the tool cannot position
to an extension of part geometry as shown in the following illustration.
Terminology used in Fixed Contour operations
Part Geometry - is geometry selected to cut.

Check Geometry - is geometry selected that is used to stop tool movement.
Drive Geometry - is geometry used to generate drive points.
drive points - are generated from the drive geometry and projected onto the
part geometry.
drive method - method of defining drive points required to create a tool path.
Some drive methods allow the creation of a string of drive points along a curve
while others allow the creation of an array of drive points within an area.
projection vector - used to describe how the drive points project to the part
surface and which side of the part surface the tool contacts. The selected
drive method determines which projection vectors are available.
The projection vector does not need to coincide with the tool axis
vector.
Drive Methods for Fixed Contouring
The drive method defines the method of creating drive points.
Each drive method contains a series of dialogs that are displayed upon
selection.
Area Milling drive method
The Area Milling drive method allows you to specify a cut area for tool path
generation. This drive method is similar to the Boundary drive method, but
does not require drive geometry.
Cut Area(s) may be defined by selecting surface regions, sheet bodies, or
faces. Unlike the Surface Area drive method, the cut area geometry does not
have to be selected in an orderly grid of rows and columns.
If you do not specify a Cut Area, the processor will use the selected part
geometry (excluding areas not accessible by the tool) as the cut area.
The Area Milling drive method is generally the preferred Fixed Contour drive
method for creating tool paths.
Surface drive method
The Surface Area drive method allows you to create an array of drive points 5
that lie on a grid of drive surface. This drive method is useful in machining
very complex surfaces. It provides additional control of both the tool axis and
the projection vector.
The tool path is created on the selected part surfaces by projecting points
from the drive surface in the direction of a specified projection vector. If part
surfaces are not defined, the tool path can be created directly on the drive
surface. The drive surfaces do not have to be planar, but must be in an orderly
grid of rows and columns. Adjacent surfaces must share a common edge
and may not contain gaps that exceed the Chaining Tolerance defined under
Preferences (Preferences Selection Chaining Tolerance). Trimmed
surfaces can be used to define drive surfaces as long as the trimmed surface
has four sides. Each side of the trimmed surface can be a single edge curve or
comprised of multiple tangent edge curves that can be considered a single
curve.
Tool Path drive method
The Tool Path drive method allows you to define drive points along the tool
path of a Cutter Location Source File (CLSF) to create a similar tool path.
Drive points are generated along the existing tool path and then projected
on to the selected part surface(s) to create the new tool path that follows the
surface contours. The direction in which the drive points are projected on to
the part surfaces is determined by the projection vector.
Radial Cut drive method
The Radial Cut drive method allows you to generate drive paths perpendicular
to and along a given boundary, using a specified Stepover distance, Bandwidth
and Cut Type. This method is useful in creating cleanup operations.
Flow Cut drive method
Flow Cut drive methods allows you to generate drive points along concave
corners and valleys formed by part surfaces. The direction and order of the
flow cuts are determined using rules based on machining best practices. The
tool path is optimized for maximum part contact to minimize non-cutting
moves.
Text drive method
Text drive methods allows you to generate drive paths based on text created
from drafting notes.
User Function drive method

5
The User Function drive method creates tool paths from special drive
methods developed in User Function code. These are optional, highly
specialized custom routines developed for specific complex applications.
Parent Groups associated with Fixed Contour operations
There are three different Geometry parent groups available for use in Fixed
Contour operations. They are:
The MILL_GEOM parent group which allows part, blank and check
geometry.
The MILL_BND parent group which also allows part, blank, check and
trim and floor boundary geometry.
The MILL_AREA parent group allows part and check but not blank
geometry. It also allows for the specification of Cut Areas ,Wall and Trim
geometry.
The parent group, MILL_AREA, which you used in Cavity Milling operations,
is also used in Fixed Contour operations. It allows you to include or exclude
areas to be machined in cut areas that you specify. These specific areas
may have been previously roughed by Cavity Milling or finished by Planar
Mill operations.
Fixed Contour also provides several template operations that use the parent
group, MILL_AREA. These operations also have the Area Milling drive
method specified allowing you to quickly create finishing operations for
contoured parts.
Fixed Contour operations are generally used to finish contoured types of
geometry.
The following diagram can be used as an aid in the determination of the

operation type needed for various types of geometry:
5
Fixed Contour Operation types
The most commonly used Fixed Contour operation types are:
FIXED_CONTOUR - Generic Fixed Contour operation type. Allows

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

cutting specific areas of part geometry.
CONTOUR_SURFACE_AREA - Uses Surface Area drive method.

Ideal for complex part surfaces where tool axis control is critical.
FLOWCUT_REF_TOOL - Uses the Flow Cut drive method. Flow

Cut RTO (reference tool) will machine certain geometry types by level and
provide you with the options to cut the two sides alternatively with a
rounded or standard turn at each end, and side by side with the option
from the steep side to non-steep side. This operation type takes into
account the previous tool diameter used for roughing (you must specify
this). This results in cutting parts with a more constant cutting load and
a shorter distance of non-cutting moves.
PROFILE_3D - Generates a profile pass utilizing three dimensional

curves, edges, faces, existing boundaries or points. Machines at a given
Z-depth offset with respect to the geometry type selected. Useful in
creation of addendum profile cuts for stamping dies.
More on Flow Cut Drive Methods
The Flow Cut drive method allows the specification of Climb, Conventional,
or Mixed cut directions for single pass operations.
The Climb and Conventional options allow the climb or conventional method
for all cutting passes in the operation. If a steep side can be determined, the
steep side is used to calculate the Climb or Conventional cut direction. If a
steep side cannot be determined, the cut direction is determined internally.
The Mixed option allows for the internal calculation of the cut direction.
Flow Cut drive method using Cut Area and Trim Boundary Geometry
The Flow Cut drive method allows Cut Area geometry to be defined the same
way as the Area Milling drive method. Surface regions, sheet bodies, faceted
bodies and or faces can be used as the cut area. Concave valleys are analyzed
within the cut area as well as concave valleys formed by the cut area and part
geometry. Valleys formed by the cut area and check geometry are excluded.
Trim boundaries can be used to further constrain cut regions. Material
Inside or Outside determines the area of the cut region to be omitted. Trim
boundaries are always Closed, always use an on condition, and are projected
to the Part geometry along the tool axis vector. More than one Trim Boundary
may be defined. Trim Stock may be specified to define the distance the tool is
positioned from the Trim Boundary.
Flow Cut Reference Tool Drive Method
Flow Cut Reference Tool drive method produces multiple cutting passes on
either side of the center flow cut by allowing you to specify a reference tool
diameter to define the total width of the area to be machined and a Stepover
Distance to define the interior passes.
This method is useful for cleanup machining after roughing out an area
with a large tool. This method also uses the Cut Type, Stepover Distance,
Sequencing, Reference Tool Diameter, Overlap Distance, and Steep
Containment options.
Flow Cut Reference Tool Options
Maximum Concavity allows you to determine where Flow Cuts are created
based on the Angle of Concavity. Cutting moves are created only where the
Angle of Concavity is less than or equal to the specified Maximum Concavity
angle. The value you enter must be positive and less than or equal to 179.0
degrees. When the Angle of Concavity exceeds the specified Maximum
Concavity angle, the tool will retract and traverse.
Minimum Cut Length allows you to eliminate short tool path segments that
may occur in isolated areas of the part. Cutting moves shorter than this value
are ignored. This option is useful in eliminating very short cutting moves
that occur at the intersection of fillets.
Hookup Distance allows you to eliminate unwanted gaps in the tool path by
connecting disjointed cutting motions that exceed the specified Maximum
Concavity angle. These unwanted motions occur where the tool retracts from
the part surface and are caused by gaps between surfaces or variations in
the Angle of Concavity that exceed the specified Maximum Concavity angle.
The value you enter determines the distance the tool will span to connect
the end points of cutting moves. The two ends will be connected by linearly
extending the two paths. 5
Cut Type (Zig-Zag and Zig) allows you to define how the cutter moves from
one cut pass to the next.
Stepover Distance allows you to specify the distance between successive
passes.
Sequencing enables you to determine the order in which the cut passes are
executed.
Inside-Out results in the cut starting at the center of the Flow Cut
pass and moving toward one of the outside passes. The tool then moves
back to the center cut and works its way toward the opposite side. You may
start the sequencing by choosing either side of the center of the Flow Cut.
Outside-In results in the cut starting at one of the outside passes

and moving to the center of the Flow Cut pass. The tool then picks up
the outside cut on the opposite side and works its way to the center cut
again. You may start the sequencing by choosing either side of the center
of the Flow Cut.
Steep Last results in the cut moving from non-steep side to the
steep side.
Steep First results in the cut moving from the outside pass on
the steep side to the outside pass on the non-steep side. The Steep First
sequence is available for Zig, Zig-Zag, and Zig-Zag with Lifts patterns.
Inside-Out Alternate always cuts a Flow Cut valley from the middle
Flow Cut pass. The cut starts at the center pass, moves to an inside pass
and then to the inside pass on the opposite side. The cut then moves to
the pass in the next pair on the first side and then to the pass in the same
pair on the second side. If one side has more offset passes then the other
side, all the extra passes on that side are machined after machining the
passes which are paired on both sides. Inside-Out Alternate sequence can
be generated with a Zig, Zig-Zag, or Zig-Zag with Lifts pattern.
Outside-In Alternate always machines a Flow Cut valley from

passes in an outside pair to inside pair, and then to the middle Flow Cut
pass when necessary. The cut starts at one outside pass and moves to the
5 other outside pass on the opposite side. The cut then moves to the pass
in the next pair on the first side and to the pass in the same pair on the
second side. After finishing the passes in the inside pair, the cut will
move to the middle Flow Cut pass, if required. If one side has more offset
passes then the other side, all the extra passes on that side are machined
before machining the passes in pairs on both sides. Outside-In Alternate
sequences can be generated in a Zig, Zig-Zag, or Zig-Zag with Lifts pattern.
Reference Tool Diameter enables you to specify the width of the finishing cut
region based on the diameter of the previous roughing (reference) tool. The
tool diameter specified must be larger than the current tool.
Overlap Distance enables you to extend the width of the area defined by the
Reference Tool Diameter along the tangent surfaces.
Steep enables the use of steepness to control the cut regions and their cut
directions. As in Area Milling drive method, Steep Containment allows the
restriction of the cut area based on the steepness of the tool path. Steepness
is defined by specifying a Steep Angle and a Steep or Non-Steep option. Cut
direction is defined by specifying a Steep Cut or Non-Steep Cut Direction.
You can also choose to machine flow cuts on both sides alternatively with a
rounded or standard turn at each end, or machine side by side from the steep
side to non-steep side.
Activity: Creating Fixed Contour Operations
The following activity creates simple Fixed Contour rough and finish
operations. You will first review a Cavity Milling operation that was used to
rough the majority of the part. You will then create Contour Area operations
that will semi-finish and finish the part. Finally, you will use Flow Cut
operations, using a Reference Tool, to remove stock that remained from
previous operations.
Step 1: Open the part file, rename and enter the Manufacturing
application.
Open the part male_cover_mfg_3.
Save As ***_male_cover_mfg_3.
Enter the Manufacturing application and display the Operation

Navigator.
Step 2: Review the Cavity Milling roughing operation.

This part file contains a Cavity Milling operation that rough cuts
the part.
Highlight the ROUGH_CM operation, using MB3, choose

REPLAY.
Note that a number of .250 steps were left in the material as
a result of the specified Cut Level. Also, .050 Floor and Side
Stock were specified in the operation.
Refresh the display.

You will create a Fixed Contour operation to semi-finish
machine the part.
Step 3: Create a Fixed Contour operation to semi-finish the part.
If necessary, change the Type to mill_contour.
In the Create Operation dialog, set:

Program to MALE_COVER
Use Geometry to WORKPIECE
Use Tool to BALLMILL-1.00
Use Method to MILL_ROUGH

5
Choose the CONTOUR_AREA icon.
Enter the Name as rough_fc.
Choose OK.
The Contour Area dialog is displayed.
Under the Geometry label, choose Display for the Part and
Check geometry.
You will use most of the default settings of the Area Milling 5
Method to create a roughing tool path.
Under the Drive Method label, choose Area Milling.

The Area Milling Method dialog is displayed.
Set the following options:
Pattern to Parallel Lines
Cut Type to Zig Zag
Cut Angle to Automatic
Stepover to Tool Diameter
Percent to 25
Choose OK.
Generate the tool path and expect warning messages.
Choose OK to all warning messages.
Choose the List icon to list the tool path.

Note that the listing contains many warnings of Interference
between the cutter and the Check geometry.
You will see messages similar to the one shown below.
Close the listing window.
Step 4: Create a Fixed Contour finishing operation using the Contour

Area operation type.
In the Create Operation dialog, set the following:

Use Method to MILL_FINISH
Enter the Name as finish_fc.
5
Choose OK.
The CONTOUR_AREA dialog is displayed.
Under the Geometry label, choose Display for the Part and
Check geometry.
Note that the part geometry as well as the check geometry
representing pins, bolts and the surface plate are displayed.
Under the Drive Method label, choose Area Milling.

The Area Milling Method dialog is displayed.

Pattern to Follow Periphery
Tool motion to Outward
Stepover to Constant
Distance to .030
Choose OK.
The next action will prevent the Warning message from
appearing.
Choose the Clearances tab.
Change the When Gouging option to Retract.
5
Choose OK.
Generate the tool path.
5 Your tool path should look similar to the above. Note that
Warnings were not generated and the tool path follows the
contour of the part.
Step 5: Create a Flow Cut finishing operation.

The tool could not fit into some areas of the part geometry because
of tool size. You will use a Flow Cut operation and a smaller tool
to remove uncut areas.
Choose the FLOWCUT_REF_TOOL icon.
In the Create Operation dialog, set:

Enter the Name as flow_fc.
Choose OK.
The FLOWCUT_REF_TOOL dialog is displayed.
Under the Geometry label, Display the Part and Check

geometry.
Note that on the dialog there is no Drive Method label since
Flow Cut is the Drive Method.
Step 6: Change the Reference Tool setting.

You will change the Reference Tool setting. The previous tool used
was a 1.00 diameter tool.
Enter 1.00 in the Ref. Tool Diameter value field.
Step 7: Generating the tool path.
Choose the Generate icon.
Note that the area being cut is in reference to the 1.000

5
Reference Tool diameter.
Choose OK.
Step 8: Create a finish Planar Milling Profile pass.

You have finish machined the core part except for the tapered
outer edge. The geometry is planar and requires a finish cut;
therefore, you will use a Planar Milling operation to generate the
tool path. The MILL_BND geometry parent group, which contains
the geometry needed for the profile pass, has already been created
for you.
Choose mill_planar as the Type.
Choose the PLANAR_PROFILE icon.
Set the following:
Use Geometry to MILL_BND
Use Tool to DRAFTED_ENDMILL
Enter the Name as finish_pm.
5
Choose OK.
The PLANAR_PROFILE dialog is displayed.
Choose the Display button.

This Parent Group (MILL_BND) contains the outer edge Part
boundary and the part Floor.
Remember, this is a Planar Milling operation, which uses

boundary geometry
You normally use a MILL_BND Parent Group for Planar

Milling operations
If necessary, set the Cut Depth to Floor Only for a single depth
of cut.
The other default PLANAR_PROFILE settings will be used to
demonstrate this operation.

Note that the tool cuts the outer boundary and forms the
tapered wall joining the part to the plate.
Save the part file.
Non-Cutting Moves
Fixed Contour operations uses Non-Cutting Moves for control of the tool
when not physically cutting metal.
There are five individual cases when the tool is not physically cutting metal.
They are:
Initial Case - At the beginning of the operation, controls how the tool
moves from its present position to cutting metal
Final Case - At the end of the operation, controls how the tool moves from
its last cutting move to a safe position above the work piece
Check Case - When the encountering check geometry, determines how

the tool retracts from the work piece and moves to a new cutting position
Reposition Case - controls how the tool retracts and re-engages the work
piece when there are gaps in the part geometry
Local Case - When the tool has to leave the part surface to complete the
step over for the next pass, this determines what action will be taken
The Case is specified at the top of the Non-Cutting Moves dialog.
Each Case has up to five moves that can be specified. The Moves are:
Retract Move - controls how the tool disengages from the work piece
Departure Move - Once the tool has retracted, controls how the tool moves
to a safe clearance area
Traverse - move from the current position to a safe area above the next
engage position
Approach Move - controls movement into position for engage motion
Engage Move - controls how the tool engages into the work piece
To avoid having you manually set all moves for all cases, the Default case was
created. This case has all the moves that the other cases have. Each move
has been pre-defined for the most common machining situation. Additionally,
all other cases have been assigned to use the Default case.
To use Non-Cutting Moves:

Create a Fixed Contour operation
Set all Cutting Parameters necessary (Drive Method, stepover, etc.)
Generate the operation
Examine the default Non-Cutting moves
If necessary, edit the Non-Cutting moves and change only the affected
moves
Activity: Using Non-Cutting Moves
This activity teaches you how to use the various Non-Cutting Moves options.
Step 1: Continue using the part file.
Continue using the ***_male_cover_mfg_3 part.
The Type should be set to mill_contour.
Set:
Use Tool to ENDMILL-2.00-.125
Use Method to MILL_ROUGH
Enter the Name as non_cutting_fc.
Choose OK.
Step 2: Generate the default tool path.

The CONTOUR_AREA dialog is displayed. The Drive Method is
Area Milling.
Also note, the geometry that you specified is WORKPIECE, which

is a MILL_GEOM Parent Group for contour geometry.
Under the Geometry label, Display the Part, and Check

geometry to verify the geometry selections.
For easier visualization, set the Tool Display to Off.
Choose the Cutting button and then select the Clearances tab.
5
If necessary, change the When Gouging parameter to Skip.
Choose OK on the Cut Parameters dialog.
Choose the Edit Parameters icon then change the Pattern to

Follow Periphery.
Change the Inward radio button to Outward.
Choose OK.

Note the Non-Cutting move to the Automatic Clearance Plane.
The move is represented as the dashed vertical line.
Step 3: Specify Non-Cutting Moves.

On the CONTOUR_FOLLOW dialog, choose the Non-Cutting
option.
Note that the Case is set to Default.
5
Also Note:
The Engage icon is highlighted by default
The Engage Status is Manual
The movement is Linear
Choose the Approach icon.

A default Automatic Clearance plane is created at a safe
distance above the highest area of the Part and Check geometry.
Next you will change the default setting from Automatic

Clearance to Clearance.
Choose Clearance from the Approach Status pull-down menu.
Choose the Departure icon.

Again, a default Automatic Clearance plane is created at a 5
safe distance above the highest area of the Part and Check
geometry.
You will now change the default setting from Automatic

Clearance to Clearance.
Choose Clearance from the Approach Status menu.
Choose OK.
Generate and review the tool path to verify that the clearance
plane moves are correct.
Note that the tool path engages the part in a linear motion. The
preferred method of engagement is a circular ramping motion.
Step 4: Change the Engage move.

Choose the Non-Cutting button.
You are still setting options for the Default case.
Choose the Engage icon.

The Engage Status should be Manual by default.
Change Movement to Arc Tangent to Approach.
Change Radius Type to Radius.
Enter .375 for the Radius.

The Retract Status setting will be set to Use Engage by
default. This can be verified by choosing the Retract icon.
Choose OK and return to the CONTOUR_AREA dialog.
Step 5: Change other Non-Cutting options.

On your own, explore the various Non-Cutting options, change
various ones and generate tool paths to see the effects.
Save and close the part file.
Summary
This lesson introduced you to Fixed Contour operations that gives you the
ability to machine complex contour geometry with numerous options.
In this lesson you:
Created Area Milling and Flow Cut operations.
Made extensive use of the MILL_GEOM and MILL_BND parent group.
Created non-cutting moves to control cutter movements to and from the

part during the machining process.
5
Lesson
6 Introduction to Four and Five

Axis Machining
Purpose
This lesson introduces the application of machining parts utilizing 4 and

5 axis machining principles.
Objective
At the conclusion of this lesson, you will be able to:

Create tool paths for 4-axis positioning and contouring operations.
Properly place the MCS for multi-axis operations.
Introduction to Four and Five Axis Machining
Multi-Axis Machining Concepts

The majority of what NC/CNC programmers term as "multi-axis" can actually
be considered planar or fixed axis machining. The spindle axis, on some
machines, is not normal to the Z direction of the machine tool and the actual
machining does not force a change in any motion of the rotary axis. This case
considers using the rotary axis for positioning mode only.
Programming of this type of operation is relatively simple, once you
understand some of the more basic concepts of multi-axis machining. Some
concepts for considerations are:
NX always requires a tool axis; if one is not specified, the default tool axis
is equal to the Z of the MCS (sometimes referred to by the vector of 0,0,1)
Fixed-Axis machining with a tool axis other than (0,0,1) involves setting
the tool axis to the proper orientation
Most, if not all, NX multi-axis operations work with a tool axis other
than + Zc 0,0,1
When performing multi-axis machining, never assume the tool axis is

currently correct; always make sure you specify the proper tool axis if it
is not 0,0,1
Prior to rotation of the table to a new position, verify the tool has been
6 retracted far enough to clear the part/fixture during rotational moves
It is a recommended practice to return the tool axis back to (0,0,1) at the

end of the operation. Clearance Planes are also suggested.
The following activity requires you to generate a tool path at other than a
normal tool axis of (0,0,1).
Activity: Operations at Other Than 0,0,1 Tool Axis
In this activity, you will machine the top and two angled areas of a sleeve
collar used in a yoke mechanism. All necessary Parent objects have been
created and the part has been previously roughed. The operations which you
will create will finish mill the top and two angled faces of the part.
Step 1: Open an existing part file and enter the Manufacturing application.
Open the part file, collar_mfg.
Choose StartManufacturing.
The Operation Navigator and the part are displayed.
Step 2: Create the finishing operation.

The operation, ROUGHING, already exists to rough the pad at
the top of the part. You will now create the operation to finish
that particular pad.
Choose the Create Operation icon from the toolbar.
If necessary, set the Type to mill_planar.
Choose FACE_MILLING as the operation type.
Choose the following Parent objects:

6 Program: FIXED_AXIS
Geometry: NORMAL_FACE
Tool: EM-1.00-0
Method: MILL_FINISH
Note that the geometry parent contains a boundary that

describes the top face of the part. The floor plane is set to the
top face.
Also note that the tool used in this operation is a 1.00" diameter
end mill with 0" corner radius.
Since this operation is used for finishing, no machining stock
will be left by the Method parent object.
Key in top_face as the name of the operation.
Choose OK.
The FACE_MILLING dialog is displayed.
Change the Cut Method to Follow Periphery and the Stepover

Percent to 50.
Generate the operation and then choose OK from the Display

Parameters dialog.
The generated tool path is displayed.
Step 3: Verify the results.

You will now verify the results by using Tool Path Visualization.
If required, change to the Program Order View of the Operation

Navigator.
Highlight the FIXED_AXIS program object.
Choose the Verify Toolpath icon from the toolbar.
Choose the 2D Dynamic tab from the Tool Path Visualization

dialog.
Choose the Play button from the bottom of the dialog.
Two operations will be replayed. The first operation is used

for roughing, the second is the finish operation that you just
created.
Verifying the operation indicates the tool path to be acceptable,

you will now continue with the next operation.
Choose Cancel from the Tool Path Visualization dialog.
Step 4: Create the first angled-face operation.

You will copy and rename the existing operation, TOP_FACE, to
use as a template for creating the next operation.
Highlight the TOP_FACE operation and choose MB3Copy.
Choose MB3Paste.
A copy of the previous operation is created, with the name
TOP_FACE_COPY. You will now rename the operation to
ANGLE_FACE_1.
Change the name of the new operation by highlighting the

TOP_FACE_COPY operation, choosing MB3Rename, then
typing ANGLE_FACE_1.
You will now change the geometry parent object.
Double-click on the ANGLE_FACE_1 operation.
Choose the Groups property page.
6
Choose the Geometry radio button at the top of the dialog,
then choose Reselect.
The Reselect Geometry dialog is displayed.
Choose ANGLE_FACE_1 from the pull-down list.
Choose OK.
Choose the Main property page from the FACE_MILLING

dialog.
Choose Generate.
Choose OK on the Display Parameters dialog.

The Operation Parameter Error dialog is displayed.
This dialog is informing you that the operation type,

FACE_MILLING, will not work unless the tool axis is set
normal to the floor axis. You will now redefine the tool axis
normal to the floor.
Choose OK from the Operation Parameter Error dialog.
Choose the Machine button located on the FACE_MILLING

dialog.
The Machine Control dialog is displayed.

As described earlier, there is always a defined tool axis. In this
particular case, the tool axis is the same as the Z of the MCS
(the definition of "+ZM Axis"). You will now change the tool axis
to one that is normal to the floor plane of the ANGLE_FACE_1
geometry parent object.
6
Choose the Tool Axis pull-down arrow.
Choose Specify Vector from the list.
The Vector Constructor dialog is displayed.
From the Vector Constructor dialog, choose the Face Normal

icon.
Note that Face Normal means to set the vector perpendicular

to the face.
Select the angled face as shown in the following figure.

Hint: You may need to blank the stock component to select the
proper face, by using the Assembly Navigator.
Choose OK until the FACE_MILLING dialog is displayed.

6
Use Verification to verify your tool path (refer to Step 3 for
detailed instructions).
Step 6: Create the second angled face operation.

You will use the copy/paste features of the Operation Navigator to
create the third finish operation.
Highlight the ANGLE_FACE_1 operation.
Choose MB3 Copy.
Choose MB3Paste.
Change the name of the new operation to ANGLE_FACE_2.
Edit the operation by doubling-clicking on ANGLE_FACE_2.
Choose the Groups property page.
Choose the Geometry radio button at the top of the dialog,

then choose Reselect.
The Reselect Geometry dialog is displayed.
Choose ANGLE_FACE_2, as the geometry parent, from the

pull-down list.
Choose OK.
Choose the Machine button located on the FACE_MILLING

dialog.
The Machine Control dialog is displayed.
Select the Tool Axis pull-down arrow.
Choose Specify Vector.

From the Vector Constructor dialog, choose the Face Normal

icon.
Select the angled face as shown in the following figure.
Choose OK until the FACE_MILLING dialog is displayed.
Choose Generate.
Choose OK on the Display Parameters dialog.
Choose OK on the FACE_MILLING dialog to save the

operation.

Use Verification to verify the tool path.
Close the part file without saving.
Defining the Center of Rotation for a Rotary Axis

To machine about a rotary axis, the position of the rotary axis must be
defined. There are two methods to accomplish this:
Place the WCS/MCS at the center of axis rotation. For a 4 or 5 axis
machine tool, position the Main MCS at the center of rotation of the 4th
or 5th axis.
Designate the MCS as a geometry group, consisting of both a Main and

Local MCS. This is used by the NX/POST post processor as either fixture
offsets or machine tool zero data.
Placing the MCS at the Center of Axis Rotation

Position the part on the fixture in a normal position. Place the MCS at the
center of rotation of the fourth axis.
At the machine tool, the operator will then set the rotary table center as
the zero point.
Advantages:
Simplest method to use and deploy
Considerably less work for the NC/CNC programmer
Disadvantages:
6 Output in created program does not match output or dimensions on part
print
Adjustment of fixtures may require some type of reprogramming
Designate the MCS as a Geometry Group, Consisting of Both a Main and

Local MCS
The programmer designates the purpose of the coordinate system as either
Main or Local in the geometry group. When post processing, using the local
MCS, the data of the Main and Local coordinate system are used and the
output will then match the print dimensions.
If the coordinate system is designated Local, then a special output parameter
can be specified for the coordinate system. The options available are:
None
Use the Main MCS
Fixture Offset
CSYS rotation
The default setting is Fixture Offset. The designated option setting is then
passed to the post processor, along with the Main and Local coordinate system
to output the appropriate fixture offset values (G54...G59). The post processor
needs to be modified for this action to occur.
Advantages:
Output in the program matches the part print
Fixture adjustments can be solved by changing the Main and Local

designation
Disadvantages:
Programmer needs to understand the complexities associated with use of
the Main and Local coordinate system and the options provided
May be more confusing for machine operators
Machine tool post processor must be set up to obtain the correct output
The following activity will address using a Main and Local MCS.
Activity: Main and Local MCS in Multi-Axis Applications
In this activity, you will use the Main and Local MCS, which is used by the
post processor for formatting output used at the machine tool. The part file
has the main and local MCS already created for you. The Main MCS is set
where the machine zero would be. When you list the tool paths, the output is
based on the Local MCS. When you post the program, the output of the tool
paths, with their respective X, Y, and Z values, are based upon the Main MCS.
Open the part file t_stone_mfg_assm.
Save the part as ***_t_stone_mfg_assm.
If necessary, choose StartManufacturing.
Step 2: Examine the Local and Main coordinate systems.

If required, change to the Geometry view of the Operation
Navigator.
Expand the WORKPIECE group object and all subsequent

objects contained within the WORKPIECE parent.
You will notice that the WORKPIECE parent contains three

different MCS coordinate systems. You will now examine each
individual one.
Double-click on the MCS_MAIN group object.

The MCS dialog is displayed.
Select the green More Options arrow to see the Coordinate
System Purpose options.
6
Note that the Coordinate System Purpose selected is Main.
Choose OK.
6
Double-click on the MCS_000 group object.
Choose the green More Options if necessary arrow to see the

coordinate system purpose options.
Note that the Coordinate System Purpose selected is Local, the

6 Special Output is set to Use Main MCS, and the Fixture Offset
is set to 1.
Choose OK.
Choose the green More Options if necessary arrow to see the

coordinate system purpose options.
Note that the Coordinate System Purpose selected is Local, the

Special Output is also set to Use Main MCS, and the Fixture
Offset is set to 2.
Choose OK.
You will now list the tool paths for the existing operations that use
the Local MCS and observe that the X, Y and Z values are output
from the Local MCS.
Step 3: Examine the tool path listing.

Highlight the FM_001 operation, replay and list the tool path.
Highlight the FM_002 operation, replay and list the tool path.
You will now post process the operations and note that the X, Y
and Z values are based on the MAIN MCS.
Step 4: Post process the existing operations and examine the output.
Change to the Program Order view in the Operation Navigator.
Highlight the T_STONE parent group.
Choose the Postprocess icon.

The Postprocess dialog is displayed.
Using the Browse button under Available Machines, browse

to your parts directory and select the mcs_purpose.pui post
processor.
Choose OK.
Choose Apply on the Postprocess dialog.
If necessary, choose OK to the Path Out of Date dialog.

The posted output is displayed.
Notice the values for the X, Y and Z axes.
Cancel the Postprocess dialog.

6
Step 5: You will now modify the local MCS so the output is from the local
MCS.
Change to the Geometry view of the Operation Navigator.
Edit the MCS_000 parent group and change the Special Output
to Fixture Offset.
6
Choose OK.
Repeat the above step action item for MCS_90 .
Choose OK.
Change to the Program Order view of the Operation Navigator.
Highlight the T_STONE parent group.

If necessary, browse to your home directory and select the

mcs_purpose.pui postprocessor.
Choose OK.
If necessary, choose OK to overwrite Output File dialog.

6
Notice the values for the X, Y and Z axes and compare with the
previously posted output. The tool path is now output from the
local MCS.
Activity: Main and Local MCS in Multi-Axis Applications

In this activity, you will use the Main and Local MCS, which is used by the
post processor for formatting output used at the machine tool. The part file
has the main and local MCS already created for you. The Main MCS is set
where the machine zero would be, the same as if you were using an ORIGIN
statement to govern the output. When you list the tool paths, all have the
same X, Y, and Z values since they are based on the Local MCS. When you
post the program, the output of the three tool paths, with their respective X,
Y, and Z values, are based upon the Main MCS.
Open the part file mcs_local_main.
Save the part as ***_mcs_local_main.
If necessary, choose StartManufacturing.
Step 2: Examine the Local and Main coordinate systems.
If required, change to the Geometry view of the Operation

Navigator.
Expand the WORKPIECE group object and all subsequent

objects contained within the WORKPIECE parent.
You will notice that the WORKPIECE parent contains four

different MCS coordinate systems. You will now examine each
individual one.
6 Double-click on the MCS_MAIN group object.

Choose the More Options arrow.
Note that the Coordinate System Purpose selected is Main.

Choose OK.

Note that the Coordinate System Purpose selected is Local and

that Special Output is set to Use Main MCS.
Choose OK.


6
Choose OK.

Choose OK.
You will now list the tool paths for the existing operations that
use the Local MCS and observe that the X, Y and Z values are
the same for each one.
Step 3: Examine the tool path listing.

Highlight the PROFILE_000 operation, replay and list the
tool path.

tool path.

tool path.
Note that all the X, Y and Z values are the same.
You will now post process the three operations and note that
the X, Y and Z values are based on the MAIN MCS.
Step 4: Post process the existing operations and examine the output.
Change to the Program Order view in the Operation Navigator.
Highlight the TT1346-AA parent group.

6

Using the Browse button under Available Machines, browse

to your parts directory and select the mam_mcs_mill.pui post
processor.
Choose OK.

Notice the values for the X, Y and Z axes.

You will now modify the local MCS by adding fixture offsets and
will re-post the operations.
Cancel the Postprocess dialog.
Step 5: Modify the Local MCS by adding fixture offsets and re-posting
the operations.
Change to the Geometry view of the Operation Navigator.
Highlight the MCS_000 parent group, key in 1 for the Fixture

Offset and change the Special Output to Fixture Offset.
Repeat the above step action item for MCS_90 and MCS_180
parent groups, using 2 as the fixture offset for the MCS_90
parent group and 3 as the fixture offset for the MCS_180
parent group.
Choose OK.
Change to the Program Order view of the Operation Navigator.
Highlight the TT1346-AA parent group.
6 Choose the Postprocess icon.

If necessary, browse to your home directory and select the

mam_mcs_mill.pui postprocessor.
Choose OK.
If necessary, choose OK to overwrite Output File dialog.

Notice the values for the X, Y and Z axes and compare with the
previously posted output. Also note the G54, G55 and G56 that is
used for fixture offsets.
Summary
The majority of "multi-axis" machining can actually be considered to be
planar or fixed axis in nature. The spindle axis, on some machines, is not
normal to the Z direction of the machine tool and the actual machining does
not force a change in rotation of the rotary axis. Designation of tool axis and
MCS is crucial to perform this type of work.
In this lesson you:
Performed planar type machining at a tool axis other than (0,0,1).
Specified the MCS at the center of rotation for multi-axis machining.
6
Lesson
7 Sequential Mill Basics
Purpose
Sequential Mill operations allow you to machine contoured parts by

cutting from one surface to the next in a sequence of moves referred to as
suboperations. These suboperation types allow the flexibility to completely
control cutter movements to obtain desired results.
Objective

use Sequential Mill operations to create multi-axis tool paths
create Sequential Mill rough and finish operations
Sequential Mill Basics
Sequential Milling Overview

Sequential Milling operations are an alternative to Fixed or Variable Contour
operations used for finishing 3, 4, and 5-axis parts. You normally use Fixed
and Variable Contour operations to finish cut areas using area tool motion.
Sequential Milling operations are used to finish cut part edges using linear
tool motion. You can area machine using Sequential Mill, however, the area
is usually limited to an offset from a single drive surface or a single part
surface (or both).
Sequential Mill also provides tool axis control capabilities in maintaining a
tool position relative to drive and part geometry, recognizing multiple check
surfaces.
Sequential Milling Terminology
The following terms pertain to Sequential Milling:

Part surface controls the bottom of the tool
Drive surface controls the side of the tool
Check surface controls the tool stopping position
In the above illustration, the tool is in contact with the Part, Drive and Check
surfaces. The bottom of the tool follows the Part surface, the side of the tool
follows the Drive surface until the tool contacts the Check surface.
Before you specify the part, drive, and check geometry, you must indicate
where the tool will stop. You have four possible choices:
Near Side indicates that the tool will stop when it reaches the closest side
of the specified part relative to the current tool position
7
Far Side indicates that the tool will stop when it reaches the farthest side
On indicates that the tool will stop when its center axis reaches the edge
Ds-Cs Tangency and Ps-Cs Tangency indicates that the tool will stop when
it is at the position that the drive (or part) surface is tangent to the check
surface
Note that when a wall is tangent to a corner radius and the tool will contact
that tangency, you must choose this option. Otherwise, you must choose the
Near Side, Far Side or On condition.
-
You must initially specify a tool Reference Point position to determine the side
of the drive, part, and check geometry for tool placement. This establishes
direction only.
Once you specify the Reference Point, you can specify the tool starting
position as the Near Side, Far Side, or On the Drive, Part, or Check geometry.
The Sequential Mill dialog -

Allows you to:
add stock to all drive and part
surfaces
specify a Minimum Clearance

value to be used in Engage and
Retract suboperations
add Corner Control
specify Path Generation which

determines whether the tool path
is output for each suboperation
Multi-axis output
After you set the Sequential Mill operation options you can create a
suboperation to control tool motion.
Suboperations are individual tool motions. The four different types of
suboperations are Engage, Continuous Path, Point to Point and Retract
motion.
Normally, you will use these suboperations in sequential order.

initially, specify an Engage move
then, specify Continuous Path motions
at the end of the tool path, specify a Point to Point
and then a Retract move
After creating or editing an operation, you choose End Operation either

generate the tool path, or save the operation without tool path generation.
The Engage Motion

The Engage Motion suboperation defines where the tool initially contacts the
part. This is usually the first suboperation dialog which you will encounter.
(1) Insert or modify suboperations

(2) toggles between 4 types of
suboperations
(3) list of suboperations
(4) replay, list or delete highlighted
suboperation
(5) change engage feed rate
(6) relative tool position (required)
(7) specify geometry (required)
(8) specify tool axis
(9) display tool at current location
The Continuous Path Motion dialog
After engaging the part, the tool motion is determined by a series of

Continuous Path Motion (CPM) suboperations.
Each tool move requires specific Drive, Part and Check geometry:
Drive geometry controls the side of the cutter
Part geometry controls the bottom of the cutter
Check geometry stops the cut movement
The cutter moves along the drive and part geometry until it reaches check
geometry.
(1) specify tool direction

(2) must be specified
(3) number of check surfaces
The Point To Point Motion dialog
The Point to Point dialog enables you to create linear, non-cutting moves. It
is used to move the tool to another position where continuous path motions
can then continue. You may or may not need to use this dialog when creating
Sequential Mill operations.
(1) specify special traverse feed rate

(2) defines the way the tool will move
to the next location
The Retract Motion dialog
The Retract Motion dialog enables you to create a non-cutting move from the
part to the avoidance geometry or to a defined retract point. It is similar to
the Engage Motion dialog.
(1) type of retract move

(2) feed rate control for feed rate
move
Defining the Check Surfaces
When you are creating a Continuous Path Motion suboperation, you must
define one or more Check Surfaces.
By default, the Check Surface for one suboperation becomes the Drive Surface
for the next suboperation. This often saves you from having to specify the
Drive Surface. The Part Surface, is by default, the same for each suboperation
throughout the tool path. This also saves you from having to specify the
Part Surface. Normally, you only need to specify the Check Surface in each
suboperation.
(1) type of geometry used for Check

surface
(2) add stock or define the tool
position with respect to Check
geometry
(3) action to take after suboperation
(4) navigating through multiple
Check surface dialogs
Multiple Check Surfaces
In a Continuous Path Motion command the cutter moves along the Drive and
Part Surface until it reaches a Check Surface.
If you specify more than one Check Surface (multiple check surfaces), motion
continues until the tool reaches the first of the possible stopping positions.
You can define up to five Check Surfaces for each Continuous Path Motion
suboperation. After you have defined the first Check Surface, you are
automatically prompted to define the next Check Surface.
The following activities will familiarize you with Sequential Mill operations.
Activity: Basic Sequential Milling Techniques

In this activity, you will use basic interactions necessary to create Sequential
Milling operations. You will drive a tool around a simple part, create several
suboperations, and establish Drive, Part, and Check geometry used in the
various operations.
Step 1: Open and rename an existing part file and then enter the
Manufacturing application.
Open the part file box_mfg.
This part is programmed in the context of an assembly. The
top-level component, box_mfg contains all of the manufacturing
data. The box_stock file contains a WAVE-linked representation
of the raw material and the box file contains the part that is to
be machined.
The raw material file, box_stock, has been hidden from the
display.
Rename the part to ***_box_mfg.

The necessary Parent Groups (i.e. Geometry, Machine,
Program and Method) have already been created for you.
Step 2: Create a Sequential Milling operation.

Choose the Create Operation icon
If necessary, change the Type to mill_multi-axis.
Choose Sequential_Mill as the subtype.

7
Set the Parent objects as shown and name the operation SM_1:
Choose OK.
The Sequential Mill dialog is displayed.
This dialog allows the input of basic global parameters that
are active throughout the operation (unless changed in an
suboperation).
7
Choose the Display Options button.
The Display Options dialog is displayed.
Change the Tool Display to 3-D and the Path Display Speed
to 9.
Choose OK.
Choose the Default Feed Rates button.
The Feeds and Speeds dialog is displayed.
Choose the Reset from Table button.

Based on the tool material, part material and number of cutter
flutes, the feeds and speeds will be recalculated and reset.
Choose OK until you return to the Sequential Mill dialog.

The global parameters are now set.
The Sequential Milling dialogs behave somewhat differently
than other operation dialogs that you are normally familiar
with.
Normally, for any operation, choosing OK from the main
dialog would save the operation, which would be subsequently
displayed in the Operation Navigator. In Sequential Milling,
however, choosing OK from the main dialog results in the
suboperation dialog being displayed. This is where the actual
programming process takes place.
Choose OK from the Sequential Mill dialog.

The Engage Motion suboperation dialog is displayed. By
default, the suboperation dialog is set to Engage.
To properly determine the tools current location for Near

Side/Far Side, establish a Pt to Pt motion as the first
suboperation.
Change the motion from Engage to Pt to Pt.
The dialog changes to match Point to Point motion.

You will now establish the tool position, specifying both the
position of the tool and the tool axis.
Change the Motion Method to Point, Tool Axis.

Change the Offset from None to Rectangular.

Note that using a Rectangular Offset allows an X, Y and Z
delta offset from the point chosen.
Choose the corner of the ledge, as shown.
The Point Constructor dialog has changed to allow the input

of delta values from the point selected.
Key in the following values:
Delta XC 1.00
7
Delta YC -1.00
Delta ZC 1.00
Choose OK.
You will accept the default tool axis vector of 0,0,1 which is the
same as the Z coordinate of the WCS.
Choose OK.
The Point to Point suboperation is complete. By choosing OK,
the suboperation will be placed in the sub-op list and you will
be ready to create the next suboperation.
Choose OK.
You will now define the Engage component.
Change to an Engage suboperation.
The Engage Motion dialog is displayed.

This dialog requires Drive, Part and Check geometry.
Additionally, you may specify an engage method.
You will specify the geometry first and then the Engage method.
Choose the Geometry button from the Engage Motion dialog.
The Engage Geometry dialog is displayed.

The defaults are set to Drive geometry, the Type is Face and
7
the Stopping Position is Near Side.
You will now select the Drive geometry.
Select the face as shown.
The geometry selection on the dialog advances to Part geometry.

7
You will now select the Part geometry.
Select the bottom of the pocket as the Part geometry.
The geometry selection on the dialog advances to Check

geometry.
Select the face, as shown below, as the Check geometry.
7 As soon as the last geometry is selected, the dialog reverts to

the Engage Motion suboperation.
You will now specify the Engage motion.
Choose the Engage Method button from the Engage Motion

dialog.
The Engage Method dialog is displayed.
Change the Method to Vector Only.


I=-1.000
J= 1.000
K=-1.000
Choose OK.
Key in 0.500 in the Distance field of the Engage Method dialog.
Change the Clearance Move to None.
Choose OK twice.
The second suboperation, 2 Eng, is created. The tool side is now
positioned tangent to Drive and Check geometry and tangent
to the Part geometry with the bottom of the tool.
You will now create a Continuous Path Motion suboperation.

The arrow displayed at the bottom of the tool indicates the
direction of the next cut. In this case the direction is correct. If
the arrow was pointed in another direction, it would have been
necessary to change direction by using the Direction option.
Notice the defaults for Drive Surf and Part Surf.
The Drive Surf is set to the Previous ds (drive surface). The Part
Surf is set to the Previous ps (part surface). It will be necessary
to set the Check surface.
Choose the Check Surfaces button.
The Check Surfaces No. 1 dialog is displayed.

You are now ready to select the first (in this case, the only)
Check surface. As soon as the surface is selected, the dialog
advances to Check Surface No. 2. It is important to specify any
changes to the dialog before the surface is selected.
Note that the current Drive surface is tangent to the next
surface that the tool will drive to. A stopping position of Near
Side is incorrect. You will change the stopping position to Drive
Surface/Check Surface Tangency.
Change the Stopping Position to Ds-Cs Tangency.
Select the Blend face as shown.
There will not be a second Check surface to select.

7
Choose OK in the Check Surface dialog.
Choose OK in the Continuous Path Motion dialog.

The third suboperation, 3 cpm, has been created. You will now
create another CPM suboperation.
The processor has automatically forwarded the Drive surface to
the previous Check surface. It has also kept the previous Part
surface as the new Part surface.
The Direction of Motion Vector setting is correct.
You need to choose a new Check surface.

The object type of face is correct as well as the Stopping
Position of Ds-Cs Tangency.
Select the face as shown.
Choose OK in the Check surface dialog.

The suboperation, 4 cpm, is now placed in the dialog list.
Sequential Mill is now ready for the next suboperation. Once

again, the defaults are correct. You only need to choose a new
Check surface.
This time, the Stopping Position of Ds-Cs Tangency is incorrect.

You will change it to Far Side, so that the tool is completely off
the Part surface, prior to stopping.
7 Change the Stopping Position to Far Side.
Select the surface as shown below.

7
The suboperation, 5 cpm, is now placed in the dialog list.
The machining operation is complete. You will now retract the
tool a safe distance from the work piece.
Change the suboperation to Retract.
The Retract Motion dialog is displayed.
Choose the Retract Method button.
The Retract Method dialog is displayed.
Change the Method from None to Vector Only.

I= 1.000
J= -1.000
K= 1.000
Choose OK.
Key in 0.500 in the Distance field of the Retract Method dialog.
Choose OK.
Choose OK in the suboperation dialog.

The suboperation, 6 Ret, is now placed in the list.
The tool retracts to the clearance plane. Programming of the

wall is complete. The End Operation button will complete the
process.
Choose the End Operation button.
To observe the tool path, refresh the screen and display the
tool path.
In the graphics window, use MB3Refresh.
Choose Redisplay Tool Path from the End Operation dialog.
The tool path is displayed.
7 Choose OK from the End Operation dialog.
Save and Close the part file.
More on Check Surfaces
In the previous activity, you used the same Part surface for each Continuous
Path Motion suboperation. The suboperation ended after the tool moved
along the Drive surface to the Check surface. The Check surface then became
the Drive surface for the next suboperation and the Continuous Path Motion
dialog anticipated this choice by selecting Previous Check Surface as the
Drive surface at the beginning of each Continuous Path Motion suboperation.
It is also possible to exchange the Part surface for the next Check surface.
One consideration that should be made when exchanging the Check surface
as the new Part surface is the Stopping Position. If the Check surface is
tangent to the present Part surface and PS-CS Tangency is chosen, the front
edge of the cutting tool will be positioned to prevent gouging of the tool into
the Check surface. This may cause the tool to be Out of Position to the new
Part surface at the beginning of the next move. To compensate for this action,
it may become necessary to drive the tool on to the Check surface, even
though a tangency condition exists.
In the following activity, the Drive and Part surfaces, as well as the Check
geometry will change throughout the operation as you generate the tool path.
You will see that the Check surface in a current suboperation can become the
Part surface, as well as the Drive surface, in the next suboperation. You will
also see that the processor is able to anticipate your choice for Drive and Part
surfaces in Continuous Path Motion suboperations, so that you only need to
specify the Check surface(s).
When selecting either Drive or Part surface from the Continuous Path Motion
dialog, you have the options of Other Surface, Previous ds, Previous ps and
Previous cs.
Activity: Sequential Milling of a Multi-Surfaced Floor
In this activity, you will machine a floor that is flat, sloped, and curved. The
part requires that you re-specify the part surface when the floor surface
changes.
Step 1: Open a new part, rename and begin a Sequential Mill operation.
Open the part file sq_3 and rename it to ***_sq_3.
In the Operation Navigator, Replay the operation named

7 DEMO.
You will now create an operation identical to the operation
which you just replayed.
Step 2: Create the Sequential Mill operation.

If necessary change the Type to mill_multi_axis.
Choose the SEQUENTIAL_MILL icon.
On the Create Operation dialog, set:

Program:MULTI-FLOOR-PROG
Use Tool:EM_.75_.125
Use Method:MILL_FINISH
Enter the operation name fin-poc-walls into the Name field.
Choose OK.
On the Sequential Mill dialog, verify that the Multiaxis Output

check box is OFF.
to 9.
The global parameters are now set and you are ready to begin
the Sequential Milling process.
7
Choose OK and continue to the Engage Motion dialog.
Step 3: Specify an Engage motion.

You will now create a vector that will be used for engaging the part.
Choose the Engage Method button.

Change the Method to Vector Only.

Key in the -1.000 value for I.
Choose OK.
Choose OK to return to the Engage Motion dialog.
Under the Reference Point label, specify a Position Point at:

X=11, Y=6.5, Z=2.
Choose OK in the Point Constructor dialog.
Choose the Geometry button and specify the Drive and Part
surfaces as shown.
(1) Drive Surface

(2) Part Surface
(3) Check Surface (add .250 stock)
Specify .250 Stock for the Check surface, prior to selecting

the surface.
You must enter any Stock value and change the Stopping
Position status before you select the Check Surface.
Choose OK.
The tool moves from the Clearance plane to the position just
specified.
The tool direction arrow shows the current direction of motion.

Throughout this activity, change the direction arrow whenever
necessary so that it points in the intended cut direction.
Step 4: Specify Continuous Path motion.

Sequential Mill expects the next Drive surface to be the previous
Drive surface, and the next Part surface to be the previous Part
surface.
For the remainder of this activity, you will be prompted to change

the Drive and Part surfaces only if the processor does not correctly
select the proper surface. Each suboperation will require you to
select a new Check surface.
Change the Check Stock to 0.
Change the Check surface Stopping Position to Ps-Cs

Tangency.
Specify a new Check surface as shown.
Return to the Continuous Path Motion dialog and choose OK.

The tool moves to the new position.
Note the status of the Part Surface to previous Check surface.

Note that the Sequential Mill processor did not change the
status of the Drive or Part surfaces.
Specify the Check surface Stopping Position as Near Side.

Note that the Sequential Mill processor expects that the next
Part surface will be the previous Part surface.
Specify the Check surface Stopping Position as Ds-Cs

Tangency.

Note that the status of the Drive or Part surfaces did not
change.
Specify the Check surface Stopping Position as Near Side.

Note the status of the Drive or Part surfaces did not change.
Specify the Check surface Stopping Position as Ps-Cs

Tangency .
Specify a new Check surface.

Note the status of the Drive and Part surfaces changed.
Specify the Check surface Stopping Position as Ps-Cs

Tangency.
Specify a new Check surface as shown below.

The status of the Drive or Part surfaces did not change.
Specify the Check surface Stopping Position as Far Side.

Change Cont. Path to Retract.

The Retract Motion dialog is displayed.
Change the Retract Method to Vector Only and then +XC Axis.
Change the Distance to .200.
Return to the Retract Motion dialog and choose OK.

The tool retracts to the Clearance Plane.
Choose End Operation and then OK to save the operation.

The entire tool path is displayed.
Summary
Sequential Milling operations allow complete control of cutter movement and
are useful in the finish machining of complex, multi-axis geometry. The more
experienced programmer will use Sequential Milling techniques to simplify
the creation of complex tool paths.
The following functions are used in Sequential Milling applications:
Selecting of specific tool axis.
Specifying tool starting and stopping positions based on contact with Part,
Drive, and Check surfaces.
Lesson
8 Sequential Mill Advanced
Purpose
Some of the more advanced features of Sequential Milling allow for multiple
passes and control of the tool axis. These options allow for increased flexibility
for roughing and finishing operations.
Objective

Use standard and nested loops for creating roughing and finishing passes.
Completely control the tool axis in 3, 4 and 5-axis applications.
Sequential Mill Advanced
Tool Axis Control

In Sequential Mill, you define the tool axis by first specifying 3, 4 or 5-axis
tool positioning which is found on the Engage and Continuous Path Motion
dialogs.
3-axis allows you to specify the ZM axis or a fixed vector.

4-axis allows the tool to remain perpendicular to a specified vector and can be
further adjusted by:
another vector - projected PS (or

DS) Normal
A "ring" height on the tool -

8 tangent to PS (or DS)
An angle - at angle to PS (or DS)
Project Part Surface (or Drive Surface) Normal indicates that the tool axis is
calculated by rotating the surface normal by a lead or lag angle, projecting
the resulting vector onto a plane perpendicular to the specified Perpto Vector,
and then rotating it in that plane by a specified angle. This option causes the
Perpto Vector and the Next Cut Direction buttons to appear.
Tangent To PS (or DS) indicates that the side of the tool is tangent to the
designated surface while the tool axis remains perpendicular to the specified
Perpto Vector.
At Angle To Ps (or Ds) indicates the tool axis maintains a fixed angle with
the designated surface normal while remaining perpendicular to the specified
Perpto Vector.
5-axis allows the tool axis to :
remain normal, parallel or angled

to the Part or Drive surfaces
fan between surfaces
pivot from a point
5Axis Tool Axis Control

Variable Contour Sequential Mill
Toward or Away From Point Thru Fixed Point

Normal to Part Normal to PS
Normal to Drive Normal to DS
Swarf Drive Parallel to PS
Parallel to DS
Relative to Drive At Angle to DS
At Angle to PS
Tangent to PS
Fan
Tangent to DS
Normal To Ps (or Ds) causes the tool axis to remain perpendicular to the
specified surface. This generally involves keeping the center of the bottom
of the tool in contact with the surface. Optionally, you can offset the contact
point from the bottom center of the tool.
(1) Surface normal at contact point

(2) new contact point
Parallel to Ps (or Ds) causes the side of the tool to be kept parallel to the
surface rulings at the contact point. A ring on the tool must be specified to
indicate where the side of the tool must touch the surface.
(1) Drive Surface ruling

(2) Ring height
(3) Part Surface
Tangent to Ps (or Ds) causes the side of the tool to be tangent to the specified
surface while the tool axis stays perpendicular to the current direction of
motion. You must specify a ring height.
(1) Drive Surface

(2) Ring height
At Angle to Ps (or Ds) causes the tool axis to maintain a fixed angle (Tilt) with
the surface normal and a fixed angle with the current direction of motion
(a Lead or Lag angle).
(1) Tool Axis

(2) Lead
(3) Lag
(4) Direction of motion
Fanning is an even distribution of tool axis change from the start to the stop
position. This can be useful, for example, when the tool is canted at either
or both positions.
(1) Final Tool Axis

(2) Check Surface
(3) Check Surface
contact point
(4) Part Surface
8
(5) 5Axis Fanning
Thru Fixed Point indicates that the tool axis always lies along the line joining
the tool end tip and a user-defined point. Use the Point Constructor dialog to
define the point.
(1) User defined pivot point

(2) Check Surface
(3) Drive Surface
(4) Part Surface
Activity: Sequential Mill Five-Axis Fan Motion

In this activity, you will create a Sequential Milling operation to finish the
walls of a pocket on an aircraft structural component.
Step 1: Open, rename and examine the part file.
Open the part file spar_mfg.
The spar is cut from a forged block of aluminum and is held in

place by clamps along the slits that run the length of the block
on either side. Dowel pins are used to locate the block.
The orange material represents the "window frame" portion
of the block. Small tabs run from it to the part to secure it
during machining.
This part has been partially machined. You will first examine
the machining progress made to this point.
8
Rename the part ***_spar_mfg.
Choose the Operation Navigator tab from the toolbar.
Highlight the SIDE_1 program object, then use MB3, choose

Tool Path, and then Verify.
Select the 3D Dynamic tab from the Tool Path Visualization

dialog.
Choose the Play Forward button from the bottom of the dialog.
The In-Process work piece of the part is represented. You will
begin machining the left most pocket in the part.
Choose OK on the Tool Path Visualization dialog.
Step 2: Create the Sequential Mill Operation.

Choose the Create Operation icon from the Manufacturing
Create toolbar.
Choose Sequential_Mill as the subtype.
8 Set the Parent objects as follows:

Program: FINISH_1
Use Geometry: PART_AND_BLANK
Use Tool: EM-.5.130CARBIDE
Name: SM_FINISH_WALLS_POCKET_1
Choose OK.
Step 3: Set Tool Display options and create a Point to Point Motion.
You will now set the tool display options, which will make the tool
easier to visualize.

to 9.
Choose OK twice.
You will now establish the tool location and axis by using a
Point to Point suboperation.
Change the motion from Engage to Pt to Pt.
The corresponding dialog changes to match Point to Point

motion.
You will now establish the tool position, specifying both the
position of the tool and the tool axis.
8
Change the Motion Method from Undefined to Point, Tool Axis.
Key in the following values for the Base Point:

XC -5.00
YC 0.00
ZC 2.00
Choose OK.
You will accept the default tool axis vector of 0,0,1 which is the
same as the Z coordinate of the WCS.
Choose OK to accept the tool axis default.
Choose OK to accept the first suboperation.
The first suboperation, 1 ptp, is created and inserted into the

suboperation list.
Step 4: Create the Engage Motion.

A best practice is to establish a cutting tool along a straight wall
as well as to feed into the wall away from a corner to eliminate tool
chatter. You will engage the wall as shown.
You will now define the Engage component.
Change to an Engage suboperation.
Choose the Engage Method button.

I= 0.000
J= 1.000
K= .500
Choose OK.
Choose OK.
Choose the Geometry button from the Engage Motion dialog.
The Engage Geometry dialog is displayed.

You will first create a temporary check plane as the Drive
geometry using the Three Points option for plane creation.
In the Engage Geometry dialog, change the Type from Face to

Temporary Plane.
Choose the Three Points option from the Plane dialog.
Select the three control points as shown. Note that in the

following views, the part has been rotated 180 degrees to
facilitate looking at the wall being created. The stock and
check geometry have been removed from the view for purposes
of clarity.
As the last point is selected, the geometry selection advances

to Part geometry.
Change the Type back to Face.
Select the bottom face of the pocket as the Part geometry.
Select the wall face as the Check geometry.
After selecting the Check geometry, the Engage Motion dialog

is displayed. Before proceeding any further you will want to
change the Tool Axis to 5-axis fan motion.
Change the Tool Axis from 3-axis to 5-axis.
8 The Five Axis Option dialog is displayed. Notice that the

Method defaults to Fan, which is acceptable in this instance.
Choose OK in the Five Axis Options dialog.
Choose OK to create the Engage suboperation.

You are now ready to create the first Continuous Path Motion.
Step 5: Create the first Continuous Path Motion.
The radii in the pocket corners are slightly larger than the tool
radius and allows the opportunity to drive the corner fillet with
less tool chatter.
Continuous Path Motion is the default as the next suboperation
type. You will need to choose the fillet as the next Check surface.
Change the Drive Surface to Previous Cs.
In the Continuous Path Motion dialog, choose the Check

Surfaces button.
In the Check Surfaces dialog, change the Stopping Position to

Ds-Cs Tangency.
Select the corner fillet surface as shown.
Choose OK in the Check Surfaces dialog.

The tool drives into the corner and suboperation 3 is created.
Select the next surface in line.
Choose OK until the next suboperation is created.
Step 6: Finish the operation.

Continue to drive around the inner wall of the pocket, using
the next surface in line as the new Check surface.
When you reach the original surface that you used for engaging
the part, drive past the temporary plane made up of control
points on the edges of the surfaces. This should prevent any
8 scallops from being left on the wall.
Retract the tool from the pocket and end the operation.
Save the part file.

You finish machined the wall of the pocket. One of the walls
of the pocket is at an extreme closed angle. Extra stock was
left on that wall.
In a future activity, you will use Sequential Mill looping
functionality, with five-axis motion, to remove the excessive
stock.
Standard and Nested Loops
Standard Loops
Loops are modified copies of an original tool path. They are copies of a portion
of a tool path that are repeated to remove extra stock.
The Loop option is located in any of the Motion dialogs (Engage, Retract,
Continuous Path, or Point to Point) under the Options Loop Control.
The Loop Control dialog follows:
(1) starts and ends the looping

routines that cut toward the drive
surface
(2) starts and ends the looping
routines that cut toward the part
surface
(3) specifies the inner and outer
loops when both start on the same
suboperation
Before you begin the creation of a loop, the tool should be in the proper
8 position within the operation (where you want the tool to start repeating
from).
Choose OptionsLoop ControlStart/End and change to Start. This

establishes the beginning of the Loop.
You can also specify Loop Stock. This is the stock that is applied to the
geometry within the loop. It is removed as the looping routine progresses.
To end the loop, you should be in the desired position within the operation 8
and then stop the loop. Choose OptionsLoop ControlStart/End and
change to End.
The tool path is then recomputed by adding the loop Stock and moving
toward the part in a specified number of steps. The path will display in the
graphics window.
You can also create an operation without a loop. You can later edit the
operation and then add the loop.
Nested Loops
A Drive surface and a Part surface loop within the same suboperation or a
later suboperation is considered a nested loop (one inside of another).
If the Ds loop and the Ps loop are started within the same suboperation, you
must determine whether you want the Ds loop or the Ps loop to be cut first.
The Nesting Status option defines this for you. This option is only available
after both the Ds and Ps Start/End Parameters are defined.
(1) Drive Surface Start/End

parameter
(2) Part Surface Start/End parameter
(3) Nesting Status option
The next activity will familiarize you with some of the basic concepts of
looping within Sequential Mill.
Activity: Sequential Mill Using Loops
In this activity, you will replay and examine Sequential Mill looping
operations.
Step 1: Open a new part file and replay an existing operation.
Open the file sq_3_loop.
From the Operation Navigator, Replay the FINWALLS tool

path.
The tool path makes several passes toward the part walls and
floors. You will now examine the loop settings.
Double-click on the FINWALLS operation.

Note that the Multiaxis Output option is selected.
Choose OK.
The Point to Point Motion dialog is displayed.
Choose OK.
Normally, you start the looping process from within this dialog.
Choose Options.
The Other Options dialog is displayed.
Choose Loop Control.

The Loop Control dialog is displayed.
Note the Ds and PS loop settings.

8
These settings will create five passes, each pass will remove
.050 stock.
Choose OK three times to return to the Continuous Path

Motion dialog.
On the Continuous Path dialog, choose Options, then Loop

Control to check the Loop Control status. They are set to
Contin.
Choose OK twice to return to the Continuous Path Motion

dialog.
Step 2: End the loop.

On the Continuous Path Motion dialog, double-click on the
suboperation 11 Ret.
The tool path updates to the current location.
On the Retract Motion dialog, choose the Options button, then

the Loop Control button to check the loop status. They are
set to End.
Step 3: Start the looping process.

Choose OK three times until the Loop Debug Options dialog
is displayed.
On the Loop Debug Options dialog, choose OK.

The tool begins to cut as specified.
Choose End Operation, then choose OK from the End Operation

dialog to save the operation and return to the Operation
Navigator.
The entire tool path is now displayed.
Close the part.
Activity: Removing Excess Stock from a Closed Wall
In this activity, you will use the looping functionality of Sequential Mill to
remove the excess stock on a undercut wall. You will make a copy of the
previous operation that you created and modify that operation for doing
looping activities.
Step 1: Copy a previous Sequential Mill operation.
Open the part file***_spar_mfg (or choose from Window on
the toolbar)
If necessary, change the view of the Operation Navigator to

the Program Order View.
Expand the SIDE_1 and FINISH_1 Program objects.
Highlight the SM_FINISH_WALLS_POCKET_1 operation that

you previously created, then use MB3, Copy.
Highlight the PM_FINISH_BOSSES operation, then use MB3,

Paste.
Use MB3, Rename to change the operation name to

SM_SEMI-FINISH_WALLS_POCKET_1.
Step 2: Edit the operation.

You will want to edit the operation which you just copied and
renamed. You will be using most of the same defaults as in the
previous operation. However, some parameters will change.
Double-click on the SM_SEMI_FINISH_WALLS_POCKET_1

operation.
Change the Global Stock on Drive Surfaces to .030. 8

Change the Global Stock on Part Surfaces to .030.
Choose OK on the Sequential Milling dialog.
Scroll down to the bottom in the suboperation list.
Highlight the 12 Ret suboperation.
Hold down the shift key, scroll back up in the dialog and choose
the 4 cpm suboperation.
Choose the Delete button and confirm the choice in the message
dialog.
There should now be three suboperations remaining in the

suboperation list a Point to Point; an Engage, and a CPM.
The dialog should look as follows:
Since this operation will leave stock on the wall and the tool
radius is nearly the size of the corner fillet, the corner fillet
radii will not be selected. When stock is added to the fillet,
it becomes impossible for the tool to reach its designated
tangency point.
8
Step 3: Edit the suboperation 3 cpm.

Double-click on suboperation 3 in the suboperation list box.
Note that in order to edit a suboperation, simply highlighting
the operation will not place it in edit mode. A double-click
on the suboperation is necessary. When successful, the word
"editing" will appear following the suboperation name.
Change the Stopping Position to Near Side.
Select the undercut wall as shown.
Choose OK on the Check Surfaces dialog.
Choose OK to accept the modified CPM suboperation.

Since there are not any more suboperations to edit, Sequential
Mill automatically switches to Insert mode.
Step 4: Create additional suboperations.

You will now create the additional suboperations, necessary to
finish the undercut area of the pocket.
Select the wall as shown below.
Choose OK on the Check Surfaces dialog.
Choose OK to create the suboperation.

The suboperation is created. You will now position the cutter to
the middle of the Check surface which you previously selected
and then will retract the tool.
Change the Type to Temporary Plane.
Choose the Three Points method.
In the Point Constructor dialog, choose the Control Point icon.
Select the three edges in the area as shown below.
8
Choose OK to accept the suboperation.
Change the motion type to Retract.
Choose the Retract Method button.
Key in the following values to create the vector:

I = 0.0
J = 1.0
K = 1.0
Choose OK in the Vector Constructor dialog.
Key in 1.0 in the Distance field.
Choose OK in the Retract Method dialog.
Choose OK to accept the suboperation.

The suboperation, 6 Ret, is created.
Choose End Operation.
Choose OK in the End Operation dialog.
Save the part file.
Activity: Using Looping to Remove Excess Stock
In this activity, you will edit the previous operation, modify the operation by
using the looping option, which will create a series of passes for stock removal.
Step 1: Edit an existing operation.
Continue using ***_spar_mfg.
In the Operation Navigator, double-click on the

SM_SEMI_FINISH_WALLS_POCKET_1 operation.
Choose OK in the Sequential Mill dialog.
Choose OK in the Point to Point Motion dialog to advance to

suboperation 2.
In the Engage Motion dialog, choose the Options button.

The Loop Control dialog is displayed.
Change the Ds loop parameters Start/end from None to Start.
Key in 0.2 in the Initial stock field and .05 in the Increment
field.
Choose OK.
Choose OK on the Other Options dialog.
Choose OK on the Engage Motion dialog.
Continue to choose OK until suboperation 6 Ret is highlighted

(Retract Motion dialog is displayed).
Choose Options.
Change the Ds loop parameters from Contin to End.
Choose OK on the Loop Control dialog.
Choose OK on the Other Options dialog.

Sequential Milling is now ready to create the additional loop
passes.
Choose OK on the Loop Debug Options dialog.

8
When satisfied with the additional passes, choose End
Operation on the Point to Point Motion dialog.
Choose OK in the End Operation dialog.
Visually examine the output using Visualization.
Save and close the part.
Additional Sequential Mill Options
The following are Sequential Mill options that you have not used in the
activities. You can review these options with your instructor or on your own.
Path Generation and Multiaxis Output
You can turn Path Generation on or off from the Sequential Mill dialog. When
this option is toggled on, the tool path segment is graphically displayed as
each suboperation is accepted. When it is off, the tool path segment is not
calculated or displayed.
Multiaxis Output is an option. This outputs the I, J, and K components of

the tool axis vector with each output point. This option must be active if 4 or
5-axis tool positioning is used. The default is ON (box is checked).
Replace Geometry Globally
Replace Geometry Globally, replaces faces, curves and temporary planes by

other faces, curves and temporary planes throughout the operation.
This option is located on the Sequential Mill dialog.
Other Options
Use the Other Options dialog to set custom tolerances, limit the step distance
and number of output points, set tool path and tool display options, use of
Corner Control, and to specify looping routines for a specific suboperation.
8 A summary of the options on the Other Options dialog follows:

Custom Surface Tolerances specifies special Intol and Outtolvalues for
the current suboperation. This option is only active in the Engage and
Continuous Path Motion dialog.
Custom Tool Axis Tolerance specifies a special tool axis tolerance for
the current suboperation. This option is only active in the Engage and
Continuous Path Motion dialog.
Custom Corner Control specifies the cutter feed rate, slowdowns, and
fillet radius at corners. By toggling the Custom Corner Control button
and selecting the Edit Parameters action button, you bring up the Corner
and Feed rate Control dialog. This option is available for Continuous Path
suboperations only.
Maximum Step specifies the maximum length of individual tool moves in the
suboperation. If you change the default value of ten inches, the new value
becomes the default value for the current and subsequent suboperations. If
you are editing a suboperation, changing the Maximum Step does not affect
subsequent suboperations. You must specify a positive value. This option is
available for Continuous Path suboperations only.
Maximum Points specifies the maximum number of points generated in a
suboperation. If you change the default value of 400, the new value becomes
the default value for the current and subsequent suboperations. If you
are editing a suboperation, changing the Maximum Points does not affect
subsequent suboperations.
Output CL Points temporarily suspends the output of points to the CL source
file. By suspending the output of CL points, you can move the tool in several
suboperations that are not included in the tool path. When you finally
position the tool to the correct geometry, activate this option and the tool path
continues (this is similar to APTs CUT/DNTCUT).
Automatic Redefinition establishes a check plane at the last valid tool
location when the processor is unable to complete the tool path for a
suboperation. You can continue programming from the new check plane.
Automatic Reposition is useful if the tool is not within tolerance to the Drive
or Part surface at the start of a suboperation.
Display Option sets tool, pattern, and tool path display options for the current
suboperation. This is the same Display Options dialog used in Operation
Parameters.
Loop Control specifies a looping routine for area clean-up of Drive or Part
geometry, or both.
Most Sequential Milling processor errors are caused by the tool being out
of tolerance to the geometry.
8
Sequential Milling Best Practices
Engaging:
use a reference point that is near the startup geometry
when using the Fan tool axis, use Tangent to Drive
use the Direction Move option on the Engage Geometry dialog when the
tool can move to more than one location or if the tool is not close to the
surface
remember that the Direction Move is applied first to the Drive, second to
the Part, and last to the one or more Check surfaces
use Side Indication on the Engage Geometry dialog when the tool is on
or overlaps a surface
You should imagine the tool moving initially after you specify the Drive
surface. Then, if you need to specify a direction for the Part surface, do so
from the imagined position. Then imagine the tool moving to the new position
if you need to specify a Direction Move for the Check surface.
Continuous Path:
if the Drive and Part surfaces are flat and long, reduce the Maximum
Step (on the Other Options dialog)
when using a Fan tool axis, reduce the Maximum Step (on the Other
Options dialog)
when using a Fan tool axis around curved geometry, limit the motion to
60 degrees
Looping:
start a loop on an Engage or Point to Point Motion suboperation; starting
8 a loop on a Continuous Path Motion suboperation can cause the tool to be
out of tolerance
the last loop suboperation should be a Retract or Point to Point Motion

move
if you do not want the tool retracting during the loop, be careful in ending
the loop on a Continuous Path Motion suboperation so that the loop ends
with the tool in the same position and orientation as at the start of the loop
use caution when specifying Added Stock to Check Geometry . In a loop,

you may want to choose None when you do not use a Check Surface as a
Drive or Part surface in the next suboperation. See the following example.
(1) Added stock =

Drive
(2) Added stock =
None
(3) Start
(4) End
Summary
The more advanced features of Sequential Milling allow for multiple passes
and complete control of the tool axis. These options allow for increased
flexibility for roughing and finishing operations. Some of the more advanced
features are:
Looping control allowing for removal of excess stock.
Fanning tool axis control.
Complete control of tool positioning.
Lesson
9 Variable Contour Basics
Purpose
Variable Contour operations are used to finish areas formed by contoured

geometry. Variable Contour tool paths are able to follow complex contours by
the control of tool axis, projection vector and drive methods.
Objective

create multi-axis tool paths by choosing a tool axis that is most
appropriate for the part geometry
incorporate complementary programming practices that are necessary for

multi-axis machining
Variable Contour Basics
Variable Contour Operations

Variable Contour operations are used to finish areas formed by contoured
geometry by the control of tool axis, projection vector and drive methods.
Tool paths are created through the generation of drive points from the drive
geometry and then projecting those points along a projection vector to the
part geometry.
The drive points are created from part geometry or can be created from other
geometry that is not associated with the part. The points are then projected
to the part geometry.
The tool path output moves the tool from the drive point along the projection
vector until contact is made with the part geometry. The position may
coincide with the projected drive point or, if other part geometry prevents the
tool from reaching the projected drive point, a new output point is generated
and the unusable drive point is ignored.
(1) Drive geometry is used

to generate points
(2) Projection vector moves
the tool from the drive
point, down the projection
vector until it contacts part
geometry
(3) Drive points
(4) Part geometry may keep
the tool from reaching the
projected drive point
(5) Contact point
(6) Cutter location output
is generated
Tool Path Accuracy
Variable Contour provides several options that help insure the accuracy of
the tool path. Included are:
9
Check geometry to stop tool movement
gouge checking to prevent gouging of the part
Various tolerance options
Variable Contour operations can position to existing locations on the part

geometry (which includes the edge of an object), but the tool cannot position
to an extension of part geometry as shown by the following illustration.
(1) Drive points

(2) Projection vector
(3) extension of part
geometry
(4) Part geometry
(5) Valid
(6) Invalid
Terminology used in Variable Contour
Part Geometry - is geometry selected to cut
Check Geometry - is used to stop tool movement
Drive Geometry - is used to generate drive points
Drive Points - are generated from the Drive geometry and projected onto
part geometry
Drive Method - method of defining Drive Points required to create a

tool path; some drive methods allow creation of a string of drive points
along a curve while others allow the creation of an array of drive points
within an area
Projection Vector - used to describe how the Drive Points project to the
Part Surface and which side of the Part Surface the tool contacts; the
selected drive method determines which Projection Vectors are available
The projection vector does not need to coincide with the tool axis
vector.
Variable Contour vs Fixed Contour
The primary difference between Fixed Contour and Variable Contour lies
with the various methods of tool axis control and the drive methods available.
Drive Methods for Variable Contouring
Curve/Point Drive Method
Allows you to define drive geometry by specifying points and curves. Using
points, the drive path is created as linear segments between the points. Using
curves, drive points are generated along the curves. The drive geometry is
projected on to the part surface(s) where the tool path is created. The curves
may be open, closed, contiguous, non-contiguous, planar or non-planar.
When points define the drive geometry, the cutter moves along the tool path
from one point to the next in the order in which they were specified. The same
point may be used more than once, provided it is not defined consecutively in
the sequence. A closed drive path can be created by defining the same point
as the first and last point in the sequence.
The Curve/Point Drive Method dialog allows you to specify the distance
between drive points and the projected location of drive points. You can also
use the Display Drive Point option to view the location of the drive points
before generating the tool path.
(1) Used to select and edit drive

geometry
(2) Controls the distance between
drive points
(3) determines the method of
projection onto the part
9 Boundary Drive Method
The Boundary Drive Method allows you to define cut regions by specifying
Boundaries and Loops. Boundaries are not dependent on the shape and size of
the part surfaces while Loops must correspond to exterior part surface edges.
Cut regions are defined by Boundaries, Loops, or a combination of both.
The Boundary Drive Method allows you to use a permanent boundary, part
curves or faces to generate drive points.
(1) Boundary
(2) Tool axis
Drive points are
generated within
the boundary and
are then projected
linearly onto the part
geometry according to
the specified projection
vector.
The Boundary Drive Method is preferred to the Surface Area Drive Method.
You can quickly create a boundary and tool path without the surface design
requirements of the Surface Area Drive Method.
This method does not allow as many choices of tool axis options that are
available in the Surface Area Drive Method and is better suited for roughing
operations. The Surface Area Method is better suited for finishing operations.
Each boundary member is assigned an On, Tanto, or Contact tool position
(unique to Variable Contour Boundary Drive Method). The Contact tool
position can be used when specifying boundaries using curves and edges.
The boundary members graphically represent the associated tool positions
as illustrated below:
(1) tanto condition (2) on condition (3) contact condition
Options associated with the boundary drive method follows:

Pattern option enables you to define the shape of the tool path. Some patterns
cut the entire region, while others cut just around the perimeter of the
region. Some patterns follow the shape of the cut region, while others are
independent of it.
The selected Pattern determines which other options are available. If you
select Parallel Lines as the cut pattern, the Cut Type, Cut Angle, and Degrees
options become available. If you select Follow Pocket, only the Inward and
Outward options are available.
Parallel Lines creates a cut pattern defined by a series of parallel passes. You
are required to specify a Cut Type of Zig-Zag, Zig, Zig With Contour, or Zig
with Stepover and a specific Cut Angle.
Radial Lines creates linear cut patterns extending from a user-specified or

system calculated optimum center point. You are required to specify a Cut
Type, a Pattern Center, and pocketing method as Inward or Outward. You
may also specify an angular stepover, which is unique to this type. The
Stepover distance for this cut pattern is measured along the arc length at the
boundary point farthest away from the center.
(1) point furthest away from center

(2) stepover distance measured along
arc length
Concentric Arcs creates progressively larger or progressively smaller circular

cut patterns from a user-specified or system calculated optimum center point.
You are required to specify a Cut Type, a pattern center, and a pocketing
method as Inward or Outward. In areas such as corners that the full circular
pattern cannot extend into, concentric arcs are created and connected by the
specified Cut Type before the cutter moves to the next corner to continue
cutting.
(1) stepover
Cut Type defines how the cutter moves from one cut pass to the next.
The options are used in combination with Parallel Lines, Radial Lines, or
Concentric Arcs cut patterns. When used in combination with the Parallel
Lines pattern, Zig-Zag, Zig and Zig with Contour work in the same way as 9
their counterparts in Planar and Cavity Milling.
Pattern Center allows interactive or automatic definition of the center point
of Concentric Arcs and Radial Lines cut patterns.
Cut Angle determines the angle of rotation for the Parallel Lines Cut
Patterns. This option is available if the Cut Angle is set to Specify. Enter the
degrees of rotation for the Parallel Lines Cut Pattern.
Outward and Inward allow you to specify a pocketing method that determines
whether to cut from the inside out or the outside in of a Follow Pocket,
Concentric Arcs, or Radial Lines cut type.
Stepover specifies the distances between successive cut passes.
Constant specifies a fixed stepover distance between successive cut passes.
When used with the Radial Lines cut type, the constant distance is measured
along the arc length at the boundary point farthest away from the center.
Scallop determines the stepover distance based on the scallop height you
enter.
Tool Diameter defines the stepover in terms of a percentage of the effective
tool diameter.
Variable allows you to vary the stepover distance within a specified minimum
and maximum value. The required input values differ depending on the
selected cut type.
Angular defines a constant stepover by keying in an angle. This option is
used only in combination with the Radial Cut pattern.
Additional Passes specifies an additional number of passes that allows the
tool to step toward the boundary in successive concentric cuts for Profile and
Standard cutting patterns.
More Drive Parameters displays a dialog containing the following options:
Options displays a dialog that enables you to create start points
automatically or interactively and to specify how cut regions will be
displayed when the Display button is selected.
Display generates a temporary screen display of the cut regions for visual
reference. The display is generated using the parameters specified under
Cut Region Display options.
Display Drive Path displays the Drive Path used to generate the tool path.
The path is created as a temporary element projected onto the WCS along
the tool axis and is for visual reference only.
9 Spiral Drive Method

The Spiral Drive Method allows you to define drive points that spiral outward
from a specified center point. The drive points are created within the plane
normal to the projection vector and contain the center point. The drive points
are projected on to the part surfaces along the projection vector.
Spiral Drive Method stepovers are a smooth, constant transition outward.

This drive method maintains a constant cutting motion and is applicable to
high speed machining applications.
(1) Drive points

projected from plane
(3) Center point defines
the center of the spiral,
cut starts here
(4) Part surface
(5) Spiral drive
If you do not specify a center point, the system uses the (0,0,0) of the Absolute
Coordinate System. If the Center Point is not on the part geometry, it follows
the defined projection vector to the part geometry. The direction of the spiral
(clockwise vs. counterclockwise) is controlled by the Climb or Conventional
cut direction.
The following parameters pertain to Spiral Drive method:
Stepover allows you to specify the distances between successive cut passes
and are a smooth constant transition outward; does not require an abrupt
change of direction.
(1) stepover
Constant allows you to specify a fixed distance between successive cut

passes. Key in the desired distance between subsequent cut passes.
Tool Diameter allows you to define the Stepover in terms of a percentage

9
of the effective tool diameter.
Maximum Spiral Radius allows you to limit the area to be machined by

specifying a Maximum Radius. This constraint reduces processing time
by limiting the number of drive points created. The radius is measured in
the plane normal to the Projection Vector.
(1) maximum spiral

radius
(2) part surface
If the specified radius is contained within the part geometry, the center of
the tool positions to the radius before retracting. If the specified radius
exceeds the part geometry, the tool continues to cut until it can no longer
position to the part geometry. The tool then retracts and engages.
Surface Area Drive Method
Surface Area Drive Method allows you to create an array of drive points that
lie on a grid of drive surfaces. This Drive Method is useful in machining very
complex surfaces. It provides additional control of both the Tool Axis and
the Projection vector.
(1) Part geometry

(2) other geometry
(3) drive geometry
To generate Drive Points from part geometry, select the surfaces as drive
geometry and do not select any part geometry. The drive points are then
9 generated on the drive geometry.
To generate Drive Points from other geometry, select the drive and part
geometry. The Drive Points are then generated on the drive geometry and are
projected onto the part geometry according to the Projection vector.
In either case, the tool axis can follow the drive geometry contour.
The Surface Area Drive method also provides an additional Projection Vector
option, Normal to Drive, which enables you to evenly distribute drive points
onto convex part geometries.
The Surface Area Drive method is much more accurate than the Boundary
Drive method for complex parts and is useful for finishing types of operations.
The limiting factor of the Surface Area Drive method is that surfaces must
be arranged in an orderly grid of rows and columns and adjacent surfaces
must share a common edge.
(1) columns
(2) rows
(3) common edge
(4) drive surface
Drive geometries must

be selected in an orderly
sequence defining the
rows
(1) Row 1
(2) Row 2
(3) Row 3
(4) Row 4
The following parameters pertain to Surface Area Drive method:

Select allows you to select the Drive Geometry. Note that you can use
part geometry as drive geometry.
Surface Stock offsets drive points along surface normals a specified

distance.
Tool Position determines the tool contact points on the drive geometry as
either On or Tanto.
Cut Direction is the tool path direction and the quadrant where the first
cut will begin. It is specified by selecting one of the vector arrows which
appear in pairs at each of the surface corners. 9
Flip Material reverses the direction of the Material Side Vector which
determines the side of the surface the tool contacts when machining
directly the drive geometry. When machining part geometry, the
Projection vector determines the Material Side.
Cut Area defines how much of the total drive geometry area to utilize
by specifying surface percentages or diagonal points and to display the
boundary of the cut area.
Surface % specifies the drive geometry area to cut by using positive or

negative percentage values for the beginning and end of first and last
pass, and the first and last Stepover.
Diagonal Points uses the cursor to indicate two diagonal points defining
the area.
Pattern defines the shape of the tool path as Follow Pocket or Parallel
Lines.
Cut Type in combination with the Parallel Lines pattern defines cutter
movement from one cut pass to the next. The types are: Zig-Zag, Zig-Zag
with Lifts and Zig.
Cut Step controls the distance between drive points created along the
drive curve. For complex parts, the closer the drive points, the more
accurate the tool path. You can control the cut step by specifying a
Tolerance or by specifying a Number of points.
Stepover controls the distance between successive cut passes. Stepover

choices are:
Scallop, (for Parallel Lines pattern) which requires you to enter the
Height of the scallop and the Horizontal and Vertical Limit to restrict
the distance the tool moves in a direction normal to the Projection
Vector. This option avoids leaving wide ridges on near vertical surfaces
by limiting the horizontal distance of the Stepover.
Number, which requires you to enter the First and Second Directions
of cutting (for Follow Pocket) or the Number of Steps (for Parallel
Lines). These are used to generate drive points.
When Gouging indicates the processor action when gouging is detected.

The actions are: None; issue a Warning in the tool path output; Skip the
output point; or Retract and avoid the gouge.
9 Cutting Parameters affect each of the Drive Methods. The corresponding

Cutting Parameters dialog follows:
The Part Stock option defines an envelope of material surrounding
the part geometry which remains on the part after machining. The
stock specified applies to those part entities which do not have Custom
Stock specified (under Custom Data in the Part geometry dialog).
The Check Stock option is an envelope of material surrounding the

Check geometry, which the tool will not gouge.
Tool Path Drive Method
The Tool Path Drive Method allows you to define drive points along the tool
path of a Cutter Location Source File (CLSF) to create a similar Variable
Contouring tool path. Drive points are generated along the existing tool path
and then projected on to the selected part surface(s) to create the new tool
path that follows the surface contours. The direction in which the drive points
are projected on to the part surface(s) is determined by the Projection Vector.
Tool path created using

Planar Mill, profile cut
type
(1) planar mill tool path
Results of using Planar

Mill tool path, projected
on to the contoured part
geometry
(1) part surface
(2) drive point projection
(3) surface contour tool
path
When you select Tool Path as the drive method, you must specify an existing
CLSF to be used to generate drive points.
Radial Cut Drive Method
The Radial Cut Drive Method allows you to generate drive paths
perpendicular and along a given boundary, using a specified Stepover
distance, Bandwidth and Cut Type. This method is useful in clean-up type
applications.
(1) selected boundary

(2) tool path
The tool will Zig or Zig-Zag along the boundary in the direction of the
boundary indicators. This can be changed by selecting Reverse Boundary.
The following Radial Cut Drive Method options are available:
Select displays the Permanent Boundary or Temporary Boundary dialog

allowing you to define the area to be cut. The Permanent Boundary dialog
is only displayed if permanent boundaries currently exist. If multiple
boundaries are defined, a lift is applied, allowing the tool to traverse from
one boundary to the next.
Bandwidth defines the total width of the machined area measured in the
plane of the boundary. The bandwidth is the sum of the Material Side and
Opposite Side offset values.
The Material Side is the right side of the boundary as you look in the
direction of the boundary indicators. The Opposite Side is the left side.
The sum of the Material Side and Opposite Side cannot equal zero.
(1) looking in the direction

of boundary indicators
(2) bandwidth
(3) material side
9 (4) opposite side
Cut Type enables you to define how the cutter moves from one cut pass to
the next. The following options are available:
(1) Zig-Zag
(2) Zig
Stepover specifies the distances between successive drive paths.

Each Stepover methods require you to enter a corresponding Distance
value.
Follow Boundary and Reverse Boundary allow you to determine the

direction the tool travels along the boundary.
Contour Profile Drive Method
This method is a simple to use drive method to cut the undercut or overcut
walls of a part and is especially effective in machining multi-pocket type
parts. Selection of the bottom of the pocket, setting of various cut parameters,
and generation of the operation are the only steps required for use.
User Function Drive Method
User Function Drive method creates tool paths from special drive methods
developed using User Function programming. These are optional, highly
specialized custom routines developed for specific applications.. Options
available are:
CAM Exit Name is the name of an operating system environment variable
which contains the path name of the shared library containing the User
Function Program.
Users Parameters access a user exit specifying parameters for the drive
path. The User Function program associates these parameters with the
calling operation, using the name of the operation as the link.
Activity: Overview of Variable Contour Options
In this activity, you will review the basic methods that Variable Contour
uses to create tool paths. You will observe that some of the Fixed Contour
options are not available in Variable Contour, as well as some options are
only available in Variable Contour.
Step 1: Open an existing part file.
Open the part file vx_0.
Select the Operation Navigator tab from the toolbar.
Step 2: Review an existing operation.

You will review the options by examining their settings.
In the Operation Navigator, expand the Program named

OVERVIEW and double-click on the operation named REVIEW.
The Variable Contour dialog is displayed.
Step 3: View the Variable Contour dialog options.
9 You will review the option settings on the Variable Contour dialog,
then you will note the option settings on the Surface Area Drive
Method dialog. These options are required to create the tool path.
Choose the Groups tab and, if necessary, choose the Geometry

radio button, then choose Display.
The geometry Parent Group, WORKPIECE, is displayed. This
is the Part geometry.
Refresh the graphics window and select the Main tab.
Under the Geometry label, note that the Part icon is already
selected. Choose Display.
The geometry Parent Group named WORKPIECE is displayed
since it was selected as the part geometry.
Choose the Check icon.

Note that no previous Check geometry was selected.
Under the Drive Method label, view the Drive Methods that
are available.
Note that the Area Milling, Flow Cut and Text Drive Methods
are not available and are grayed out.
On the Variable Contour dialog, under the Tool Axis label, note
the various tool axes which are available.
Step 4: View the Surface Area Drive Method settings.

The Surface Area Drive Method is the most commonly used
method of creating variable axis tool paths.
Under the Drive Method label, choose Surface Area.

The Surface Drive Method dialog is displayed.
Under the Drive Geometry label, choose Display.

Note that the top face was selected as the Drive Geometry. The
Drive Points will be generated on this surface and projected to
the part geometry based on the Projection Vector.
Under the Projection Vector label, choose Specify Vector.

The Projection Vector is I=0, J=0, K=-1 and is displayed
pointing downward.
9
The Drive Points will be projected to the top of the part
geometry, which are also their current location.
Choose Cancel.
Choose Display Drive Path.

The temporary Drive Points are displayed (which are used to
create contact points.
Choose Display Contact Points.

The surface normals are displayed at each tool contact point.
The Surface Area Drive Method is the only Drive Method that
allows you to display contact points.
Choose Cancel.
Step 5: Generate and view the tool path.

You will now create a tool path using the settings which you just
reviewed.
Tool Axis Control
The Variable Contour Tool Axes can be grouped based on the geometry that
determines the tool axis.
The choice of tool axis depends upon the Drive Method you choose. For
instance, the Surface Area Drive Method allows you to specify many 4 and 5
axis tool positions that are not available by using any other Drive Method.
The table which follows shows the various drive methods with permissible
tool axis:
Tool Drive method

Axis Curve/ Spiral Bndry Surface Tool Path Radial
Area
Point
Away
From X X X X X X
point
Toward
X X X X X X
Point
Away
From X X X X X X
Line
Toward
X X X X X X
Line
Relative
to X X X X X X
Vector
4axis
Norm. X X X X X X
To Part
4axis
Rel. To X X X X X X
Part
Dual
4Axis X X X X X X
on Part
Inter
X X
polate
Swarf
X
Drive
Normal
X
To Drive
Relative
X
To Drive
4axis
Norm. X
To Drive
4axis
Rel. To X
Drive
Dual
4Axis X
on Drive
9 Same
as Drive X
Path
Point and Line Tool Axes
The following tool axis types use focal points and can produce 5-axis
movements:
Away From Point
Towards Point
The following tool axis types use focal lines and can produce 4-axis
movements:
Away From Line
Towards Line
Away and Towards refers to a vector direction.

Consideration must be given to machine configuration, part fixturing and
amount of swing or tilt of the table and or head when selecting tool axis
types. It is advisable to select the method which minimizes the amount of
table and or head tilt.
Activity: Point and Line Tool Axis Types
In this activity, you will replay a series of Variable Contour operations that
use point and line geometry to control the tool axis.
Open the part file vx_4.
If necessary, enter the Manufacturing application and display

the Program Order view in the Operation Navigator.
Step 2: Replay the operations.

Replay the AWAYLINE operation.
(1) Focal line used

with tool axis
The tool path is replayed using the tool axis option Away from
Line.
Replay the AWAYPT operation.
(1) Focal point used

with tool axis
The tool path is replayed using the tool axis option Away from
Point.
Notice the amount of difference in tool tilt between the two
different methods. Proper placement of the focal point and line
can greatly reduce the amount of tool tilt resulting in reduced
risk of head or tool interference with clamps and or fixturing.
9 Replay the TOWARDLINE operation.
Replay the tool path.
(1) Focal line used

with tool axis
The tool path is replayed using the tool axis option Towards
Line.
Replay the TOWARDPT operation.
(1) Focal point

used with tool axis
The tool path is replayed using the tool axis option Towards
Point.
Notice the difference in the amount of tool tilt. The method
chosen, towards or away from a point or line, along with their
respective placement of the geometry being cut, gives you
precise control of the tilt of the tool.

9
Normal Tool Axis
Normal Tool Axis maintains a tool axis that is perpendicular to the part
geometry, drive geometry, or rotational axis (4-axis) at each contact point.
This is a preferred method of tool axis control when the contoured geometry
that is being machined does not change radically in shape and or direction.
(1) Normal
to part
geometry at
each drive
point
The following tool axis types use the Normal tool axis:
Normal To Part
4-axis Norm To Part
Normal To Drive Surf (Surface Area Drive)
4-axis Norm To Drive (Surface Area Drive)
The 4-axis type options allow you to apply a rotational angle to the tool axis.
This rotational angle effectively rotates the part about an axis as it would on
a machine tool with a single rotary table. The 4-axis orientation causes the
tool to move within planes which are normal to the defined rotational axis.
In the following example, the rotational angle causes the tool axis to lean
forward in relation to an otherwise normal tool axis.
(1) axis normal to part

geometry
(2) rotation angle of
15 degrees
(3) plane normal to
rotation axis
(4) axis parallel to
plane
Relative Tool Axis
Relative tool axis maintains a tool axis that is perpendicular to the part
geometry, drive geometry, or rotational axis (4-axis) at each contact point and
allows the application of Lead or Tilt angle to the tool axis.
You can apply Lead or Tilt to the following tool axis types:
Relative To Part
4-axis Rel To Part
Relative to Vector
Dual 4-axis
Relative To Drive (Surface Area Drive)
4-axis Rel To Drive (Surface Area Drive)
Lead and Tilt Angle
Lead Angle defines the angle of the tool forward or backward along the tool
path. A positive Lead Angle leans the tool forward based on the direction of
the tool path. A negative Lead Angle (lag) leans the tool backwards based on
the direction of the tool path.
9
Tilt Angle defines the angle of the tool, 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.
(1) Tool direction

(front view)
(2) Tool direction
(right view)
(3) Lead
(4) Lag
(5) Normal axis
(6) Negative tilt
(7) Positive tilt
You can specify a Minimum and Maximum angle of movement for the Lead
and Tilt of the tool axis.
Unlike a Lead angle, a 4-axis rotational angle always leans to the same side
of the normal axis and is independent of the direction of the tool movement.
The rotational angle causes the tool axis to lean to the right of the part
geometry normal axis in both zig and zag moves. The tool moves within
planes normal to the defined rotational axis.
(1) axis normal to part geometry

(2) rotational angle of 15 degrees
Dual 4-Axis
Dual 4-Axis applies rotational, Lead and Tilt angle to the Zig and the Zag
moves independently.
You can specify a 4-axis rotation angle, a lead angle, and a tilt angle. The
4-axis rotation angle rotates the part about an axis as it would on a machine
tool with a single rotary table.
In Dual 4-Axis mode, these parameters may be defined separately for Zig
and Zag moves.
(1) zig cut

(2) zag cut
(3) zig cut,
tool axis
(4) zag cut,
tool axis
Activity: Normal to Part and Relative to Part

In this activity, you will compare two similar and frequently used tool axes;
normal to Part and Relative to Part.
Open the part file vx_0 and enter the Manufacturing
application.
Step 2: View the tool path.

Note the tool axis in the first pass. The tool axis is Normal to Part,
always perpendicular to the part geometry.
Expand the TOOL_AXIS Program Parent Group.
Replay the operation NORM_PART.
You will change the Tool Axis to Relative to Part and compare
the tool paths.
Step 3: Create a tool path using Relative to Part Tool Axis.

Edit the operation NORM_PART.
Under the Tool Axis area of the dialog, choose Relative to Part
9 as the tool axis.
You are prompted to change the Lead and Tilt angles. Use the
defaults of 0
Choose OK.
Compare this tool path to the previous one. Note that the tool
paths are nearly identical. Both tool paths are created using
the surface normal at each contact point.
Choose Cancel.
Step 4: Use Lead with Relative to Part tool axis.

You will now see the effect of adding a Lead angle to the Relative
to Part tool axis.
Edit the operation REL_PART_LEAD.

Under the Tool Axis label, choose Relative to Part.

You are prompted for Lead and Tilt angle settings.
You will use the specified settings, which are exaggerated so
that you can easily see the angle of Lead.
Choose OK.
Note that the tool leans forward as it cuts.
Choose Cancel.
Step 5: Use Tilt with a Relative to Part Tool Axis.

This time you will see the effect of adding a Tilt angle to the
Relative to Part tool axis.
Edit the operation REL_PART_TILT.

Under the Tool Axis label, choose, Relative to Part.

You are prompted for Lead and Tilt angle settings.
Note the specified settings.
Choose OK.
Note that the tool tilts to the right as it cuts.
Choose Cancel.
Swarf Drive Tool Axis
Swarf Drive tool axis maintains a tool axis that is parallel to the drive
geometry. The drive geometry guides the side of the tool while the part
geometry guides the end of the tool.
(1) drive geometry

(2) part geometry
The Swarf Drive tool axis should be used only when the drive geometry
consists of ruled surfaces, since the drive geometry rulings define the swarf
ruling projection vector.
9
This projection vector can prevent the gouging of the drive geometry when
using a tapered tool as shown by the following:
(1) tool axis projection

vector
(2) swarf ruling
projection vector
(3) ruled drive
geometry
(4) part surface
(5) tapered tool
(6) gouge
(7) drive point
(8) tool position
In this example, a comparison is made between the Swarf Drive Projection

Vector and the Tool Axis Projection Vector. The drive points are projected
along the specified vector to determine the tool position, showing the Tool
Axis Projection Vector method gouging the drive geometry, while the Swarf
Ruling Projection Vector method results in the tool positioning tangent to the
drive geometry.
Activity: Using Special Tool Axis and non Part Geometry

The part in this activity has been partially machined. You are going to
continue to machine the core for a hub cover used on a four wheel drive
vehicle. To maximize the part finish, you will be using a short tool to prevent
cutter deflection.
Open the part file hub_core_mfg_asmb.
There are two existing sample operations that you will examine
and then create like operations. First you will examine the
various parts which comprise the assembly.
Save the part as ***_hub_core_mfg_asmb.
Step 2: Examine the assembly.

If necessary, enter the Manufacturing application.
Choose the Assembly Navigator tab from the toolbar.

The Assembly Navigator and the part model are displayed.
Note that the assembly consists of a mounting plate, compound
rotary table, numerous bolts and the hub cover core part. 9
Step 3: Examine various operations.
Choose the Operation Navigator tab from the toolbar.
If necessary, change to the Program Order view of the

Operation Navigator.
Examine the various operations.

Note that the HUB-PROJECT-PROGRAM group object
contains a rough and finish operation.
Change to the Machine Tool view of the Operation Navigator.

Note the various tools that are defined.

For creating additional operations, it would be somewhat easier
for selection and visualization purposes, to remove from the
display, various parts of the manufacturing setup.
Select the red check marks for the screws (soc_hd_screw.5x8),

table assembly (compound_table_asmb) and mounting plate
(mounting_plate). This will turn off the display of these
components.
Step 4: Create the operations to finish the fluted area of the part.
If necessary, set the Type to mill_multi_axis.
Choose the VARIABLE_CONTOUR icon.
Set the Parent Groups as follows:

Program: HUB-FINISH
Use Tool: BALL_MILL-.75
Name: vc_flute_fin
9
Choose OK.
The Variable_Contour dialog is displayed.
Change the Drive Method from Boundary to Surface Area.
Choose OK on the Drive Method Information dialog.

You will now select the drive geometry to control the tool
motion. The part consists of many faces which are irregular
in shape and uneven in contour. You will begin the selection
process by selection of the outer face of the cylinder that defines
the raw stock.
Make Layer 2 and 5 selectable.
Choose the Select button and select the outside face of the
cylinder that represents the stock (1).
Choose OK.
You will now set the direction of cut and its cut area in relation
to the overall size of the outside face of the stock geometry.
You will also set the Cut Type.
9
Choose the Cut Direction button.
Cut direction vectors are displayed.
Choose the vector as shown (1).
Choose Surface % from the Cut Area pull-down menu.
Note the system highlight at the top and bottom of the cylinder.
Refresh the screen.
Set the start and end values as shown:
Choose OK.
Note the area that is now highlighted. The cutter will now be
limited to this area which encompasses the flutes. 9
Change the Cut Type to Zig.
You will now set the tool axis and projection vector.
Change the Tool Axis from Normal to Part to Relative to Drive.
Set the Tilt angle to 45.
Choose OK.
Set the Projection Vector to Toward Line.

The Line Definition dialog is displayed.
Choose the Point and Vector button.
Choose OK on the Point Constructor dialog (accept the

defaults).
Choose the ZC Axis icon
Choose OK twice.
The Variable_contour dialog is displayed.

Notice the last pass make an erratic move next to the clearance
hole near the bottom of the part.
To avoid this move, you will need to select Check (2) geometry.
Choose the Check geometry icon from the Variable_contour

dialog.
Choose the Select button and then choose the small disc area
located near the bottom of the part.
You will now set the parameters used in collision detection.
Choose OK.
Select the Clearances tab.
Select Skip from the When Gouging pull-down menu.
Set the Check Safe Clearance parameter to .01
Choose OK.
Choose Generate and review the tool path.
Activity: Swarf Drive Tool Axis
In this activity, you will create an operation to finish the walls of a tapered
walled part using the Swarf Drive Tool Axis. The part will be modified in
order to start the tool path at the center of one of the walls, which prevents
the cutter from engaging the interior corner of the part.
Step 1: Open a part file and rename it for the current activity.
Open the part file tub_ftg_mfg_asmb.
Rename the part to ***_tub_ftg_mfg_asmb.
To prevent engaging and then gouging an interior corner of the

part, you will engage the part from the middle of one of the long
sides of the part. You must first subdivide one of the tapered
side walls by creating a curve (in this case a line) before you
can subdivide the face.
Step 2: Enter the Assemblies application and create a WAVE Linked body
used for dividing the faces.
You will first change the work layer to the layer used for
manufacturing data and will then create the WAVE linked body.
Verify that Assemblies is turned on.
Set the work layer to 151.
Choose InsertAssociative CopyWave Geometry Linker

from the main menu bar.
The WAVE Geometry Linker dialog is displayed.
9
Select the Body icon.
Select the solid body that is the part.
Choose OK.
A linked body has been added to layer 151 which is associative
to the engineering model (tub_fitting) that appears in the
Assembly Navigator. This linked body can now be modified,
whereas the engineering model (tub_fitting) can not.
Step 3: Turn off the display of the component and change the color of the
linked body.
9 Using the Assembly Navigator, turn off the display of the
component by clicking the check mark in front of the tub_fitting
component (the check mark will turn from red to gray).
Change the color of the linked body by choosing EditObject

Display from the main menu bar.
Select the linked body and OK the selection.

The Edit Object Display dialog is displayed.
Select the check box for Apply to all faces.
Change the color to one that is not the same as the engineering
part.
Choose OK.
Step 4: Enter the Modeling application, create a datum plane and curve
for subdividing and subdivide the tapered sidewall face.
Enter the Modeling application.
Choose InsertDatum/PointDatum Plane from the menu bar.
Select the end face and key in the value 6.0 (Hint: use Offset
as a constraint).
Choose OK. 9
Choose InsertCurve from BodiesIntersect from the menu
bar.
The Intersect Curve dialog is displayed.
Choose the First Set icon from the dialog and then select the
contoured face.
Choose the Second Set icon from the dialog, then select the
datum plane.
Choose OK.
You created a line that will be used to subdivide the face. A
Datum Plane was used to create the curve to allow movement
of the line easily. You will now move the Datum Plane to its
proper layer and then subdivide the face.
9
Choose FormatMove to Layer and select the datum plane.
Choose OK.
In the Layer Move dialog, set the Destination Layer to 61.
Choose OK.
Choose InsertTrimDivide Face from the menu bar.
Change the face selection filter to Single face.
Select the face to subdivide.
Choose OK from the Selection Confirmation dialog.

The curve Subdivide Face dialog is displayed.
Choose Blank dividing objects.

You must select the curve you are going to use to subdivide
the face.
Select the newly created line.
Choose OK.
The face is divided into two faces.
Choose Cancel.
From the menu bar, choose PreferencesSelection.
Set the Chaining tolerance to .001.
Choose OK.
You will now create the tool path to cut the part.
Step 5: Change to the Manufacturing application.

Choose mill_multi-axis as the CAM Session Configuration.
Choose mill_multi-axis as the CAM Setup.

This will initialize the part with multi-axis parameters. 9
Choose Initialize.
Step 6: Create an end mill needed to machine the part.

Choose the Create Tool icon.
Choose the Mill tool icon.
Name the tool EM-.75-.06.
Choose OK.
In the Milling Tool-5 Parameters dialog, enter a diameter of

.75 and a lower radius of .06.
Choose OK.
Step 7: Edit the MCS in the Operation Navigator and set the Clearance
Plane 1.000 above the top face of the part.
Double-click the MCS group object in the Geometry view of
the Operation Navigator.
The MILL_ORIENT dialog is displayed.
Check the Clearance box and choose the Specify button.

The Plane Constructor dialog is displayed.
Set the clearance plane as being 1.000 above the uppermost

top face of the part.
Step 8: Specify the Part Geometry.

You will now select the floor of the part as the Part Geometry.
Choose the Create Geometry icon.
Set the Operation Navigator to the Geometry View.
Choose the Mill_Geom icon.
Choose WORKPIECE as the Parent Group.
Name the geometry Parent Group PART_FLOOR.

Note that the Type is mill_multi_axis.
Choose OK.
9
In the MILL_GEOM dialog, under the Geometry label, choose
the Part icon.
Choose Select.
The Part Geometry dialog is displayed.
The Selection Options should be set to Geometry.
Change the Filter Methods to Faces.
Select the floor of the part.
Choose Accept from the Selection Confirmation dialog.
Choose OK until you return to the Create Geometry dialog.
Verify that the Parent Group, PART_FLOOR was created in

the Operation Navigator.
Step 9: Create the Variable Contour operation using the Surface Area
Drive Method.
Choose the Variable Contour icon.

9
Set the following:

Program: Program
Use Geometry: PART_FLOOR
Use Tool: EM-.75-06
Name: fin-poc-walls
Choose OK.
Step 10: Define an Engage and Retract move using the Non-cutting Moves
option.
Choose Non-cutting from the Machining Parameters area.
The Non-cutting Moves dialog is displayed.
You will now define an Approach move for the Default Case.
You can also define different Approach moves for the Initial,
Final Check, Local, and Reposition moves.
Choose the Approach icon.

The options available have changed to reflect the Approach
move options.
Next to the Status label, change None to Clearance.

The Clearance geometry is assigned to the default Approach
move. The Non-cutting Moves dialog is displayed again.
You will now specify a Departure move for the Default case.
Choose the Departure icon.
Next to the Status label, change None to Clearance.

9 You will now define an Engage move for the Initial case.
Choose the Engage icon.
Next to the Status label, change None to Manual.
Under the Movement label, change Linear to Arc: Normal

Tool axis.
Change the Radius Type to Radius.
Key in .500 into the Radius value field.
Step 11: Set the Display options.

Choose the Edit Display icon in the Tool Path section of the
dialog.

Tool Display = 3D
Frequency = 5
Path Display Speed = 8
Choose OK.
You have specified how to drive the bottom of the tool. You
must specify how to drive the side of the tool. This is done by
choosing a Drive Method from the available types.
Step 12: Define the Drive Method.

If necessary, accept the warning message.

Step 13: Select the Drive Geometry.

Choose Select from the Drive Geometry area.
The Drive Geometry dialog is displayed.
Select all the interior faces, beginning at (1) and ending at (9),
in a counterclockwise direction.
Choose OK from the Drive Geometry dialog when the face

selection is complete.
If the material side and direction indicator appears as follows:
Choose Flip Material from the Surface Drive Method dialog

9 (perform this action only if the indicators appears as above).
Step 14: Define the drive direction.

You must now define the direction of the cut.
Choose Cut Direction from the Surface Drive Method dialog.

Cut direction arrows are displayed. You will select the direction
arrow that points in the direction that you will want to cut.
Choose the lower left arrow (1).
Step 15: Set the Number of Passes.

Next to Stepover, set the option to Number.
In the Number of Steps field, enter 0.

Zero indicates that only one pass will be made.
Step 16: Define the Gouge Action.

Next to the When Gouging label, change None to Skip.
The Skip option will move the tool to the next non-gouging
point if gouging is detected.
Step 17: Define the Tool Axis.

Under the Tool Axis label, change Normal to Part to Swarf
Drive.
Remember, Swarf Drive enables you to define a tool axis that
follows the swarf rulings of the drive geometry with the side
of the tool.
Notice that several vector indicators appear. They are relative
to the first drive geometry you selected. The vector you select
defines the swarf ruling direction that the tool axis will follow.
The vector should point towards the tool holder.
Select the arrow pointing up.

9
Step 18: Define the Projection Vector.
The Projection Vector determines the direction that the drive
points are projected upon the part geometry.
Under Projection Vector, change Specify Vector to Tool Axis.

The Surface Area Drive Method parameters are now complete.
Choose OK.
Step 19: Create the tool path.

Choose the Generate button.
The tool path is generated and the option menu is displayed.
The tool engages and retracts along the defined radius of the
non-cutting move.
The side of the tool maintains wall contact throughout the cut.
Notice that the tool appears as to be gouging the part. It is not.
The tool is longer than the surface it is cutting which makes it
appear to be violating the geometry.
(1) retract
(2) engage
Choose OK from the option menu.
Interpolated Tool Axis
Interpolate tool axis enables the control of the tool axis at specific points by
defining vectors. It allows for control of excessive change of the tool axis as
a result of very complex drive or part geometry, without the construction of
additional tool axis control geometry (e.g., points, lines, vectors, smoother
drive geometry). Interpolate can also be used to adjust the tool axis to avoid
overhangs or other obstructions.
You can define as many vectors extending from specified positions on the
drive geometry as required to create smooth tool axis movements. The tool
axis, at any arbitrary point on the drive geometry, will be interpolated by the
user-specified vector. The more vectors specified, the more control you have
of the tool axis.
This option is available only when using the Curve/Point or Surface Area
drive method.
(1)
user-defined
controlling
vectors
(2) excessive
tool axis
change
(3) smoother
tool axis
movement
(4) drive
surfaces
(5) tool axis
normal to
drive surface
(6)
interpolated
tool axis
Interpolated tool axis dialog options are:

Specify as defines the vectors used to interpolate the tool axis. You can 9
define as many vectors as necessary to control the tool axis.
Vector defines vectors by first specifying a data point on the drive
geometry and then specifying a vector.
Angle/PS (or DS) defines vectors by specifying a data point on the

drive geometry and then specifying Lead and Tilt angles relative to
the part (or drive geometry) surface normal at the tool contact point
with the part geometry. Lead and Tilt angles must be within -90 to
90 degree range.
After you choose OK to accept the desired vector or angle, you can continue
defining data points and vectors until you choose Back in the Point
Constructor dialog. Selecting Back accepts all of the defined vectors and
returns you to the Interpolated Tool Axis dialog.
Data Point allows you to create, delete and modify vectors used to
interpolate the tool axis.
Add enables you to create new data points. First specify a data point
on the drive geometry and then a vector direction. After specifying the
data point, a vector normal to the drive geometry is displayed.
Remove enables you to delete data points. Use the Arrow Buttons
to highlight the desired data point or select the desired data point
directly from the screen and then choose Remove.
Edit enables you to modify the tool axis at an existing data point. It
does not allow you to move data points.
Display displays all currently defined data points for visual reference.
Interpolation method determines which algorithm is used to calculate the tool

axis from one drive point to the next.
Linear interpolates the tool axis using a constant rate of change between
drive points
Cubic Spline interpolates the tool axis using a variable rate of change
between drive points; this method allows a smoother transition between
points
Interpolate displays drive tool axis vectors at each drive point (when Specify
as Vector is used) or drive points and interpolated lead and tilt angle values
(when Specify as Angle/PS or Angle/DS is used).
Reselect removes all defined data points.
9
Activity: Using the Interpolated Tool Axis

In this activity, you will create an operation using an Interpolated Tool Axis.
The tool will start at the rear of the part with a tool axis that is normal and
will then cut to the front of the part, ending with a tool axis that is aligned
with the ZC axis. As the tool moves from the rear to the front, its orientation
changes incrementally along the tool path.
Step 1: Open a part file, rename and enter the Manufacturing application.
Open the part file interpolate_mfg_asmb and rename it to
***_interpolate_mfg_asmb.
Choose the Operation Navigator icon from the toolbar.
Step 2: Create a Variable Contour Operation.

Choose the Variable Contour icon.
In the Create Operation dialog, set the following:

Program: PROGRAM-AXIS-LIMITS

9
Use Tool: BALL_MILL-1.0
Name: interpolate
Choose OK.
Under the Machining Parameters label, select Non-Cutting.
Specify the Approach and Departure motions to Clearance

Plane.
Step 3: Define the Drive Geometry.

Step 4: Specify a Drive Method.

Under the Drive Geometry label, choose Select.
Choose the surfaces as shown.
Choose OK.
Choose the Cut Direction button.
Choose the Cut Direction arrow as shown.
Change the Cut Type to Zig.
Change the Cut Step to Tolerances.
Under the Stepover label, change the Number of Steps to 4.

9
Change the Tool Axis to Interpolate.
The Interpolated Tool Axis dialog is displayed.
The default vector arrows show the current tool axis vector
direction.
As shown, select the front arrows (using the cursor or the

Selection Arrows, select one at a time) and under the Data
Point label, specify EditZC Axis for each vector direction
arrow selected.
Each vector now points along the +ZC axis.

9
Choose OK.
Choose OK to return to the Variable Contour dialog.
Under the Tool Path label, choose the Edit Display icon and
change the Tool Display to Axis.
Choose OK to return to the Variable Contour dialog.
9
Notice that the tool starts cutting along the surface normal
vector at the rear of the part, gradually changing its axis to the
vectors specified at the front of the part, which is parallel to
the +ZC axis.
Verify the Interpolate Tool Axis positions.
List the tool path and verify the start and finish tool axis.
By listing the tool path, you can see the tool axis position at the
first GOTO, is not parallel to the ZC axis. As the tool moves,
the tool axis position interpolates and becomes parallel to the
ZC axis at the last GOTO.
Close the Information window.
Choose OK.
Save the part file.
A Comparison of Variable Contour vs. Sequential Milling

Variable Contour and Sequential Mill operations allow you to specify Drive,
Part and Check surfaces. Generally, the Drive geometry guides the side of the
tool and the Part geometry guides the bottom of the tool. The Check geometry
stops tool movement. Specifying Part and Check geometry is very similar in
Variable Contour and Sequential Mill operations.
Part Geometry
Variable Contour does not always require that you specify Part geometry.
When you do not, Drive geometry is used as Part geometry.
Sequential Mill requires selection of Part geometry. The default selection is
the previous Part geometry.
Drive Geometry
Drive geometry is used to create drive points that are projected to the Part
geometry. You may use geometry other than that contained within the model.
This "external" drive geometry can be points, curves, a boundary, etc. that
you select after you choose an appropriate Drive Method.
Drive geometry in Sequential Mill is used to control the side of the tool
without developing and projecting drive points. Typically, you select a part
wall that you want the side of the tool to contact as it follows the Part surface.
Check Geometry
Variable Contour does not require Check geometry. Check geometry is

typically used to prevent collision and gouging.
Sequential Mill requires selection of Check geometry. The Check geometry
is used for tool positioning at the beginning of the next suboperation and
for preventing collision and gouging.
General Considerations
The overriding consideration in choosing between Variable Contour and

Sequential Mill is: "Which method creates the best tool path and is easiest
to use."
The answer depends upon whether the part model has features that only
Variable Contour or Sequential Mill can resolve. If both processors are
capable, you should consider the following relative strength of each processor:
preferred method for area milling preferred method for linear milling
primary cutting with bottom of tool primary cutting with side of tool
numerous drive methods for tool single drive method
path containment
numerous cut patterns for specific no cut patterns other than looping or
applications nested loops
sheet body and surface region temporary plane geometry allowed
geometry allowed
constant tool axis can change tool axis during operation
edits apply to entire tool path edits apply to part of tool path
best at convex wall cuts best at overcut and undercut type
walls
easy to create operation numerous steps in operation creation
easy to create multiple depth paths N/A
Tool Axis Usage
The following table compares tool axis usage in Variable Contour and
Sequential Mill operations:
Tool Axis Usage

3 Axis
Normal to Part (default) ZM Axis (default)
Relative to Vector Vector
4 Axis
Away from line (4) / Toward line (4) -
4axis normal to part / 4axis normal -
to drive
4axis relative to part -
4axis relative to drive at angle to Drive Surface/at angle to
Part Surface
dual 4axis on part / dual 4axis on -
drive
- tangent to Part Surface
- tangent to Drive Surface
- project Drive Surface Normal
- project Part Surface Normal
5 Axis
Away from point thru fixed point
toward point thru fixed point
normal to part normal to Part Surface
normal to drive normal to Drive Surface
swarf drive parallel to PS /Parallel to DS
relative to drive at angle to DS / at angle to PS
interpolate -
same as drive path -
user function -
9 -
-
tangent to PS
tangent to DS
- fan
Summary
Variable Contour operations provide an efficient and robust capability to
machine complex geometry for multiple axes machining processes (4 plus
axis). Numerous types of tool axis control and drive methods, give the
NC/CNC programmer the ability to machine the simplest to the most complex
of parts. The following features are common to variable contour operations.
Complete tool axis control that allows for minimal tool and table rotations.
Numerous drive methods to achieve the simplest to the more complex

of surface machining techniques.
9
Lesson
10 Variable Contour Advanced
Purpose
This lesson will introduce advanced concepts in conjunction with Variable

Contour operations.
Objective

create associative drive surfaces used to control the tool axis
use Associative Datum planes to create surfaces and geometric objects

used for creation of start points and initial tool axis
10
Variable Contour Advanced
Advanced Variable Contour Machining

The activity which follows will take you through some of the steps that allow
greater control of the tool axis and avoids chaining tolerance errors that occur
when drive surfaces edges do not match precisely.
Surfaces will be extracted from the solid body by use of the WAVE Geometry
Linker with timestamp applied. The use of the timestamp will prevent new
geometry, which is created after the timestamp, from being used by the
WAVE Linked surfaces.
Associative Datum planes are created for use in creating the initial start
point and tool axis as well as for the creation of various geometric elements
that will be required for tool control.
All surfaces which have not been intersected by parallel datum planes will
be selected as part surfaces. The tool axis will be set to swarf drive and the
projection vector will be the tool axis.
10
Activity: Examining the Part and Part Objects

The part in this activity can represent any type of five-axis work that could be
performed on an aircraft structural assembly, the inside of a mold or some
other type of part that requires five-axis machining. You will be required to
semi-finish and finish the walls with two different diameter cutters. Assume
that the part has already been roughed.
Open the part file vc_nc_assy.
There are two existing sample operations that you will examine
and then create like operations. First you will examine the
various parts which comprise the assembly. 10
Step 2: Examine the assembly.

If necessary, enter the Manufacturing application.

The Assembly Navigator and the part model are displayed.
Make the vc_solidbody component the Displayed Part.
Note the cut out areas on top of the walls.
Make the vc_assy the Work Part.
Step 3: Examine layers in the assembly.

Choose FormatLayer Settings from the menu bar.
10
Check the Show Object Count and Show Category Names

boxes.
Note the change in the Layer/Status/Count/Category area of

the dialog.
You will now examine the layers.
Make all layers Invisible.
Make layer 15 Selectable.
Choose OK.
Now examine the WAVE Linked surfaces.
Note that the cut outs were not passed to the WAVE Linked
geometry due to the use and placement of the timestamp.
10
The view now shows the part with the Associative Datum
planes that are used to create the necessary intersection curves.
The view now shows the part with the Associative Curves that
are used to create the necessary ruled surface.
10
The view now shows the part with the Associative Ruled
surface that is used to create the Drive surfaces.
10
Make layer 15 Invisible.
The single vertical plane was used to split the WAVE Linked
surface prior to the creation of the Intersection Curves. This
can be at any angle to establish the initial tool axis.
Dismiss the Layer Settings dialog by choosing Cancel.
Step 4: Enter the Manufacturing application and review the existing

operations.
You will review the operations by examining their settings.
Choose the Operation Navigator tab from the menu bar.

View.
Expand the MCS and WORKPIECE Parent group objects.
Double-click on the operation VC_RGH_POC_1.50_WO_CS.

The Variable_Contour dialog is displayed.
10
Display the Part geometry and then the Check geometry.

Notice that the Select button appears when you choose the
Check geometry icon. There is no Check geometry available
for display.
Replay the operation and zoom in at the corner of the part.

Notice the cutter violates the drive surfaces.
Double-click on the operation VC_RGH_POC_1.50_W_CS.
10
Display the Part geometry, then the Check geometry.
Notice that the side walls of the part have been selected as
Check surfaces.
10
Replay the operation and zoom in at the corner of the part.
Notice the cutter does not violate the walls.
Replay the operation VC_FIN_POC_1.00.
Examine the operation parameters and the surfaces used.

Notice that this operation does not need Check surfaces.
Step 5: Create new operations.

Create operations to semi-finish and finish the pocket, using
the previous operations as a guide only. Do not copy them.
10
Contour Profile Drive Method

The Contour Profile Drive Method in Variable Axis Surface Contouring
machines canted walls with the side of the cutter. Variable axis profiling lets
you automatically generate a tool path to machine the walls of a cavity or a
region bounded by floor(s) and wall(s), with the sides of the cutter. After
selecting the floor, the software can find all the walls that bound the floor.
The tool axis is constantly adjusted to get a smooth path. At concave corners,
the side of the tool is tangent to both adjacent walls. At convex corners, the
software adds a radius and rolls the cutter around to keep the tool axis
tangent to each corner wall. Contour Profile also allows you to machine walls
that are not bounded by floors, such as the outside periphery of a part. There
are two options to control the placement of the cutter against the wall when
your part has no floors. Either use Follow Wall bottom to follow the periphery
of the wall or use an auxiliary floor that behaves as a real floor.
10
Activity: Contour Profile Drive Method

In this activity you will use the Contour Profile drive method to machine
the canted walls of the part.
Open the part file spar_mfg.
This part has already been roughed machined as well as the

floor have been finished. All that remains to finish is the
interior walls of the three rectangular pockets.
Step 2: Create a Variable Axis Profiling operation.

10
Choose the CONTOUR_PROFILE icon.
Set the group objects as shown:
The CONTOUR_PROFILE dialog is displayed.
Choose OK.
Step 3: Selection of Parameters.

As stated earlier, the only requirements necessary to use this drive
method is the selection of the floor of the pocket, setting various
cutting parameters and generating the operation. You will first
select the floor of the pocket.
10
Under the Geometry area of the dialog, choose the Floor (1)
icon and then Select (2).
10
Choose the bottom of the pocket as shown.
Choose OK.
10
Choose the Wall icon (1) from the Geometry area of the
CONTOUR_PROFILE dialog.
Choose Display (2).
Note that the Automatic Wall parameter is On. The walls,

forming the sides of the pockets are automatically detected
(even though the floor is a radius). The operation is now ready
to be generated, however we need to make multiple passes
to keep the cutter from deflecting. You will now select those
parameters.
Choose the Cutting button from the CONTOUR_PROFILE

dialog.
The Cutting Parameters dialog is displayed.
10
Select the Multiple Passes tab.
Turn on the Wall (1) option.
Key in 0.1 for the Wall Stock Offset (2).
Set the Step Method to Passes (3).
Set the Number of Passes to 3 (4).
Choose OK (5).
You have set the cutting parameters to remove .100 stock in
three equally spaced passes.
Step 4: Generate the operation and examine the tool path.

Choose the Generate button from the CONTOUR_PROFILE
10 dialog.
Examine the tool path.
(1) Tool path prior to stock removal; (2) tool path after stock
removal
10
If time permits, create a second Contour Profile operation to

machine the walls of the next pocket.
10
Geometry Selection
Creating a Contour Profile tool path requires Part geometry, Wall geometry
and Floor geometry. There are several options that can be used to define
the geometry. You can define the geometry by selecting the geometry or by
allowing parts of the geometry to be detected automatically.
Part Geometry
Use Part geometry to specify the complete set of geometry that represents the
finished part. In many cases, roughing and finishing operations are done on
sections of the finished part
Floor Geometry
The floor is the geometry that limits the location of the cutter when it is placed
against the wall. Floor geometry may be specified by selecting geometry from
your part, from another geometry or in some cases it can be defined for you.
Wall Geometry
Wall Geometry defines the area to be cut. The cutter is first placed
against the wall, and once a tool axis is established, the cutter
is then positioned against the floor. Wall geometry can also be
selected manually or in some cases it can be defined automatically.
The following activities will examine some of the possible geometry selection
methods and combinations.
10
Automatic Wall
When using the Automatic Wall selection you will select the part geometry
and the floor geometry and turn on the Automatic Wall option. The walls
will be detected for you.
10
Activity: Floor selection and Automatic Wall

You will create a new operation and specify the Part and Floor geometry for
the operation. You will select Automatic for the Wall selection.
Open the part file wedge_mfg.

10
Set the group objects as shown and select OK.
Step 3: Specify the Floor Geometry.

Under the Geometry area of the dialog, choose the Floor (1)
icon and then Select (2).
10
Choose the bottom of the pocket as shown.
Choose OK.
10
Choose the Wall icon (1) from the Geometry area of the
CONTOUR_PROFILE dialog.
Choose Display (2).
Note that the Automatic Wall parameter is On. The walls,

forming the sides of the pockets are automatically detected.
The operation is now ready to be generated.

dialog.
Examine the tool path using Replay or Verify.
10
Follow Bottom Wall

The Follow Bottom Wall option uses the bottom of the selected walls to
determine the floor. The access vector determines the tool axis direction.
10
Activity: Follow Bottom Wall

You will create a new operation and specify the part and wall geometry for the
operation. You will select Follow Bottom Wall to detect the floor. Multiple level
cutting is not available for Follow Bottom Wall. Multiple passes are available.
Step 1: Continue to use the existing part file.
The part file mfg_wedge should be open.

10
Step 3: Turn off the Automatic Wall option.

Turn off Automatic Wall.
Step 4: Specify the Wall Geometry.
10
Under the Geometry area of the dialog, choose the Wall icon
and then Select .
Choose all of the walls on the outside of the part.
Choose OK.
10 Select Follow Bottom Wall on the CONTOUR_PROFILE dialog.
The operation will detect the bottom of the walls to use for floor
geometry. The path could also be offset from the Bottom Wall.

dialog.
The tool path follows the bottom contour of the wall geometry
while using the wall geometry to guide the tool axis.
The tool path cuts to the bottom of the selected walls. You will
edit the operation to apply a depth offset so the cutter cuts deeper
than the part geometry.
Step 6: Add a depth offset for the tool path.

Set the Tool Position Offset to .250 and Generate the
operation.
Step 7: Move the operation to the Unused Items group on the Operation
Navigator You will cut the same area of the part using slightly
different options.
Highlight the operation CONTOUR_PROFILE_1 and drag it
to the Unused Items group. 10
Automatic Auxiliary Floor

Use Automatic Auxiliary Floor to define an infinite plane that is perpendicular
to the access vector at the bottom of the wall. You define the access vector
to determine which direction the cutter should be positioned with respect
to the wall.
10
Activity: Automatic Auxiliary Floor

You create a new operation using the Automatic Auxiliary Floor option. After
generating the operation you will offset the floor and add multiple levels.
10

10
and then Select .
Choose OK.
10
Select Automatic Auxiliary Floor on the CONTOUR_PROFILE

dialog.
The operation will detect the bottom of the part to use for floor
geometry. Use the Automatic Auxiliary Floor to define an infinite
plane that is perpendicular to the access vector at the bottom
of the wall. The path could also be offset from the Automatic
Auxiliary Floor.

dialog.
The tool path follows a plane at the bottom of the geometry while
using the wall geometry to guide the tool axis.
Multiple depth and multiple passes are available with Automatic

Auxiliary Floor. You can also set a depth offset. In the next steps
you will add a depth offset and multiple depths.
Step 6: Set a depth offset for the tool path.

Select the Edit Parameters icon next to Automatic Auxiliary
10 Floor.
In the graphics screen click and drag the cone head to specify
an offset of -.3 and select the Green Check Mark to accept it.
Step 7: You will now select multiple floor passes.

Choose Cutting Multiple Passes and select Floor.
Set the Floor Stock Offset to 2.00, the Step Method to Passes
and the Number of Passes to 4.
Choose OK to return to the CONTOUR_PROFILE dialog.
Choose Generate. 10
Choose OK to accept the operation and tool path.
You will also add multiple Wall passes to the operation.
10
Step 8: Choose Cutting Multiple Passes and select Walls.

Set the Wall Stock Offset to .100, the Step Method to Passes and
the Number of Passes to 2.
Choose Generate.
10
Navigator.
to the Unused Items group.
10
Auxiliary Floor
Auxiliary Floor allows you to select geometry that doesnt belong to the model
being cut to represent the floor geometry. In the following activity you will
use another face to simplify the tool motion for the cut.
10
Activity: Auxiliary Floor

You will create a new operation using the Auxiliary Floor option.

10
Step 3: Make the layer containing the auxiliary floor selectable.

Select Format Layer Settings , highlight layer 52 and choose
Selectable.
Choose OK.

10
and then Select.
Choose OK.
10
Select Auxiliary Floor on the CONTOUR_PROFILE dialog and

then choose Select.
You will select the sheet body as the Auxiliary Floor.
Step 6: Generate the operation and examine the tool path

dialog.
Examine the tool path. 10

The tool path follows the Auxiliary Floor geometry while using the
wall geometry to guide the tool axis.

Choose Cutting Multiple Passes, and select Floor.
10 Choose Generate.
In this case the Auxiliary floor establishes a smoother tool path

than the Follow Bottom Wall path. It also allows multiple floor
passes.
Navigator.
to the Unused Items group.
10
Auxiliary Floor and Automatic Auxiliary Floor

You can combine Automatic Auxiliary Floor along with Auxiliary Floor. The
infinite plane created by Automatic Auxiliary Floor is treated as another
face in the Auxiliary Floor definition.
10
Activity: Auxiliary Floor and Automatic Auxiliary Floor

You will create a new operation using the Auxiliary Floor and Automatic
Auxiliary Floor.
.

10

10
and then Select .
Choose OK.
10
Select Auxiliary Floor on the CONTOUR_PROFILE dialog and

then choose Select.
You will select the sheet body as the Auxiliary Floor.
Step 5: You will also turn on the Automatic Auxiliary Floor option.
Choose Automatic Auxiliary Floor.
10 Step 6: Generate the operation and examine the tool path

dialog.
The tool path follows the Auxiliary Floor and the Automatic
Auxiliary floor geometry while using the wall geometry to guide
the tool axis.
10

Choose Cutting Multiple Passes and select Floor.
Choose Generate.
10
Summary
Variable Contour operations provide an efficient and robust capability to
machine complex geometry for 4 and 5-axis machining centers. This lesson
familiarizes you with some the requirements that are necessary to make the
programming task simpler.
10
10
A
Appendix
A Projection Vectors
The Projection Vector indicates the side of the part surface to be cut. It is also
used to project drive points from the drive to the part surface.
The following illustration shows a Projection Vector (defined as Away From
Line, i.e. the center line) indicating the side of the part surface to be cut. It
also shows a drive point projected, along the projection vector, from the drive
surface (P1) to the part surface (P2).
(1) projection vector

(2) part surface
(3) drive surface
Note that, in this example, the drive point is projected in the opposite
direction of the Projection Vector arrowhead. The drive point is always
projected toward the part surface along the projection vector but without
regard to the Projection Vector arrowhead.
A Projection Vector is required for all Variable Contour Drive
Methods.
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide A-1
Projection Vectors
A
The following options allow you to define the Projection Vector:
Specify Vector fixed projection vectors
Tool Axis variable projection vector
Away from Point variable projection vector
Toward Point variable projection vector
Away from line variable projection vector
Toward line variable projection vector
Normal to Drive surface area drive method only
Swarf Ruling surface area drive method only
User Function
Specify Vector Fixed Projection Vectors
I, J, K define the vector by keying in values relative to the origin of the Work
Coordinate System.
Line End Points by defining two points, selecting an existing line, or defining
a point and a vector.
2 Points by using the point Constructor to specify two points. The first point
defines the tail of the vector; the second point defines the arrowhead of the
vector.
Tangent to Curve defines a vector tangent to a selected curve. Specify a
point on the curve, select an existing curve, and select one of two displayed
tangent vectors.
A-2 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
Projection Vectors
A
Spherical Coordinates defines a fixed vector by keying in two angular values,
designated as Phi and Theta. Phi is the angle measured from +ZC and rotated
in the ZC-XC plane from ZC to XC. Theta is the rotation angle about the ZC
axis from XC to YC.
(1) Phi
(2) Theta
Variable Contour Projection Vectors
Tool Axis define a projection vector relative to the existing tool axis. When
using tool axis, the vector always points in the opposite direction of the tool
axis vector.
Away From Point creates a projection vector extending away from a specified
focal point toward the part surface. Useful in machining the inside spherical
(or sphere like) surfaces where the focal point is the center of the sphere.
Towards Point creates a projection vector extending from the part surface to
a specified focal point. Useful in machining the outside spherical (or sphere
like) surfaces where the focal point is the center of the sphere.
Away From Line creates a projection vector extending from a specified line to
the part surface.
Towards Line creates a projection vector extending from the part surface to
a specified line.
Surface Area Drive Method Projection Vectors
Normal to Drive define projection vectors relative to the drive surface normals.
Swarf Ruling allows you to define the projection vector parallel to the swarf
rulings of the drive surfaces when you use a swarf drive tool axis. It should be
used only when the drive surfaces are equivalent to ruled surfaces, since the
drive surface rulings define the swarf projection vector.
Projection Vectors
A
The Swarf Ruling projection vector can prevent gouging the drive surface
when using a tapered tool as illustrated below:
(1) Tool Axis Projection

Vector
(2) Swarf Ruling
Projection Vector
(3) Ruled Drive Surface
(4) Part Surface
(5) Tapered Tool
(6) gouge
(7) drive point
(8) tool position
The above figure compares the Swarf Ruling projection vector to the Tool Axis
projection vector (the Tool Axis projection vector is the reverse of the Tool Axis
Vector). Drive points are projected along the specified vector to determine the
tool position. When using the Tool Axis projection vector, drive points are
projected along the tool axis (at an angle to the drive surface), causing the tool
to gouge the drive surface. When using the Swarf Ruling projection vector,
drive points are projected along the drive surface swarf rulings causing the
tool to position tangent to the drive surface.
A-4 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
Projection Vectors
A
The following is a summary table showing the types of projection methods
available for each tool axis. The x indicates that the Projection Method
is not available.
Tool Axis Projection Methods
Fixed Tool Toward Toward Norm Swarf
Vector Axis / Away / Away Drive Rule
Point Line
Away From Point X
Toward Point X
Away From Line X
Toward Line X
Relative To Vector X
Normal to Part X
Relative to Part X
4axis Normal to Part X
4axis Relative to Part X
Dual 4Axis on Part X
Interpolate X
Normal to Drive X
Swarf Drive
Relative to Drive
4axis Norm to Drive
4axis Rel to Drive
Dual 4Axis on Drive
Same as Drive Path X X
A
Appendix
B Zig-Zag Surface Machining

B
Zig-Zag Surface machining is designed for 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. Either Zig or Zig-Zag cut types are available.
(1) trim
(2) specify
cut
direction
by selecting
direction
arrows
Zig-Zag Surface tool paths are generated in parallel passes. The drive
points are generated on the surface to be machined. You can control the
number of input points by a chordal deviation (adjusting the step tolerance)
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.
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide B-1
B
Appendix
C Advanced Surface Contouring
Projection C
Mathematics of Projection:
Place tool end at drive point
Project tool along projection vector
Tool stops when making contact with part
If necessary, adjust the tool axis and repeat the above steps until the
tool axis is satisfied
Add more intermediate drive points to satisfy the Intol/Outol with the part
(1) drive
point
(2)
projection
vector
(3) tool
position
(4) part
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide C-1
Advanced Surface Contouring
Projection and Steep Surface:

X = d/sin d/
X becomes large if is very small (steep surface)
The source of d is the chordal deviation of the drive path
(1) drive
path
C
(2) drive
point
(3) d
(4) x
(5)
C-2 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
Projection and Material Side:

Surface contouring does not have explicit definition of material side for
part geometry, only the drive surface has explicit material side
Material side of the part is determined implicitly by the projection vector
(1) drive point

(2) projection
vector
C
(3) focal point
(4) A
(5) B
(6) C
(7) away from
point
(8) all other
cases
In the case of Area Milling Drive (no projection vector), the tool axis vector
is used to decide Material Side
Tool Axis
Definition of Lead/Tilt angles:
(1) lead
(2) tilt
(3) tool axis
vector
(4) reference
vector
(5) cut vector
(6) tool axis
Begin with cut vector, rotate it toward the Reference vector 90- degrees
Then rotate around the cut vector degrees (counter clockwise)
Reference vector is the surface normal relative to the part/drive or a

vector which is relative to a vector
Definition of 4-axis rotation angle:
(1) rotation angle

(2) perpendicular plane
(3) tool axis
(4) projected tool axis
(5) 4axis vector
C Compute tool axis
vector without 4axis
constraint first
Project this tool

axis vector onto the
perpendicular plane of
the 4axis vector
Rotate the projected

tool axis vector
along 4axis vector
(counterclockwise)
The unconstrained tool axis vector could be:

Normal to Part / Drive
Relative to Part / Drive
Interpolated tool axis algorithm:

(1) data point 1; (2) data point 2
(3) data point 3; (4) data point 4
(5) grid cell
divide the whole parameter (u,v)
space for the drive surfaces by a
19x19 grid
C
compute the tool axis at each grid
pt using the data pts weighted by
the inverse of the distance square
inside each grid cell, calculate the

tool axis vector as the linear/spline
interpolation of the tool axis vector
at the four corners.
Drive Surface
Remap of drive surface:
Remap algorithm:
(1) trimmed face; (2) underlined

surface
C merge the exterior edges of the

trimmed face to 4 sides
re-proportion the parameters of

the exterior edges according to arc
length
use the arc length proportional

edge parameters to construct the
new (u,v) space for the trimmed
face (Coons mapping).
align the multiple drive surfaces

into a rectangular grid pattern
Limitations of remap
fails on 3sided faces
fails on faces that do not have rectangular shapes
may fail on faces with too many edges
multiple drive surfaces must be in grid formation
Swarf developable surface:

Developable surfaces are special kinds of ruled surfaces when the surface
normal vectors on any given rule line are the same (ruled surface without
twisting)
Only developable surfaces can be milled by swarfing without undercut or

overcut
Planar Milling
Blank - the region to be included
C
Part - the region that can not be violated
Check - the additional region that can not be violated
Trim - as a final step, the region to be trimmed away
(1) check inside

(2) blank inside
(3) trim outside
(4) part inside
Boolean Logic
Boundary Drive
Drive boundary - similar to "blank" if no part containment, otherwise
it is like "part"
Part containment - similar to "blank"
Area Milling Drive

Cut area - similar to "blank"
Trim - behaves slightly different from planar milling
Stock
Part offset and part stock
What Where
Part Offset Offset of part as the Geometry Group
permanent definition of
the final shape of the
product
Part Stock Leftover material Operation
on part by a given
operation
C
Part stock is defined on "top" of part offset
(1) part stock of

roughing
(2) part
(3) part stock of
semi-finish
(4) part offset
Safe clearance and part stock offset
What Where
Part Stock Offset Difference between the Operation
part stock from the
previous operation and
the part stock of the
current operation
Safe Clearance The additional safety Operation
zone for collision C
checking
Safe clearance is defined on "top" of part stock offset
(1) safe clearance

(2) part
(3) part stock
(4) part offset
(5) part stock
offset
Part stock offset is used in multiple pass, engage/retract and collision

checking
Safe clearance is used in engage/retract and collision checking
Gouge / Collision
Definitions:
Rapid moves Feed moves

Cutting part of tool Collision Gouge
assembly
Non-cutting part of tool Collision Collision
assembly
Usually gouge check against part offset + part stock
Usually collision check against part offset + part stock + part stock offset
+ safe clearance
C
(1) collision
(2) gouge
Usage:
Collision check Gouge check

Tool Path Generation No Yes on Part
Drive Path Generation No Optional on Drive
Engage/Retract No Optional on Part
Transfer Moves Optional on Part Optional on Part
Cut Region Optional (holder) on Yes on Part
Computation Part/Check
(Cut Area)
Check Geometry No Optional on Check
Gouge Check No (No Part Stock)
(Operation Navigator)
Noncut Moves
Azimuth / Latitude:
(1) latitude
(2) azimuth
(3) part normal C
(4) cut vector
(5) engage/retract vector
Begin with cut vector, rotate it toward the part normal degrees
Then rotate around the part normal degrees (counter clockwise)

End / Intermediate traverse:
(1) retract
(2) departure
(3) int traverse
(4) end traverse
(5) approach
(6) engage
There is only one End Traverse in the sequence, but there may be zero or
multiple Int Traverse
The Start and End positions of the End Traverse move are determined by
other moves in the sequence
C
Index
A Class Standards . . . . . . . . . . . . . . . 9
Course Description . . . . . . . . . . . . . 7
advanced surface contouring topics
Intended Audience . . . . . . . . . . . . . 7
boolean logic . . . . . . . . . . . . . . . . . C-7
Objectives . . . . . . . . . . . . . . . . . . . . 8
drive surface . . . . . . . . . . . . . . . . . C-5
Prerequisites . . . . . . . . . . . . . . . . . 7
remap of . . . . . . . . . . . . . . . . C-5
Student and Workbook parts . . . . . 13
swarf developable . . . . . . . . . . C-7
System Privileges . . . . . . . . . . . . . 13
gouge/collision . . . . . . . . . . . . . . . C-9
Workbook overview . . . . . . . . . . . . 12
noncut moves . . . . . . . . . . . . . . . C-11
Cut Area
planar milling . . . . . . . . . . . . . . . C-7
MILL_AREA . . . . . . . . . . . . . . . . 4-3
projection . . . . . . . . . . . . . . . . . . . C-1
Cut Area Geometry
material side . . . . . . . . . . . . . C-3
Z-Level Milling . . . . . . . . . . . . . . . 3-3
steep surface . . . . . . . . . . . . . C-2
Cut Levels . . . . . . . . . . . . . . . . . . . . 2-2
stock . . . . . . . . . . . . . . . . . . . . . . C-7
Cut Patterns . . . . . . . . . . . . . . . . . . 2-9
tool axis . . . . . . . . . . . . . . . . . . . . C-3
lead/tilt . . . . . . . . . . . . . . . . . C-3
Approach Move D
Non_Cutting Moves . . . . . . . . . . 5-33 Departure Move
Non_Cutting Moves . . . . . . . . . . 5-33
C
Case E
Fixed Contour . . . . . . . . . . . . . . 5-33 Engage Move
Cavity Mill Non_Cutting Moves . . . . . . . . . . 5-33
Cut Levels . . . . . . . . . . . . . . . . . . 2-2
Cut Patterns
F
Cut Pattern . . . . . . . . . . . . . . 2-9
In-Process work piece . . . . . . . . . 2-16 Final Case
Cavity Milling Non_Cutting Moves . . . . . . . . . . 5-33
cut parameters Fixed Contour
tolerant machining . . . . . . . . 2-44 Case . . . . . . . . . . . . . . . . . . . . . . 5-33
trim by . . . . . . . . . . . . . . . . 2-44 drive geometry . . . . . . . . . . . . . . . 5-2
undercut handling . . . . . . . . 2-45 drive methods
cut region start points . . . . . 2-32, 2-34 area milling . . . . . . . . . . . . . . 5-5
pre-drill engage . . . . . . . . . . . . . 2-32 flow cut . . . . . . . . . . . . . . . . . 5-6,
topology . . . . . . . . . . . . . . . . . . . 2-46 5-125-13, 5-155-16
Check Case radial cut . . . . . . . . . . . . . . . . 5-6
Non_Cutting Moves . . . . . . . . . . 5-33 surface . . . . . . . . . . . . . . . . . . 5-5
Course Overview tool path . . . . . . . . . . . . . . . . 5-5
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide Index-1
Index
User Function . . . . . . . . . . . . 5-6 multi-axis

drive points . . . . . . . . . . . . . . . . . 5-2 positioning . . . . . . . . . . . . . . . 6-2
Non_Cutting Moves . . . . . . . . . . 5-32 rotary axis . . . . . . . . . . . . . . 6-16
operation types . . . . . . . . . . 5-105-11 tool axis . . . . . . . . . . . . . . . . . 6-2
contour_area . . . . . . . . . . . . 5-10
contour_surface_area . . . . . . 5-10 N
fixed_contour . . . . . . . . . . . . 5-10 Non_Cutting Moves
flowcut_ref_tool . . . . . . . . . . 5-10 Approach Move . . . . . . . . . . . . . . 5-33
Overview . . . . . . . . . . . . . . . . . . . 5-2 Check Case . . . . . . . . . . . . . . . . . 5-33
parent groups . . . . . . . . . . . . . . . . 5-6 Departure Move . . . . . . . . . . . . . 5-33
MILL_AREA . . . . . . . . . . . . . 5-9 Engage Move . . . . . . . . . . . . . . . 5-33
MILL_BND . . . . . . . . . . . . . . 5-8 Final Case . . . . . . . . . . . . . . . . . 5-33
MILL_GEOM . . . . . . . . . . . . . 5-7 Fixed Contour . . . . . . . . . . . . . . 5-32
terminology . . . . . . . . . . . . . . . . . 5-3 Initial Case . . . . . . . . . . . . . . . . 5-33
check geometry . . . . . . . . . . . 5-3 Local Case . . . . . . . . . . . . . . . . . 5-33
drive geometry . . . . . . . . . . . . 5-3 Reposition Case . . . . . . . . . . . . . 5-33
drive method . . . . . . . . . . . . . 5-4 Retract Move . . . . . . . . . . . . . . . 5-33
drive points . . . . . . . . . . . . . . 5-3 Traverse . . . . . . . . . . . . . . . . . . . 5-33
part geometry . . . . . . . . . . . . 5-3
projection vector . . . . . . . . . . . 5-4 P
use of . . . . . . . . . . . . . . . . . . . . . . 5-2
Part Geometry
G Check Geometry
Z-Level Milling . . . . . . . . . . . 3-3
General Milling Enhancements Projection Vectors
In-Process Workpiece for fixed axis definition of . . . . . . . . . . . . . . . . . A-1
milling applications specification of . . . . . . . . . . . . . . . A-2
how to use . . . . . . . . . . . . . . 2-16 as used in variable contour . . . A-3
Geometry Parent Groups as used ins surface area
MILL_AREA . . . . . . . . . . . . . . . . 4-1 drive . . . . . . . . . . . . . . . . . A-3
Geometry Types fixed . . . . . . . . . . . . . . . . . . . A-2
Z-Level Milling . . . . . . . . . . . . . . . 3-3 table of methods . . . . . . . . . . . . . . A-5
I R
Initial Case Reposition Case
Non_Cutting Moves . . . . . . . . . . 5-33 Non_Cutting Moves . . . . . . . . . . 5-33
Retract Move
L Non_Cutting Moves . . . . . . . . . . 5-33
Local Case
Non_Cutting Moves . . . . . . . . . . 5-33 S
Sequential Milling
M Check surface . . . . . . . . . . . . 7-3, 7-11
MILL_AREA . . . . . . . . . . . . . . . . . . 4-1 creating operation . . . . . . . . . . . 7-37
Cut Area . . . . . . . . . . . . . . . . . . . 4-3 dialog . . . . . . . . . . . . . . . . . . . . . . 7-5
Trim Boundary . . . . . . . . . . . . . . 4-12 Drive surface . . . . . . . . . . . . . . . . 7-3
Multi-axis engage motion dialog . . . . . . . . . . 7-6
Index-2 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
Index
loops . . . . . . . . . . . . . . . . . . . . . 8-19 V
multiaxis output . . . . . . . . . . . . . 8-36
multiple check surface . . . . . . . . 7-12 Variable Contour . . . . . . . . . . . . . . 10-2
nested loops . . . . . . . . . . . . 8-19, 8-22 drive geometry . . . . . . . . . . . . . . . 9-2
other options . . . . . . . . . . . . . . . 8-38 drive methods
overview . . . . . . . . . . . . . . . . . . . . 7-2 boundary . . . . . . . . . . . . . . . . 9-6
Part surface . . . . . . . . . . . . . . . . . 7-3 curve/point . . . . . . . . . . . . . . . 9-6
path generation . . . . . . . . . . . . . 8-36 radial cut . . . . . . . . . . . . . . . 9-16
point to point motion dialog . . . . . 7-9 spiral . . . . . . . . . . . . . . . . . . 9-10
reference point . . . . . . . . . . . . . . . 7-3 surface area . . . . . . . . . . . . . 9-12
replace geometry globally . . . . . . 8-36 tool path . . . . . . . . . . . . . . . 9-15
retract motion dialog . . . . . . . . . 7-10 User Function . . . . . . . . . . . 9-17
stopping position drive points
Ds-Cs Tangency . . . . . . . . . . . 7-3 drive geometry . . . . . . . . . . . . 9-2
far side . . . . . . . . . . . . . . . . . 7-3 terminology . . . . . . . . . . . . . . . . . 9-4
near side . . . . . . . . . . . . . . . . 7-3 check geometry . . . . . . . . . . . 9-4
on . . . . . . . . . . . . . . . . . . . . . 7-3 drive geometry . . . . . . . . . . . . 9-4
Ps-Cs Tangency . . . . . . . . . . . 7-3 drive method . . . . . . . . . . . . . 9-4
suboperations . . . . . . . . . . . . . . . . 7-5 drive points . . . . . . . . . . . . . . 9-4
continuous path motion part geometry . . . . . . . . . . . . 9-4
commands . . . . . . . . . . . . . 7-6 projection vector . . . . . . . . . . . 9-4
continuous path motion tool axis
dialog . . . . . . . . . . . . . . . . 7-7 dual 4-axis . . . . . . . . . . . . . . 9-31
engage . . . . . . . . . . . . . . . . . . 7-6 interpolated . . . . . . . . . . . . . 9-59
point to point motion normal . . . . . . . . . . . . . . . . . 9-28
commands . . . . . . . . . . . . . 7-6 relative . . . . . . . . . . . . . . . . 9-29
terminology . . . . . . . . . . . . . . . . . 7-3 swarf drive . . . . . . . . . . . . . . 9-35
tool axis control . . . . . . . . . . . . . . 8-2 tool path accuracy . . . . . . . . . . . . . 9-2
at angle to Ps or Ds . . . . . . . . 8-5 used for . . . . . . . . . . . . . . . . . . . 10-2
fan . . . . . . . . . . . . . . . . . . . . . 8-5 Variable Contour and Sequential Mill
normal to Ps or Ds . . . . . . . . . 8-4 comparison . . . . . . . . . . . . . . . . . 9-68
parallel to Ps or DS . . . . . . . . 8-4 part, drive, check surfaces . . 9-68
tangent to Ps or Ds . . . . . . . . 8-5 general considerations . . . . . . . . 9-68
thru fixed point . . . . . . . . . . . 8-6
W
T
Traverse WAVE Geometry Linker
Non_Cutting Moves . . . . . . . . . . 5-33 Assemblies and Wave . . . . . . . . . 1-10
Trim Boundary At Timestamp . . . . . . . . . . . . 1-3, 1-6
MILL_AREA . . . . . . . . . . . . . . . 4-12 Blank Original . . . . . . . . . . . . . . . 1-3
Trim Geometry Create Non-Associative . . . . . . . . . 1-3
Steep Angle definition of . . . . . . . . . . . . . . . . . 1-2
Z-Level Milling . . . . . . . . 3-3, 3-8 deleting parent geometry . . . . . . . 1-9
editing links . . . . . . . . . . . . . . . . . 1-5
Extracted feature . . . . . . . . . . . . . 1-6
linking procedure . . . . . . . . . . . . 1-16
UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide Index-3
Index
Links Check Geometry . . . . . . . . . . . . . . 3-3

Break Links . . . . . . . . . . . . . . 1-6 Cut Area Geometry . . . . . . . . . . . . 3-3
broken . . . . . . . . . . . . . . . . . . 1-7 Geometry Types . . . . . . . . . . . . . . 3-3
deleting of . . . . . . . . . . . . . . 1-10 Part Geometry . . . . . . . . . . . . . . . 3-3
newly broken . . . . . . . . . . . . . 1-8 Steep Angle . . . . . . . . . . . . . . . . . 3-8
simplify . . . . . . . . . . . . . . . . . . . 1-19 Trim Geometry . . . . . . . . . . . . . . . 3-3
Simplify Body . . . . . . . . . . . 1-20 Types . . . . . . . . . . . . . . . . . . . . . . 3-2
Z
Z-Level Milling
Index-4 Multi-Axis Techniques Student Guide UGS Corporation, All Rights Reserved mt11050_g NX 4
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Multi Axis Techniques- Course Agenda
Day One
Course Overview
Lesson 1. WAVE Geometry Linker in Manufacturing
Lesson 2. Advanced Cavity Milling Topics
Afternoon
Lesson 3 Z-Level Milling
Lesson 4. MILL_AREA Geometry Parent Groups
Workbook Drilling the Top Flange
Day Two
Lesson 5. Fixed Contour Operation Types
Afternoon
Lesson 6. Introduction to Four and Five Axis Machining
Lesson 7. Sequential Mill Basics
Workbook Sequential Mill - Cutting the Manifold Flange
Day Three
Lesson 8 Sequential Mill Advanced
Lesson 9. Variable Contour Basics
Afternoon
Lesson 10. Variable Contour Advanced
Workbook Variable Contour - Cutting the Manifold Flange
Workbook Variable Contour Additional Activities
Accelerators
The following Accelerators can be listed from within an NX session by choosing
InformationCustom MenubarAccelerators.
Function Accelerator
FileNew... Ctrl+N
FileOpen... Ctrl+O
FileSave Ctrl+S
FileSave As... Ctrl+Shift+A
FilePlot... Ctrl+P
FileExecuteGrip... Ctrl+G
FileExecuteDebug Grip... Ctrl+Shift+G
FileExecuteNX Open... Ctrl+U
EditUndo Ctrl+Z
EditCut Ctrl+X
EditCopy Ctrl+C
Edit-Paste Ctrl+V
EditDelete... Ctrl+D or Delete
EditSelectionTop Selection Priority - Feature F
EditSelectionTop Selection Priority - Face G
EditSelectionTop Selection Priority - Body B
EditSelectionTop Selection Priority - Edge E
EditSelectionTop Selection Priority - Component C
EditSelection-Select All Ctrl+A
EditBlankBlank... Ctrl+B
EditBlankReverse Blank All Ctrl+Shift+B
EditBlankUnblank Selected... Ctrl+Shift+K
EditBlankUnblank All of Part Ctrl+Shift+U
EditTransform... Ctrl+T
EditObject Display... Ctrl+J
ViewOperationZoom... Ctrl+Shift+Z
ViewOperationRotate... Ctrl+R
ViewOperationSection... Ctrl+H
ViewLayoutNew... Ctrl+Shift+N
ViewLayoutOpen... Ctrl+Shift+O
ViewLayoutFit All Views Ctrl+Shift+F
ViewVisualizationHigh Quality Image... Ctrl+Shift+H
ViewInformation Window F4
ViewCurrent Dialog F3
ViewReset Orientation Ctrl+F8
InsertSketch... S
InsertDesign FeatureExtrude... X
InsertDesign FeatureRevolve... R
InsertTrimTrimmed Sheet... T
InsertSweepVariational Sweep... V
FormatLayer Settings... Ctrl+L
FormatVisible in View... Ctrl+Shift+V
FormatWCSDisplay W
ToolsExpression... Ctrl+E
ToolsJournalPlay... Alt+F8
ToolsJournalEdit Alt+F11
ToolsMacroStart Record... Ctrl+Shift+R
ToolsMacroPlayback... Ctrl+Shift+P
ToolsMacroStep... Ctrl+Shift+S
InformationObject... Ctrl+I
AnalysisCurveRefresh Curvature Graphs Ctrl+Shift+C
PreferencesObject... Ctrl+Shift+J
PreferencesSelection... Ctrl+Shift+T
StartModeling... M or Ctrl+M
StartAll ApplicationsShape Studio... Ctrl+Alt+S
StartDrafting... Ctrl+Shift+D
StartManufacturing... Ctrl+Alt+M
StartNX Sheet Metal... Ctrl+Alt+N
StartAssemblies A
StartGateway... Ctrl+W
HelpOn Context... F1
Refresh F5
Fit Ctrl+F
Zoom F6
Rotate F7
Orient View-Trimetric Home
Orient View-Isometric End
Orient View-Top Ctrl+Alt+T
Orient View-Front Ctrl+Alt+F
Orient View-Right Ctrl+Alt+R
Orient View-Left Ctrl+Alt+L
Snap View F8
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Mt11050 - Nx4 2 2006 - Multi Axis Techniques Student Guide February 2006 MT11050 NX 4 PDF

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Multi-Axis Techniques

Manual Unigraphics Publication

This edition obsoletes all previous editions.

Proprietary & Restricted Rights Notice

This software and related documentation are proprietary to UGS Corp.

2006 UGS Corporation

2 Multi-Axis Techniques Student Guide mt11050_g NX 4

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

Advanced Cavity Milling Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 3

Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

MILL_AREA Geometry Parent Groups . . . . . . . . . . . . . . . . . . . . . . . 4-1

MILL_AREA Geometry Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Fixed Contour Operation Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Fixed Contour Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Introduction to Four and Five Axis Machining . . . . . . . . . . . . . . . . 6-1

Multi-Axis Machining Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Sequential Mill Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Sequential Mill Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Variable Contour Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour Advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 5

Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32

Projection Vectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Zig-Zag Surface Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

Advanced Surface Contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 7

develop multi-axis machining practices

develop NX multi-axis programming practices

Focus on the subject matter.

Listen attentively and take notes.

Enjoy the class.

Class Standard for NX Parts

Class Part Naming

This class uses the following file naming standard:

The Arrow Symbol

The arrow symbol ( ), represents that you choose an option, then

press mouse button #1 to display the pull-down menu.

slide the cursor down to Operation Navigator (continuing to press mouse

slide the cursor down to Tool path

slide the cursor down to Replay

release mouse button #1

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 9

Layers and Categories

The following colors are preset to indicate different object types.

Object Color Used

commonly used expressions

user-defined views and layouts

How to Use This Manual

Choose Edge Lengths, Corner for the creation method.

The general format for lesson content is:

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 11

Classroom System Information

Student and Workbook Parts

UGS Corporation, All Rights Reserved Multi-Axis Techniques Student Guide 13

1 WAVE Geometry Linker in

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

Make modifications to linked geometry.

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

Create Non-Associative option will create a broken link. The geometry

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

Choose FileSave As _mixer_mfg where represents