MANUFACTURING ESSENTIALS
The Operation Navigatior
The Manufacturing application allows you to interactively create NC machining programs, generate tool paths, visualize material removal, and postprocess.
This course will familiarize you with the essential functions used throughout the
Manufacturing application. You will learn how to use the Operation Navigator and step through the process of creating a program. With few exceptions, this process is consistent throughout the Manufacturing application.
Once you have completed this course, you will be ready to move on to courses that pertain to your specific areas of interest such as milling, drilling, turning, or wire edm.
Audience
This course is intended for users who require a general overview of the Manufacturing application. New users should complete this course before moving on. Subsequent courses allow you to selectively examine your particular areas of interest.
Prerequisites
The prerequisite for this course is the Unigraphics NX Essentials CAST Online Library course. In addition, you should be familiar with basic manufacturing processes and terminology.
Course Contents
The Operation Navigator — You will learn about the relationship between parent groups and operations, how the Operation Navigator organizes objects, and how operations inherit parameters from parent groups. You will explore some of the essential functions of the Operation Navigator, including how to change views, edit parameters, cut and paste objects, and specify a machining environment.
Creating Objects — You will learn how to create Program, Tool, Geometry, and Method objects.
Creating Operations — You will learn how to create operations individually and how to edit and respecify parent groups from within the operations.You will also learn how to customize dialogs to update legacy operations by adding the Main, Groups and Viewing tabs that are found on newly created operations.
Creating Operation Sequences — You will learn how to use a Process Assistant to create a program containing a predefined sequence of operations.
UG/Post — You will learn how to postprocess using UG/Post.
Graphics Postprocessor Module — You will learn how to create and edit a Cutter Location Source File (CLSF) and how to postprocess the CLSF using the Graphics Postprocessor Module (GPM).
Shops — You will learn how to use Shops, a product designed to step the occasional user (such as the shop floor machine operator) through the process of creating an operation using a Process Assistant.
Shop Documentation — You will learn how to create shop documentation in HTML format for use by machine tool operators.
Parent Groups and Operations
The Operation Navigator allows you to view and manage relationships between operations, programs, machining methods, geometry, and tools. Most importantly, it allows you to define parameters just once within parent groups and then use them in as many operations as desired, eliminating the repetitious and tedious task of specifying parameters separately for each operation.
The Operation Navigator organizes objects (parent groups and operations) within in a tree structure. Objects that contain other objects are known as parent groups. Parent groups define parameters that can be passed down and used (inherited) by operations.
In the above illustration, the WORKPIECE object inherits parameters from its parent, the MCS_MILL object. The MILL_AREA object inherits parameters from its parent, the WORKPIECE object (which inherits parameters from the MCS_MILL object). The operations all inherit parameters from the MILL_AREA object (which inherits parameters from the WORKPIECE and MCS_MILL objects).
Parent Groups and Operations
Opening the Part File
You will open a part file and go into the Manufacturing application. You will then begin working with the operations and objects displayed in each view of the Operation Navigator.
Open part file mfe_navigator_1.prt from the mfe subdirectory. Choose Application Manufacturing.
Parent Groups and Operations
Operation Navigator Tab
In Windows, you can display the Operation Navigator by clicking or double-clicking on the Operation Navigator tab in the resource bar. Clicking on the tab temporarily displays the Operation Navigator by sliding it to the left over the graphics display. Once you move the cursor out of the Operation Navigator the Operation Navigator disappears from the screen. Clicking on the pin at the upper left corner of the Operation Navigator allows the Operation Navigator to remain on the screen when you move the cursor out of the area.
Double-clicking on the tab displays the Operation Navigator in a separate window which can then be moved and docked (Ctrl key undocks).
Clicking the Close icon at the upper right corner closes the window and restores the tab.
Practice using the Operation Navigator tab, pinning, docking, and undocking as described above.
Parent Groups and Operations
MB3 Options
Commonly used options available in the toolbar are also available in the pop-up menu by clicking MB3 on the Operation Navigator background.
Parent Groups and Operations
Columns and Properties
Columns and Properties options are displayed in a pop-up menu by clicking MB3 on the Operation Navigator background.
Parent Groups and Operations
Adding and Removing Columns in the Operation Navigator
Display the Program Order view in the Operatuion Navigator.
Turn the Tool Description option on.
OK to accept the Operation Navigator Properties dialog.
The Tool Description column now displays in the Operation Navigator (you may need to scroll to the right).
Click MB3 on the Operation Navigator background and choose Columns and Configure. Turn the Tool Description option off.
OK to accept the Operation Navigator Properties dialog.
Parent Groups and Operations
Changing Operation Navigator Views
The Operation Navigator displays in one of four views: the Machining Method view, Program Order view, Machine Tool view, or Geometry view. Each view organizes the operations according to the theme of the view.
You can easily switch from one view to another by choosing one of the icons in the toolbar.
Parent Groups and Operations
Displaying the Machine Tool View
You will display the Machine Tool View. This view allows you to see the tools used by the operations.
Choose the Machine Tool View icon in the toolbar (or choose Tools Operation
Navigator View Machine Tool View in the menu bar).
Click on the plus (+) signs to fully expand the objects.
The Machine Tool View organizes the operations according to tools. The three operations outlined below use the MILL_1 tool.
Parent Groups and Operations
Displaying the Program Order View
You will display the Program Order View. This view allows you to see the order in which the operations will be executed on the machine tool.
Choose the Program Order View icon in the toolbar. Click on the plus (+) sign to fully expand the PROGRAM object.
The Program Order View displays the program that each operation belongs to and the order in which operations will be executed on the machine tool. This is the only view in which the order of the listed operations is relevant or important.
Parent Groups and Operations
Displaying the Geometry View
You will display the Geometry View. This view allows you to see the geometry objects and the operations contained within the objects.
Choose the Geometry View icon in the toolbar. Click on the plus (+) signs to fully expand the objects.
The Geometry View organizes the operations according to machining geometry. Parameters such as part, blank, and check geometry, MCS orientation, and clearance plane are defined by geometry objects. The four operations outlined below use the MCS_MILL, WORKPIECE, MILL_AREA geometry objects.
Parent Groups and Operations
Displaying the Machining Method View
You will display the Machining Method View. This view allows you to see the cut methods the operations use.
Choose the Machining Method View icon in the toolbar. Click on the plus (+) signs to fully expand the objects.
The Machining Method View organizes operations according to cut method (rough, finish, semi finish). Parameters such as Intol, Outtol, and part stock are defined by machining method objects.
The program below consists of one roughing operation, two semi-finishing operations, and two finishing operations.
Remember, the only view in which the order of the listed operations is relevant is the Program Order view.
Cutting and Pasting Operations
You can move objects within any view of the Operation Navigator by cutting and pasting. Cutting and pasting operations within the Program Order View allows you to change the order in which the operations are executed on the machine tool. Cutting and pasting operations within the Machine Tool View allows you to change the tool the operation uses.
Cutting and Pasting Operations
Reordering Operations
You will cut and paste an operation within the Program Order View to change the order in which it is executed on the machine tool.
Choose the Program Order View icon in the toolbar. Choose the CONTOUR_ZIGZAG icon and MB3 Cut.
The object you choose in the next step is the operation below which the pasted operation will appear.
CONTOUR_ZIGZAG is now the last operation in the program sequence.
Cutting and Pasting Operations
Respecifying the Cutting Tool
You will cut and paste an operation within the Machine Tool View to change the cutting tool the operation uses.
Choose the Machine Tool View icon in the toolbar.
The CONTOUR_FOLLOW_1 operation currently uses MILL_1 as the parent group that defines cutting tool.
Choose the CONTOUR_FOLLOW_1 icon and MB3 Cut.
The object you choose in the next step is the parent group inside of which the operation will be pasted.
CONTOUR_FOLLOW_1 now uses MILL_2 as the cutting tool.
A slashed red circle now appears in front of the pasted operation. This indicates that operation parameters have changed and that the tool path must be regenerated to reflect the change.
Operation Status Symbols
Operations and program groups in the Operation Navigator are preceded by one of three status symbols; Complete, Regenerate, or Repost as illustrated below.
A green check mark indicates a complete status
Complete status means that the operation or program has been generated, incorporating the current operation parameters, and has been either postprocessed or output to an operating system text file.
A slashed red circle indicates a regenerate status
Regenerate means that a tool path has not been generated for the operation or that operation parameters have changed and that the tool path must be regenerated to reflect the change.
An exclamation point indicates repost status
Repost status means that the tool path for the operation has been generated, but it has not been postprocessed or exported from the part file.
The status symbols are dynamic and will update as the status of the operation or group changes.
Cutting and Pasting Operations
Generating a Tool Path
You will generate the tool path for the operation you just moved. The tool path will be recalculated using the new tool.
Choose the CONTOUR_FOLLOW_1 icon and MB3 Generate.
OK the Tool Path Generation dialog.
The new tool path is recalculated and generated using the MILL_2 tool. The tool path is graphically displayed by tracing the tip of the tool.
An exclamation point now appears in front of the operation and PROGRAM object indicating that the operations have been generated but have not yet been postprocessed or exported.
Cutting and Pasting Operations
Replaying a Program
You will Replay the entire program so you can see the tool paths displayed in the sequence in which they will be executed on the machine tool.
Choose the Program Order View icon in the toolbar. Choose the PROGRAM icon and MB3 Replay.
You can replay tool paths selectively by holding down the Ctrl key and choosing individual operations.
Cutting and Pasting Operations
Visualizing the Tool Path
You will use the Toolpath Visualization options to animate the cutter movement and dynamically display material removal.
The Toolpath Visualization dialog displays with the Replay tab chosen.
Cutting and Pasting Operations
Replaying a Program
You will Replay the entire program.
Choose the Shaded icon in the toolbar to display the part as a shaded solid. Choose the Play Forward icon.
The tool paths replay in the program sequence with the tool tip tracing each path. Each operation highlights in the Operation Navigator as it replays.
Cutting and Pasting Operations
Displaying Dynamic Material Removal
You will dynamically display the material removal. This method of visualization allows you to clearly see the material as it is removed by each successive tool path.
Choose the Dynamic tab. Choose Reset.
This option resets the program so that the operations are again played in order from first to last.
Choose the Play Forward icon.
The material removed by each successive tool path is displayed in a contrasting color. OK to complete the tool path visualization.
More About: Dynamic Material Removal Colors
The colors displayed for dynamic material removal are determined by the Preference settings (Preferences Manufacturing).
Once the colors have been defined in the Manufacturing Preferences dialog, the Verify function uses these colors in the order defined when displaying Dynamic Material Removal.
Redefining the Machining Environment
You can delete the current Machining Environment associated with the part and define a new CAM Session Configuration and CAM Setup. In doing so, all operations and parent groups are deleted from the part. It essentially enables you to "start over" as though the part file is being brought into the Manufacturing module for the first time.
Redefining the Machining Environment
Deleting the Machining Environment
You will delete the current configuration file and CAM setup data associated with the part. Choose Tools Operation Navigator Delete Setup from the main menu bar.
A confirmation message warns you that all manufacturing data will be deleted and cannot be recovered.
OK to delete the setup.
All CAM data, operations, tools, geometry, etc., have been deleted from the part file. The Machining Environment dialog displays requiring you to specify a configuration file and setup.
The Machining Environment dialog displays when a part file has been brought into the Manufacturing module for the first time or when the setup has been deleted.
More About Machining Environment
When Unigraphics NX starts, it reads the ugii_env.dat file to define a large number of environment variables setting system defaults, the location of resource files, etc. One of the things that is set by the ugii_env.dat file is the location of the configuration directory. This is done by the environment variable UGII_CAM_CONFIG_DIR. This directory contains a number of files with the file extension. ".dat".
Unigraphics NX reads the names of these files and displays this list in the top half of the Machining Environment dialog, in the CAM Session Configuration list box.
A default Configuration is also defined in the ugii_env.dat file by the environment variable UGII_CAM_CONFIG. It is set to point to cam_general.dat. That is why the Machining Environment initially displays with the cam_general configuration highlighted.
Cam_general.dat sets up a number of environment variables pointing towards template files for documentation, postprocessors that are correct for the machine tool you're using, feeds and speeds, etc. One environment variable it defines is TEMPLATE_OPERATION. This is pointed towards an "opt" file. By default, for cam_general.dat, this environment variable points towards cam_general.opt.
Cam_general.opt contains a list of template part files:
mill_planar.prt mill_contour.prt mill_multi-axis.prt drill.prt turning.prt wire_edm.prt A list of these part files is displayed in the CAM Setup list box.
When you selected the lathe configuration, the CAM Setup list box was updated to show the only files listed in lathe.opt, lathe.prt and legacy_lathe.prt.
The general flow of definition of environment variables is something like the illustration below:
Any changes to all these dat and opt files to customize them to your own manufacturing environment must be done carefully. In most cases, it will require system administrator privileges to make these changes.
Redefining the Machining Environment
Choosing the Session Configuration
You will choose a CAM Session Configuration that allows you to create all types of operations including Milling, Drilling, Turning, and Wire EDM.
The CAM Session Configuration defines the available machining processors, tool libraries. postprocessors, and other high level parameters for the logon session.
The cam_general configuration allows you to create all types of operations including Milling, Drilling, Turning, and Wire EDM. Other session configurations such as lathe or mill_contour restrict you to a specific type of operation.
Redefining the Machining Environment
Choosing the CAM Setup
You will choose a CAM Setup that allows you to create planar milling operations and then initialize the new machining environment.
Choose the mill_planar setup.
Choose Initialize.
The new machining environment is complete. The geometry objects required to create planar mill operations are created automatically. They give you a basic starting point from which you can begin creating operations and other objects.
Redefining the Machining Environment
Viewing the Geometry and Machining Method Objects
You will look at the Geometry and Machining Method Views of the Operation Navigator and notice that the objects required to create planar mill operations are created automatically based on the specified CAM Setup.
Choose the Geometry View icon in the toolbar.
Choose the Expand All icon in the toolbar to fully expand the objects.
Notice that the MCS_MILL and WORKPIECE geometry objects have been created. The machining method objects required to create planar mill operations are also created automatically.
Choose the Machining Method View icon in the toolbar.
In the next lesson, you will learn more about creating objects and the parameters they define. Close the part file.
Creating Objects
In this lesson, you will learn how to create Program, Tool, Geometry, and Method objects.
Tool, Geometry, and Method objects define operation parameters. These parameters can be inherited by operations contained within the objects. By specifying these objects as parent groups, you can eliminate the repetitious and tedious task of respecifying parameters each time you create an operation.
Program objects do not define operation parameters. Instead, they simply contain operations and determine the sequence in which operations are executed on the machine tool. For
example, the sequence of operations required to machine the top of a part may be contained in one program while the sequence of operations required to machine the end of a part may be contained in another program.
Creating Tool Objects
In this section, you will learn how to create tool objects. You will learn how to define new tools as well as how to retrieve existing tools from a library.
Open part file mfe_objects_1.prt from the mfe subdirectory. Choose Application Manufacturing.
Creating Tool Objects
Displaying the Machine Tool View
Choose the Machine Tool View icon in the toolbar (or choose Tools Operation
Navigator View Machine Tool View in the menu bar).
Choose the Expand All icon in the toolbar (or choose Tools Operation
Navigator Expand All in the menu bar).
The Operation Navigator shows that both the PLANAR_MILL and FACE_MILLING operations use the same tool: MILL.
Creating Tool Objects
Creating a Face Mill Tool Object
You will create a 5-parameter face mill tool object and then cut and paste the
FACE_MILLING operation into that object so that the operation uses the new tool.
Choose the Create Tool icon in the toolbar.
The Type determines the available Subtypes you have to choose from. In the Create Tool dialog, Set the Type option to mill_planar.
The Subtype section displays only tools that are appropriate for milling operations. Choose the FACE_MILL icon.
Be sure GENERIC_MACHINE is chosen as the parent group. This way, the tool you create will have the same parent as the existing mill tool.
The tool name defaults to FACE_MILL based on the subtype you chose. You may name the tool using the following rules:
Up to 20 characters
Start with an alphabetic character
The only acceptable special characters are the dash (-) and period (.) No spaces are allowed.
Creating Tool Objects
Defining the Tool Parameters
You will specify parameters that define the size and material of the tool. Key in the following values to define the tool.
The tool material is one of several parameters that the Reset from Table option uses to determine the speeds and feeds for cutting.
Choose Material: CARBIDE.
Highlight TMCO_00001 HSS and OK.
OK to create the FACE_MILL tool object.
Creating Tool Objects
Respecifying the Tool
You will respecify the tool the operation uses by dragging and dropping the operation onto the tool object.
Highlight the FACE_MILLING operation with the mouse button 1 and hold the button down while you drag the icon on top of the FACE_MILL object. Release the mouse button
to drop the operation.
The FACE_MILLING operation now uses FACE_MILL as the cutting tool.
This can also be accomplished by cutting and pasting the operation inside the tool object. The slashed red circle indicates that operation parameters have changed and that the tool path must be regenerated to reflect the change.
Creating Tool Objects
Generating the Tool Path
You will generate the tool path using the FACE_MILL tool. This will update the operation status.
Choose the FACE_MILLING icon and MB3 Generate.
An exclamation point now appears in front of the operation indicating that the operation has been generated not yet been postprocessed or exported.
Creating Tool Objects
Visualizing the Tool Paths
You will use the Toolpath Visualization options to animate the cutter movement and dynamically display material removal for the program.
Choose the Shaded icon in the toolbar to display the part as a shaded solid. Choose the Program Order View icon in the toolbar.
Highlight the PROGRAM object.
Choose the Verify Toolpath icon in the toolbar or MB3 Toolpath Verify. The Toolpath Visualization dialog displays with the Replay tab chosen.
Choose the Dynamic tab.
Choose the Play Forward icon.
Because the part does not contain or inherit blank geometry, the Automatic Blank for Visualize dialog displays allowing you to define blank geometry temporarily to perform dynamic material removal.
Creating Tool Objects
Defining the Blank Geometry
You will define the blank geometry as a solid body bounding the part geometry. OK to accept Auto Block as the Blank Type.
Auto Block creates a solid body bounding the part geometry with faces parallel to the WCS. The material removed by each successive tool path is displayed in a contrasting color
allowing you to clearly see that the face milling operation leaves some uncut material behind.
The tool changes to the FACE_MILL tool for the second operation. OK to complete the tool path visualization.
Creating Tool Objects
Retrieving a Tool From the Library
You will now retrieve a predefined tool from the library.
Choose the Create Tool icon in the toolbar. Choose Retrieve Tool and OK.
Click on the plus (+) sign next to Milling to expand the list and choose End Mill (non
indexable).
OK to accept the selection.
Creating Tool Objects
Specifying Search Criteria
You will use the Search Criteria Dialog to narrow down the library search by specifying parameters.
Choose Count Matches.
A number appears next to the button (in this example, 64). This indicates the number of tools in the library that match the parameters you have specified so far.
You can narrow the search even further by specifying exact numeric values or a range of values using <, >, <=, and >= signs.
Key in 0.50 in the Diameter field.
Choose Count Matches.
You have narrowed the search to only those tools in the library with a diameter of 0.50. Choose Result Info.
This displays an Information listing of all the tools matching the search criteria. It will allow you to determine the values (Flute Length and Corner Radius for example) that can be specified to continue narrowing the list.
Dismiss the Information window. Key in the following values.
Choose Count Matches.
You have narrowed the search to the only those .50 diameter tools in the library with a flute length greater than 1 and a corner radius greater than or equal to .05 .
OK to accept the search criteria.
Creating Tool Objects
Choosing Tools
You will use the Search Result listing to choose the desired tool or tools.
Use the left mouse button to choose a single tool. Use the left mouse button in combination with the Shift key to choose a range of tools. Use the left mouse button with the Ctrl key to selectively choose tools from the list. The Ctrl key also enables you to deselect.
Choose the two tools indicated below.
Choose the Machine Tool View icon in the toolbar.
The tools retrieved from the library appear in the Machine Tool view of the Operation Navigator and are now available to be used in operations.
You can easily obtain information about the tools.
Highlight the UGTI0201_064 icon and MB3 Properties.
Dismiss the Information window.
Creating Tool Objects
Respecifying the Tool
You will respecify the tool that the PLANAR_MILL operation uses by dragging and dropping the operation onto the UGTI0201_064 tool object.
Drag and drop the PLANAR_MILL operation onto the the UGTI0201_064 object.
The red circle indicates that operation parameters have changed and that the tool path must be regenerated to reflect the change.
Creating Tool Objects
Generating the Tool Path
You will generate the tool path using the new tool.
Choose the PLANAR_MILL icon in the Operation Navigator and MB3 Generate. OK to accept the tool path generation.
Close the part file.
Creating Machining Method Objects
In this section, you will learn how to create Machining Method objects. These objects allow you to organize operations according to cut method (rough, finish, semi finish) by defining parameters such as , Outtol, and part stock.
Open part file mfe_objects_2.prt from the mfe subdirectory. Choose Application Manufacturing.
Creating Machining Method Objects
Displaying the Machining Method View
Choose the Machining Method View icon in the toolbar.
Choose the Expand All icon in the toolbar to see all of the objects as illustrated below.
The PLANAR_MILL operation uses the MILL_ROUGH method and the FACE_MILLING operation uses the MILL_FINISH method. The SEMI_FINISH_LEVELS operation does not use a method.
Creating Machining Method Objects
Creating a Semi-Finish Machining Method Object
You will create a semi-finish machining method object to use as parent group.
The Type determines the available Subtypes. Choose mill_planar as the Type.
MILL_METHOD is the only available Subtype.
Be sure METHOD is chosen as the parent group. This way, the object you are creating will have the same parent group as the other machining method objects.
Key in SEMI_FINISH for the name.
OK to begin creating the SEMI_FINISH machining method object. Key in 0.01 or the Part Stock.
Part Stock is the amount of material remaining on the part after roughing and semi-finishing operations. This is the parameter that primarily determines the difference between a roughing, semifinishing, and a finishing operation.
Intol and Outtol define an allowable range the tool may use to deviate from the part surfaces. The smaller the values, the more accurate the cut. Intol allows you to specify the maximum amount by which the tool may penetrate through the surface. Outtol allows you to specify the the maximum amount by which the tool may avoid contacting the surface.
OK to create the SEMI_FINISH object.
Creating Machining Method Objects
Moving an Operation into the Object
You will drag and drop the SEMI_FINISH_LEVELS operation onto the SEMI_FINISH machining method object.
Highlight the SEMI_FINISH_LEVELS operation with mouse button 1 and hold the button down while you drag the icon on top of the SEMI_FINISH object. Release the mouse button to drop the operation.
The SEMI_FINISH machining method is now a parent group containing the SEMI_FINISH_LEVELS operation.
Creating Machining Method Objects
Generating the Tool Path
You will generate the tool path using SEMI_FINISH as the machining method. Choose the SEMI_FINISH_LEVELS icon and MB3 Generate.
Creating Machining Method Objects
Visualizing the Tool Paths
Visualization allows you to see the material removal as the program progresses through the sequence of rough, semi-finish, and finish operations.
Choose the Shaded icon in the toolbar to display the part as a shaded solid. Choose the Program Order View icon in the toolbar.
Choose the PROGRAM object.
Choose the Verify Toolpath icon in the toolbar. Choose the Dynamic tab.
Drag the slider bar to the left to slow down the Animation Speed to 7. Choose the Play Forward icon.
Because the part does not contain or inherit blank geometry, the Automatic Blank for Visualize dialog displays allowing you to define blank geometry temporarily to perform dynamic material removal.
Creating Machining Method Objects
Defining the Blank Geometry
You will define the blank geometry as a solid body bounding the part geometry. OK to accept Auto Block as the Blank Type.
Auto Block creates a solid body bounding the part geometry with faces parallel to the WCS.
The material removed by each successive tool path is displayed in a contrasting color. OK to complete the tool path visualization.
Close the part file.
Creating Geometry Objects
Different types of operations require different types of geometry. Planar milling operations require boundaries while surface contouring operations require faces or bodies. In this section, you will learn how to create geometry objects for planar milling operations.
Open part file mfe_objects_3.prt from the mfe subdirectory. Choose Application Manufacturing.
Creating Geometry Objects
Displaying the Geometry View
Choose the Geometry View icon in the toolbar.
The PLANAR_MILL and SEMI_FINISH_LEVELS operations are contained in the MCS_MILL parent group. This parent group defines the location and orientation of the Machine Coordinate System.
Machine Coordinate System
Like other applications, Manufacturing uses the WCS, or Work Coordinate System. However, the Manufacturing application has its own coordinate systems as well - the Machine
Coordinate System (MCS).
As illustrated below, the WCS and MCS are in the same location. The MCS is displayed similar to the WCS, but the axes are labeled XM, YM, and ZM.
What is the significance of these coordinate systems for the Manufacturing application? WCS - All the parameter values that you input (for example, values for the Start Point, a Z value for the Clearance Plane, or I,J,K values for the tool axis vector, and other vector data) will be in relationship to the WCS.
MCS - All coordinate values in the tool path (all of the output coordinates) are in relationship to the MCS. The ZM axis of the MCS is particularly important since, if no tool axis is
specified, the ZM axis is the default tool axis.
The output tool path consists of a number of different commands. The most frequent command is probably the linear positioning move, GOTO. There are at most 6 coordinate fields in a GOTO: X, Y, Z, I, J and K. The X, Y and Z fields are the coordinates of the tool tip relative to the MCS and the I, J, K values indicate the tool axis vector.
Depending on the circumstances, you may want to specify your Machine Coordinate System and Work Coordinate System in the same location to avoid confusion.
Before you start creating any machining operations, you should always display the Work Coordinate System and Machine Coordinate System and check their location and orientation. A MCS is one of the default CAM objects created by all templates. The name assigned to this MCS varies, dependent upon the CAM template part file selected in creating the setup. The default MCS is created coincident with the absolute coordinate system. You can edit the location of the default MCS to change the coordinates of the output tool path or create a new MCS. Even though you may have many MCS objects created, only one machine coordinate system is displayed at a time.
Creating Geometry Objects
Creating a Mill Boundary Object
Part geometry is required to generate tool paths. You will create an object that defines part boundaries.
Choose the Create Geometry icon in the toolbar.
The Type determines the available Subtypes you have to choose from. Be sure mill_planar has been chosen as the Type.
Be sure MCS_MILL has been chosen as the Parent Group.
The object you are creating inherits the Machine Coordinate System parameters. The name defaults to MILL_BND based on the chosen subtype.
OK to begin defining the MILL_BND object.
Creating Geometry Objects
Defining Part Boundaries
You will create the part boundaries required to generate the tool paths. You will first define the main containment boundary.
Choose the Part icon and Select.
Choose the Curve Boundary icon.
Choose Outside for the Material Side.
This specifies that the material retained is outside the boundary and allows the tool to cut only inside the boundary.
Choose the Custom Data tab.
Turn on the Offset option under Custom Boundary Data and key in -0.1.
This defines a negative stock that assures the material along the outside edge of the part is completely removed.
Creating Geometry Objects
Defining the Main Containment Boundary
You will select the edges that define the main containment boundary. This boundary defines the overall part and encloses other boundaries that define islands.
Select the four outside edges in order as illustrated below.
Choose the Main tab.
Choose Create Next Boundary.
The main containment boundary should display as illustrated below.
Creating Geometry Objects
You will create boundaries that define the top of each island. Choose the Face Boundary icon.
Choose Inside for the Material Side.
This specifies that the material retained is inside the boundary and does not allow the tool to cut inside the boundary.
Select the first face as illustrated below.
Select the second and third faces as illustrated below.
OK to accept the part boundary definition. OK to finish creating the MILL_BND object.
Creating Geometry Objects
Moving Operations into the Object
You will cut and paste the two operations into the MILL_BND geometry object. Highlight the PLANAR_MILL operation and MB3 Cut.
Highlight the MILL_BND object and MB3 Paste Inside.
MILL_BND is now a parent group of the PLANAR_MILL operation.
Cut and paste the SEMI_FINISH_LEVELS operation inside the MILL_BND object so that MILL_BND contains both operations.
Creating Geometry Objects
Generating the Tool Paths
You will generate the tool paths for both operations.
Choose the first operation and hold down the Ctrl key to choose the second operation.
MB3 Generate.
OK to accept the first tool path generation. OK to accept the second tool path generation.
MB3 Refresh to remove the tool path display.
Creating Geometry Objects
Creating a Workpiece Object
You will create a workpiece object that defines the part material and the blank geometry. The part material is one of several parameters used in determining the cut feed rate. Adding operations to the program such as Cavity Milling will require blank geometry.
Choose Edit Blank Reverse Blank All in the menu bar. This displays the body you will select to define the blank geometry.
Choose the Create Geometry icon in the toolbar. Be sure mill_planar has been chosen as the Type. Choose the WORKPIECE icon.
Be sure MCS_MILL is chosen as the parent group so that the object you are creating inherits the Machine Coordinate System parameters defined in MCS_MILL.
The name defaults to WORKPIECE based on the subtype you chose. OK to begin defining the workpiece.
Creating Geometry Objects
Specifying the Part Material
You will specify the part material. This is one of several parameters that the Reset from Table option uses to determine the speeds and feeds for cutting.
Choose Material: CARBON STEEL.
Highlight MATO_00266 ALUMINUM and OK.
Creating Geometry Objects
Defining Blank Geometry
You will select the solid body to define the blank geometry. Choose the Blank icon and Select.
Select the body.
OK to accept the blank geometry.
OK to finish creating the workpiece object.
Choose Edit Blank Reverse Blank All in the menu bar to display the part.
Creating Geometry Objects
You will cut and paste the MILL_BND object into the WORKPIECE object. In doing so, you will also move the operations.
Highlight the MILL_BND object and MB3 Cut.
Highlight the WORKPIECE operation and MB3 Paste Inside.
The PLANAR_MILL and SEMI_FINISH_LEVELS operations are still contained in the MILL_BND parent group.
Creating Geometry Objects
Generating the Tool Path
You will generate the tool paths.
Choose the Program Order View icon in the toolbar. Choose the PROGRAM object and MB3 Generate.
OK to accept the second tool path generation.
Creating Geometry Objects
Visualizing the Tool Paths
You will use the Toolpath Visualization options to animate the cutter movement and dynamically display material removal for the program.
Choose the PROGRAM object in the Operation Navigator. Choose the Verify Toolpath icon.
Choose the Dynamic tab.
Choose the Play Forward icon.
Because the part inherits blank geometry from the workpiece object, the Automatic Blank for Visualize dialog does not display as it did in the previous examples.
OK to complete the tool path visualization. Close the part file.
Creating Program Objects
In this section, you will learn how to create program objects. Program objects allow you to gather and order operations into logical programs. For example, one program may contain operations that machine the top of the part while another program may contain operations that machine the side of the part.
Open part file mfe_objects_4.prt from the mfe subdirectory. Choose Application Manufacturing.
Creating Program Objects
Displaying the Program Order View
Choose the Program Order View icon in the toolbar.
Expand the program by clicking on the (+) sign so you can see all the operations.
Creating Program Objects
Visualizing the Tool Paths
The program machines both the top and the side of the part. Choose the PROGRAM object in the Operation Navigator. Choose the Verify Toolpath icon.
Choose the Dynamic tab.
Choose the Play Forward icon.
OK to complete the tool path visualization.
Creating Program Objects
Creating a Program Object
Choose the Create Program icon in the toolbar. PROGRAM is the only available Subtype.
Key in TOP for the name.
OK to create the TOP program object.
The TOP currently does not contain any objects and is not a parent group.
Creating Program Objects
Copying a Program Object
You will copy the TOP program object to create an object that will contain the operations that machine the side of the part.
Choose TOP and MB3 Copy.
The object you choose in the next step is the object below which the pasted objects will appear.
With TOP chosen, MB3 Paste.
TOP_COPY is now the last object in the program.
Creating Program Objects
Renaming a Program Object
You will change the name of TOP_COPY to SIDE. Be sure TOP_COPY is still highlighted.
Choose Tools Operation Navigator Rename in the menu bar. Key in side and press the Enter key.
Creating Program Objects
Moving Operations into the Top Program
Choose the PLANAR_MILL operation and hold down the Ctrl key to choose the SEMI_FINISH_LEVELS and FACE_MILLING operations.
MB3 Cut.
Highlight the TOP object and MB3 Paste Inside.
TOP is now a parent group of the three operations.
This can also be accomplished by dragging and dropping multiple objects.
Creating Program Objects
Moving Operations into the Side Program
You will cut and paste operations into the SIDE program object.
Cut and paste the PLANAR_MILL_SIDE, SEMI_FINISH_LEVELS_SIDE, and FACE_MILLING_SIDE operations inside the SIDE object.
Creating Program Objects
Deleting an Object
You will delete the PROGRAM object since it is no longer needed. Choose PROGRAM and MB3 Delete.
OK to delete the object.
Creating Program Objects
Visualizing the Tool Paths
You can now visualize each program separately. Choose the TOP object.
Choose the Verify Toolpath icon. Choose the Dynamic tab.
OK to complete the tool path visualization.
Choose the SIDE object and visualize the program as you did for the TOP object.
You can visualize the entire program by choosing the NC_PROGRAM object. OK to complete the tool path visualization.
Close the part file.
Creating Operations
In this lesson, you will learn how to create individual operations and edit and respecify parent groups from within the operations.
You will also learn how to customize dialogs to update legacy operations by adding the Main, Groups and Viewing tabs that are found on newly created operations.
Although some of the parameters for milling, drilling, turning, and wire edm operations differ, the process of creating any operation is basically the same. You first specify the Type,
Subtype, and Parent Groups. You then define any additional parameters required for the specific operation. Finally, you generate the tool path and make any necessary modifications.
Open part file mfe_operation_1.prt from the mfe subdirectory. Choose Application Manufacturing.
Creating an Operation
Beginning the Operation
You will begin creating a planar mill operation that roughs out material in multiple cut levels.
Choose the Create Operation icon in the toolbar. Be sure mill_planar is displayed as the Type.
The Type determines the subtype icons and the parent groups that are available to choose from in the dialog.
Choose ROUGH_FOLLOW as the subtype.
Choosing the appropriate operation subtype will set many of the required operation parameters and can save a significant amount of time and effort in defining the operation.
Specify the following parent groups.
Parent groups determine common parameters that can be used by multiple operations. This operation is automatically named ROUGH_FOLLOW based on the Subtype you chose.
OK to begin creating the operation.
Creating an Operation
Specifying the Cut Depth
You will specify multiple cut levels at a fixed depth. Choose Cut Depths.
Choose Fixed Depth.
Fixed Depth generates cut levels at a constant depth. Key in 0.1 in the Maximum field.
Maximum defines the largest allowable cut depth for each level. OK to accept the cut depth.
Creating an Operation
You will allow the system to recommend appropriate feed rates and speeds based on the user specified part material, tool type and material, cut method, and cut depth parameters.
Choose Feed Rates.
Notice that the current Surface Speed and Feed per Tooth values are set to zero.
Choose Reset from Table.
The system extracts Surface Speed and Feed Per Tooth values from tables (maintained by system administration) based on the user input. The other values are then calculated.
OK to accept the Feeds and Speeds.
Generating the Tool Path
You will observe how the operation generates the tool path at the specified cut depths. Generate the tool path.
Turn the Pause After Display and Refresh Before display options off.
This will allow you to generate all the cut levels at once and continue viewing them after they have generated.
OK the generate the tool paths.
Refresh the display.
Creating an Operation
Displaying the Part Boundaries
A planar mill operation must contain properly defined part boundaries in order to generate a tool path. You will display the part boundaries for visual verification.
Choose the Part icon.
Choose Display to highlight the part boundaries.
Notice that the Select/Reselect button is blanked. Part boundaries are inherited from the MILL_BND parent group and can only be modified by editing the parent group. In just a moment, you will see how to edit the MILL_BND parent group from this dialog.
Refresh the graphics display.
Creating an Operation
Displaying the Floor Plane
A planar mill operation must contain a floor plane in order to generate a tool path. You will display the floor plane for visual verification.
Choose the Floor icon.
Choose Display to highlight the floor.
Notice that the Select/Reselect button is blanked. The floor plane is inherited from the MILL_BND parent group and can only be modified by editing the parent group that defines it.
Refresh the graphics display.
Creating an Operation
Visualizing the Tool Path
You will use the Toolpath Visualization options to animate the cutter movement and dynamically display material removal for the program.
Choose the Verify icon at the bottom of the dialog. Choose the Dynamic tab.
Choose the Play Forward icon.
Because the part inherits blank geometry from the workpiece object, the Automatic Blank for Visualize dialog does not display as it did in the previous examples.
The operation leaves a thin wall of uncut material along the outside edge of the part.
OK to complete the Toolpath Visualization.
Creating an Operation
Editing the Geometry Parent Group
You will edit the MILL_BND parent group so that the material along the outside edge of the part is completely removed. The options at the top of the operation dialog allow you to edit and reselect parent groups.
Choose the Groups tab.
A message displays informing you that the MILL_BND parent group contains more than one member and that editing it will affect all members. MILL_BND is a parent of the operation you are currently creating as well as the existing FINISH_FLOOR operation. Editing the part boundaries defined in this parent group will therefore affect both operations.
OK the message.
The MILL_BND dialog displays allowing you to edit the parent group.
Creating an Operation
Editing the Main Containment Boundary
You will edit the main containment boundary so that the operation no longer leaves a thin wall of uncut material along the outside edge of the part.
Choose the Part icon and Edit.
The part boundaries highlight with the main containment boundary selected.
This defines a "negative stock" that assures the material along the outside edge of the part is completely removed.
OK to accept the part boundary offset.
OK to finish editing the MILL_BND parent group. OK to complete the ROUGH_FOLLOW operation.
The ROUGH_FOLLOW operation now appears in the Operation Navigator.
Creating an Operation
Generating Tool Paths
You will generate the tool path to remove the material along the outside edge of the part.
Choose the Program Order View icon in the toolbar.
Notice that slashed red circles appear in front of both operations. This indicates that the tool paths for both operations must be regenerated to reflect the changes made in the MILL_BND parent group.
Choose the PROGRAM icon and MB3 Generate.
OK to accept the first tool path generation. OK to accept the second tool path generation. Refresh the display.
Exclamation points now appear in front of the operations indicating that the operations have been generated but have not yet been postprocessed or exported.
Creating an Operation
Reordering Operations
The Program Order View displays the order in which operations will be executed on the machine tool. Notice that the finishing operation precedes the roughing operation.
You will change the order in which operations are listed in the program so that the finishing operation follows the roughing operation.
Choose the FINISH_FLOOR icon and MB3 Cut.
The operation you choose in the next step is the object below which the pasted operation will appear.
Choose the ROUGH_FOLLOW icon and MB3 Paste.
FINISH_FLOOR is now the second operation in the program sequence.
Creating an Operation
Visualizing the Tool Paths
You will now verify that the negative boundary offset you specified earlier in the parent group removes the excess material along the outside edge of the part.
Choose the PROGRAM object.
Choose the Verify Toolpath icon in the toolbar. Choose the Dynamic tab.
Choose the Play Forward icon.
The operations execute in the correct order and the excess material along the outside edge of the part is completely removed.
OK to complete the Toolpath Visualization.
Creating an Operation
Reselecting the Tool Parent Group
You will change the tool used in the finishing operation.
Choose the Machine Tool View icon in the toolbar. Expand the tool object so you can see the operations. Double-click on the FINISH_FLOOR icon.
The FINISH_FLOOR dialog displays, allowing you to edit the operation. Choose Tool: UGTI0201_063 and Reselect.
The Reselect Tool dialog displays, allowing you to choose a new parent group or to define a new tool.
Choose UGTI0201_076.
The tools available in this list are the same as those that appear in the Machine Tool view of the Operation Navigator.
OK to accept the tool.
The dialog now displays UGTI0201_076 as the tool used in the operation.
Remember, you can also respecify the tool by dragging and dropping, or by cutting and pasting the operation onto the tool object.
Creating an Operation
Completing the Operation
You will complete the operation and observe how the Operation Navigator now displays UGTI0201_076 as the parent group.
OK to complete the FINISH_FLOOR operation. Expand the object to see the operation.
The Operation Navigator now displays UGTI0201_076 as a parent of the FINISH_FLOOR operation.
A slashed red circle indicates that the tool path must be regenerated to reflect the tool change.
Creating an Operation
Generating the Tool Path
You will generate the tool path to update the operation status. Choose the FINISH_FLOOR icon and MB3 Generate.
OK to accept the tool path generation. Close the part file.
Updating a Legacy Operation Dialog
Legacy operation dialogs can be customizing so that they appear the same as the dialogs for newly created operations.
Updating a Legacy Operation Dialog
Opening the Part File
Open part file mfe_legacy_1.prt from the mfe subdirectory. Choose Application Manufacturing.
Updating a Legacy Operation Dialog
Viewing the Legacy Operation Dialog
You will first view an existing legacy operation dialog. You will then customize it by distributing the parameters among property pages to make the dialog shorter.
ROUGH_TURN_OD icon to display the operation parameters dialog.
The dialog is very large and in some cases it may be too large for the viewing screen. Click on the dialog so that it is active and press the Esc key to dismiss it.
Updating a Legacy Operation Dialog
Customizing the Operation Dialog
You will customize the dialog box and make it smaller by adding Main, Groups and Viewing property pages.
Highlight ROUGH_TURN_OD in the Operation Navigator.
Press MB3 and choose Object Customize. The Customize Dialog dialog displays.
Updating a Legacy Operation Dialog
Adding a Main Page
Key in Main in the Label field and choose the Property Pages icon.
Start Page Main and End Page Main are added to the Items Used list box. Moving the End Page Main to the bottom of the items used will put all those items on the Main page.
With End Page Main highlighted, choose the Move Down arrow until End Page Main is the last item in the list.
When you are finished moving End Page Main to the bottom, the list box will appear as illustrated below.
Updating a Legacy Operation Dialog
Adding a Groups Page
The second property page you will add is the Groups property page. Key in Groups in the Label field and choose the Property Pages icon.
Start Page Groups and End Page Groups are displayed at the bottom of the list box.
Scroll to the top of the Items Used list box, highlight Group Editing, and choose the Move
Down arrow until Group Editing is between the Start Page and End Page of Groups.
When you are finished moving Group Editing, the list box will look as illustrated below.
Updating a Legacy Operation Dialog
Adding a Viewing Page
Key in Viewing in the Label field and choose the Property Pages icon.
Move End Page Viewing and Start Page Viewing to the end of the list box using the
Move Down arrow.
The list box should look as illustrated below.
Highlight Save View and choose Add.
Choose the Move Up arrow so that Save View is between the Start Page and End Page of Viewing as illustrated below.
OK to complete the dialog customization.
Updating a Legacy Operation Dialog
Viewing the Dialog
The parameters have been divided among three property pages.
Double-click on the ROUGH_TURN_OD icon to display the operation parameters dialog.
The top of the dialog displays the three tabs found in newly created turning operations.
Cancel the Dialog. Close the part file.
Creating Operation Sequences
In this lesson, you will learn how to create a program containing a predefined sequence of operations. A Process Assistant will provide step-by-step instructions on how to create the sequence of operations.
Creating a Sequence
You will create a sequence of operations designed to machine a die. Although specific parameters may vary, the process of creating any sequence is similar.
Choose Application Manufacturing.
Creating a Sequence
Defining the Machining Environment
Because this part has not yet been saved in the Manufacturing application, the Machining Environment dialog displays. You will choose a CAM Session Configuration and a CAM Setup
Choose mill_contour as the CAM Session Configuration.
Die_Sequences and Mold_Sequences are generic sequence setups supplied with the system. Other setups may also be available depending on your working environment.
Choose die_sequences as the CAM Setup.
Choose Initialize.
Creating a Sequence
You will begin following the step-by-step instructions provided by the CAM Process Assistant.
OK to continue with the assistant.
Creating a Sequence
Defining the MCS
Step 1 of the Process Assistant prompts you to define the Machine Coordinate system. You may specify new MCS parameters or accept the current MCS.
OK to accept the current MCS.
Creating a Sequence
Defining the Clearance Plane
Step 2 of the Process Assistant prompts you to define the clearance plane. Be sure Clearance has been turned on and choose Specify.
Choose Plane Subfunction. Choose Two Lines.
Select the two lines illustrated below.
OK to continue to the next step.
Creating a Sequence
Defining the Part Geometry
Step 3 of the Process Assistant prompts you to define the part geometry. Choose Select.
OK to complete the selection. OK to continue to the next step.
Creating a Sequence
Defining the Blank Geometry
Step 4 of the Process Assistant prompts you to define the blank geometry. Choose Select.
Select the blank body as illustrated below.
OK to complete the selection. OK to continue.
At this point in the process, the Setup has been created and you are prompted to follow the instructions in the Information window.
OK to continue.
Creating a Sequence
Creating the Geometry Parent Group
The next set of steps defines the geometry parent group. You will follow these steps to create a sequence of operations:
Choose the Create Geometry icon in the toolbar.
Choose Sequence_Zlevel as the Subtype and Workpiece as the Parent Group.
OK to create the geometry parent group. Dismiss the Information window.
Creating a Sequence
Defining the Cut Area
The next step prompts you to define the cut area. Choose Select.
Select the Surface Region as illustrated below.
OK to complete the selection. OK to continue to the next step.
Creating a Sequence
Defining the Trim Boundary
The next step prompts you to define the trim boundary. A trim boundary is used to constrain the cut area. Because you are going to machine the entire part, the program does not require a trim boundary.
OK to proceed to the next step.
Creating a Sequence
Choosing the Operation Types
The next step prompts you to choose optional flowcut operations to include in the sequence.
You will not include these operations. OK to proceed to the next step.
Completing the Sequence
The final step prompts you to specify whether or not the tool paths are to be generated immediately after creating the operations. Due to the potential processing time involved for this sequence, you will not generate the tool paths.
Be sure Generate Tool Paths is off.
OK to create the sequence of operations.
In the Program Order View of the Operation Navigator, expand the objects to display the sequence of operations.
The operations would machine the part as illustrated below.
Creating a Sequence
The CAM Session Configuration you specified at the beginning of this lesson provides CAM Setups only for mill contour type operations. Before continuing on to other courses, you should choose a CAM Session Configuration that allows you to create all types of operations including Milling, Drilling, Turning, and Wire EDM.
Choose Tools Operation Navigator Delete Setup from the main menu bar. OK to delete the setup.
The cam_general configuration file provides the widest range of available setups for your current work session.
Choose cam_general in the CAM Session Configuration list.
The specific setup you choose at this time is not critical since the setup can be respecified when creating an operation.
Choose the mill_planar setup. Choose Initialize.
Close the part file.
UG/Post
Postprocessing is the preparation of machine code used to drive a specific machine tool. In this lesson, you will learn how to postprocess using UG/Post.
Postprocessing with UG/Post
UG/Post converts the internal tool path containing events and motions into a format
compatible to the machine tool's controller. To postprocess, UG/Post requires a tool path and a postprocessor.
Open part file mfe_ugpost.prt from the mfe subdirectory.
Postprocessing with UG/Post
Replaying an Operation
Operations must contain internal tool paths in order to be postprocessed. You will replay the existing tool path.
Expand the objects so you can see the operations.
Repost status ( ) means that the tool paths for the operations in the program have been generated, but they have not been postprocessed or exported from the part file.
Choose the operation named FIXED_CONTOUR.
Choose MB3 Replay.
The tool path is a simple follow pocket cut pattern.
Postprocessing with UG/Post
Listing the Internal Tool Path
The tool motion to cut the path you just displayed is stored in the part file as an internal tool path. A machine tool cannot use the internal path as commands because they are written in Standard APT. You will display the internal tool path using the List function.
Choose MB3 Toolpath List.
The internal tool path is listed in an Information window.
UG/Post converts the internal tool path containing events and motions into a format compatible to the machine tool's controller. For example, the FEDRAT/MMPM,250.0000 command might be converted to the format F250.0 and the GOTO/0.0000.45,0000,3.0000 might be converted to G00X0.0000Y45.0000Z3.0000.
Dismiss the Information window.
Postprocessing with UG/Post
Accessing the UG/Post Postprocessor
UG/Post will process only one program or operation at a time. You will postprocess a simple program containing two operations.
