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Fixed Axis Techniques Student Guide May 2007 MT11065 – NX 5 Publication Number mt11065_g NX 5 Proprietary and restricted rights notice This software and related documentation are proprietary to UGS Corp. Copyright 2007 UGS Corp. All Rights Reserved. All trademarks belong to their respective holders. 2 Fixed Axis Techniques – Student Guide mt11065_g NX 5 Contents Course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Course description . . . . . . . . . . . . . . Course objectives . . . . . . . . . . . . . . . Intended audience . . . . . . . . . . . . . . Prerequisites . . . . . . . . . . . . . . . . . . Student responsibilities . . . . . . . . . . Class standards for NX part files . . . Class part file naming . . . . . . Layers and categories . . . . . . Activity format . . . . . . . . . . . Workbook overview . . . . . . . . . . . . . Classroom system information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 8 8 8 9 9 9 10 10 10 WAVE Geometry Linker in Manufacturing . . . . . . . . . . . . . . . . . . . . 1-1 The WAVE Geometry Linker . . . . . . . . . . . . . . . . . . Geometry types used by the Geometry Linker Edit links . . . . . . . . . . . . . . . . . . . . . . . . . . . Broken links . . . . . . . . . . . . . . . . . . . . . . . . . Delete parent geometry . . . . . . . . . . . . . . . . . Delete linked geometry . . . . . . . . . . . . . . . . . Activity: Create an assembly for WAVE . . . . . Link procedure . . . . . . . . . . . . . . . . . . . . . . . Activity: Create WAVE geometry . . . . . . . . . . Simplify . . . . . . . . . . . . . . . . . . . . . . . . . . . . Simplify Body procedure . . . . . . . . . . . . . . . . Activity: Simplify Body . . . . . . . . . . . . . . . . . Activity: Other modeling techniques . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 . 1-3 . 1-4 . 1-6 . 1-7 . 1-8 . 1-9 1-12 1-13 1-15 1-16 1-17 1-19 1-23 Advanced Cavity Milling topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Cut Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Cut Levels parameters . . . . . . . . . . . . . Cut patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Zig-Zag cut pattern . . . . . . . . . . . . . . . . In-Process Work Piece for Cavity Milling . . . . . . . . . . . . Level Based IPW . . . . . . . . . . . . . . . . . . . . . . . . . Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Level Based In-process Workpiece (IPW) ©UGS Corp., All Rights Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . 2-3 . 2-6 . 2-8 2-11 2-12 2-13 2-14 Fixed Axis Techniques – Student Guide 3 Contents Pre-Drill Engage and Cut Region Start Points Activity: Pre-Drill Engage Point . . . . . . . . . . Cavity Milling stock options . . . . . . . . . . . . . Activity: Blank Distance option . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2-19 2-22 2-23 2-26 Plunge Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Plunge milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Activity: Create a Plunge Milling operation . . . . . . . . . . . . . . . . . 3-5 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Z-Level Milling . . . . . . . . . . . . . . . . . Steep Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: ZLEVEL_PROFILE_STEEP Operations . . . . Activity: Z-Level Profile Milling . . . . . . . . . . . . . . . . . Z-Level Cutting Between Levels (aka Gap Machining) Activity: Z-Level Gap Machining . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 . 4-4 . 4-8 . 4-9 4-13 4-17 4-19 4-22 NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Overview of the NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Activity: The NC Assistant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Machining options that require change for High Speed Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Create a High Speed Machining operation . . . . Mixed Cut Directions . . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Mixed Cut Directions . . . . . . . . . . . . . . . . . . . Trochoidal Cut pattern . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Trochoidal cut pattern . . . . . . . . . . . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 . 6-4 . 6-8 . 6-9 6-11 6-12 6-14 Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Fixed Contour overview . . . . . . . . . . . . . . . . . . . More on Flow Cut drive methods . . . . . . . Activity: Create Fixed Contour operations Cut Area . . . . . . . . . . . . . . . . . . . . . . . . . Activity: Mill Area geometry groups . . . . Trim Boundary . . . . . . . . . . . . . . . . . . . . Activity: Trim Boundaries . . . . . . . . . . . . 4 Fixed Axis Techniques – Student Guide . . . . . . . . . . . . . . . . . . . . . ©UGS Corp., All Rights Reserved . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 . 7-6 . 7-9 7-15 7-16 7-20 7-21 mt11065_g NX 5 Contents Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24 Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Streamline drive method . . . . . . . . . . . . . . . . . . . . . . . . . . Flow and Cross curves . . . . . . . . . . . . . . . . . . . . . . . Activity: Create an Automatic Streamline operation Activity: Create a Manual Streamline operation . . . Activity: Add additional curves for more control . . . . . . . . . Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 . 8-3 . 8-5 . 8-9 8-15 8-20 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1 Figures 3-1. Step Ahead (A) and Stepover (B) . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 5 Course overview Course description Fixed Axis Techniques course teaches the use of the NX Manufacturing application for creating 2–1/2 and 3–axis tool paths. Course objectives After successfully completing this course, you should be able to perform the following activities in NX: • Create group objects that supply information to operations • Utilize options and parameters that are common to various operation types • Create Associative Machining Geometry, Advanced Roughing operations and Finishing operations. ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 7 Intended audience Intended audience This course is designed for Manufacturing Engineers, Process Planners and NC/CNC Programmers that have the basic knowledge of NC/CNC manual programming of 3–axis positioning and contouring equipment. Prerequisites • Essentials of NX for Designers or CAST equivalent • Basic understanding of the Master Model concept Working knowledge of the following: • NX User Interface • Part file saving conventions • Experience as an NC/CNC programmer Student responsibilities 8 • Be on time • Participate in class • Listen attentively and take notes • Practice what you have learned • Enjoy the class Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 Course overview Class standards for NX part files The following standards will be used in this class. Standardization allows users to work with other parts while being able to predict the organization of the part file. All work should be performed in accordance with these standards. Class part file naming This class utilizes the following file naming standard: Where the student is requested to save a part file for later use, the initials of the student’s given name, middle name, and surname replace the course identifier "***" in the new filename with the remainder of the filename matching the original. These files should reside in the student’s personal directory. Currently up to 128 characters are valid for file names. A four character extension (.prt) is automatically added to define the file type. This means the maximum number of user defined characters for the file name is actually 124. Layers and categories Parts used in this course were creating using layer categories the same as or very similar to those found in the Model template parts. Layers provide an advanced alternative to display management (Show and Hide) to organize data Layers 1–10 11–20 21–40 41–60 61–80 91–255 Categories SOLIDS SHEETS SKETCHES CURVES DATUMS no category assigned ©UGS Corp., All Rights Reserved Description solid bodies sheet bodies all external sketches non-sketch curves planes, axes, coordinate systems Fixed Axis Techniques – Student Guide 9 Workbook overview Activity format Activities have the following format: Step 1: This is an example of a step. Steps specify what will be accomplished. This is an example of an action bullet. Action bullets detail how to complete the step. Workbook overview The workbook contains a project that requires you to apply the knowledge that you learned in the class and in the student activities. The projects do not contain detailed instructions as do the student activities. It is the intent of this project to allow you to apply the skills taught in this course. However, the time constraint of this course is also a factor, at any point when progress is not being made, enlist the help of your instructor. Classroom system information Your instructor will provide you with the following items for working in the classroom: Student Login: User name: Password: Work Directory: Parts Directory: Instructor: Date: 10 Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 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 designer’s 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 Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 1-1 WAVE Geometry Linker in Manufacturing 1 The WAVE Geometry Linker The WAVE Geometry Linker is used to associatively copy geometry from a component part in an assembly into the work part. The resulting linked geometry is associated to the parent geometry. Modifying the parent geometry will cause the linked geometry in the other parts to update. The WAVE Geometry Linker is available with a Manufacturing Bundle license. It does not require a NX WAVE license. Different types of objects can be selected for linking, including points, curves, sketches, datums, faces, and bodies. The linked geometry can be used for creating and positioning new features in the work part. The Wave Geometry linker is accessed by choosing Insert→Associative Copy→WAVE Geometry Linker from the menu bar, or from the WAVE Geometry Linker button on the Assemblies toolbar. 1-2 • The Fix at Current Timestamp determines weather or not features added to parent body after linked body is created will propagate to liked body. When turned off, any new features added altering the parent geometry will be reflected in the linked geometry. When turned on, new features added after the link was created will not be affected. • Hide Original lets you blank the original geometry so that the linked geometry in the work part will be easier to work with while the assembly is displayed. • Associative determines weather or not linked body will update to reflect changes in parent.. Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 WAVE Geometry Linker in Manufacturing 1 Geometry types used by the Geometry Linker Several different types of geometry can be used in the WAVE application. • Composite Curve • Point • Datum • Face • Region of Faces • Body • Mirror Body • Routing Object When selecting geometry to copy, you should consider how permanent the geometry will be. If you copy as little geometry as possible to do the job, performance will be improved but updates will be less robust when the parent geometry is altered. For example, if you copy individual curves to another part, the link may not update correctly if one of the curves is deleted. Conversely, if you copy an entire sketch, curves may be removed or added and the link will update. ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 1-3 WAVE Geometry Linker in Manufacturing 1 Edit links Links may be edited by choosing Edit→Feature→Edit Parameters in the Part Navigator and selecting a linked feature. Linked features have an dialog box similar to the one below. 1-4 Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 WAVE Geometry Linker in Manufacturing When this dialog box is displayed, the cursor is active in the graphic window allowing new parent geometry selection for the link being edited. The new parent geometry must be the same type as the old geometry (curve, datum, solid body, etc.) • Parent indicates the parent geometry type, work part or other part. • Wave Information shows the name of the part where the parent geometry is located, parent feature, and link status. If the parent geometry is located in the current work part, the part name given is Work Part. If the feature was linked, but the link has been broken, the parent is shown as a Broken Link. The dialog box information updates when you select new parent geometry, which you can do at any time. • The Fix at Current Timestamp determines weather or not features added to parent body after linked body is created will propagate to liked body. When turned off, any new features added altering the parent geometry will be reflected in the linked geometry. When turned on, new features added after the link was created will not be affected. • Associative lets you break the association between the linked feature and its parent. This means that the linked feature will no longer update if its parent changes. You can later define a new parent by selecting geometry with the cursor. • Replacement Assistant allows replacement of one linked object with another (cannot be used on linked sketches or strings). Objects must be of the same type. • Reverse Direction reverses the normal of the face selected. Depending on the geometry type of the feature being edited, other options may appear on the dialog box. When editing links and selecting new parent geometry, it may be easier to temporarily work in an exploded view to distinguish between the existing linked geometry and the new parent geometry. ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 1-5 1 WAVE Geometry Linker in Manufacturing 1 Broken links A link may become broken for several of the following reasons: 1-6 • The parent geometry is deleted. • The path from the linked geometry to the parent part is broken. This can occur if the component part containing the parent geometry is deleted or substituted. • If the parent is removed from the start part reference set that defines the linked part. • If you deliberately break the link (e.g., using Edit Feature or the Break option on the WAVE Geometry Navigator dialog box). Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 WAVE Geometry Linker in Manufacturing 1 Delete parent geometry To prevent unintentional deletion of the parents of linked geometry, a message will warn you if a delete operation would cause inter-part links to break. • The Information option provides details about the links that will be broken in an Information window. ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 1-7 WAVE Geometry Linker in Manufacturing 1 Delete linked geometry Linked geometry is created as a feature and can be deleted by choosing Edit→Feature→Delete (or choosing the Delete Feature icon). Linked bodies may also be deleted by choosing Edit→Delete. 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. 1-8 Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5 WAVE Geometry Linker in Manufacturing 1 Activity: Create an assembly for WAVE In this activity, you will create an assembly structure for later use with the WAVE Geometry Linker. Remember that WAVE only works in the context of an assembly. 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: Create a new part. On the Standard toolbar, click New . Notice that the dialog box has several tabbed pages. ©UGS Corp., All Rights Reserved Fixed Axis Techniques – Student Guide 1-9 WAVE Geometry Linker in Manufacturing 1 Click the Model tab. Expand the Units list and select Inches. On the Model page, select the Assembly template. This template will provide the standard Layer settings and Category Names as defined for this class. In the New File Name group, in the Name input box, replace the default name with ***_mixer_mfg , where *** represents your initials. Ensure Folder is set to your “home” folder. Saving parts to your home is standard practice for this class. Parts that you create must be saved in a folder to which you have read and write permissions. Click OK. Step 2: The Add Component dialog box appears. This will allow you to add the part we are going to work on. In the Part group, click Open . Select mixer_body from the parts folder, then choose OK. In the Add Component dialog box, expand the Settings group and change Name to mixer; select SOLID from the Reference Set list. Click OK. Step 3: Examine the current assembly structure. Click 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: 1-10 Create an empty component. Fixed Axis Techniques – Student Guide ©UGS Corp., All Rights Reserved mt11065_g NX 5