Mat mt11050 G

Multi-Axis Techniques
Student Guide
May 2007
MT11050 NX 5
Publication Number
mt11050_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.
Multi-Axis Techniques Student Guide
mt11050_g NX 5
Contents
Course overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Course description . . . . . . . . . . . . .
Intended audience . . . . . . . . . . . . .
Prerequisites . . . . . . . . . . . . . . . . .
Objectives . . . . . . . . . . . . . . . . . . .
Student responsibilities . . . . . . . . .
Class standard for NX parts . . . . . .
Class part naming . . . . . . . .
Colors . . . . . . . . . . . . . . . . .
Seed part . . . . . . . . . . . . . . . . . . . .
How to use this manual . . . . . . . . .
Workbook overview . . . . . . . . . . . .
Classroom system information . . . .
Student and workbook parts
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7
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10
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12
13
13
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 1-2
. 1-4
. 1-5
. 1-7
. 1-8
. 1-9
1-10
1-13
1-14
1-16
1-17
1-18
1-20
1-24
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 . . . . . . . . . . . . .
UGS Corp., All Rights Reserved
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. 2-2
. 2-3
. 2-6
. 2-8
2-11
2-12
Contents
Use 3D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Level Based In-process Workpiece (IPW)
Pre-Drill Engage and Cut Region Start Points . . .
Activity: Pre-Drill Engage Point . . . . . . . . . . . . .
Cavity Milling stock options . . . . . . . . . . . . . . . .
Activity: Blank Distance option . . . . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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2-13
2-14
2-18
2-19
2-22
2-23
2-26
Z-Level Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 3-2
. 3-4
. 3-8
. 3-9
3-13
3-17
3-19
3-22
Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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 . . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 4-2
. 4-6
. 4-9
4-15
4-16
4-20
4-21
4-23
Introduction to four and five axis machining . . . . . . . . . . . . . . . . . 5-1

Multi-Axis Machining concepts . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Operations at other than 0,0,1 tool axis . . . . .
Define the center of rotation for a rotary axis . . . . . . . . . . . . .
Activity: Main and local MCS in multi-axis applications
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 5-3
. 5-4
5-10
5-12
5-17
5-22
Five Axis Z Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Z Level Five Axis Overview . . . . . . . . . . . . . . . . . . . . .
Tool Axis tilt . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Creating a Z Level Five Axis operation
Activity: Changing the Maximum Wall Height . .
More Tool Axis tilt options . . . . . . . . . . . . . . . . .
Activity: Away from point tool axis tilt . . . . . . . .
Activity: Away from curve tool axis tilt . . . . . . .
Activity: Away from multiple curve tool axis tilt .
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. 6-3
. 6-4
. 6-7
. 6-9
6-11
6-12
6-15
6-18
mt11050_g NX 5
Contents
Optimized cut levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Activity: Optimized cut levels . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Sequential Mill basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Sequential Milling overview . . . . . . . . . . . . . . . . . . . . . . . .
Sequential Milling terminology . . . . . . . . . . . . . . . .
Define the Check Surfaces . . . . . . . . . . . . . . . . . . . .
Multiple Check Surfaces . . . . . . . . . . . . . . . . . . . . .
........................................
Activity: Basic Sequential Milling techniques . . . . .
More on Check Surfaces . . . . . . . . . . . . . . . . . . . . .
Activity: Sequential Milling of a multi-surfaced floor
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 7-3
. 7-4
7-11
7-12
7-14
7-14
7-27
7-28
7-42
Sequential Mill advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Tool axis control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Sequential Mill Five-Axis fan motion . .
Standard and nested loops . . . . . . . . . . . . . . . . .
Activity: Sequential Mill using loops . . . . . . . .
Activity: Remove excess stock from a closed wall
Activity: Use looping to remove excess stock . . .
Additional Sequential Mill options . . . . . . . . . . .
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 8-3
. 8-8
8-17
8-18
8-21
8-28
8-30
8-34
Variable Contour basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour operations . . . . . . . . . . . . . . . . . . . . . .
Terminology used in variable contour . . . . . . . . . .
Variable Contour vs Fixed Contour . . . . . . . . . . .
Drive methods for Variable Contouring . . . . . . . .
Activity: Overview of Variable Contour options . .
Tool axis control . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Point and Line tool axis types . . . . . . . .
Activity: Normal to Part and Relative to Part . . . . . . . . .
Activity: Special tool axis and non part geometry .
Activity: The Interpolated tool axis . . . . . . . . . . .
A comparison of Variable Contour vs. Sequential Milling
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. 9-3
. 9-5
. 9-6
. 9-7
9-12
9-15
9-19
9-26
9-31
9-38
9-46
9-49
Variable Contour advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Contour Profile Drive Method . . . . . . . . . . .
Activity: Contour Profile Drive Method . . . .
Geometry selection . . . . . . . . . . . . . . . . . . .
Automatic Wall . . . . . . . . . . . . . . . . . . . . .
Activity: Floor selection and Automatic Wall
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. 10-3
. 10-4
10-11
10-12
10-13
Contents
Tilting the tool axis . . . . . . . . . . . . . . . . . . . . . . . . . . .

Activity: Tilting the tool axis . . . . . . . . . . . . . . . . . . . .
Follow Bottom Wall . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Follow Bottom Wall . . . . . . . . . . . . . . . . . . . .
Automatic Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . .
Activity: Automatic Auxiliary Floor . . . . . . . . . . . . . . .
Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activity: Auxiliary Floor . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary Floor and Automatic Auxiliary Floor . . . . . . .
Activity: Auxiliary Floor and Automatic Auxiliary Floor
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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10-16
10-17
10-19
10-20
10-23
10-24
10-31
10-32
10-37
10-38
10-43
Projection Vectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Zig-Zag Surface machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Advanced surface contouring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
mt11050_g NX 5
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 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.
mt11050_g NX 5
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.
10
Object
Solid Bodies
Color Used
Green
Sheet Bodies
Yellow
Lines and Arc

(non-sketch curves)
Green
Conics and Splines

(non-sketch curves)
Blue
Sketch Curves
Reference Curves
(in sketches)
Datum Features
Cyan
Gray
Points and Coordinate Systems
White
System Display Color
Red
Aquamarine
mt11050_g NX 5
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.
11
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.
12
mt11050_g NX 5
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.
13
Lesson
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.
1-1
WAVE Geometry Linker in Manufacturing
The WAVE Geometry Linker

The WAVE Geometry Linker is used to associatively copy geometry from a
component part in an assembly into the work part. The resulting linked
geometry is associated to the parent geometry. Modifying the parent geometry
will cause the linked geometry in the other parts to update.
The WAVE Geometry Linker is available with a Manufacturing Bundle
license. It does not require a NX WAVE license.
Different types of objects can be selected for linking, including points, curves,
sketches, datums, faces, and bodies. The linked geometry can be used for
creating and positioning new features in the work part.
The Wave Geometry linker is accessed by choosing InsertAssociative
CopyWAVE Geometry Linker from the menu bar.
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mt11050_g NX 5
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.
1-3
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.
1-4
mt11050_g NX 5
Edit links
Links may be edited by choosing EditFeature Parameters in the Model
Navigator and selecting a linked feature. Linked features have an Edit dialog
box similar to the one below.
When this dialog box is displayed, the cursor is active in the graphic window
allowing new parent geometry selection for the link being edited. The new
parent geometry must be the same type as the old geometry (curve, datum,
solid body, etc.)
Parent indicates the parent geometry type. 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 box information updates when you select new parent
geometry, which you can do at any time.
1-5
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 box.
When editing links and selecting new parent geometry, it may be easier
to temporarily work in an exploded view to distinguish between the
existing linked geometry and the new parent geometry.
1-6
mt11050_g NX 5
Broken links
A link may become broken for several of the following reasons:
The parent geometry is deleted.
The path from the linked geometry to the parent part is broken. This can
occur if the component part containing the parent geometry is deleted
or substituted.
If the parent is removed from the start part reference set that defines
the linked part.
If you deliberately break the link (e.g., using Edit Feature or the Break
option on the WAVE Geometry Navigator dialog box).
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
box or the Edit during Update dialog box.
After a link is accepted, its status is changed to broken until a new parent is
defined.
1-7
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. This
applies to operations using EditFeatureDelete, EditDelete, and Model
NavigatorDelete while the parts containing the linked geometry are loaded.
1-8
The Information option provides details about the links that will be
broken in an Information window.
mt11050_g NX 5
Delete linked geometry

Linked geometry is created as a feature and can be deleted by choosing
EditFeatureDelete (or choosing the Delete Feature icon).
Linked bodies may also be deleted by choosing EditDelete. If you choose
this method, you will not have an opportunity to verify child features before
they are removed.
Assemblies and WAVE
The WAVE Geometry Linker only works in the context of an assembly. An
assembly link must exist between two part files before a WAVE link can be
established.
1-9
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.
1-10
mt11050_g NX 5
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 pulldown.
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:
Create an empty component.
1-11
Choose AssembliesComponentsCreate New from the

menu bar.
OK the Class Selection dialog box.
Expand the Units list and select Inches.
On the Model page, select the Model template.
In the File Name group, in the Name input box, replace the
default name with ***_mixer_casting.
Ensure Folder is set to your home folder.
Click OK.
In the Create New Component dialog box, change the
component name to casting.
Click OK.
A new component, named CASTING, is displayed in the
Component Name column of the Assembly Navigator. The name
of the part file is ***_mixer_casting. You may need to display
the Component Name column by right-clicking and selecting
ColumnsComponent Name.
Step 5:
Save the assembly.

Click Save
on the toolbar.
When you save an assembly, all modified components below

the work part are saved as well.
1-12
mt11050_g NX 5
Link procedure
You use the InsertAssociative CopyWAVE Geometry Linker dialog box
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 Mixer assembly you will use the sideways functionality.
To create linked geometry:
Arrange your assembly display so that the part containing the geometry
to be copied is visible, and the geometry of interest is selectable.
Change Work Part to the part that is to receive the linked copies.
Change your roll to a higher level of design functionality.
Choose Insert Associative Copy WAVE Geometry Linker.
Use the linker dialog box to filter the type of object(s). You may select
several objects of different types.
Choose Apply to make copies and remain in the Selection dialog box, or
OK to copy objects and exit the dialog box.
1-13
Activity: Create WAVE geometry

In this activity, you will practice using the geometry linker. You will create
a WAVE linked copy of the mixer body, then perform modifications to that
copy to simulate a casting.
Step 1:
Prepare the assembly.

If necessary, open the ***_mixer_mfg assembly part and then
the Assembly Navigator.
Choose Start Modeling.
Select the component ***_mixer_casting in the Assembly
Navigator, right-click and select Make Work Part.
The mixer body changes to the color Dark Faded Green. This is
a visual clue that geometry is no longer in the current modeling
hierarchy.
Step 2:
Select the System Defaults Role 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.
Set Type to BODY
box.
in the WAVE Geometry Linker dialog
Select the mixer body.

Click OK.
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 right-click over the
***_mixer_casting component, and choose Make Displayed
Part.
In the graphics window change the view orientation and shade
status if required.
1-14
mt11050_g NX 5
Choose EditObject Display.

Select the linked body and choose OK.
Using Edit Object Display is a powerful method of
differentiating between bodies that are similar in
appearance.
In the Basic group, change Color to Yellow.
Choose OK in the Edit Object Display dialog box.
Step 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, right-click on the
***_mixer_casting component, choose Display
Parent***_mixer_mfg.
In the Assembly Navigator, right-click on ***_mixer_mfg,
choose Make Work Part.
Click on the red check mark in front of Mixer_body and the
yellow casting will remain on the screen.
Click on the red check mark in front of ***_mixer_casting and
it will leave the screen.
Click on the grey checkmark in front of mixer_body and the
original model will appear.
Click on the grey checkmark in front of ***_mixer_casting
and it will appear, but will blend completely with the original
model. This will be changed in the next activity.
Click Save
1-15
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:
1-16
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.
mt11050_g NX 5
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.
1-17
Activity: 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.
Right-click 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 if required.
Choose InsertDirect ModelingSimplify.
The Simplify Body dialog box is displayed.
The cue line reads: Select retained faces.

1-18
mt11050_g NX 5
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 Less Than field and press the
return key.
Click Apply in the Simplify Body dialog box.
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 box by choosing

OK.
Click Cancel in the Simplify Body dialog box.
Click Save
1-19
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.
Click 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 dialog box is displayed.
If required, on the Selection Intent toolbar change the type
filter to Face and change the curve rule to Face Edges.
1-20
mt11050_g NX 5
Choose the bottom face of the ring groove, as shown below.
In the Limits group, set End to Until Extended and select the
outlet face.
Set Boolean to Unite.
OK the Extrude dialog box.
Step 3:
Use the Offset Face option to add machining stock.

In this step, you will add machining stock to the inlet and outlet
faces, as well as the mixer tube faces.
From the menu bar choose InsertOffset/ScaleOffset Face.
In the Offset Faces dialog box, type 0.250 for the Offset value.
Select the inlet and outlet faces, and the two mixer tube faces.
1-21
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 the original designed part
from the casting, you will make the casting model translucent.
If necessary, turn on Shaded mode.
From the menu bar choose EditObject Display.
Select the body and choose OK.
Slide the Translucency bar to 50% and choose OK.
If the solid body does not become semi-transparent, choose
PreferencesVisualization Performance, and turn off
Disable Translucency, located on the General Settings tab
under Session Settings.
Step 5:
Make ***_mixer_mfg the work part, and compare the two solid
bodies.
To fully realize the extent of the changes made, you will display
both the original and the linked body together.
1-22
mt11050_g NX 5
Open the Assembly Navigator.

Right-click 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.
1-23
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:
1-24
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.
mt11050_g NX 5
Lesson
Advanced Cavity Milling topics
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
2-1
Cut Levels
Cavity Milling cuts geometry in planes or levels.
The advantage to this approach is that tool paths remain relatively short, due
to minimum tool path movement, which is performed in layers.
The disadvantage is that when machining geometry that is close to horizontal

more stock may remain than desired. See the diagram below.
The closer the geometry approaches horizontal, the more stock that remains.
Through the use of Cut Level parameters, you can reduce the amount of stock
that remains by reducing the depth of cut in these near level areas.
Use Cut Levels
dialog box.
in the Cavity Mill dialog box to access the Cut Levels
The Cut Levels dialog box serves these primary functions:
Create, delete or modify Ranges
Modify Cut Levels within Ranges
To reduce the amount of additional stock, a new range can be added. The
Depth per Cut in that Range only is modified.
In the next activity, you will use various Cut Level parameters.
2-2
mt11050_g NX 5
Activity: Cut Levels parameters

In this activity, you will replay an operation and review the various Cut
Levels. You will then modify the range to allow the tool to cut without any
warning messages.
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:
Generate the operation.

Double click on the CAVITY_MILL operation in the Operation
Navigator to Edit the operation.
Generate
the operation.
2-3
A warning message states that the Tool cannot fit into level 14.
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.
OK the warning message.

Refresh or hit F5 to remove the path display.
Step 4:
Edit the Bottom of Range #1.

The first step is to remove the warning from this operation by
changing the cut range.
Click Cut Levels
from the Path Settings group in the
Cavity Mill dialog box.
Large and small plane symbols appear. The large plane represents
the Range, and the small planes are the Levels within the Range.
Some Ranges do not have any additional levels.
2-4
mt11050_g NX 5
At the very top of the dialog box, there are three buttons for
defining ranges. The Auto Generate (1) button defines ranges
that will align with planar horizontal faces. The User Defined (2)
button defines ranges by selection of the bottom plane for each
new range. The Single (3) button defines the cut range based on
part and blank geometry.
In the Cut Levels dialog box, click

Level 1) once.
(beneath Range 1,
The color changes for the active planes, and the Range number and
Level numbers change to Range 2, Levels 2-7.
Click
until Range 4, Levels 12-14 is highlighted, and the
Range Depth value is 3.25.
This is where we want to stop machining at, but there is one more
Range left.
Click
one more time and Range 5, Levels 15-16 are
highlighted, and the Range Depth value will read 3.75. Now
click Delete Current Range
and delete Range 5.
OK the Cut Levels dialog box.
Generate
the operation.
The operation successfully generates without warning messages.

OK to the Cavity Mill dialog box.
Save the part file, but do not close the file.
2-5
Cut patterns
In the Path Settings Group, Cut Pattern determines the pattern the cutter
will use when machining the part.
The Cut Patterns are as follows:

machines in a series of parallel straight line passes. Climb
Zig-Zag
or conventional cut directions are not maintained since the cut direction
changes from one pass to the next.
Zig
always cuts in one direction. The tool retracts at the end of each
cut, then positions to the start of the next cut.
Zig with Contour

also machines with cuts going in one direction.
However, contouring of the boundary is added between passes, before and
after the cut motion. The tool then retracts and re-engages at the start of
the contouring move for the next cut.
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.
2-6
mt11050_g NX 5
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.
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.
2-7
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 start the Manufacturing application.

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.

In the Operation Navigator, double-click on the CAVITY_MILL
operation.
In the Cavity Mill dialog box, in the Path Settings group, select
Zig-Zag
2-8
for the Cut Pattern.
mt11050_g NX 5
Step 3:
Click Generate
The tool path is generated.

Step 4:
Change the Cutting options.

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

based on the selected Cut Pattern.
Click the Strategy tab, then type 45.0 in the Degrees field.
Click Display Cut Direction
An arrow indicates the applied Cut Angle.

You may need to refresh the screen in order to see the Cut
Direction Arrow.
OK the Cut Parameters dialog box.
Step 5:
Click Generate
Click Verify
to generate the operation.
Use 3D Dynamic verification to analyze the results.

The Zig-Zag cut pattern does not have a stepover on every pass,
resulting in a less than desirable tool path.
Cancel the Tool Path Visualization dialog box.
Change the Cut Pattern to Zig with Contour.
2-9
Step 6:

Choose Generate to generate 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.
Save the part.
2-10
mt11050_g NX 5
In-Process Work Piece for Cavity Milling

To make the various Cavity Milling operations as efficient as possible,
you must determine what has been machined in each previous operation.
Variables such as cutting tool lengths and diameters, draft angles and
undercuts, fixture and tool clearances, will affect the amount of material
that each operation may leave.
The material that remains after each operation is executed is referred to

as the In Process work piece or IPW.
The remaining material (IPW) can be used for input into a subsequent
operation which may be used for additional roughing. To use the previous
IPW, tool path generation must be done sequentially, from the first operation
to the last, within a certain geometry group.
Two methods for creating the In Process work piece are available:
1. 3D IPW
2. Level Based IPW
2-11
Level Based IPW

Level Based IPW uses the 2D cut regions from the previous Cavity Milling
and/or Z-Level operation to identify and machine the remaining (Rest)
material.
2-12
Must be Cavity Mill or Z-Level operations.
Must be under the same Geometry Group.
Must have the same Tool Axis.
mt11050_g NX 5
Use 3D
Use 3D uses a 3D internal definition to represent the remaining material.
All milling operations can produce a 3D IPW. Using 3D is the correct IPW
option if you are also using other types of operations to remove material from
the blank. For example, if your cavity milling operation follows a surface
contouring operation, then you must use the 3D IPW.
2-13
Activity: Level Based In-process Workpiece (IPW)

In this activity, you will machine the part using three different cutter sizes.
You will start with a cavity mill operation and activate the use of the Level
Based IPW by using the REST_MILLING operation type and generate the
multiple operations.
You will make three operations, all using the same WORKPIECE and
MILL_AREA. Planning ahead when programming will lead you to make and
use Geometry groups
Step 1:
Open level_based_mfg and start the Manufacturing application.

Rename the part ***_level_based_mfg using the File Save
As option on the menu bar.
Step 2:

Click the Operation Navigator tab on the Resource Bar.
2-14
mt11050_g NX 5
Step 3:
Display the Geometry View in the Operation Navigator and

expand the objects.
Click Geometry View

on the Operation Navigator
tool bar, then expand the MCS_MILL , WORKPIECE, and
INSIDE_MILL_AREA parent groups.
In this case, Cavity Mill will use only the MILL_AREA to contain
the tool to inside of the pockets, rather than the entire part.
Step 4:
Create the first operation.

From the Manufacturing Create toolbar, click Create Operation
.
Make sure Type is set to mill_contour and select CAVITY_MILL
.
Set the following location specifications:
Program
Tool
Geometry
Method
PROGRAM
EM-1.25
INSIDE_MILL_AREA
MILL_ROUGH
For Name type CM_ROUGH_1 and click OK.

No additional parameters are going to be changed in this operation.
Click Generate
to generate the tool path.
Click OK to accept the path.

Step 5:
Create the second operation.

On the Manufacturing Create toolbar, click Create Operation
.
Make sure Type is set to mill_contour and click Rest Milling
.
2-15
Set the following location options:

Program
Tool
Geometry
Method
PROGRAM
EM-.75
INSIDE_MILL_AREA
MILL_ROUGH
Name the operation RM_ROUGH_2 and click OK.
Click Generate
A Tool Path generate message is displayed.

Click OK.
The Information Window appears because the tool cannot fit into
some of the areas of the part, namely the square corners.
Dismiss the Information Window, and OK to accept the path
Step 6:
Create the third operation.

.
Make sure Type is set to mill_contour and click Rest Milling
.
Set the following location options:
Program
Tool
Geometry
Method
PROGRAM
EM-.5
INSIDE_MILL_AREA
MILL_ROUGH
Name the operation RM_ROUGH_3 and click OK

No additional parameters are going to be changed for this activity.
Click Generate
Again the Tool Path generate message comes up and states that
warning have been generated. Click Cancel this time, as we know
that there are square corners in our model which cannot be cut.
2-16
mt11050_g NX 5
Click OK to accept the path.

Step 7:
Verify the Tool Path.

Display the Program View in the Operation Navigator and expand
the objects.
Right-click the Program Tool Path Verify.
Verify the tool path, using the 3D Dynamic option.
Save and close the part file.
2-17
Pre-Drill Engage and Cut Region Start Points

Pre-Drill Engage and Cut Region Start Points are used in the following:
Operation
Cavity Mill
Corner Rough
Rest Milling
Z-Level Processors
Profile 3D
Face Milling Processors
Planar Mill Processors
Plunge Mill
Where Found
Non Cutting Moves Start/Drill
Points
Points
Points
Points
Points
Points
Points
Points in Path Settings
Pre-Drill Engage Points

Operations normally determine where they start.
You can use the Pre-Drill Engage Points option to specify where you want
the tool to start cutting. With this option, the tool moves to the pre-drilled
engage point you specify, then to the specified cut level. It then moves to the
processor generated start point and generates the remainder of the tool path.
Region Start Points
Region Start Points allows you to specify cut start points for each region in
a multi-region cavity. When you use circular engages, this option can avoid
engages into pocket corners by selecting either Mid Point or Corner in the
Default Region Start pull down.
2-18
mt11050_g NX 5
Activity: Pre-Drill Engage Point

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

application.
From the menu bar, select FileOpen.
Select form_mold_mfg, then choose OK.
Rename the part ***_form_mold_mfg using the File Save As
Step 2:

Choose the Operation navigator tab from the Resource Bar.
active.
Step 3:
Edit an existing operation.

Double-click the CM_ROUGH operation.
The Cavity Mill dialog box is displayed. You will now define a point
that represents a hole which has been previously drilled.
Step 4:
Define a Pre-drill Engage Point for this operation.

In the Path Settings group, click Non Cutting Moves
Click the Start/Drill Points tab and expand the Pre-Drill Points
group.
Click the Point Constructor
and select the arc center of
the drilled hole in the Blank that we are going to engage into.
OK the Point dialog box.
Expand the List and verify that a value of 5.2500, 2.5000, and
3.1250 is present.
2-19
Expand the Region Start Points group.

Click Point Constructor
edge shown here.
and select the Mid Point of the
OK the Point dialog box.

Expand the List and verify that a value of 4.4575, 2.5000, and
.2000 is present.
Click the Engage tab.
In the Closed Area group, select Plunge for the Engage Type.
OK the Non-Cutting Moves dialog box.
2-20
mt11050_g NX 5
Step 5:
Generate the tool path.

Click Generate
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.
Click Verify
In the Tool Path Visualization dialog box, set Display (under

Motion Display) to Current Level.
Click Play
You may want to slow the animation speed down.

OK the Tool Path Visualization dialog box.
OK to accept the operation.
Save and Close the part.
2-21
Cavity Milling stock options

Stock options for Cavity Milling are found on the Cut Parameters dialog box.
This dialog box is activated by selecting the Cutting button found on the
Cavity Mill operation dialogs.
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.
2-22
mt11050_g NX 5
Activity: Blank Distance option

In this activity, you will learn how to set the Blank Distance for a core type
part. The MCS, Part geometry and Program Name have already been created
for you.
Step 1:
Open a new part file, rename and start 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 the Operation Navigator tab from the Resource Bar.
active.
Step 2:
Create an operation utilizing Blank Distance as a part offset.

.
The Create Operation dialog box is displayed.
Set Type to mill_contour.
2-23
Select Cavity Milling
Set the following:
Program: ROUGH_WITHOUT_CASTING
Use Tool: EM-.375-.06
Use Geometry: WORKPIECE
Use Method: MILL_FINISH
Name the operation CM_.20_BLANKDISTANCE.

Click OK.
The Cavity Milling dialog box is displayed.
Step 3:
Verify the Part Geometry selection.

For Specify Part click Display
Note that the Part geometry is displayed.

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

In the Path Settings group, set Cut Pattern to Follow Part.
Set Global Depth per Cut to .125.
Click Cutting Parameters
The Cut Parameters dialog box is displayed.

Click the Strategy tab if required.
In the Cutting group, set Cut Order to Depth First.
In the Blank group, set Blank Distance to .20.
Click OK.
The Cavity Mill dialog box is displayed.
2-24
mt11050_g NX 5
Step 5:

Click Generate
to create the tool path.
Click OK.
The tool path cuts all of the core geometry.
Notice that the tool path follows the part contour since you used
the Blank Distance option 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
.200" stock overall.
Choose OK to accept the tool path.
2-25
Summary
The Cavity Milling module provides efficient and robust capabilities
of removing large amounts of stock, primarily in cavity and core type
applications.
The following functions are available in Cavity Milling:
2-26
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
mt11050_g NX 5
Lesson
Z-Level Milling
3
Purpose
This lesson is an introduction to the Z-Level operation type, which is useful
when profiling steep areas. You can also isolate specific areas that you want
to cut or avoid cutting within a Z-Level operation.
Objective
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.
3-1
Z-Level Milling
Z-Level Milling
Z-Level Milling is designed to profile bodies or faces at multiple depths. It
will cut steep areas (the steepness of the part at any given area is defined by
the angle between the tool axis and the normal of the face) or the entire part.
The following Z-Level operation types are available:
CORNER ROUGH - Cavity milling with a reference tool that can be

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

Angle being set
ZLEVEL_CORNER - Z-Level milling that uses an existing reference

tool; and compliments flowcut machining
Part geometry and Cut Area geometry can be specified to limit the area to
be cut. If cut area geometry is not defined, then the entire part is used as
the cut area.
1. Create new Geometry

2. Select or Edit the Part Geometry
3. Select or Edit the Check Geometry
4. Select or Edit the Cut Area Geometry
5. Select or Edit the Trim Boundaries Geometry
3-2
mt11050_g NX 5
Z-Level Milling
Many of the option settings found in Z-Level Milling are the same as in other
operation types. A description of some of these options are as follows:
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.
3-3
Z-Level Milling
Activity: Z-Level Milling

In this activity, you will generate tool paths using Z-Level Milling. Z-Level
is designed to profile an entire part or steep areas that were previously left
by the roughing operations.
Step 1:
Open the part file and enter the Manufacturing application.

Open the part base_mfg_3.
Rename the part ***_base_mfg_3 using the File Save As

Start the Manufacturing application if necessary.
Step 2:

and change to the Program Order View.
Expand the BASE_MALE_DIE group.
Step 3:
Create a Z-Level operation.

Click Create Operation
tool bar.
on the Manufacturing Create
Make sure Type is set to mill_contour.

In the Operation Subtype group, click ZLEVEL_PROFILE
.
3-4
mt11050_g NX 5
Z-Level Milling
In the Location group set the following parameters:
Set Program to BASE_MALE_DIE.
Set Tool to EM_1.25_.25.
Set Geometry to WORKPIECE
Set Method to MILL_FINISH
Name the operation zlevel_finish.
Click OK.
The Zlevel Profile dialog box is displayed.
Step 4:
Change the Depth of Cut.

For ease of viewing turn model shading off.
In the Path Settings group, set Global Depth per Cut to 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 of
the part.
Click Cut Levels
The Cut Levels dialog box is displayed, and plane symbols appear
on our part which represent Ranges and Levels.
3-5
Z-Level Milling
Select the Downward icon and observe the Range change and
the highlighted area move down on the model.
Index to the 4th range and click Delete Current Range
Choose OK.
Step 5:

Click Generate
3-6
to generate the tool path.
mt11050_g NX 5
Z-Level Milling
Step 6:
Verify the Program that you have created.

Click Toolpath Verification
results.
to examine the tool path
Choose OK to accept the operation.

Save and Close the part file.
3-7
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.
3-8
mt11050_g NX 5
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.
Step 1:

Open the part steep_form_mfg.
Rename the part ***_steep_form_mfg using the File Save

Enter the Manufacturing application.
Step 2:

and change to Geometry View.
The MCS_MILL Parent Group is displayed in the Operation
Navigator.
Expand the MCS_MILL and WORKPIECE Geometry Parent
Groups.
The CM_ROUGH operation is listed in the Operation Navigator
along with a MILL_AREA that will be used in our activity.
3-9
Z-Level Milling
Change the view of the Operation Navigator to the Program

Order View.
Step 3:
Create the ZLEVEL_PROFILE operation.

Select Create Operation
toolbar.
from the Manufacturing Create
The Create Operation dialog box is displayed.
Select mill_contour from the Type pull down, if required.

In the Operation Subtype group, select ZLEVEL_PROFILE
.
Set the following:
Program: INTERIOR-PROGRAM
Tool: EM-.500-.06
Geometry: MILL_AREA
Method: MILL_FINISH
Click OK.
In the Geometry group, click Edit
(beside Geometry).
In the Mill Area dialog box, click Display

Part.
next to Specify
The entire part highlights.

In the Mill Area dialog box, click Display
Cut Area.
next to Specify
Only the inside faces highlight.

Click OK to return to the Z-Level Profile dialog box
Step 4:
3-10
Set the Steep Parameter and Depth of Cut.
mt11050_g NX 5
Z-Level Milling
In the Path Settings group, click the Steep Containment pull

down and select Steep Only.
The Angle option appears and is defaulted to 65 Degree.
Set Global Depth per Cut to .125.
Step 5:

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

Step 6:
Verify the tool path

With Program Order View on in the Operation Navigator,
right-click on INTERIOR-PROGRAM Tool Path Verify
The Tool Path Visualization dialog box is displayed.
Click the 3D Dynamic tab.
Select Suppress Animation near the bottom of the dialog box.
Click Forward to Next Operation
The system prepares a display of what our stock looks like after
the two operations, but we do not need to watch the step by step
material removal.
Notice the areas cut by the tool paths. Many of the
areas near the blends were not machined so that another
operation with a more appropriate tool radius could be used.
Remember that the Steep Angle was set to 65 degrees and
may need to be changed.
Save the part file, but do not close as you will be using it in
the next activity.
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.
3-11
Z-Level Milling
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.
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.
This is an example of Depth First in which the right raised area was cut first,
then the cutter was picked up and the left side was then cut and then the
operation went around the base till completion.
3-12
mt11050_g NX 5
Z-Level Milling
Activity: Z-Level Profile Milling

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

Continue using ***_steep_form_mfg.
3
Select Create Geometry
tool bar.
from the Manufacturing Create
The Create Geometry dialog box is displayed.

In the Geometry Subtype group, click Mill_Area
If necessary, set the Geometry Location to WORKPIECE.

Enter ZLEVEL_AREA as the Name.
Click OK.
The Mill Area dialog box is displayed.
Click Specify Cut Area
The Cut Area dialog box is displayed.
3-13
Z-Level Milling
Select the interior island geometry as shown. Having the

model in a top view will aid in the selection process.
Make sure that the system you are using has the Preference
Selection Multi-Selection set to Rectangle for the Mouse
Gesture, and Inside for the Selection rule.
Click OK.
To briefly review you have created a Geometry Parent Group,
named ZLEVEL_AREA which contains the geometry of the island.
This Geometry Group will be used in the ZLEVEL_PROFILE
operation.
You will now create the operation.
Step 2:
Create the ZLEVEL_PROFILE Operation.

On the Manufacturing Workpiece toolbar, select Create
Operation
In the Operation Subtype group, click ZLEVEL_PROFILE

.
3-14
mt11050_g NX 5
Z-Level Milling
Set the following:

Program: INTERIOR-PROGRAM
Tool: EM-.500-.06
Geometry: ZLEVEL_AREA
Method: MILL_FINISH
Click OK.
The ZLEVEL_PROFILE dialog box is displayed.

The Part geometry is displayed. It was specified in the
WORKPIECE Parent Group.
In the Geometry group, select Cut Area and choose Display
.
The Cut Area geometry is displayed. It was specified in the
ZLEVEL_AREA Parent under the WORKPIECE Parent Group.
Change the Global Depth per Cut to .15.
Step 3:
3-15
Z-Level Milling
Click Generate to generate the tool path.

3-16
mt11050_g NX 5
Z-Level Milling
Z-Level Cutting Between Levels (aka Gap Machining)

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

regardless of the angle of steepness, incorporating fewer engages and retracts,
producing a more consistent surface finish.
Stepover option
Stepover pertains to machining the gap areas.
When used with the default Use Depth of Cut parameter, the stepover
matches the depth of cut of the current cut range.
3-17
Z-Level Milling
Max Cut Traverse option

Max Cut Traverse defines the longest distance that the cutting tool feeds
along the part when not cutting.
Sequencing of Gap and Z-Level tool paths
Z-Level and gap tool paths are sequenced and ordered as follows:
Z-Level tool path is machined from the top-down and uses the same
connection methods as it would without the Cut Between Levels option
When a gap is discovered, the gap is cut, cutting continues until another
gap is found or the cut is complete at that level.
Z-Level Gap machining is activated from the Cut Parameters dialog box by
selecting the Connections tab and selection of Cut Between Levels. Modify the
parameters on that dialog box as needed.
Additional information on Z-Level Gap Machining can be found in the
on-line documentation from within the NX Help pull down.
3-18
mt11050_g NX 5
Z-Level Milling
Activity: Z-Level Gap Machining

In this activity, you will activate Gap Machining option in an existing Z-Level
operation.
Step 1:

Choose File Open male_cover_mfg.
Rename the part ***_male_cover_mfg using the File Save

If necessary, display the Operation Navigator in the Program
Order view.
Step 2:
Replay an existing Z-Level operation.

Double-click on the ZLEVEL_PROFILE operation for editing
purposes.
Click Replay
3-19
Z-Level Milling
The tool path is displayed. Note the non-steep areas and the
numerous engage retracts that occur.
The operation does a fairly good job of machining the steep

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

Click the Connections tab.
Turn On the Cut Between Levels option.
Set the Stepover to Constant.
Change the Distance to 0.15.
ChooseOK.
Step 3:
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Z-Level Milling
Click Generate to generate the tool path.
The non-steep areas are now machined as well as the steep areas
of the part.
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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:
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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).
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Lesson
Fixed Contour operation types

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

creating tool paths
4-1
Fixed Contour overview

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

The Area Milling drive method allows you to specify a cut area for tool path
generation.
Cut Area(s) may be defined by selecting surface regions, sheet bodies, or
faces. They can be selected in any order.
If you do not specify a Cut Area, the processor will use the selected part
geometry (excluding areas not accessible by the tool) as the cut area.
Surface drive method
The Surface Area drive method allows you to create an array of drive
points that lie on an orderly grid of faces, and must share a common edge;
they must not contain gaps that exceed the Chaining Tolerance defined
under Preferences (PreferencesSelectionChaining Tolerance). Trimmed
surfaces can be used to define drive surfaces as long as the trimmed surface
has four sides.
Tool Path drive method
The Tool Path drive method allows you to define drive points along the tool
path of a Cutter Location Source File (CLSF) to create a similar tool path.
Radial Cut drive method
The Radial Cut drive method allows you to generate drive paths perpendicular
to and along a given boundary, using a specified Stepover distance, Bandwidth
and Cut Type. This method is useful in creating cleanup operations.
Flow Cut drive method
Flow Cut drive methods allows you to generate drive points along concave
corners and valleys formed by part surfaces. The direction and order of the
flow cuts are determined using rules based on machining best practices.
Text drive method
Text drive methods allows you to generate drive paths based on text created
from drafting notes.
User Function drive method
The User Function drive method creates tool paths from special drive
methods developed in User Function code.
Geometry groups associated with Fixed Contour operations
There are three different Geometry groups available for use in Fixed Contour
operations. They are:
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The MILL_GEOM group which allows part, blank and check geometry.
The MILL_BND group which also allows part, blank, check and trim
and floor boundary geometry.
The MILL_AREA group allows part and check but not blank geometry. It
also allows for the specification of Cut Areas ,Wall and Trim geometry.
Fixed Contour operations are generally used to finish contoured types of

geometry.
The Fixed Contour operation types are:
4-4
FIXED_CONTOUR - Generic Fixed Contour operation type. Allows

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

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

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

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

where orderly rows and columns of faces (grids) are available.
STREAMLINE - Operation is new for NX5 and will be covered in a later

lesson.
FLOWCUT_REF_TOOL - Operations have 4 main operations: 1)

Flowcut Single Pass, one pass down a groove. 2) Flowcut Multiple Pass,
Multiple passes down a groove. 3) Flowcut Multiple Pass Reference Tool,
uses previous tool to control ares to be cut. 4) Flowcut Smooth, uses
smooth loops to exit and engage.
mt11050_g NX 5
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.
4-5
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.
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Flow Cut drive method using Cut Area and Trim Boundary Geometry
The Flow Cut drive method allows Cut Area geometry to be defined the same
way as the Area Milling drive method. Concave valleys are analyzed within
the cut area as well as concave valleys formed by the cut area and part
geometry. Valleys formed by the cut area and check geometry are excluded.
Trim boundaries:
Are defined as an On condition
Are defined as Trim Inside or Trim Outside.
Can be used to further constrain cut regions.
Can be multiple for needed control.
Can have stock added.
Flow Cut Reference Tool Drive Method

Flow Cut Reference Tool drive method uses the previously used tool diameter
to determine the width that needs to be cleaned up with multiple passes at
user defined stopovers. The user can control order of cuts, amount of overlap
and any steep containment.
Flow Cut options
Maximum Concavity controls where Flow Cuts are created based on the
Angle of Concavity that is defaulted to 179 degrees.
Minimum Cut Length allows the removal of short cut motion, defaulted to a
value of .030
Hookup Distance allows you to eliminate small gaps in the cut motion
defaulted to a value of .030
Cut Type is either Zig, Zig Zag or Zig with Lifts.
Stepover Distance allows you to specify the distance between passes,
defaulted to .100.
Sequencing enables you to determine the order in which the cut passes are
executed.
Inside-Out starts in the center and moves to the outside with the passes.
Outside-In starts on the outside passes, and works to the center.
Steep Last starts the cut motion from non-steep side to the steep side.
Steep First starts on the Outside of the steep to the outside of the non-steep.
Inside Out Alternate cuts a Flow Cut valley from the middle to the outside.
4-7
Outside In Alternate cuts a Flow Cut valley from outside towards the middle
Reference Tool Diameter lets you specify the diameter of the tool from the
previous operation on this part of the part.
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.
Much additional information on Flow Cut can be found in the Help
Documentation NX5 Help Library Manufacturing Manufacturing
Milling Fixed and Variable Contour Fixed Only Flow Cut Drive
Methods and then choose the area of interest.
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Activity: Create Fixed Contour operations

The following activity creates simple Fixed Contour rough and finish
operations. You will first review a Cavity Milling operation that was used to
rough the majority of the part. You will then create Contour Area operations
that will semi-finish and finish the part. Finally, you will use Flow Cut
operations, using a Reference Tool, to remove stock that remained from
previous operations.
Step 1:
Open the part 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 in the Program Order.
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, right-click Tool Path and
select Verify.
Click the 3D Dynamics tab
Select the Suppress Animation check box.
Click Forward to Next Operation

4-9
After a momentary pause, the system will show the 3D Dynamics

display
Note that a number of .250 steps were left in the material as a
result of the specified Cut Level. Also, .050 Floor and Side Stock
were specified in the operation.
You will create a Fixed Contour operation to semi-finish machine
the part.
Step 3:
Create a Fixed Contour operation to semi-finish the part.

Operation

In the Operation Subtype group, click CONTOUR_AREA
.
In the Location group, set:
Program to MALE_COVER
Tool to BALLMILL-1.00
Geometry to WORKPIECE
Method to MILL_SEMI_FINISH
Enter the Name as semi_rough_fc.

Choose OK.
The Contour Area dialog box is displayed.
In the Geometry group, next to Specify Part click Display
and check geometry.
In the Drive Method group, click Edit
The Area Milling Drive Method dialog box is displayed.

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In the Drive Settings group set or verify the following options:
Pattern to Parallel Lines
Cut Type to Zig Zag
Stepover to Tool Diameter
Percent to 25
Cut Angle to Automatic
Click OK.
Generate
4
the tool path.
OK to accept the operation.

Step 4:
Create a Fixed Contour finishing operation using the Contour

Area operation type.
On the Manufacturing Workpiece toolbar, click Create
Operation
In the Operation Subtype group, click CONTOUR_AREA

.
In the Create Operation dialog box, set the following:
Method to MILL_FINISH
For Name type finish_fc.

Click OK.
The Contour Area dialog box is displayed.
In the Drive Method group, choose Area Milling.
4-11
The Area Milling Method dialog box is displayed.

Set the following options:
Pattern to Follow Periphery
Tool motion to Outward
Stepover to Scallop
Height to .002
Stepover Applied to On Plane.
Choose OK.
Generate
the tool path.
Your tool path should look similar to the above.

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.
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Operation
The Create Operation dialog box appears.

In the Operation Subtype group, click FLOWCUT_REF_TOOL
.
In the Location group, set:
Method to MILL_FINISH
Enter the Name as flow_fc.

Click OK.
The Flowcut Reference Tool dialog box is displayed.
Note that on the dialog box there is no Drive Method label since
Flow Cut is the Drive Method.
Step 6:
Change the Reference Tool setting.

You will change the Reference Tool setting. The previous tool used
was a 1.00 diameter tool.
Expand the Reference Tool group.
Enter 1.00 in the Ref. Tool Diameter value field.
Leave the Overlap distance set to .03. The amount of overlap with
the previous operation may change due to size of cutters and your
company preferences.
Step 7:
4-13
Click Generate
Note that the area being cut is in reference to the 1.000 Reference
Tool diameter.
Choose OK.
Save and Close the part.
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Cut Area
In the previous activity, we attacked the entire part with our operations for
semi-finish and finishing. Now we are going to break our part down into
smaller pieces. This may be due to machine time consideration or other shop
driven reasons.
If an area of our part requires numerous machining operation on any given
area, then a separate Geometry Group should be made under the Create
Geometry group. We are going to create our Cut Area as a Geometry Group.
We will break our part down to an even smaller machining area by using a
Trim Boundary in the next activity.
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.
4-15
Activity: Mill Area geometry groups

This activity will demonstrate how to create and use a MILL_AREA geometry
group in an operation. You will Replay and examine the results of an existing
operation. You will then create a MILL_AREA geometry group consisting of
faces and will modify the inheritance of the operation to use the MILL_AREA
parent.
Step 1:
Open the part 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

Choose Start Manufacturing .
Change the Operation Navigator to the Geometry View.
Expand the MCS_MILL and WORKPIECE geometry groups.
Step 2:
4-16
Replay the current operation.
mt11050_g NX 5
Highlight the FC_FINISH_RIBS operation, rightclick and

select Replay.
4
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 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. Rightclick Refresh
2. Press the F5 button
3. From the top menu bar, choose View Refresh
Step 3:
Create the MILL_AREA geometry group.

On the Manufacturing Create toolbar, click Create Geometry
.
If necessary, change the Type to mill_contour.
Set the Geometry Subtype to MILL_AREA
In the Location group, set Geometry to WORKPIECE.

In the Name field, type two_ribs.
4-17
Click OK.
The MILL_AREA dialog box is displayed.
Step 4:
Define the Cut Area geometry.

Click Cut Area
At this time, it will make it easier to select the rib faces by

selecting the Assembly Navigator Tab and unchecking the
red check mark in front of the male_cover_stock, bolt_5 and
the male_cover_mach_plate components. This will prevent
the selection of faces that are not part of the Workpiece.
Rotating the model to a top view would let you do a

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

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

You will move the FC_FINISH_RIBS operation, so that the
operation will machine only the faces specified.
4-18
mt11050_g NX 5
Click and drag the FC_FINISH_RIBS operation so that it

resides under the TWO_RIBS Parent Group, then release the
mouse click.
Highlight the FC_FINISH_RIBS operation, right-click, select
Generate from the pop-up menu.
The tool path is generated and cuts the faces selected in the
MILL_AREA group.

Save the part file, but do not close, as we will use it in the
next activity.
4-19
Trim Boundary
A Trim Boundary is like any other boundary except it can control the tool
path and prevent the generation either inside or outside of the boundary.
A Trim Boundary can be part of the Mill Area Geometry group, or as an
addition to the operation. Does the area in question require multiple
machining will determine where it should be placed.
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Activity: Trim Boundaries

In this activity, you will create a trim boundary inside of a MILL_AREA
Parent Group and will then generate the corresponding operation.
Step 1:
Continue using the part file.

Continue using ***_male_cover_mfg_2.
4
Step 2:
Create a Trim Boundary.

Change the view to TOP.
Change the Operation Navigator to the Geometry View.
You will now edit the operation.
Double-click on the TWO_RIBS geometry.
Click TRIM
The boundary you will create will be developed using cursor

location points.
For Filter Type click Point Boundary
Change the Point Method to Cursor Location.

Notice that the Trim Side setting is defaulted to Inside. This
means that the area inside of the Trim Boundary will not be
machined. Changing to Outside would allow for machining only
inside of the Trim Boundary.
Using four screen position points create a trim boundary
similar to the one shown below.
Only four points are needed, as the boundary processor will close
the shape for you.
4-21
Choose OK to return to the main dialog box.

Step 3:

Generate the tool path for the FC_FINISH_RIBS operation and
examine the results.
Any tool path that falls within the Trim boundary is removed. This
is because our Trim Side was set to Inside.
4-22
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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.
4-23
Lesson
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.
5-1
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 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
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
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.
5-3
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_setup_1.
Choose StartManufacturing.
Click the Operation Navigator tab
The Operation Navigator and the part are displayed.

5-4
mt11050_g NX 5
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 FACE_MILLING_AREA as the operation type.

Choose the following Parent objects:
Program
Tool
Geometry
Method
FIXED_AXIS
EM-1.00-0
TOP
MILL_FINISH
Note that the geometry parent contains a face that describes

the top of the part.
Also note that the tool used in this operation is a 1.00" diameter
end mill with 0" corner radius.
Type top_face in the Name box.
Click OK.
The FACE_MILLING_AREA dialog box is displayed.
Select Follow Periphery from the Cut Pattern list..
Type 50 in the Perecnt box.
Generate the operation and then choose OK from the Display
Parameters dialog box.
The generated tool path is displayed.
Click OK to accept the operation.
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.
5-5
Highlight the FIXED_AXIS program object.
Click Verify Tool Path
In the Tool Path Visualization dialog box click the 2D Dynamic

tab.
Click Play
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.
Click Cancel.
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.
Right-click TOP_FACE and choose Copy.
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mt11050_g NX 5
RIght-click TOP_FACE again and choose Paste.

A copy of the previous operation is created, with the name
TOP_FACE_COPY. You will now rename the operation to
ANGLE_FACE_1.
Right-click TOP_FACE_COPY and choose Rename, type
INSIDE_CHAMFER.
You will now change the geometry parent object.
Double-click the INSIDE_CHAMFER operation.
Select INSIDE_CHAMFER from the Geometry list.
Choose OK.
Choose Generate.
Choose OK on the Display Parameters dialog box.
The Operation Parameter Error dialog box is displayed.

This dialog box is informing you that the operation 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 box.
As described earlier, there is always a defined tool axis. In this
case, the tool axis is the same as the Z of the MCS. You will now
change the tool axis to one that is normal to the floor plane of the
INSIDE_CHAMFER geometry parent object.
Expand Tool Axis.
Select Specify Vector from the Tool Axis list
Click Specify Vector.
5-7
Select the angled face as shown in the following figure.
Choose OK until the FACE_MILLING dialog box is displayed.

Click OK to save the operation.
Step 5:
Verify the results.

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 INSIDE_FACE operation.
Right-click Copy.
Right-clickPaste.
Change the name of the new operation to OUTSIDE_CHAMFER.
Edit the operation by doubling-clicking on
OUTSIDE_CHAMFER.
Select OUTSIDE_CHAMFER from the Geometry list.
Choose Specify Vector from the Tool Axis list.
5-8
mt11050_g NX 5
Click Inferred Vector
Select the angled face as shown in the following figure.
Click Generate.
Choose OK on the FACE_MILLING_AREA dialog box to save
the operation.
Step 7:
Verify the results.

Use Verification to verify the tool path.
Close the part file without saving.
5-9
Define 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.
Place 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:
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:
5-10
None
Use the Main MCS
Fixture Offset
CSYS rotation
mt11050_g NX 5
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.
5-11

In this activity, you will use the Main and Local MCS. The the main and local
MCS have been created for you. The Main MCS is set at the machine zero.
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.
Step 1:

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.
5-12
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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
one.
Double-click on the MCS_MAIN group object.
The MILL_ORIENT dialog box is displayed.

Expand the Details arrow to see the Coordinate System
Purpose options.
Note that the Coordinate System Purpose selected is Main.
Choose OK.
Double-click on the MCS_000 group object.
TheMILL_ORIENT dialog box is displayed.
Expand the Details arrow to see the coordinate system purpose
options.
Note that the Coordinate System Purpose selected is Local, the
Special Output is set to Use Main MCS, and the Fixture Offset
is set to 1.
Choose OK.
Expand the Details arrow 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.
5-13
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.
Click Postprocess
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 box.
5-14
mt11050_g NX 5
If necessary, choose OK to the Path Out of Date dialog box.

The posted output is displayed.
5
Notice the values for the X, Y and Z axes.
Cancel the Postprocess dialog box.
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.
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.
Click Postprocess
The Postprocess dialog box is displayed.

5-15
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 box.
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.
5-16
mt11050_g NX 5

In this activity, you will use the Main and Local MCS.. The main and local
MCS have been created for you. The Main MCS is set at the machine zero
would be. 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 process the program,
the output of the three tool paths, with their respective X, Y, and Z values, are
based upon the Main MCS.
Step 1:

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.
5-17
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.
Double-click on the MCS_MAIN group object.

The MCS dialog box is displayed.
Expand the Details 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.
5-18
mt11050_g NX 5
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.
Click Postprocess
Using the Browse button under Available Machines, browse

to your parts directory and select the mam_mcs_mill.pui post
processor.
Choose OK.
5-19

%
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G40 G17 G90 G70

G91 G28 Z0.0
T00 M06
G00 G90 G53 X37.775 Y20.4 B0.0 S764 M03
G43 Z-17.5 H00
Z-17.9
Z-18.4
G01 Z-18.5 F1.4 M08
G03 X37.575 Y20.5 I.2 J.15
G01 X37.5
X36.5 F1.5
Y19.5
X38.5
Y20.5
X37.425
G03 X37.225 Y20.4 I0.0 J.25
G00 Z-17.5
G00 X29.6 Y27.775 B0.0 S764 M03
Z-17.9
Z-18.4
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 box.
Step 5:
Modify the Local MCS by adding fixture offsets and re-posting

the operations.
Change to the Geometry view of the Operation Navigator.
Edit the MCS_000 parent group, type 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.
Right-click the program TT1346AA and choose Generate.
Click OK as needed until you return to the Operation Navigator.
Highlight the TT1346-AA parent group.
5-20
mt11050_g NX 5
Click Postprocess
The Postprocess dialog box is displayed.

If necessary, browse to your home directory and select the
mam_mcs_mill.pui post processor.
Choose OK.
If necessary, choose OK to overwrite Output File dialog box.
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G40 G17 G90 G70

G91 G28 Z0.0
T00 M06
G00 G90 G54 X1.7 Y.4 B0.0 S764 M03
G43 Z.5 H00
Z-.4
G01 Z-.5 F1.4 M08
G03 X1.5 Y.5 I.2 J.15
G01 X.5 F1.5
Y-.5
X2.5
Y.5
X1.5
X1.35
G03 X1.15 Y.4 I0.0 J.25
G00 Z-.4
Z.5
G00 G55 X1.7 Y.4 B0.0 S764 M03
Z-.4
G01 Z-.5 F1.4
G03 X1.5 Y.5 I.2 J.15
G01 X.5 F1.5
Y-.5
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.
5-21
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.
5-22
mt11050_g NX 5
Lesson
Five Axis Z Level

Purpose
The Z Level Five Axis operations allow you to create Z level operations with
the addition of four and five axis options. These operations can then be
utilized for roughing and finishing multi axis and deep wall parts.
Objective
Create five axis Z Level operations
Create Z Level operations utilizing tool axis tilt options.
Optimize Z Level Cut Depths.
6-1
Five Axis Z Level
Z Level Five Axis Overview

Z Level Five Axis applies a tool axis to the Z Level tool path. Z Level Five
Axis tool paths are planar Z Level paths, the tool axis tilt is applied to the
path. Z Level Five Axis can apply the tool axis tilt using several methods.
6-3
Five Axis Z Level
Tool Axis tilt

The following tool axis tilt options are available:
Away From Part
Away From Point
Toward Point
Away From Curve
Toward Curve
Tilt Angle
The Tilt Angle can be set by using Specify or Automatic.
The Automatic Tilt angle is determined using the Maximum Wall Height and
the Part Safe Clearance. The Maximum Wall Height is the distance from
the tool tip, along the tool axis that the wall is encountered. In the example
below, if the Maximum Wall Height is set to 1.5 the holder will avoid the
geometry using the 1.00 diameter of the holder plus the Part Safe Clearance.
6-4
mt11050_g NX 5
Five Axis Z Level
This tool path was generated using an Maximum Wall Height of 1.00. The tool
rests on the part surface but the tool holder interferes with the part geometry.
The same operation generated with a Maximum Wall Height of 2.00. Notice
that the tool leans over so the first diameter of the holder doesnt collide
with the part. The Part Safe Clearance is the clearance distance for the
holder. The large diameter still collides because the Maximum Wall Height
still needs to be adjusted.
6-5
Five Axis Z Level
The same operation generated with an Maximum Wall Height of 3.00. Notice
that the tool tilts so the large diameter of the holder doesnt collide with
the part.
Setting the Maximum Wall Height smaller can keep the tool from tilting
excessively when your cuts arent going to cause interference.
6-6
mt11050_g NX 5
Five Axis Z Level
Activity: Creating a Z Level Five Axis operation

In this activity, you will create a Z Level Five Axis operation. You will use an
Away From Part tool axis with an Automatic tool axis tilt.
Step 1:
Open and rename an existing part file.

Open the file zl_multi_axis_2_setup_1.
Rename the part to ***zl_multi_axis_2_setup_1.

The necessary Parent Groups (i.e. Geometry, Machine,

Program and Method) have already been created for you.
Step 2:
Create a Z Level Five Axis operation.

Choose StartManufacturing.
If necessary, change the Type to mill_multi-axis.
Click ZLEVEL_5AXIS
Set the Parent objects as shown:

Program
Tool
Geometry
Method
1234
BN-10
MILL_AREA
MILL_FINISH
6-7
Five Axis Z Level
Type away_part in the name box.

Click OK.
The Z Level 5 Axis dialog box is displayed.
The Tool Axis Tilt is set to Away From Part.
The cutting tool is 30 mm long, the tool holder is an additional
30 mm. The tool will cut just over 56 mm deep, you will set the
Maximum Wall Height to 60. Sixty is the total length of the tool
and holder.
Type 60 in the Maximum Wall Height box.
Step 3:

Click Generate
Orient your view to the left view and observe the tool axis. The
tool axis is tilted far enough to clear the entire tool holder.
Step 4:
Verify the tool path and examine the tool axis.
Click Verify
Change the Animation Speed to 3.
Click Play
Click OK.
The tool axis tilts away from the part so that the entire tool holder clears
the part geometry.
Click OK to return to the operation.
6-8
mt11050_g NX 5
Five Axis Z Level
Activity: Changing the Maximum Wall Height

In this activity, you will create a Z Level Five Axis operation. You will use an
Away From Part tool axis with an Automatic tool axis tilt. You will apply a
smaller Maximum Wall Height.
Step 1:
Create another Z Level Five Axis operation.

Click ZLEVEL_5AXIS
Set the Parent objects as shown;

Program
Tool
Geometry
Method
1234
BN-10
MIL_AREA
MILL_FNIISH
Type max_wall in the Name box.
Click OK.
The Z Level 5 Axis dialog box is displayed.
The Tool Tilt Axis is set to Away From Part.
The cutting tool is 30 mm long, the first step of the tool holder is
an additional 15 mm. The tool will cut 50 mm deep so we will set
the Maximum Wall Height to 45. Forty-five is the total length of
the tool and the first step of the holder.
Type 45 in the Maximum Wall Height box.
Step 2:
Change the Cut Levels

Click Cut Levels
Type 50 in the Range Depth box.

Click OK.
This tool path is set shallower to demonstrate the new tool axis.
6-9
Five Axis Z Level
Step 3:

Click Generate.
Right-click in the graphics screen and choose Orient viewLeft.
Step 4:
Verify the tool path and examine the tool axis.
Click Verify
Change the Animation Speed to 3.
Click Play
6
The tool axis tilts away from the part so that only the first step of the tool
holder clears the part geometry. If the path was cut to the depth in the
previous operation the tool holder would collide with the part geometry.
6-10
mt11050_g NX 5
Five Axis Z Level
More Tool Axis tilt options

In the previous activities you used an Away from part tool axis tilt and an
automatic angle. The following activities will examine some other tool axis
tilt options. These options include Away from part, Away from point, Toward
point, Away from curve and Toward curve. All of the tool axis tilt options
allow an Automatic or a Specified angle.
Tool Axis tilt methods
Away from part Tilts away from the part geometry at an angle relative
to the MCS Z axis.
Away from point Tilts away from the specified point at an angle to
the MCS Z axis.
Toward point Tilts toward the specified point at an angle to the MCS Z
axis.
Away from curve Tilts away from the curve or curves at an angle to
the MCS Z axis.
Toward curve Tilts toward the curve or curves at an angle to the MCS
Z axis.
6-11
Five Axis Z Level
Activity: Away from point tool axis tilt

In this activity, you will machine the outside vertical walls of the part. The
Away from point tool axis tilt will be used.
Step 1:
Continue using the ***_zl_multi_axis_2_setup_1.prt part and

create a new operation.
Click ZLEVEL_5AXIS

Program
Tool
Geometry
Method
1234
BN-10
MILL_AREA
MILL_FINISH
Type point in the Name box.

Click OK to create the operation.
6-12
mt11050_g NX 5
Five Axis Z Level
Step 2:
Specify the tool axis tilt options.

Choose Away from point from the Tool Axis Tilt list.
Select the arc at the top of the part to select the arc center.
Click Specify from the Tilt Angle list.
Type 30 in the Degrees box.

Step 3:
Generate and verify the tool path.

Click Generate
6-13
Five Axis Z Level
Right-click in the graphics screen and Orient view to the top.
Click Verify
Click Play
The tool axis is tilted 30 degrees from the ZM axis about the
point that was selected.
The tool axis is tilted away from the point along the curved portion
of the part but also continues to rotate along the linear section
of the part.
6-14
mt11050_g NX 5
Five Axis Z Level
Activity: Away from curve tool axis tilt

Away from curve tool axis will be used. You will use a single curve to control
the tool axis. The tool axis will tilt away from the curve at the specified angle.
Step 1:
Continue using the***_zl_multi_axis_2_setup_1 part and create a

new operation.
Click ZLEVEL_5AXIS

Program
Tool
Geometry
Method
1234
BN-10
MILL_AREA
MILL_FINISH
Type curve in the Name box.

Step 2:

Click FormatLayer Settings.
Type 51 in the Work box.
6-15
Five Axis Z Level
Click OK.
You will select the line to control the tool axis tilt.
Choose Away from curve(s) from the Tool Axis Tilt list.
Select the curve as shown below.

Step 3:

Click Generate
6-16
mt11050_g NX 5
Five Axis Z Level
Right-click in the graphics screen and select Orient ViewTop.
The tool axis tilts away from the selected curve at the angle
specified from the ZM axis.
Click Verify
6
Click Play

6-17
Five Axis Z Level
Activity: Away from multiple curve tool axis tilt

Away from curve tool axis will be used. You will select multiple curves to
control the tool axis tilt.
Step 1:
Continue using the***_zl_multi_axis_setup_1 part and create a

new operation.
Click ZLEVEL_5AXIS
Set the Parent objects as shown;

Program
Tool
Geometry
Method
1234
BN-10
MILL_AREA
MILL_FINISH
Type multi_curve in the Name box.

6-18
mt11050_g NX 5
Five Axis Z Level
Step 2:

Choose Away from curve(s) from the Tool Axis Tilt list.
Select the curves as shown below.

Step 3:

Click Generate
Right-click in the graphics screen and select OrientTop.
Click Verify
.
6-19
Five Axis Z Level
Click Play

The tool axis is tilted away from the arc along the cylindrical face
and away from the line along the planar face.
6-20
mt11050_g NX 5
Five Axis Z Level
Optimized cut levels

Optimized adjusts the depth of cut to help maintain a more consistent on part
spacing and scallop height. Optimized creates additional cuts as the slope
changes from steep or near vertical to shallow or flat. The maximum cut
depth does not exceed the Global Depth per Cut value.
6-21
Five Axis Z Level
Activity: Optimized cut levels

In this activity, you will machine around the fins of the part. The Away from
part tool axis tilt will be used. You will generate the path using constant cut
depths. Then you will optimize the cut levels and generate a new tool path.
Step 1:
Open the impeller_zlevel_setup_2 part.
6
Click ZLEVEL_5AXIS

Program
Tool
Geometry
1234
EM-3.0_BN
MIL_AREA
Method
MILL_SEMI_FINIISH
Type optimize in the Name box.

Click OK to create the operation
Step 2:

Choose Away from part from the Tool Axis Tilt list.
6-22
mt11050_g NX 5
Five Axis Z Level
Step 3:
Specify the cut levels.

Click Cut Levels
Type 3.0 in the Global Depth per Cut.

Click OK.
Step 4:

Click Generate
Click Verify
Move the Animation Speed slider bar to 3.
Click Play
The tool axis is tilted 3 degrees from the ZM axis away from
the part geometry and the cut depths are constant.
Step 5:
Optimize the cut levels to leave more consistent stock.

Click Cut Levels
.
6-23
Five Axis Z Level
Choose Optimized from the Cut Levels list.

Click OK.
Step 6:

Click Generate
6
Click Verify
Click Play
The tool axis is tilted 3 degrees from the ZM axis away from the
part geometry. The cut levels are closer together in the flatter
areas of the part.
6-24
mt11050_g NX 5
Five Axis Z Level
Summary
Z Level 5 Axis operations utilize tool axis tilt allowing shorter tools to be
used. The tool axis is applied using ball nose cutters to planar cut levels.
These cut levels are perpendicular to the Machine Coordinate System
You can now create 5 Axis Z Level operations and incorporate;
Several tool axis tilt options.
Constant and Optimized cut levels.
6-25
Lesson
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
7-1
Sequential Milling overview

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 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.
7-3
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.
Several dialogs are used in Sequential milling. The operation starts with the
Sequential Mill dialog where you set global parameters and progresses to
suboperation dialogs that control each suboperation.
7-4
mt11050_g NX 5
Global operation parameters

When you create a new Sequential Mill operation you first see the Sequential
Mill dialog where global operation parameters are set.
The Sequential Mill dialog
box 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 creating or editing an operation, you choose End Operation either

generate the tool path, or save the operation without tool path generation.
7-5
Suboperations
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
7-6
mt11050_g NX 5
The Engage Motion

The Engage Motion suboperation defines where the tool initially contacts
the part. This is usually the first suboperation dialog box which you will
encounter.
To create an Engage Motion suboperation you must
Specify the Engage Method
Specify a Reference Point
Specify Geometry including Part, Drive and Check
Other options are also available.
7-7
The Continuous Path Motion dialog box

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.
7-8
mt11050_g NX 5
Point To Point Motion

The Point to Point motion 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 box when
creating Sequential Mill operations.
To create a Point to Point suboperation you must define the Motion Method
7-9
Retract Motion
The Retract Motion dialog box 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.
To create a Retract Motion suboperation you must specify the Retract Method.
7-10
mt11050_g NX 5
Define the Check Surfaces

When you are creating a Continuous Path Motion or Engage suboperations,
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.
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
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
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.
7-11
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.
7-12
mt11050_g NX 5
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.
7
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
7-14
mt11050_g NX 5
Click Sequential_Mill
Set the Location objects as shown and name the operation

SM_1:
Program
Tool
Geometry
Method
BASIC_SM
EM-1.00-0
WORKPIECE
MILL_FNIISH
Choose OK.
The Sequential Mill dialog box is displayed.
This dialog box allows the input of basic global parameters
that are active throughout the operation (unless changed in
an suboperation).
Click Display Options.
Choose 3-D from the Tool Display list.
Choose OK.
The global parameters are now set.
The Sequential Milling dialogs behave somewhat differently
than other operation dialogs that you are normally familiar
with.
Choosing OK from the main dialog box results in the
suboperation dialog box being displayed. This is where the
actual programming process takes place.
Choose OK from the Sequential Mill dialog box.

The Engage Motion suboperation dialog box is displayed. By
default, the suboperation dialog box 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.
Choose Pt to Pt from the Engage list.
The dialog box 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.
7-15
Choose Point, Tool Axis from the Motion Method list.

The Point Constructor dialog box is displayed.
Select the existing point:
Choose OK.
The Vector dialog box is displayed.
Click ZC Axis
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 Pt to Pt to an Engage suboperation.
The Engage Motion dialog box is displayed.
This dialog box requires Drive, Part and Check geometry.
Additionally, you may specify an engage method.
You will specify the geometry first and then the Engage method.
7-16
mt11050_g NX 5
Click Geometry.
The Engage Geometry dialog box is displayed.
You will now select the Drive geometry.
Select the face as shown.
7
The geometry selection on the dialog box advances to Part
geometry.
You will now select the Part geometry.
7-17
Select the bottom of the pocket as the Part geometry.
The geometry selection on the dialog box advances to Check

geometry.
7-18
mt11050_g NX 5
Select the face, as shown below, as the Check geometry.
As soon as the last geometry is selected, the dialog box reverts

to the Engage Motion suboperation.
You will now specify the Engage motion.
Click Engage Method.
The Engage Method dialog box is displayed.
Choose Vector Only from the Method list
The Vector Constructor dialog box is displayed.
Change Inferred Vector to By Coefficients.
7-19
Key in the following values:

I=-1.000
J= 1.000
K=-1.000
Choose OK.
Key in 0.500 in the Distance field of the Engage Method dialog
box.
Choose None from the Clearance Move list.
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.
7-20
mt11050_g NX 5
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 box is displayed.
You are now ready to select the Check surface. As soon as the
surface is selected, the dialog box advances to Check Surface
No. 2. It is important to specify any changes to the dialog box
before the surface is selected.
The current Drive surface is tangent to the next surface that
the tool will drive to. You will change the stopping position to
Drive Surface/Check Surface Tangency.
Change the Stopping Position to Ds-Cs Tangency.
7-21
Select the Blend face as shown.
There will not be a second Check surface to select.
Choose OK in the Check Surface dialog box.

Choose OK in the Continuous Path Motion dialog box.
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.
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The object type of face is correct as well as the Stopping
Position of Ds-Cs Tangency.
Select the face as shown.
7
Choose OK in the Check surface dialog box.
The suboperation, 4 cpm, is now placed in the dialog box 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.
7-23
Change the Stopping Position to Far Side.

Select the surface as shown below.
Choose OK in the Check Surface dialog box.

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

Change Inferred Vector to By Coefficients.
I= 1.000
J= -1.000
K= 1.000
Choose OK.
Key in 0.500 in the Distance field of the Retract Method dialog
box.
Choose OK.
Choose OK in the suboperation dialog box.
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, right-clickRefresh.
7-25
Choose Redisplay Tool Path from the End Operation dialog

box.
The tool path is displayed.
Choose OK from the End Operation dialog box.

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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 box 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..
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).
7-27
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.

Click the Operation Navigator tab from the resource bar.
In the Operation Navigator, Replay the operation named
DEMO.
You will now create an operation identical to the operation

which you just replayed.
Step 2:
Create the Sequential Mill operation.

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

Program
Tool
Geometry
Method
MULTI-FLOOR-PROG
EM_.75_.125
WORKPIECE
MILL_FINISH
Type fin-poc-walls in the Namebox.

Click OK.
Clear the Multiaxis Output check box.
The Display Options dialog box is displayed.
Choose 3-D from the Tool Display list
Select 9 from the Path Display Speed slider.
Click OK.
The global parameters are now set and you are ready to begin
the Sequential Milling process.
Click OK and continue to the Engage Motion dialog box.
Step 3:
Specify an Engage motion.

You will now create a vector that will be used for engaging the part.
The Engage Method dialog box is displayed.
Change the Method to Vector Only.
Click XC Axis
Click Revere Direction
Click OK.
Type 0.500 in the Distance box.
Click OK to return to the Engage Motion dialog box.
7-29
Select Point from the Reference Point Position list.

Select the point as shown.
Click OK .
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Click 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.
7-31
Click 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.
Drive Surf
Part Surf
Previous ds
Previous ps
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.
Click Check Surfaces.

Change the Check Stock to 0.
Change the Check surface Stopping Position to Ps-Cs
Tangency.
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Specify a new Check surface as shown.
Return to the Continuous Path Motion dialog box and click OK.
The tool moves to the new position.
Note the status of the Part Surface to previous Check surface.
7-33
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.
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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.
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Note that the status of the Drive or Part surfaces did not
change.
Specify the Check surface Stopping Position as Near Side.
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Note the status of the Drive or Part surfaces did not change.
Specify the Check surface Stopping Position as Ps-Cs
Tangency .
7-37
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.
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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.
7-39
Change Cont. Path to Retract.

The Retract Motion dialog box is displayed.
Change the Retract Method to Vector Only .
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Click XC Axis
Change the Distance to .200.
Return to the Retract Motion dialog box and click OK.
The tool retracts to the Clearance Plane.
Choose End Operation and then OK to save the operation.

The entire tool path is displayed.
7-41
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.
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Lesson
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.
8-1
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 - 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
8-3
5Axis Tool Axis Control

Variable Contour
Sequential Mill
Toward or Away From Point
Normal to Part
Normal to Drive
Swarf Drive
Thru Fixed Point

Normal to PS
Normal to DS
Parallel to PS
Relative to Drive
Parallel to DS
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.
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(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.
8-5
(1) Final Tool Axis

(2) Check Surface
(3) Check Surface
contact point
(4) Part Surface
(5) 5Axis Fanning
8-6
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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
box to define the point.
(1) User defined pivot point

(2) Check Surface
(3) Drive Surface
(4) Part Surface
8-7
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.
Rename the part ***_spar_mfg.

Click the Operation Navigator tab from the toolbar.
Highlight the SIDE_1 program.object..
Right-clickTool Path, and choose Verify
8-8
mt11050_g NX 5
Select the 3D Dynamic tab from the Tool Path Visualization

dialog.
Click 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.
Click OK on the Tool Path Visualization dialog.

Step 2:
Create the Sequential Mill Operation.

Click Create Operation from the Manufacturing Create toolbar.
The Create Operation dialog is displayed.
Click mill_multi-axis from the Type list.
Click Sequential_Mill as the subtype.

Set the Parent objects as follows:
Program
Tool
Geoemtry
Method
FINISH_1
EM-.5.130CARBIDE
PART_AND_BLANK
MILL_FINISH
Type SM_FINISH_WALLS_POCKET_1 in the Name box.

8-9
Click OK.
The Sequential Mill dialog is displayed.
Step 3:
Set Tool Display options and create a Point to Point Motion.

The Display Options dialog is displayed.
Choose 3-D from the Tool Display list and change the Path
Display Speed to 9.
Click OK twice.
The Engage Motion dialog is displayed.
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.
Choose Point, Tool Axis from the Motion Method list..
The Point Constructor dialog is displayed.
Select the following point for the base point.
The Vector Constructor dialog is displayed.

Click ZC Axis
Click OK to accept the tool axis.

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mt11050_g NX 5
Click 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.
You will now define the Engage component.

Change Pt to Pt to Engage.
The Engage Method dialog is displayed.
Choose Vector Only from the Method list.
The Vector Constructor dialog is displayed.

Choose By Coefficients from the Type list
I= 0.000
J= 1.000
K= .500
Click OK.
8-11
Key in 2.00 in the Distance field of the Engage Method dialog.

Click OK.
Click 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.
Click Point and Direction
Select the control point as shown.
8
Select the linear edge to define the vector as shown.
8-12
mt11050_g NX 5
A temporary plane is displayed.
8
Click OK.
The dialog advances to Part.
Choose Face from the Type list..
8-13
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.
Choose 5-axis from the Tool Axis list.

The Five Axis Option dialog is displayed. Notice that the
Method defaults to Fan, which is acceptable in this instance.
Click OK in the Five Axis Options dialog.
Click OK to create the Engage suboperation.
You are now ready to create the first Continuous Path Motion.
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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, click the Check
Surfaces button.
In the Check Surfaces dialog, change the Stopping Position to
Ds-Cs Tangency.
Select the corner fillet surface as shown.
Click Left in the Direction list.
Click OK in the Check Surfaces dialog.
8-15
Click OK in the Continuous Path Motion dialog.

The tool drives into the corner and suboperation 3 is created.
Click the Check Surfaces button.

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 a temporary plane selected like the original
temporary plane. This should prevent any 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.
8-16
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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.
Creating loops
The Loop option is located in any of the Motion dialogs (Engage, Retract,
Continuous Path, or Point to Point) under the Options Loop Control.
Before you begin the creation of a loop, the tool should be in the proper
position within the operation (where you want the tool to start repeating
from).
You can 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
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.
The next activity will familiarize you with some of the basic concepts of
looping within Sequential Mill.
8-17
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.
8-18
mt11050_g NX 5
Double-click on the FINWALLS operation.

Note that the Multiaxis Output option is selected.
Click OK.
The Point to Point Motion dialog is displayed.
Click OK.
Normally, you start the looping process from within this dialog.
Click Options.
The Other Options dialog is displayed.
Click Loop Control.
The Loop Control dialog is displayed.
Note the Ds and PS loop settings.
These settings will create five passes, each pass will remove
.050 stock.
Click OK three times to return to the Continuous Path Motion
dialog.
On the Continuous Path dialog, Click Options, then Loop
Control to check the Loop Control status. They are set to
Contin.
Click 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, click the Options button, then
the Loop Control button to check the loop status. They are
set to End.
Step 3:
Start the looping process.

Click OK three times until the Loop Debug Options dialog is
displayed.
8-19
On the Loop Debug Options dialog, click 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.
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Activity: Remove 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.
Right-click SM_FINISH_WALLS_POCKET_1 and choose Copy.
Right-click PM_FINISH_BOSSESand choose Paste.
Right-click 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 SM_SEMI_FINISH_WALLS_POCKET_1 .
Change the Global Stock on Drive Surfaces to .030.
Change the Global Stock on Part Surfaces to .030.

Click OK on the Sequential Milling dialog box.
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 box and
choose the 4 cpm suboperation.
8-21
Click the Delete button and confirm the choice in the message
dialog box.
There should now be three suboperations remaining in the
suboperation list a Point to Point; an Engage, and a CPM.
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.
8-22
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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.
Click OK on the Check Surfaces dialog box.
Click 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.
8-23
Select the wall as shown below.
Click OK on the Check Surfaces dialog box.

Click 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.
Click Temporary Plane from the Type list.
Click Point and Direction
8-24
mt11050_g NX 5
Select the control point as shown.
Select the linear edge to define the vector as shown.
A temporary plane is displayed.
8-25
Click OK in the Check Surface dialog box.

Click OK to accept the suboperation.
Change the motion type to Retract.
Click the Retract Method button.
Change the Method from None to Vector Only.
Choose By Coefficients from the Type list.
Key in the following values to create the vector:
I = 0.0
J = 1.0
K = 1.0
Click OK in the Vector Constructor dialog box.
Key in 1.0 in the Distance field.
Click OK in the Retract Method dialog box.
Click OK to accept the suboperation.
The suboperation, 6 Ret, is created.
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mt11050_g NX 5
Click End Operation.

Click OK in the End Operation dialog box.
Save the part file.
8-27
Activity: Use 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.
Click OK in the Sequential Mill dialog box.
Click OK in the Point to Point Motion dialog box to advance
to suboperation 2.
In the Engage Motion dialog box, click the Options button.
Click Loop Control.
The Loop Control dialog box is displayed.
Choose Start from the Ds loop parameters.
Key in 0.2 in the Initial stock field and .05 in the Increment
field.
Click OK.
Click OK on the Other Options dialog box.
Click OK on the Engage Motion dialog box.
Continue to click OK until suboperation 6 Ret is highlighted
(Retract Motion dialog box is displayed).
Click Options.
Click Loop Control.

Change the Ds loop parameters from Continue to End.
Click OK on the Loop Control dialog box.
Click OK on the Other Options dialog box.
Sequential Milling is now ready to create the additional loop
passes.
Click OK on the Loop Debug Options dialog box.
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When satisfied with the additional passes, Click End Operation

on the Point to Point Motion dialog box.
Click OK in the End Operation dialog box.
Visually examine the output using Visualization.
Save and close the part.
8-29
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.
Replace geometry globally
Replace Geometry Globally, replaces faces, curves and temporary planes by
other faces, curves and temporary planes throughout the operation.
8-30
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This option is located on the Sequential Mill dialog box.
8-31
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 box 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 box 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 box)
When using a Fan tool axis, reduce the Maximum Step (on the Other
Options dialog box)
When using a Fan tool axis around curved geometry, limit the motion to
60 degrees
Looping:
8-32
Start a loop on an Engage or Point to Point Motion suboperation; starting

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
ifIyou 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
mt11050_g NX 5
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
8-33
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.
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Lesson
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
9-1
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:
Check geometry to stop tool movement
Gouge checking to prevent gouging of the part
Various tolerance options

9-3
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.
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Terminology used in variable contour
Part Geometry - Geometry selected to cut
Check Geometry - Used to stop tool movement
Drive Geometry - Used to generate drive points
Drive Points - 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.
9-5
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.
9-6
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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.
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 correspond to exterior part surface edges.
Cut regions are defined by Boundaries, Loops, or a combination of both.
The boundary members graphically represent the associated tool positions
as illustrated below:
(1) tanto condition
(2) on condition
(3) contact condition
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.
9-7
(1) Drive points

projected from plane
(2) Projection vector
(3) Center point defines
the center of the spiral,
cut starts here
(4) Part surface
(5) Spiral drive
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
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 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.
9-8
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(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
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
9-9
When you select Tool Path as the drive method, you must specify an existing
CLSF to be used to generate drive points.
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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
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.
9-11
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 box is displayed.
Step 3:
View the Variable Contour dialog box options.

You will review the option settings on the Variable Contour dialog
box, then you will note the option settings on the Surface Area
Drive Method dialog box. These options are required to create
the tool path.
Click Display
next to Specify Part.
Refresh the graphics window .

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Under the Drive Method label, view the Drive Methods that
are available.
Expand Tool Axis and 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 box is displayed.
Click Display
next to Specify Drive Geometry.
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.
Click 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.
9-13
Close the part file.
9-14
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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:
9-15
Tool
Axis
Curve/
Spiral
Point
Away
From
X
point
Toward
X
Point
Away
From
X
Line
Toward
X
Line
Relative
to
X
Vector
4axis
Norm.
X
To Part
4axis
Rel. To
X
Part
Dual
4Axis
X
on Part
Inter
X
polate
Swarf
Drive
Optimized
to
Drive
Normal
To
Drive
Relative
To
Drive
4axis
Norm.
To
Drive
4axis
Rel. To
Drive
9-16
Bndry
Drive method
Surface Streamline
Tool
Area
Path
Radial
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Dual
4Axis
on
Drive
Same
as
Drive
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
9-17
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.
9-18
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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.
Step 1:

Open the part file vx_4.
If necessary, enter the Manufacturing application and display

the Program Order view in the Operation Navigator.
9-19
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.
Replay the TOWARDLINE operation.
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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.
9-21
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.
9-22
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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.
9-23
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
9-24
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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
9-25
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.
Step 1:

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.
Expand Tool Axis and choose Relative to Part from the Axis
list.
You are prompted to change the Lead and Tilt angles. Use the
defaults of 0
Choose OK.
9-26
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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.
list.
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.
9-27
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.
list.
Under the Tool Axis label, choose, Relative to Part.
You are prompted for Lead and Tilt angle settings.
Note the specified settings.
Choose OK.
9-28
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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.
9-29
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.
9-30
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Activity: 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.
Step 1:

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.
Step 3:
Examine various operations.
Choose the Operation Navigator tab from the toolbar.

The Operation Navigator is displayed.
If necessary, change to the Program Order view of the
Operation Navigator.
9-31
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.
Choose the Assembly Navigator tab from the toolbar.
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.

Choose the Create Operation icon.
If necessary, set the Type to mill_multi_axis.
Choose the VARIABLE_CONTOUR icon.
Set the Parent Groups as follows:
Program: HUB-FINISH
Tool: BALL_MILL-.75
Geometry: WORKPIECE
Method: MILL_FINISH
Name: vc_flute_fin
Choose OK.
The Variable_Contour dialog box is displayed.

Change the Drive Method from Boundary to Surface Area.
9-32
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Choose OK on the Drive Method Information dialog box.

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.
Click Specify Drive Geometry

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.
Click Cut Direction
Cut direction vectors are displayed.

9-33
Choose the vector as shown (1).
Choose Surface % from the Cut Area list.

Note the system highlight at the top and bottom of the cylinder.
Refresh the screen.
Set the start and end values as shown:
Start step
End step
20
55
Choose OK.
Note the area that is now highlighted. The cutter will now be
limited to this area which encompasses the flutes.
Change the Cut Type to Zig.

You will now set the tool axis and projection vector.
Click OK.
Change the Tool Axis from Normal to Part to Relative to Drive.
9-34
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Set the Tilt angle to 45.

Choose OK.
Set the Projection Vector to Toward Line.
The Line Definition dialog box is displayed.
Choose the Point and Vector button.
Choose OK on the Point Constructor dialog box (accept the
defaults).
Choose the ZC Axis icon
Choose OK twice.
The Variable_contour dialog box is displayed.
Step 5:
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
9-35
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 box options are:
Specify as defines the vectors used to interpolate the tool axis. You can
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.
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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 box. Selecting Back accepts all of the defined vectors and
returns you to the Interpolated Tool Axis dialog box.
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.
9-37
Activity: 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.

9
Click Variable Contour
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In the Create Operation dialog box, set the following:

Program: PROGRAM-AXIS-LIMITS
Geometry: WORKPIECE
Tool: BALL_MILL-1.0
Method: MILL_FINISH
Name: interpolate
Choose OK.
Step 3:
Define the Drive Geometry.

Choose Surface Area from the Drive Method list
The Surface Drive Method dialog box is displayed.
Step 4:
Specify a Drive Method.

Click Specify Drive Geometry
9-39
Choose the surfaces as shown.
Choose OK.
Click Cut Direction
9-40
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Choose the Cut Direction arrow as shown.
ChooseZig from the Cut Type list.

Expand More.
Type 4 in the Number of Steps box.
Choose Tolerances from the Cut Step list.

Click OK.
Expand Tool Axis.
9-41
Select Interpolate from the Tool Axis list.

The Interpolated Tool Axis dialog box is displayed.
The default vector arrows show the current tool axis vector
direction.
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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.

Choose OK.
Choose OK to return to the Variable Contour dialog box.
9-43
Expand Options.
Click Edit Display icon and change the Tool Display to Axis.
Choose OK to return to the Variable Contour dialog box.
Choose the Generate icon.
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.
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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.
9-45
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."
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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:
Variable Contour
Sequential Mill
preferred method for area milling

primary cutting with bottom of tool
preferred method for linear milling

primary cutting with side of tool
numerous drive methods for tool

path containment
single drive method
numerous cut patterns for specific

applications
no cut patterns other than looping or

nested loops
sheet body and surface region

geometry allowed
temporary plane geometry allowed
constant tool axis
can change tool axis during operation

edits apply to part of tool path
edits apply to entire tool path

best at convex wall cuts
easy to create operation
easy to create multiple depth paths
best at overcut and undercut type

walls
numerous steps in operation creation
N/A
9-47
Tool Axis usage

The following table compares tool axis usage in Variable Contour and
Sequential Mill operations:
Tool Axis Usage
Variable Contour
3 Axis
Sequential Mill
Normal to Part (default)
ZM Axis (default)
Vector
Relative to 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
dual 4axis on part / dual 4axis on
drive
-
tangent to Drive Surface

project Drive Surface Normal
project Part Surface Normal
5 Axis
thru fixed point
toward point
normal to part
thru fixed point

normal to Part Surface
normal to drive
normal to Drive Surface

parallel to PS /Parallel to DS
interpolate
same as drive path
user function
-
9-48
tangent to Part Surface
Away from point
swarf drive
relative to drive
at angle to Drive Surface/at angle to

Part Surface
-
at angle to DS / at angle to PS
tangent to PS
tangent to DS
fan
mt11050_g NX 5
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.
9-49
Lesson
10 Variable Contour advanced

Purpose
This lesson will introduce advanced concepts in conjunction with Variable
Contour operations.
Objective
Create Contour Profile tool paths to cut pocket walls.
use Associative Datum planes to create surfaces and geometric objects

used for creation of start points and initial tool axis
10
10-1
10
Variable Contour advanced
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
10-3
Activity: Contour Profile Drive Method

In this activity you will use the Contour Profile drive method to machine
the canted walls of the part.
Step 1:

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
Click CONTOUR_PROFILE
10-4
mt11050_g NX 5
Set the group objects as shown:

Program
Tool
Geometry
Method
SIDE_1
EM-0.5-.13-CARBIDE
PART_AND_BLANK
MILL_FINISH
Click OK.
The CONTOUR_PROFILE dialog box is displayed.
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.
Click Specify Floor
Choose the bottom of the pocket as shown.
10
10-5
Click OK.
10
10-6
mt11050_g NX 5
Click Display next to Specify Wall
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.
The Cutting Parameters dialog box is displayed.
10
10-7
Click the Multiple Passes tab.

Select the Multiple Passes on Wall check box.
Type 0.1 in the Wall Stock Offset box..
Choose Passes from the Step Method list.
Type 3 in the Number of Passes box.
Click OK .
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.

Click Generate from the CONTOUR_PROFILE dialog box.
10
10-8
mt11050_g NX 5
Examine the tool path.
(1) Tool path prior to stock removal; (2) tool path after stock
removal
10
10-9
If time permits, create a second Contour Profile operation to

machine the walls of the next pocket.
10
10-10
mt11050_g NX 5
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
10-11
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
10-12
mt11050_g NX 5
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.
Step 1:

Open the part file wedge_mfg.

Step 2:

Set the group objects as shown ;

Program
Tool
Geometry
Method
PROGRAM
EM-.5-.125-CARBIDE
WORKPIECE
MILL_FINISH
10
10-13
Click OK
Step 3:
Specify the Floor Geometry.

Click Specify Floor
Choose the bottom of the pocket as shown.
Click OK.
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10-14
mt11050_g NX 5
Click Display next to Specify Walls.

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.
Step 4:

Examine the tool path using Replay or Verify.
10
10-15
Tilting the tool axis

The tool axis can be tilted away from the part geometry. Tilting the tool away
from the part walls allows cutting without dragging the side to the cutting
tool. Tools with shorter flute lengths may also be used.
10
10-16
mt11050_g NX 5
Activity: Tilting the tool axis

You will copy the previous operation and add a 10 degree tilt to the tool axis.
Step 1:
Continue to use the existing part file.

The part file mfg_wedge should be open.
Step 2:
Copy and rename the previous operation.

Right-click the operation CONTOUR_PROFILE, choose Copy,
right-click the operation again and choose Paste.
Right-click the operation CONTOUR_PROFILE_COPY, choose
Rename.
Rename the operation TILT_AXIS
Step 3:
Edit the operation and add the tool axis settings.

Right-click the operation and choose Edit.
Choose the Tool Axis Control tab.
10
Type 10.0 in the Tilt Angle box.

10-17
Click OK.
Step 4:

The tool path follows the bottom contour of the wall geometry
while tilting 10 degrees from the walls.
10
10-18
mt11050_g NX 5
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
10-19
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:

Step 2:

If necessary, choosemill_multi_axis from the Type list.
Set the group objects as shown and select OK.

Program
Tool
Geometry
Method
10
PROGRAM
EM-.5-.125-CARBIDE
WORKPIECE
MILL_FINISH

10-20
mt11050_g NX 5
Step 3:
Turn off the Automatic Wall option.

Clear the Automatic Wall check box.
Step 4:
Specify the Wall Geometry.

Clcik Specify Walls
Select all of the walls on the outside of the part.
Click OK.
Select Follow Bottom Wall on the CONTOUR_PROFILE dialog
box.
The operation will detect the bottom of the walls to use for floor
geometry. The path could also be offset from the Bottom Wall.
Step 5:

10

10-21
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.

Type .250 in the Tool Position Offset 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
10-22
mt11050_g NX 5
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
10-23
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.
Step 1:

Step 2:


Program
Tool
Geometry
Method
PROGRAM
EM-.5-.125-CARBIDE
WORKPIECE
MILL_FINISH
Click OK.
10

10-24
mt11050_g NX 5
Step 3:

Step 4:

Click Specify Wall
Choose all of the walls on the outside of the part.
Click OK.
Select the Automatic Auxiliary Floor check box.
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.
Step 5:
10

10-25

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
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.
10
10-26
mt11050_g NX 5
Step 7:
You will now select multiple floor passes.

Select the Multiple Passes tab.

Select the Floor check box. .
Type 2.00 in the Floor Stock Offset box.
Click OK to return to the CONTOUR_PROFILE dialog box.
Click Generate.
10
10-27
10
10-28
mt11050_g NX 5
Step 8:
You will also add multiple Wall passes to the operation.


Select the Wall check box. .
Type 0.1 in the Wall Stock Offset box.
Click Generate.
Click Generate.

Step 9:

Navigator.
10-29
10

10
10-30
mt11050_g NX 5
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
10-31
Activity: Auxiliary Floor

You will create a new operation using the Auxiliary Floor option.
Step 1:

Step 2:

Set the group objects as shown.

Program
Tool
Geometry
Method
PROGRAM
EM-.5-.125-CARBIDE
WORKPIECE
MILL_FINISH
Click OK.
10

10-32
mt11050_g NX 5
Step 3:
Make the layer containing the auxiliary floor selectable.

Select Format Layer Settings , highlight layer 52 and click
Selectable.
Click OK.
Step 4:

Step 5:

Click Specify Wall
Click OK.
Click Specify Auxiliary Floor
10
You will select the sheet body as the Auxiliary Floor.

10-33
Step 6:
Generate the operation and examine the tool path

The tool path follows the Auxiliary Floor geometry while using the
wall geometry to guide the tool axis.
10
10-34
mt11050_g NX 5
Step 7:


Click Generate.
10
10-35
Click OK to accept the operation and tool path.

In this case the Auxiliary floor establishes a smoother tool path
than the Follow Bottom Wall path. It also allows multiple floor
passes.
Step 8:

Navigator.
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10-36
mt11050_g NX 5
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
10-37
Activity: Auxiliary Floor and Automatic Auxiliary Floor

You will create a new operation using the Auxiliary Floor and Automatic
Auxiliary Floor.
.
Step 1:

Step 2:


Program
Tool
Geometry
Method
10
PROGRAM
EM-.5-.125-CARBIDE
WORKPIECE
MILL_FINISH

10-38
mt11050_g NX 5
Step 3:

Step 4:

Click Specify Wall
Click OK.
Click Specify Auxiliary Floor
You will select the sheet body as the Auxiliary Floor.
10
10-39
Step 5:
You will also turn on the Automatic Auxiliary Floor option.

Click Automatic Auxiliary Floor.
Step 6:
Generate the operation and examine the tool path

The tool path follows the Auxiliary Floor and the Automatic
Auxiliary floor geometry while using the wall geometry to guide
the tool axis.
10
10-40
mt11050_g NX 5
10
10-41
Step 7:


Click Generate.
Click OK to accept the operation and tool path.
10
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mt11050_g NX 5
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
10-43
10
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.
A-1
Projection Vectors
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
mt11050_g NX 5
Projection Vectors
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.
A-3
Projection Vectors
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
mt11050_g NX 5
Projection Vectors
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
Fixed
Vector
Away From Point
Toward Point
Away From Line
Toward Line
Relative To Vector
Normal to Part
Relative to Part
4axis Normal to Part
4axis Relative to Part
Dual 4Axis on Part
Interpolate
Normal to Drive
Swarf Drive
Relative to Drive
4axis Norm to Drive
4axis Rel to Drive
Dual 4Axis on Drive
Same as Drive Path
Projection Methods
Tool Toward Toward Norm
Axis / Away / Away Drive
Point
Line
Swarf
Rule
X
X
X
X
X
X
X
X
X
X
X
X
A-5
Appendix
B Zig-Zag Surface machining
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.
B-1
Appendix
C Advanced surface contouring

C
Projection
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
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
(2) drive
point
(3) d
(4) x
(5)
C-2
mt11050_g NX 5
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
(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
degrees
Begin with cut vector, rotate it toward the Reference vector 90-
Then rotate around the cut vector
Reference vector is the surface normal relative to the part/drive or a

vector which is relative to a vector
degrees (counter clockwise)
C-3
Definition of 4-axis rotation angle:

(1) rotation angle
(2) perpendicular plane
(3) tool axis
(4) projected tool axis
(5) 4axis vector
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:
C-4
Normal to Part / Drive
Relative to Part / Drive
mt11050_g NX 5
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
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:
C-5
(1) trimmed face; (2) underlined

surface
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
C-6
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
mt11050_g NX 5
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
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
C-7
Part Offset
Part Stock
What
Offset of part as the
permanent definition of
the final shape of the
product
Where
Geometry Group
Leftover material
on part by a given
operation
Operation
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
C-8
mt11050_g NX 5
Safe clearance and part stock offset

What
Where
Part Stock Offset
Difference between the

part stock from the
previous operation and
the part stock of the
current operation
Operation
Safe Clearance
The additional safety

zone for collision
checking
Operation
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
Cutting part of tool
Collision
assembly
Non-cutting part of tool Collision
assembly
Feed moves
Gouge
Collision
Usually gouge check against part offset + part stock

C-9
Usually collision check against part offset + part stock + part stock offset
+ safe clearance
C
(1) collision
(2) gouge
Usage:
Tool Path Generation

Drive Path Generation
Engage/Retract
Collision check
No
No
No
Gouge check
Yes on Part
Transfer Moves
Optional on Part
Cut Region
Computation
Optional (holder) on
Part/Check
Optional on Part
Yes on Part
(Cut Area)
Check Geometry
No
Optional on Check
Gouge Check
No
(No Part Stock)
Optional on Drive
Optional on Part
(Operation Navigator)
C-10
mt11050_g NX 5
Noncut moves
Azimuth / Latitude:
(1) latitude
(2) azimuth
(3) part normal

(4) cut vector
(5) engage/retract vector
Begin with cut vector, rotate it toward the part normal
Then rotate around the part normal
degrees
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-11
Index
advanced surface contouring topics

boolean logic . . . . . . . . . . . . . . . .
drive surface . . . . . . . . . . . . . . . .
remap of . . . . . . . . . . . . . . .
swarf developable . . . . . . . . .
gouge/collision . . . . . . . . . . . . . .
noncut moves . . . . . . . . . . . . . . .
planar milling . . . . . . . . . . . . . .
projection . . . . . . . . . . . . . . . . . .
material side . . . . . . . . . . . .
steep surface . . . . . . . . . . . .
stock . . . . . . . . . . . . . . . . . . . . .
tool axis . . . . . . . . . . . . . . . . . . .
lead/tilt . . . . . . . . . . . . . . . .
Fixed Contour
drive geometry . . . . . . . .
drive methods
flow cut . . . . . . . . . .
radial cut . . . . . . . . .
tool path . . . . . . . . .
User Function . . . . .
drive points . . . . . . . . . .
operation types . . . . . . . .
contour_area . . . . . .
contour_surface_area
fixed_contour . . . . . .
terminology . . . . . . . . . .
check geometry . . . .
drive geometry . . . . .
drive method . . . . . .
drive points . . . . . . .
part geometry . . . . .
projection vector . . . .
use of . . . . . . . . . . . . . . .
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C-7
C-5
C-5
C-7
C-9
C-11
. C-7
. C-1
. C-3
. C-2
. C-7
. C-3
. C-3
C
Cavity Mill
Cut Levels . . . . . . . . . . . . .
Cut Patterns
Cut Pattern . . . . . . . . .
Cavity Milling
cut region start points . . . . .
Course Overview
Class Standards . . . . . . . . .
Course Description . . . . . . .
Intended Audience . . . . . . .
Objectives . . . . . . . . . . . . . .
Prerequisites . . . . . . . . . . .
Student and Workbook parts
System Privileges . . . . . . . .
Workbook overview . . . . . . .
Cut Area Geometry
Z-Level Milling . . . . . . . . . .
Cut Levels . . . . . . . . . . . . . . .
Cut Patterns . . . . . . . . . . . . .
. . . . . 2-2
. . . . . 2-6
. . . . 2-18
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9
7
7
8
7
13
13
12
. . . . . 3-3
. . . . . 2-2
. . . . . 2-6
. . . . . . . 4-2
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4-3, 4-64-7
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. . . . . . 4-3
. . . . . . 4-3
. . . . . . 4-2
. . . 4-44-5
. . . . . . 4-4
. . . . . . 4-4
. . . . . . 4-4
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
. . . . . . 4-2
G
Geometry Types
Z-Level Milling . . . . . . . . . . . . . . . 3-3
M
Multi-axis
multi-axis
positioning . . . . . . . . . . . . . . . 5-3
rotary axis . . . . . . . . . . . . . . 5-10
tool axis . . . . . . . . . . . . . . . . . 5-3
P
Part Geometry
Index-1
Index
Check Geometry
Z-Level Milling . . . . . . . .
Projection Vectors
definition of . . . . . . . . . . . . . .
specification of . . . . . . . . . . . .
as used in variable contour
as used ins surface area
drive . . . . . . . . . . . . . .
fixed . . . . . . . . . . . . . . . .
table of methods . . . . . . . . . . .
. . . 3-3
. . . A-1
. . . A-2
. . . A-3
. . . A-3
. . . A-2
. . . A-5
S
Sequential Milling
Check surface . . . . . . . . . . .
creating operation . . . . . . .
dialog . . . . . . . . . . . . . . . . .
Drive surface . . . . . . . . . . .
engage motion dialog . . . . .
loops . . . . . . . . . . . . . . . . .
multiple check surface . . . .
nested loops . . . . . . . . . . . .
overview . . . . . . . . . . . . . . .
Part surface . . . . . . . . . . . .
point to point motion dialog
reference point . . . . . . . . . .
replace geometry globally . .
retract motion dialog . . . . .
stopping position
Ds-Cs Tangency . . . . . .
far side . . . . . . . . . . . .
near side . . . . . . . . . . .
on . . . . . . . . . . . . . . . .
Ps-Cs Tangency . . . . . .
suboperations . . . . . . . . . . .
continuous path motion
commands . . . . . . . .
continuous path motion
dialog . . . . . . . . . . .
engage . . . . . . . . . . . . .
point to point motion
commands . . . . . . . .
terminology . . . . . . . . . . . .
tool axis control . . . . . . . . .
at angle to Ps or Ds . . .
fan . . . . . . . . . . . . . . . .
normal to Ps or Ds . . . .
Index-2
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7-4, 7-11
. . . 7-27
. . . . 7-5
. . . . 7-4
. . . . 7-7
. . . 8-17
. . . 7-12
. . . 8-17
. . . . 7-3
. . . . 7-4
. . . . 7-9
. . . 7-11
. . . 8-30
. . . 7-10
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7-11
7-11
7-11
7-11
7-11
. 7-6
. . . . . 7-6
. . . . . 7-8
. . . . . 7-6
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parallel to Ps or DS . . . . . . . . 8-4
tangent to Ps or Ds . . . . . . . . 8-5
thru fixed point . . . . . . . . . . . 8-7
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7-6
7-4
8-3
8-5
8-5
8-4
T
Trim Geometry
Steep Angle
Z-Level Milling . . . . . . . . 3-3, 3-8
V
Variable Contour
drive geometry . . . . . . . . . . . . . . . 9-3
drive methods
boundary . . . . . . . . . . . . . . . . 9-7
curve/point . . . . . . . . . . . . . . . 9-7
radial cut . . . . . . . . . . . . . . . 9-11
spiral . . . . . . . . . . . . . . . . . . . 9-7
surface area . . . . . . . . . . . . . . 9-8
tool path . . . . . . . . . . . . . . . . 9-9
User Function . . . . . . . . . . . 9-11
drive points
drive geometry . . . . . . . . . . . . 9-3
terminology . . . . . . . . . . . . . . . . . 9-5
check geometry . . . . . . . . . . . 9-5
drive geometry . . . . . . . . . . . . 9-5
drive method . . . . . . . . . . . . . 9-5
drive points . . . . . . . . . . . . . . 9-5
part geometry . . . . . . . . . . . . 9-5
projection vector . . . . . . . . . . . 9-5
tool axis
dual 4-axis . . . . . . . . . . . . . . 9-25
interpolated . . . . . . . . . . . . . 9-36
normal . . . . . . . . . . . . . . . . . 9-22
relative . . . . . . . . . . . . . . . . 9-23
swarf drive . . . . . . . . . . . . . . 9-29
tool path accuracy . . . . . . . . . . . . . 9-3
Variable Contour and Sequential Mill
comparison . . . . . . . . . . . . . . . . . 9-46
part, drive, check surfaces . . 9-46
general considerations . . . . . . . . 9-46
W
WAVE Geometry Linker
Assemblies and Wave . . . . . . . . . . 1-9
At Timestamp . . . . . . . . . . . . 1-3, 1-6
mt11050_g NX 5
Index
Blank Original . . . . . . . .
Create Non-Associative . .
definition of . . . . . . . . . .
deleting parent geometry
editing links . . . . . . . . . .
Extracted feature . . . . . .
linking procedure . . . . . .
Links
Break Links . . . . . . .
broken . . . . . . . . . . .
deleting of . . . . . . . .
newly broken . . . . . .
simplify . . . . . . . . . . . . .
Simplify Body . . . . .
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1-3
1-3
1-2
1-8
1-5
1-6
1-13
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1-6
1-7
1-9
1-7
1-16
1-17
Z
Z Level Five Axis
overview . . . . . . . .
Tool Axis . . . . . . .
Z-Level Milling
Check Geometry . .
Cut Area Geometry
Geometry Types . .
Part Geometry . . .
Steep Angle . . . . .
Trim Geometry . . .
Types . . . . . . . . . .
. . . . . . . . . . . . 6-3
. . . . . . . . . . . . 6-4
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3-3
3-3
3-3
3-3
3-8
3-3
3-2
Index-3
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STUDENT PROFILE
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Thank you for your participation and we hope your training experience will be an outstanding one.
Multi Axis Techniques 301 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. Five Axis Z Level
Lesson 8. Sequential Mill Basics
Workbook Sequential Mill - Cutting the Manifold Flange
Day Three
Lesson 9 Sequential Mill Advanced
Lesson 10. Variable Contour Basics
Afternoon
Lesson 11. 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
FileNew...
FileOpen...
FileSave
FileSave As...
FilePlot...
FileExecuteGrip...
FileExecuteDebug Grip...
FileExecuteNX Open...
EditUndo
EditCut
EditCopy
Edit-Paste
EditDelete...
EditSelectionTop Selection Priority - Feature
EditSelectionTop Selection Priority - Face
EditSelectionTop Selection Priority - Body
EditSelectionTop Selection Priority - Edge
EditSelectionTop Selection Priority - Component
EditSelection-Select All
EditShow and HideShow and Hide...(by type)
EditShow and HideHide
EditShow and HideInvert Shown and Hidden
EditShow and HideShow...
EditShow and HideShow All
EditTransform...
EditObject Display...
ViewOperationZoom...
ViewOperationRotate...
ViewOperationSection...
ViewLayoutNew...
ViewLayoutOpen...
ViewLayoutFit All Views
ViewLayoutFit
ViewVisualizationHigh Quality Image...
ViewInformation Window
Hide or show the current dialog box
ViewReset Orientation
InsertSketch...
InsertDesign FeatureExtrude...
Accelerator
Ctrl+N
Ctrl+O
Ctrl+S
Ctrl+Shift+A
Ctrl+P
Ctrl+G
Ctrl+Shift+G
Ctrl+U
Ctrl+Z
Ctrl+X
Ctrl+C
Ctrl+V
Ctrl+D or Delete
F
G
B
E
C
Ctrl+A
Ctrl+W
Ctrl+B
Ctrl+Shift+B
Ctrl+Shift+K
Ctrl+Shift+U
Ctrl+T
Ctrl+J
Ctrl+Shift+Z
Ctrl+R
Ctrl+H
Ctrl+Shift+N
Ctrl+Shift+O
Ctrl+Shift+F
Ctrl+F
Ctrl+Shift+H
F4
F3
Ctrl+F8
S
X
InsertDesign FeatureRevolve...
InsertTrimTrimmed Sheet...
InsertSweepVariational Sweep...
FormatLayer Settings...
FormatVisible in View...
FormatWCSDisplay
ToolsExpression...
ToolsJournalPlay...
ToolsJournalEdit
ToolsMacroStart Record...
ToolsMacroPlayback...
ToolsMacroStep...
InformationObject...
AnalysisCurveRefresh Curvature Graphs
PreferencesObject...
PreferencesSelection...
StartModeling...
StartAll ApplicationsShape Studio...
StartDrafting...
StartManufacturing...
StartNX Sheet Metal...
StartAssemblies
StartGateway...
HelpOn Context...
Refresh
Fit
Zoom
Rotate
Orient View-Trimetric
Orient View-Isometric
Orient View-Top
Orient View-Front
Orient View-Right
Orient View-Left
Snap View
R
T
V
Ctrl+L
Ctrl+Shift+V
W
Ctrl+E
Alt+F8
Alt+F11
Ctrl+Shift+R
Ctrl+Shift+P
Ctrl+Shift+S
Ctrl+I
Ctrl+Shift+C
Ctrl+Shift+J
Ctrl+Shift+T
M or Ctrl+M
Ctrl+Alt+S
Ctrl+Shift+D
Ctrl+Alt+M
Ctrl+Alt+N
A
Ctrl+W
F1
F5
Ctrl+F
F6
F7
Home
End
Ctrl+Alt+T
Ctrl+Alt+F
Ctrl+Alt+R
Ctrl+Alt+L
F8
Evaluation Delivery
NX 5 Multi Axis Techniques, Course #MT11050
Dates
thru
STRONGLY
AGREE
AGREE
SOMEWHAT
AGREE
Instructor:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
SOMEWHAT
DISAGREE
If there were 2 instructors, please evaluate the 2nd instructor with Xs
DISAGREE
Instructor:
STRONGLY
DISAGREE
Please share your opinion in all of the following sections with a check in the appropriate box:
clearly explained the course objectives

was knowledgeable about the subject
answered my questions appropriately
encouraged questions in class
was well spoken and a good communicator
was well prepared to deliver the course
made good use of the training time
conducted themselves professionally
used examples relevant to the course and audience
provided enough time to complete the exercises
used review and summary to emphasize important information
did all they could to help the class meet the course objectives
Comments on overall impression of instructor(s):

Overall impression of instructor(s)
Poor
Excellent
Suggestions for improvement of course delivery:
What you liked best about the course delivery:
Class Logistics:
1.
The training facilities were comfortable, clean, and provided a good learning
environment
2. The computer equipment was reliable
3. The software performed properly
4. The overhead projection unit was clear and working properly
5. The registration and confirmation process was efficient
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Name of the hotel
Best hotel Ive stayed at
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Was this hotel recommended during your registration process?
3.
Problem? (brief description)
YES
NO
SEE BACK
Evaluation - Courseware
NX 5 Multi Axis Techniques, Course #MT11050
STRONGLY
AGREE
AGREE
SOMEWHAT
AGREE
SOMEWHAT
DISAGREE
DISAGREE
Please share your opinion for all of the following sections with a check in the appropriate box
STRONGLY
DISAGREE
Material:
1.
2.
3.
4.
5.
The training material supported the course and lesson objectives

The training material contained all topics needed to complete the projects
The training material provided clear and descriptive directions
The training material was easy to read and understand
The course flowed in a logical and meaningful manner
6.
How appropriate was the length of the course relative to the material?
Too short
Too long
Just right
Comments on Course and Material:
Overall impression of course
Poor
Student:
1.
2.
3.
4.
5.
I met the prerequisites for the class (I had the skills I needed)
My objectives were consistent with the course objectives
I will be able to use the skills I have learned on my job
My expectations for this course were met
I am confident that with practice I will become proficient
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Multi-Axis Techniques Student Guide

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

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

Multi-Axis Techniques Student Guide

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

Fixed Contour operation types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Introduction to four and five axis machining . . . . . . . . . . . . . . . . . 5-1

Five Axis Z Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Multi-Axis Techniques Student Guide

UGS Corp., All Rights Reserved

Optimized cut levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Sequential Mill advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

Variable Contour basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Variable Contour advanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Multi-Axis Techniques Student Guide

Tilting the tool axis . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Multi-Axis Techniques Student Guide

UGS Corp., All Rights Reserved

UGS Corp., All Rights Reserved

Multi-Axis Techniques Student Guide

choose between Variable Contour and Sequential Mill operation types

develop multi-axis machining practices

develop NX multi-axis programming practices

Focus on the subject matter.

Listen attentively and take notes.

Enjoy the class.

Multi-Axis Techniques Student Guide

UGS Corp., All Rights Reserved

Class standard for NX parts

Class part naming

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

slide the cursor down to Tool path

slide the cursor down to Replay

release mouse button #1

UGS Corp., All Rights Reserved

Multi-Axis Techniques Student Guide

Class standard for NX parts

Layers and categories

Lines and Arc

Conics and Splines

Points and Coordinate Systems

System Display Color

Multi-Axis Techniques Student Guide

UGS Corp., All Rights Reserved

commonly used expressions

user-defined views and layouts

How to use this manual

This is an example of a step.

The general format for lesson content is:

Multi-Axis Techniques Student Guide

Multi-Axis Techniques Student Guide

UGS Corp., All Rights Reserved

Classroom system information

Student and workbook parts

UGS Corp., All Rights Reserved

Multi-Axis Techniques Student Guide

WAVE Geometry Linker in