Manufacturing Essentials

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MANUFACTURING ESSENTIALS
The Operation Navigatior
The Manufacturing application allows you to interactively create NC machining programs,
generate tool paths, visualize material removal, and postprocess.
This course will familiarize you with the essential functions used throughout the
Manufacturing application. You will learn how to use the Operation Navigator and step
through the process of creating a program. With few exceptions, this process is consistent
throughout the Manufacturing application.
Once you have completed this course, you will be ready to move on to courses that pertain to
your specific areas of interest such as milling, drilling, turning, or wire edm.
Audience
This course is intended for users who require a general overview of the Manufacturing
application. New users should complete this course before moving on. Subsequent courses
allow you to selectively examine your particular areas of interest.
Prerequisites
The prerequisite for this course is the Unigraphics NX Essentials CAST Online Library
course. In addition, you should be familiar with basic manufacturing processes and
terminology.
Course Contents
The Operation Navigator You will learn about the relationship between parent groups
and operations, how the Operation Navigator organizes objects, and how operations inherit
parameters from parent groups. You will explore some of the essential functions of the
Operation Navigator, including how to change views, edit parameters, cut and paste objects,
and specify a machining environment.
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Creating Objects You will learn how to create Program, Tool, Geometry, and Method
objects.
Creating Operations You will learn how to create operations individually and how to edit
and respecify parent groups from within the operations.You will also learn how to customize
dialogs to update legacy operations by adding the Main, Groups and Viewing tabs that are
found on newly created operations.
Creating Operation Sequences You will learn how to use a Process Assistant to create a
program containing a predefined sequence of operations.

UG/Post You will learn how to postprocess using UG/Post.
Graphics Postprocessor Module You will learn how to create and edit a Cutter Location
Source File (CLSF) and how to postprocess the CLSF using the Graphics Postprocessor
Module (GPM).
Shops You will learn how to use Shops, a product designed to step the occasional user
(such as the shop floor machine operator) through the process of creating an operation using a
Process Assistant.
Shop Documentation You will learn how to create shop documentation in HTML format
for use by machine tool operators.
Parent Groups and Operations

The Operation Navigator allows you to view and manage relationships between operations,
programs, machining methods, geometry, and tools. Most importantly, it allows you to define
parameters just once within parent groups and then use them in as many operations as desired,
eliminating the repetitious and tedious task of specifying parameters separately for each
operation.
The Operation Navigator organizes objects (parent groups and operations) within in a tree
structure. Objects that contain other objects are known as parent groups. Parent groups define
parameters that can be passed down and used (inherited) by operations.
In the above illustration, the WORKPIECE object inherits parameters from its parent, the
MCS_MILL object. The MILL_AREA object inherits parameters from its parent, the
WORKPIECE object (which inherits parameters from the MCS_MILL object). The
operations all inherit parameters from the MILL_AREA object (which inherits parameters
from the WORKPIECE and MCS_MILL objects).

Opening the Part File
You will open a part file and go into the Manufacturing application. You will then begin
working with the operations and objects displayed in each view of the Operation Navigator.
Open part file mfe_navigator_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.

Operation Navigator Tab
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In Windows, you can display the Operation Navigator by clicking or double-clicking on the
Operation Navigator tab in the resource bar. Clicking on the tab temporarily displays the
Operation Navigator by sliding it to the left over the graphics display. Once you move the
cursor out of the Operation Navigator the Operation Navigator disappears from the screen.
Clicking on the pin at the upper left corner of the Operation Navigator allows the Operation
Navigator to remain on the screen when you move the cursor out of the area.
Double-clicking on the tab displays the Operation Navigator in a separate window which can
then be moved and docked (Ctrl key undocks).
Clicking the Close icon at the upper right corner closes the window and restores the tab.
Practice using the Operation Navigator tab, pinning, docking, and undocking as described
above.

MB3 Options
Commonly used options available in the toolbar are also available in the pop-up menu by
clicking MB3 on the Operation Navigator background.

Columns and Properties
Columns and Properties options are displayed in a pop-up menu by clicking MB3 on the
Operation Navigator background.

Adding and Removing Columns in the Operation Navigator
Display the Program Order view in the Operatuion Navigator.
Click MB3 on the Operation Navigator background and choose Columns and Configure.
Turn the Tool Description option on.
OK to accept the Operation Navigator Properties dialog.

The Tool Description column now displays in the Operation Navigator (you may need to
scroll to the right).
Turn the Tool Description option off.
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Changing Operation Navigator Views
The Operation Navigator displays in one of four views: the Machining Method view, Program
Order view, Machine Tool view, or Geometry view. Each view organizes the operations
according to the theme of the view.
You can easily switch from one view to another by choosing one of the icons in the toolbar.

Displaying the Machine Tool View
You will display the Machine Tool View. This view allows you to see the tools used by the
operations.
Choose the Machine Tool View icon

in the toolbar (or choose Tools
Navigator View Machine Tool View in the menu bar).
Operation
Click on the plus (+) signs to fully expand the objects.

The Machine Tool View organizes the operations according to tools. The three operations
outlined below use the MILL_1 tool.

Displaying the Program Order View
You will display the Program Order View. This view allows you to see the order in which the
operations will be executed on the machine tool.
Choose the Program Order View icon
in the toolbar.
Click on the plus (+) sign to fully expand the PROGRAM object.
The Program Order View displays the program that each operation belongs to and the order in
which operations will be executed on the machine tool. This is the only view in which the
order of the listed operations is relevant or important.

Displaying the Geometry View
You will display the Geometry View. This view allows you to see the geometry objects and
the operations contained within the objects.
Choose the Geometry View icon
in the toolbar.

The Geometry View organizes the operations according to machining geometry. Parameters
such as part, blank, and check geometry, MCS orientation, and clearance plane are defined by
geometry objects. The four operations outlined below use the MCS_MILL, WORKPIECE,
MILL_AREA geometry objects.
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Displaying the Machining Method View
You will display the Machining Method View. This view allows you to see the cut methods
the operations use.
Choose the Machining Method View icon
in the toolbar.

The Machining Method View organizes operations according to cut method (rough, finish,
semi finish). Parameters such as Intol, Outtol, and part stock are defined by machining
method objects.
The program below consists of one roughing operation, two semi-finishing operations, and
two finishing operations.
Remember, the only view in which the order of the listed operations is relevant is the Program
Order view.
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Cutting and Pasting Operations

You can move objects within any view of the Operation Navigator by cutting and pasting.
Cutting and pasting operations within the Program Order View allows you to change the order
in which the operations are executed on the machine tool. Cutting and pasting operations
within the Machine Tool View allows you to change the tool the operation uses.

Reordering Operations
You will cut and paste an operation within the Program Order View to change the order in
which it is executed on the machine tool.
in the toolbar.
Choose the CONTOUR_ZIGZAG icon and MB3
Cut.
The object you choose in the next step is the operation below which the pasted operation will
appear.
Choose the CONTOUR_AREA_DIR_STEEP icon and MB3
Paste.
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CONTOUR_ZIGZAG is now the last operation in the program sequence.

Respecifying the Cutting Tool
You will cut and paste an operation within the Machine Tool View to change the cutting tool
the operation uses.
in the toolbar.
The CONTOUR_FOLLOW_1 operation currently uses MILL_1 as the parent group that
defines cutting tool.
Choose the CONTOUR_FOLLOW_1 icon and MB3
Cut.
The object you choose in the next step is the parent group inside of which the operation will
be pasted.
Choose the MILL_2 icon and MB3
Paste Inside.
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CONTOUR_FOLLOW_1 now uses MILL_2 as the cutting tool.
A slashed red circle now appears in front of the pasted operation. This indicates that
operation parameters have changed and that the tool path must be regenerated to reflect the
change.
Operation Status Symbols
Operations and program groups in the Operation Navigator are preceded by one of three
status symbols; Complete, Regenerate, or Repost as illustrated below.
A green check mark
indicates a complete status
Complete status means that the operation or program has been generated, incorporating the
current operation parameters, and has been either postprocessed or output to an operating
system text file.
A slashed red circle
indicates a regenerate status
Regenerate means that a tool path has not been generated for the operation or that operation
parameters have changed and that the tool path must be regenerated to reflect the change.
An exclamation point
indicates repost status
Repost status means that the tool path for the operation has been generated, but it has not been
postprocessed or exported from the part file.
The status symbols are dynamic and will update as the status of the operation or group
changes.
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Generating a Tool Path
You will generate the tool path for the operation you just moved. The tool path will be
recalculated using the new tool.
Choose the CONTOUR_FOLLOW_1 icon and MB3
Generate.
OK the Tool Path Generation dialog.

The new tool path is recalculated and generated using the MILL_2 tool. The tool path is
graphically displayed by tracing the tip of the tool.
An exclamation point now appears in front of the operation and PROGRAM object
indicating that the operations have been generated but have not yet been postprocessed or
exported.
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Replaying a Program
You will Replay the entire program so you can see the tool paths displayed in the sequence in
which they will be executed on the machine tool.

Choose the PROGRAM icon and MB3
in the toolbar.
Replay.
You can replay tool paths selectively by holding down the Ctrl key and choosing individual
operations.

Visualizing the Tool Path
You will use the Toolpath Visualization options to animate the cutter movement and
dynamically display material removal.
Toolpath
Verify.
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The Toolpath Visualization dialog displays with the Replay tab chosen.

Replaying a Program
You will Replay the entire program.
Choose the Shaded icon
in the toolbar to display the part as a shaded solid.
Choose the Play Forward icon.
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The tool paths replay in the program sequence with the tool tip tracing each path. Each
operation highlights in the Operation Navigator as it replays.

Displaying Dynamic Material Removal
You will dynamically display the material removal. This method of visualization allows you
to clearly see the material as it is removed by each successive tool path.
Choose the Dynamic tab.
Choose Reset.
This option resets the program so that the operations are again played in order from first to
last.
The material removed by each successive tool path is displayed in a contrasting color.
OK to complete the tool path visualization.
More About: Dynamic Material Removal Colors
The colors displayed for dynamic material removal are determined by the Preference settings
(Preferences Manufacturing).
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Once the colors have been defined in the Manufacturing Preferences dialog, the Verify
function uses these colors in the order defined when displaying Dynamic Material Removal.
Redefining the Machining Environment

You can delete the current Machining Environment associated with the part and define a new
CAM Session Configuration and CAM Setup. In doing so, all operations and parent groups
are deleted from the part. It essentially enables you to "start over" as though the part file is
being brought into the Manufacturing module for the first time.
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Deleting the Machining Environment
You will delete the current configuration file and CAM setup data associated with the part.
Choose Tools
Operation Navigator
Delete Setup from the main menu bar.
A confirmation message warns you that all manufacturing data will be deleted and cannot be
recovered.
OK to delete the setup.
All CAM data, operations, tools, geometry, etc., have been deleted from the part file. The
Machining Environment dialog displays requiring you to specify a configuration file and
setup.
The Machining Environment dialog displays when a part file has been brought into the
Manufacturing module for the first time or when the setup has been deleted.
More About Machining Environment
When Unigraphics NX starts, it reads the ugii_env.dat file to define a large number of
environment variables setting system defaults, the location of resource files, etc.
One of the things that is set by the ugii_env.dat file is the location of the configuration
directory. This is done by the environment variable UGII_CAM_CONFIG_DIR. This
directory contains a number of files with the file extension. ".dat".
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Unigraphics NX reads the names of these files and displays this list in the top half of the
Machining Environment dialog, in the CAM Session Configuration list box.
A default Configuration is also defined in the ugii_env.dat file by the environment variable
UGII_CAM_CONFIG. It is set to point to cam_general.dat. That is why the Machining
Environment initially displays with the cam_general configuration highlighted.
Cam_general.dat sets up a number of environment variables pointing towards template files
for documentation, postprocessors that are correct for the machine tool you're using, feeds and
speeds, etc. One environment variable it defines is TEMPLATE_OPERATION. This is
pointed towards an "opt" file. By default, for cam_general.dat, this environment variable
points towards cam_general.opt.
Cam_general.opt contains a list of template part files:
mill_planar.prt mill_contour.prt mill_multi-axis.prt drill.prt turning.prt wire_edm.prt
A list of these part files is displayed in the CAM Setup list box.
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When you selected the lathe configuration, the CAM Setup list box was updated to show the
only files listed in lathe.opt, lathe.prt and legacy_lathe.prt.
The general flow of definition of environment variables is something like the illustration
below:
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Any changes to all these dat and opt files to customize them to your own manufacturing
environment must be done carefully. In most cases, it will require system administrator
privileges to make these changes.

Choosing the Session Configuration
You will choose a CAM Session Configuration that allows you to create all types of
operations including Milling, Drilling, Turning, and Wire EDM.
The CAM Session Configuration defines the available machining processors, tool libraries.
postprocessors, and other high level parameters for the logon session.
Choose the cam_general configuration file.
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The cam_general configuration allows you to create all types of operations including Milling,
Drilling, Turning, and Wire EDM. Other session configurations such as lathe or mill_contour
restrict you to a specific type of operation.

Choosing the CAM Setup
You will choose a CAM Setup that allows you to create planar milling operations and then
initialize the new machining environment.
Choose the mill_planar setup.
Choose Initialize.
The new machining environment is complete. The geometry objects required to create planar
mill operations are created automatically. They give you a basic starting point from which you
can begin creating operations and other objects.

Viewing the Geometry and Machining Method Objects
You will look at the Geometry and Machining Method Views of the Operation Navigator and
notice that the objects required to create planar mill operations are created automatically
based on the specified CAM Setup.

Choose the Expand All icon
in the toolbar.
in the toolbar to fully expand the objects.
Notice that the MCS_MILL and WORKPIECE geometry objects have been created.
The machining method objects required to create planar mill operations are also created
automatically.
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in the toolbar.
In the next lesson, you will learn more about creating objects and the parameters they define.
Close the part file.
Creating Objects
In this lesson, you will learn how to create Program, Tool, Geometry, and Method objects.
Tool, Geometry, and Method objects define operation parameters. These parameters can be
inherited by operations contained within the objects. By specifying these objects as parent
groups, you can eliminate the repetitious and tedious task of respecifying parameters each
time you create an operation.
Program objects do not define operation parameters. Instead, they simply contain operations
and determine the sequence in which operations are executed on the machine tool. For
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example, the sequence of operations required to machine the top of a part may be contained in
one program while the sequence of operations required to machine the end of a part may be
contained in another program.
Creating Tool Objects

In this section, you will learn how to create tool objects. You will learn how to define new
tools as well as how to retrieve existing tools from a library.
Open part file mfe_objects_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.

Displaying the Machine Tool View
Navigator View Machine Tool View in the menu bar).
Navigator Expand All in the menu bar).
Operation
Operation
The Operation Navigator shows that both the PLANAR_MILL and FACE_MILLING
operations use the same tool: MILL.
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Creating a Face Mill Tool Object
You will create a 5-parameter face mill tool object and then cut and paste the
FACE_MILLING operation into that object so that the operation uses the new tool.
Choose the Create Tool icon
in the toolbar.
The Type determines the available Subtypes you have to choose from.
In the Create Tool dialog, Set the Type option to mill_planar.
The Subtype section displays only tools that are appropriate for milling operations.
Choose the FACE_MILL icon.
Be sure GENERIC_MACHINE is chosen as the parent group. This way, the tool you create
will have the same parent as the existing mill tool.
The tool name defaults to FACE_MILL based on the subtype you chose. You may name the
tool using the following rules:
Up to 20 characters
Start with an alphabetic character
The only acceptable special characters are the dash (-) and period (.)
No spaces are allowed.
OK to begin defining the FACE_MILL tool parameters.
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Defining the Tool Parameters
You will specify parameters that define the size and material of the tool.
Key in the following values to define the tool.
The tool material is one of several parameters that the Reset from Table option uses to
determine the speeds and feeds for cutting.
Choose Material: CARBIDE.
Highlight TMCO_00001 HSS and OK.
OK to create the FACE_MILL tool object.

Respecifying the Tool
You will respecify the tool the operation uses by dragging and dropping the operation onto the
tool object.
Highlight the FACE_MILLING operation with the mouse button 1 and hold the button
down while you drag the icon on top of the FACE_MILL object. Release the mouse button
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to drop the operation.
The FACE_MILLING operation now uses FACE_MILL as the cutting tool.
This can also be accomplished by cutting and pasting the operation inside the tool object.
The slashed red circle indicates that operation parameters have changed and that the tool
path must be regenerated to reflect the change.

Generating the Tool Path
You will generate the tool path using the FACE_MILL tool. This will update the operation
status.
Choose the FACE_MILLING icon and MB3
OK to accept the tool path generation.
Generate.
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An exclamation point now appears in front of the operation indicating that the operation has
been generated not yet been postprocessed or exported.

Visualizing the Tool Paths
dynamically display material removal for the program.
in the toolbar.
Highlight the PROGRAM object.
Choose the Verify Toolpath icon
in the toolbar or MB3
Toolpath
Drag the slider bar to the left to slow down the Animation Speed to 7.
Verify.
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Because the part does not contain or inherit blank geometry, the Automatic Blank for
Visualize dialog displays allowing you to define blank geometry temporarily to perform
dynamic material removal.

Defining the Blank Geometry
You will define the blank geometry as a solid body bounding the part geometry.
OK to accept Auto Block as the Blank Type.
Auto Block creates a solid body bounding the part geometry with faces parallel to the WCS.
The material removed by each successive tool path is displayed in a contrasting color
allowing you to clearly see that the face milling operation leaves some uncut material behind.
The tool changes to the FACE_MILL tool for the second operation.
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Retrieving a Tool From the Library
You will now retrieve a predefined tool from the library.
in the toolbar.
Choose Retrieve Tool and OK.
Click on the plus (+) sign next to Milling to expand the list and choose End Mill (non
indexable).
OK to accept the selection.

Specifying Search Criteria
You will use the Search Criteria Dialog to narrow down the library search by specifying
parameters.
Choose Count Matches.
A number appears next to the button (in this example, 64). This indicates the number of tools
in the library that match the parameters you have specified so far.
You can narrow the search even further by specifying exact numeric values or a range of
values using <, >, <=, and >= signs.
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Key in 0.50 in the Diameter field.

You have narrowed the search to only those tools in the library with a diameter of 0.50.
Choose Result Info.
This displays an Information listing of all the tools matching the search criteria. It will allow
you to determine the values (Flute Length and Corner Radius for example) that can be
specified to continue narrowing the list.
Dismiss the Information window.
Key in the following values.

You have narrowed the search to the only those .50 diameter tools in the library with a flute
length greater than 1 and a corner radius greater than or equal to .05 .
OK to accept the search criteria.

Choosing Tools
You will use the Search Result listing to choose the desired tool or tools.
Use the left mouse button to choose a single tool. Use the left mouse button in combination
with the Shift key to choose a range of tools. Use the left mouse button with the Ctrl key to
selectively choose tools from the list. The Ctrl key also enables you to deselect.
Choose the two tools indicated below.
OK to accept the tools.
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in the toolbar.
The tools retrieved from the library appear in the Machine Tool view of the Operation
Navigator and are now available to be used in operations.
You can easily obtain information about the tools.

Highlight the UGTI0201_064 icon and MB3
Properties.

Respecifying the Tool
You will respecify the tool that the PLANAR_MILL operation uses by dragging and dropping
the operation onto the UGTI0201_064 tool object.
Drag and drop the PLANAR_MILL operation onto the the UGTI0201_064 object.
The PLANAR_MILL operation now uses UGTI0201_064 as the cutting tool.
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The red circle indicates that operation parameters have changed and that the tool path must
be regenerated to reflect the change.

You will generate the tool path using the new tool.
Choose the PLANAR_MILL icon in the Operation Navigator and MB3
Generate.
Creating Machining Method Objects

In this section, you will learn how to create Machining Method objects. These objects allow
you to organize operations according to cut method (rough, finish, semi finish) by defining
parameters such as , Outtol, and part stock.
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Choose Application
Manufacturing.

Displaying the Machining Method View
below.
in the toolbar.
in the toolbar to see all of the objects as illustrated
The PLANAR_MILL operation uses the MILL_ROUGH method and the FACE_MILLING
operation uses the MILL_FINISH method. The SEMI_FINISH_LEVELS operation does not
use a method.

Creating a Semi-Finish Machining Method Object
You will create a semi-finish machining method object to use as parent group.
Choose the Create Method icon
in the toolbar.
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The Type determines the available Subtypes.
Choose mill_planar as the Type.
MILL_METHOD is the only available Subtype.
Be sure METHOD is chosen as the parent group. This way, the object you are creating will
have the same parent group as the other machining method objects.
Key in SEMI_FINISH for the name.
OK to begin creating the SEMI_FINISH machining method object.

Key in 0.01 or the Part Stock.
Part Stock is the amount of material remaining on the part after roughing and semi-finishing
operations. This is the parameter that primarily determines the difference between a roughing,
semifinishing, and a finishing operation.
Intol and Outtol define an allowable range the tool may use to deviate from the part surfaces.
The smaller the values, the more accurate the cut. Intol allows you to specify the maximum
amount by which the tool may penetrate through the surface. Outtol allows you to specify the
the maximum amount by which the tool may avoid contacting the surface.
OK to create the SEMI_FINISH object.

The SEMI_FINISH object is not a parent group because it does not contain any operations.
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Moving an Operation into the Object
You will drag and drop the SEMI_FINISH_LEVELS operation onto the SEMI_FINISH
machining method object.
Highlight the SEMI_FINISH_LEVELS operation with mouse button 1 and hold the button
down while you drag the icon on top of the SEMI_FINISH object. Release the mouse
button to drop the operation.
The SEMI_FINISH machining method is now a parent group containing the

SEMI_FINISH_LEVELS operation.

You will generate the tool path using SEMI_FINISH as the machining method.
Choose the SEMI_FINISH_LEVELS icon and MB3
Generate.
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Visualization allows you to see the material removal as the program progresses through the
sequence of rough, semi-finish, and finish operations.
Choose the Shaded icon in the toolbar to display the part as a shaded solid.
in the toolbar.
Choose the PROGRAM object.
in the toolbar.
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Because the part does not contain or inherit blank geometry, the Automatic Blank for
Visualize dialog displays allowing you to define blank geometry temporarily to perform
dynamic material removal.

You will define the blank geometry as a solid body bounding the part geometry.
OK to accept Auto Block as the Blank Type.
The material removed by each successive tool path is displayed in a contrasting color.
Creating Geometry Objects

Different types of operations require different types of geometry. Planar milling operations
require boundaries while surface contouring operations require faces or bodies. In this section,
you will learn how to create geometry objects for planar milling operations.
Choose Application
Manufacturing.
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Displaying the Geometry View
in the toolbar.
The PLANAR_MILL and SEMI_FINISH_LEVELS operations are contained in the

MCS_MILL parent group. This parent group defines the location and orientation of the
Machine Coordinate System.
Machine Coordinate System
Like other applications, Manufacturing uses the WCS, or Work Coordinate System. However,
the Manufacturing application has its own coordinate systems as well - the Machine
Coordinate System (MCS).
As illustrated below, the WCS and MCS are in the same location. The MCS is displayed
similar to the WCS, but the axes are labeled XM, YM, and ZM.
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What is the significance of these coordinate systems for the Manufacturing application?
WCS - All the parameter values that you input (for example, values for the Start Point, a Z
value for the Clearance Plane, or I,J,K values for the tool axis vector, and other vector data)
will be in relationship to the WCS.
MCS - All coordinate values in the tool path (all of the output coordinates) are in relationship
to the MCS. The ZM axis of the MCS is particularly important since, if no tool axis is
specified, the ZM axis is the default tool axis.
The output tool path consists of a number of different commands. The most frequent
command is probably the linear positioning move, GOTO. There are at most 6 coordinate
fields in a GOTO: X, Y, Z, I, J and K. The X, Y and Z fields are the coordinates of the tool tip
relative to the MCS and the I, J, K values indicate the tool axis vector.
Depending on the circumstances, you may want to specify your Machine Coordinate System
and Work Coordinate System in the same location to avoid confusion.
Before you start creating any machining operations, you should always display the Work
Coordinate System and Machine Coordinate System and check their location and orientation.
A MCS is one of the default CAM objects created by all templates. The name assigned to this
MCS varies, dependent upon the CAM template part file selected in creating the setup. The
default MCS is created coincident with the absolute coordinate system. You can edit the
location of the default MCS to change the coordinates of the output tool path or create a new
MCS. Even though you may have many MCS objects created, only one machine coordinate
system is displayed at a time.

Creating a Mill Boundary Object
Part geometry is required to generate tool paths. You will create an object that defines part
boundaries.
Choose the Create Geometry icon
in the toolbar.
The Type determines the available Subtypes you have to choose from.
Be sure mill_planar has been chosen as the Type.
Choose the MILL_BND icon.
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Be sure MCS_MILL has been chosen as the Parent Group.
The object you are creating inherits the Machine Coordinate System parameters.
The name defaults to MILL_BND based on the chosen subtype.
OK to begin defining the MILL_BND object.

Defining Part Boundaries
You will create the part boundaries required to generate the tool paths. You will first define
the main containment boundary.
Choose the Part icon and Select.
Choose the Curve Boundary icon.
Choose Outside for the Material Side.
This specifies that the material retained is outside the boundary and allows the tool to cut only
inside the boundary.
Choose the Custom Data tab.
Turn on the Offset option under Custom Boundary Data and key in -0.1.
This defines a negative stock that assures the material along the outside edge of the part is
completely removed.
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Defining the Main Containment Boundary
You will select the edges that define the main containment boundary. This boundary defines
the overall part and encloses other boundaries that define islands.
Select the four outside edges in order as illustrated below.
Choose the Main tab.

Choose Create Next Boundary.
The main containment boundary should display as illustrated below.

Defining Boundaries at Island Tops
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You will create boundaries that define the top of each island.
Choose the Face Boundary icon.
Choose Inside for the Material Side.

This specifies that the material retained is inside the boundary and does not allow the tool to
cut inside the boundary.
Select the first face as illustrated below.
Select the second and third faces as illustrated below.
OK to accept the part boundary definition.

OK to finish creating the MILL_BND object.
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Moving Operations into the Object
You will cut and paste the two operations into the MILL_BND geometry object.
Highlight the PLANAR_MILL operation and MB3
Highlight the MILL_BND object and MB3
Cut.
Paste Inside.
MILL_BND is now a parent group of the PLANAR_MILL operation.
Cut and paste the SEMI_FINISH_LEVELS operation inside the MILL_BND object so that
MILL_BND contains both operations.
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Generating the Tool Paths
You will generate the tool paths for both operations.
Choose the first operation and hold down the Ctrl key to choose the second operation.
MB3
Generate.
OK to accept the first tool path generation.

OK to accept the second tool path generation.
MB3
Refresh to remove the tool path display.

Creating a Workpiece Object
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You will create a workpiece object that defines the part material and the blank geometry. The
part material is one of several parameters used in determining the cut feed rate. Adding
operations to the program such as Cavity Milling will require blank geometry.
Choose Edit
Blank
Reverse Blank All in the menu bar.
This displays the body you will select to define the blank geometry.
in the toolbar.
Be sure mill_planar has been chosen as the Type.

Choose the WORKPIECE icon.
Be sure MCS_MILL is chosen as the parent group so that the object you are creating inherits
the Machine Coordinate System parameters defined in MCS_MILL.
The name defaults to WORKPIECE based on the subtype you chose.

OK to begin defining the workpiece.

Specifying the Part Material
You will specify the part material. This is one of several parameters that the Reset from Table
option uses to determine the speeds and feeds for cutting.
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Choose Material: CARBON STEEL.
Highlight MATO_00266 ALUMINUM and OK.

Defining Blank Geometry
You will select the solid body to define the blank geometry.
Choose the Blank icon and Select.
Select the body.
OK to accept the blank geometry.

OK to finish creating the workpiece object.
Choose Edit
Blank
Reverse Blank All in the menu bar to display the part.

Moving the Mill Boundary Object
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You will cut and paste the MILL_BND object into the WORKPIECE object. In doing so, you
will also move the operations.
Highlight the MILL_BND object and MB3
Cut.
Highlight the WORKPIECE operation and MB3
Paste Inside.
The PLANAR_MILL and SEMI_FINISH_LEVELS operations are still contained in the

MILL_BND parent group.

You will generate the tool paths.
Choose the Program Order View icon in the toolbar.
Choose the PROGRAM object and MB3
Generate.
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Choose the PROGRAM object in the Operation Navigator.
Choose the Verify Toolpath icon.
Because the part inherits blank geometry from the workpiece object, the Automatic Blank for
Visualize dialog does not display as it did in the previous examples.
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Creating Program Objects

In this section, you will learn how to create program objects. Program objects allow you to
gather and order operations into logical programs. For example, one program may contain
operations that machine the top of the part while another program may contain operations that
machine the side of the part.
Choose Application
Manufacturing.

Expand the program by clicking on the (+) sign so you can see all the operations.
The Operation Navigator shows that all operations are contained in a single program object.
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The program machines both the top and the side of the part.
Choose the PROGRAM object in the Operation Navigator.

Creating a Program Object
You will create a program object to contain the operations that machine the top of the part.
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Choose the Create Program icon
in the toolbar.
PROGRAM is the only available Subtype.
Key in TOP for the name.

OK to create the TOP program object.
The TOP currently does not contain any objects and is not a parent group.

Copying a Program Object
You will copy the TOP program object to create an object that will contain the operations that
machine the side of the part.
Choose TOP and MB3
Copy.
The object you choose in the next step is the object below which the pasted objects will
appear.
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With TOP chosen, MB3
Paste.
TOP_COPY is now the last object in the program.

Renaming a Program Object
You will change the name of TOP_COPY to SIDE.
Be sure TOP_COPY is still highlighted.
Choose Tools
Operation Navigator
Rename in the menu bar.
Key in side and press the Enter key.

Moving Operations into the Top Program
You will cut and paste operations into the TOP program object.
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Choose the PLANAR_MILL operation and hold down the Ctrl key to choose the
SEMI_FINISH_LEVELS and FACE_MILLING operations.
MB3
Cut.
Highlight the TOP object and MB3
Paste Inside.
TOP is now a parent group of the three operations.
This can also be accomplished by dragging and dropping multiple objects.

Moving Operations into the Side Program
You will cut and paste operations into the SIDE program object.
Cut and paste the PLANAR_MILL_SIDE, SEMI_FINISH_LEVELS_SIDE, and
FACE_MILLING_SIDE operations inside the SIDE object.
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Deleting an Object
You will delete the PROGRAM object since it is no longer needed.
Choose PROGRAM and MB3
Delete.
OK to delete the object.

You can now visualize each program separately.
Choose the TOP object.
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Choose the SIDE object and visualize the program as you did for the TOP object.
You can visualize the entire program by choosing the NC_PROGRAM object.
Creating Operations
In this lesson, you will learn how to create individual operations and edit and respecify parent
groups from within the operations.
You will also learn how to customize dialogs to update legacy operations by adding the Main,
Groups and Viewing tabs that are found on newly created operations.
Creating an Operation
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Although some of the parameters for milling, drilling, turning, and wire edm operations differ,
the process of creating any operation is basically the same. You first specify the Type,
Subtype, and Parent Groups. You then define any additional parameters required for the
specific operation. Finally, you generate the tool path and make any necessary modifications.
Open part file mfe_operation_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.
Beginning the Operation
You will begin creating a planar mill operation that roughs out material in multiple cut levels.
Choose the Create Operation icon
in the toolbar.
Be sure mill_planar is displayed as the Type.
The Type determines the subtype icons and the parent groups that are available to choose
from in the dialog.
Choose ROUGH_FOLLOW as the subtype.
Choosing the appropriate operation subtype will set many of the required operation
parameters and can save a significant amount of time and effort in defining the operation.
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Specify the following parent groups.
Parent groups determine common parameters that can be used by multiple operations.
This operation is automatically named ROUGH_FOLLOW based on the Subtype you chose.
OK to begin creating the operation.
Specifying the Cut Depth
You will specify multiple cut levels at a fixed depth.
Choose Cut Depths.
Choose Fixed Depth.
Fixed Depth generates cut levels at a constant depth.

Key in 0.1 in the Maximum field.
Maximum defines the largest allowable cut depth for each level.
OK to accept the cut depth.
Calculating Feeds and Speeds
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You will allow the system to recommend appropriate feed rates and speeds based on the user
specified part material, tool type and material, cut method, and cut depth parameters.
Choose Feed Rates.
Notice that the current Surface Speed and Feed per Tooth values are set to zero.
Choose Reset from Table.

The system extracts Surface Speed and Feed Per Tooth values from tables (maintained by
system administration) based on the user input. The other values are then calculated.
OK to accept the Feeds and Speeds.
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You will observe how the operation generates the tool path at the specified cut depths.
Generate the tool path.
Turn the Pause After Display and Refresh Before display options off.
This will allow you to generate all the cut levels at once and continue viewing them after they
have generated.
OK the generate the tool paths.
Refresh the display.
Displaying the Part Boundaries
A planar mill operation must contain properly defined part boundaries in order to generate a
tool path. You will display the part boundaries for visual verification.
Choose the Part icon.
Choose Display to highlight the part boundaries.
Notice that the Select/Reselect button is blanked. Part boundaries are inherited from the
MILL_BND parent group and can only be modified by editing the parent group. In just a
moment, you will see how to edit the MILL_BND parent group from this dialog.
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Refresh the graphics display.
Displaying the Floor Plane
A planar mill operation must contain a floor plane in order to generate a tool path. You will
display the floor plane for visual verification.
Choose the Floor icon.
Choose Display to highlight the floor.
Notice that the Select/Reselect button is blanked. The floor plane is inherited from the
MILL_BND parent group and can only be modified by editing the parent group that defines
it.
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Choose the Verify icon
at the bottom of the dialog.

Because the part inherits blank geometry from the workpiece object, the Automatic Blank for
Visualize dialog does not display as it did in the previous examples.
The operation leaves a thin wall of uncut material along the outside edge of the part.
OK to complete the Toolpath Visualization.
Editing the Geometry Parent Group
You will edit the MILL_BND parent group so that the material along the outside edge of the
part is completely removed. The options at the top of the operation dialog allow you to edit
and reselect parent groups.
Choose the Groups tab.
Choose Geometry: MILL_BND and Edit.
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A message displays informing you that the MILL_BND parent group contains more than one
member and that editing it will affect all members. MILL_BND is a parent of the operation
you are currently creating as well as the existing FINISH_FLOOR operation. Editing the part
boundaries defined in this parent group will therefore affect both operations.
OK the message.
The MILL_BND dialog displays allowing you to edit the parent group.
Editing the Main Containment Boundary
You will edit the main containment boundary so that the operation no longer leaves a thin
wall of uncut material along the outside edge of the part.
Choose the Part icon and Edit.
The part boundaries highlight with the main containment boundary selected.
Turn the Offset option on and key in -0.1.
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This defines a "negative stock" that assures the material along the outside edge of the part is
completely removed.
OK to accept the part boundary offset.
OK to finish editing the MILL_BND parent group.
OK to complete the ROUGH_FOLLOW operation.
The ROUGH_FOLLOW operation now appears in the Operation Navigator.
Generating Tool Paths
You will generate the tool path to remove the material along the outside edge of the part.
in the toolbar.
Notice that slashed red circles appear in front of both operations. This indicates that the
tool paths for both operations must be regenerated to reflect the changes made in the
MILL_BND parent group.
Generate.

Exclamation points now appear in front of the operations indicating that the operations have
been generated but have not yet been postprocessed or exported.
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Reordering Operations
The Program Order View displays the order in which operations will be executed on the
machine tool. Notice that the finishing operation precedes the roughing operation.
You will change the order in which operations are listed in the program so that the finishing
operation follows the roughing operation.
Choose the FINISH_FLOOR icon and MB3
Cut.
The operation you choose in the next step is the object below which the pasted operation will
appear.
Choose the ROUGH_FOLLOW icon and MB3
Paste.
FINISH_FLOOR is now the second operation in the program sequence.
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You will now verify that the negative boundary offset you specified earlier in the parent group
removes the excess material along the outside edge of the part.
Choose the PROGRAM object.
in the toolbar.

The operations execute in the correct order and the excess material along the outside edge of
the part is completely removed.
Reselecting the Tool Parent Group
You will change the tool used in the finishing operation.
in the toolbar.
Expand the tool object so you can see the operations.

Double-click on the FINISH_FLOOR icon.
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The FINISH_FLOOR dialog displays, allowing you to edit the operation.

Choose Tool: UGTI0201_063 and Reselect.
The Reselect Tool dialog displays, allowing you to choose a new parent group or to define a
new tool.
Choose UGTI0201_076.
The tools available in this list are the same as those that appear in the Machine Tool view of
the Operation Navigator.
OK to accept the tool.
The dialog now displays UGTI0201_076 as the tool used in the operation.
Remember, you can also respecify the tool by dragging and dropping, or by cutting and
pasting the operation onto the tool object.
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Completing the Operation
You will complete the operation and observe how the Operation Navigator now displays
UGTI0201_076 as the parent group.
OK to complete the FINISH_FLOOR operation.
Expand the object to see the operation.
The Operation Navigator now displays UGTI0201_076 as a parent of the FINISH_FLOOR
operation.
A slashed red circle

change.
indicates that the tool path must be regenerated to reflect the tool
You will generate the tool path to update the operation status.
Choose the FINISH_FLOOR icon and MB3

Generate.
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Updating a Legacy Operation Dialog

Legacy operation dialogs can be customizing so that they appear the same as the dialogs for
newly created operations.

Open part file mfe_legacy_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.

Viewing the Legacy Operation Dialog
You will first view an existing legacy operation dialog. You will then customize it by
distributing the parameters among property pages to make the dialog shorter.
In the Program Order View of the Operation Navigator, double-click on the
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ROUGH_TURN_OD icon to display the operation parameters dialog.
The dialog is very large and in some cases it may be too large for the viewing screen.
Click on the dialog so that it is active and press the Esc key to dismiss it.

Customizing the Operation Dialog
You will customize the dialog box and make it smaller by adding Main, Groups and Viewing
property pages.
Highlight ROUGH_TURN_OD in the Operation Navigator.
Press MB3 and choose Object
Customize.
The Customize Dialog dialog displays.

Adding a Main Page
The first property page you will add is the Main property page.
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Key in Main in the Label field and choose the Property Pages icon.
Start Page Main and End Page Main are added to the Items Used list box. Moving the End
Page Main to the bottom of the items used will put all those items on the Main page.
With End Page Main highlighted, choose the Move Down arrow until End Page Main is
the last item in the list.
When you are finished moving End Page Main to the bottom, the list box will appear as
illustrated below.

Adding a Groups Page
The second property page you will add is the Groups property page.
Key in Groups in the Label field and choose the Property Pages icon.
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Start Page Groups and End Page Groups are displayed at the bottom of the list box.
Scroll to the top of the Items Used list box, highlight Group Editing, and choose the Move
Down arrow until Group Editing is between the Start Page and End Page of Groups.
When you are finished moving Group Editing, the list box will look as illustrated below.

Adding a Viewing Page
The last property page you will add is the Viewing property page.
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Key in Viewing in the Label field and choose the Property Pages icon.
Move End Page Viewing and Start Page Viewing to the end of the list box using the
Move Down arrow.
The list box should look as illustrated below.
Highlight Save View and choose Add.
Choose the Move Up arrow so that Save View is between the Start Page and End Page of
Viewing as illustrated below.
OK to complete the dialog customization.

Viewing the Dialog
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The parameters have been divided among three property pages.
Double-click on the ROUGH_TURN_OD icon to display the operation parameters
dialog.
The top of the dialog displays the three tabs found in newly created turning operations.
Cancel the Dialog.

Creating Operation Sequences

In this lesson, you will learn how to create a program containing a predefined sequence of
operations. A Process Assistant will provide step-by-step instructions on how to create the
sequence of operations.
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Creating a Sequence
You will create a sequence of operations designed to machine a die. Although specific
parameters may vary, the process of creating any sequence is similar.
Open part file mfe_sequence_1.prt from the mfe subdirectory.
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Choose Application
Manufacturing.
Creating a Sequence
Defining the Machining Environment
Because this part has not yet been saved in the Manufacturing application, the Machining
Environment dialog displays. You will choose a CAM Session Configuration and a CAM
Setup
Choose mill_contour as the CAM Session Configuration.
Die_Sequences and Mold_Sequences are generic sequence setups supplied with the system.
Other setups may also be available depending on your working environment.
Choose die_sequences as the CAM Setup.
Choose Initialize.
Creating a Sequence
Using the Process Assistant
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You will begin following the step-by-step instructions provided by the CAM Process
Assistant.
OK to continue with the assistant.
Creating a Sequence
Defining the MCS
Step 1 of the Process Assistant prompts you to define the Machine Coordinate system. You
may specify new MCS parameters or accept the current MCS.
OK to accept the current MCS.
Creating a Sequence
Defining the Clearance Plane
Step 2 of the Process Assistant prompts you to define the clearance plane.
Be sure Clearance has been turned on and choose Specify.
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Choose Plane Subfunction.

Choose Two Lines.
Select the two lines illustrated below.
OK to continue to the next step.
Creating a Sequence
Defining the Part Geometry
Step 3 of the Process Assistant prompts you to define the part geometry.
Choose Select.
Select the part body as illustrated below.
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OK to complete the selection.

Creating a Sequence
Step 4 of the Process Assistant prompts you to define the blank geometry.
Choose Select.
Select the blank body as illustrated below.

OK to continue.
At this point in the process, the Setup has been created and you are prompted to follow the
instructions in the Information window.
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OK to continue.
Creating a Sequence
Creating the Geometry Parent Group
The next set of steps defines the geometry parent group. You will follow these steps to create
a sequence of operations:
in the toolbar.
Choose Sequence_Zlevel as the Subtype and Workpiece as the Parent Group.
OK to create the geometry parent group.

Creating a Sequence
Defining the Cut Area
The next step prompts you to define the cut area.
Choose Select.
Choose Features as the Selection Option.
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Select the Surface Region as illustrated below.

Creating a Sequence
Defining the Trim Boundary
The next step prompts you to define the trim boundary. A trim boundary is used to constrain
the cut area. Because you are going to machine the entire part, the program does not require a
trim boundary.
OK to proceed to the next step.
Creating a Sequence
Choosing the Operation Types
The next step prompts you to choose optional flowcut operations to include in the sequence.
You will not include these operations.

OK to proceed to the next step.
Creating a Sequence
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Completing the Sequence

The final step prompts you to specify whether or not the tool paths are to be generated
immediately after creating the operations. Due to the potential processing time involved for
this sequence, you will not generate the tool paths.
Be sure Generate Tool Paths is off.
OK to create the sequence of operations.

In the Program Order View of the Operation Navigator, expand the objects to display the
sequence of operations.
The operations would machine the part as illustrated below.
Creating a Sequence
Respecifying the Session Configuration
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The CAM Session Configuration you specified at the beginning of this lesson provides CAM
Setups only for mill contour type operations. Before continuing on to other courses, you
should choose a CAM Session Configuration that allows you to create all types of operations
including Milling, Drilling, Turning, and Wire EDM.
Choose Tools
Operation Navigator
Delete Setup from the main menu bar.
OK to delete the setup.

The cam_general configuration file provides the widest range of available setups for your
current work session.
Choose cam_general in the CAM Session Configuration list.
The specific setup you choose at this time is not critical since the setup can be respecified
when creating an operation.
Choose the mill_planar setup.
Choose Initialize.
UG/Post
Postprocessing is the preparation of machine code used to drive a specific machine tool. In
this lesson, you will learn how to postprocess using UG/Post.
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Postprocessing with UG/Post

UG/Post converts the internal tool path containing events and motions into a format
compatible to the machine tool's controller. To postprocess, UG/Post requires a tool path and
a postprocessor.
Open part file mfe_ugpost.prt from the mfe subdirectory.
Choose Application
Manufacturing from the menu bar.
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Replaying an Operation
Operations must contain internal tool paths in order to be postprocessed. You will replay the
existing tool path.
Expand the objects so you can see the operations.
Repost status ( ) means that the tool paths for the operations in the program have been
generated, but they have not been postprocessed or exported from the part file.
Choose the operation named FIXED_CONTOUR.
Choose MB3
Replay.
The tool path is a simple follow pocket cut pattern.

Listing the Internal Tool Path
The tool motion to cut the path you just displayed is stored in the part file as an internal tool
path. A machine tool cannot use the internal path as commands because they are written in
Standard APT. You will display the internal tool path using the List function.
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Choose MB3
Toolpath
List.
The internal tool path is listed in an Information window.
UG/Post converts the internal tool path containing events and motions into a format
compatible to the machine tool's controller. For example, the FEDRAT/MMPM,250.0000
command might be converted to the format F250.0 and the GOTO/0.0000.45,0000,3.0000
might be converted to G00X0.0000Y45.0000Z3.0000.

Accessing the UG/Post Postprocessor
UG/Post will process only one program or operation at a time. You will postprocess a simple
program containing two operations.
Choose the PROGRAM icon.
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Choose UG/Post Postprocess from the toolbar.

An alternate way to access UG/Postprocess is to choose Tools
Output UG/Post Process from the menu bar.
Operation Navigator

Choosing a Postprocessor
The generic postprocessors provided by the system are displayed in the Available Machines
list box. You will choose a postprocessor for a 3 axis milling machine tool.
Highlight the MILL 3_AXIS postprocessor.
All of the operations contain 3 axis tool paths, so the MILL_3_AXIS machine is appropriate
to use here.
More About: Postprocessors
The postprocessors provided by the system are displayed in the Available Machines list box.
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These postprocessors are stored in the main directory in Mach/resource/postprocessor. The

environment variable UGII_CAM_POST_CONFIG_FILE in ugii_env.dat points to a file
named template_post.dat. The Available Machines are listed in the template_post.dat file and
each machine entry points to the correct tcl and def files for that machine tool. System
administrator privileges are required to change these files.

Specifying a Write Directory
By default, the postprocessor will create a file in the mfe directory with the root name of the
part file and a "ptp" extension. You probably cannot write to the mfe directory and will need
to change to a directory you can write to.
Choose Browse.
Set the Look in: field to a directory you can write to.
Key in ugpost_output.ptp in the File name: field.
The file extension "ptp" is an abbreviation for paper tape punch file, a historical holdover
from the use of paper tape to read n/c programs into machine tool controllers. You can use
any file extension you prefer.
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OK to accept the output specification.
OK to postprocess the tool paths. This will take some processing time.
The tool paths are postprocessed and listed in an Information window. The file has been
created and saved in the specified directory.
Graphics Postprocessor Module (GPM)

Postprocessing prepares machine code for use in driving a specific machine tool. In this
lesson, you will learn how to create and edit a Cutter Location Source File (CLSF) and how to
postprocess the CLSF using the Graphics Postprocessor Module (GPM).
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GPM is a legacy product. It is covered here because it is still commonly used at many sites.
Postprocessing should now be done using UG/Post.
Creating a CLSF
The CLSF is an ASCII text file containing Standard APT commands. A CLSF is required
when using a 3rd party postprocessor or the legacy Graphics Postprocessor Module (GPM).
The first step in creating a Cutter Location Source File (CLSF) is to select the operations from
which you would like to write the internal tool paths to the operating system file.
A single part file might contain tool paths for different machine tools (for example, lathes and
3 axis mills) and you would not want to have tool paths for different machine tools in the
same CLSF. If this were the case, you would organize the different types of machining into
separate programs, such as a 3 axis mill program and a lathe program, so that you could create
separate CLSF's.
In the current part file, all the tool paths are for a 3 axis milling machine and are all included
in the NC_PROGRAM object.
Creating a CLSF
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Open part file mfe_post_1.prt from the mfe subdirectory.
Choose Application
Manufacturing from the toolbar.
Ten operations with a Repost status ( ) are displayed in the Program Order View of the
Operation Navigator. Repost status means that the tool path for the operation has been
generated, but it has not been postprocessed or exported from the part file.
Creating a CLSF
Selecting the Operations
You will select the operations from which you would like to write the internal tool paths.
Highlight the NC_PROGRAM object.
Highlighting the object selects all of the operations contained within the object.
Creating a CLSF
Outputting the CLSF
You will specify the file name and directory to which you will output the CLSF.
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Choose the Output CLSF icon in the toolbar.

An alternate way to Output CLSF is to choose Tools
CLSF in the menu bar.
Operation Navigator
Output
Choose Browse.
Make sure the Look in field is a directory to which you have write access.
Key in 3axis_mill_program in the File Name field and OK to accept it.
CLSF_STANDARD is the default format.

OK to accept CLSF_STANDARD as the format and write the file.
CLSF_STANDARD is the default format.
OK to write the file.
The Information window displays a listing of the output written to that file.
More About: CLSF Formats
When you choose the Output
CLSF option, a string of environment variables is executed.
The variables are, roughly, UGII_CAM_CONFIG_DIR UGII_CAM_CONFIG, in the

ugii_env.dat file, which points to cam_general.dat. The file cam_general.dat has a pointer
TEMPLATE_CLSF that points to the file template_clsf.dat in the
Mach/resource/template_set/tool_path directory.
The cam_general.dat file determines what you will see in the list box of the CLSF formats
dialog.
Notice the five text strings on the far left above. These text strings are the ones displayed in
the dialog below:
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The first of the formats listed, CLSF_STANDARD, uses two files to create output in the
APT-like format familiar to Unigraphics NX users. These two files are clsf.tcl and clsf.def.
clsf.tcl is a tcl file -Tcl (Tool Command Language) is a programming language.
Tcl is distributed free from a number of different web sites and the programs written in it are
very portable between different operating systems. The clsf.tcl file is an event handler; it tells
the Manufacturing Output Manager (MOM) what to do with the information stored in the
operations which have been selected for output.
One command in this tcl file, set mom_kin_clsf_generation TRUE, is particularly important
as it tells MOM to use an alternate path to a faster, optimized C code executable for
generating either the GOTO values or the Post commands.
clsf.def defines the format for the output generated by MOM from the event handler,
clsf.tcl and the post commands generated by the parameters stored in the operations
being processed.
The MOM is multifunctional in managing manufacturing output. Some of its functionality can
be visualized in the illustration below:
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The Output CLSF selection on the left leads to various intermediate clsf formats, while the
UG/Post Postprocessor option on the right leads directly to machine code.
The MOM analyzes the relationships between the various CAM objects and the pointers from
operations to sections of the Internal Tool path. These relationships and the tcl and def files,
determine the format of the output.
The CLSF_STANDARD is designed to handle legacy manufacturing data. To run faster, the
switch set mom_kin_clsf_generation TRUE is set to use previously generated post
commands.
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CLSF_COMPRESSED provides a shortened form of the CLSF useful for determining which
tools are used and when. The output is the same as CLSF_STANDARD, without the GOTO
values.
CLSF_ADVANCED will extract operation parameters, such as tool information and
automatically generated post commands, in addition to the tool positioning (X,Y,Z,I,J,K) data
CLSF_BCL generated binary centerline information for controllers requiring that output.
CLSF_ISO will generate International Standard format center line files.
A user defined output format can be added by editing the template_clsf.dat file and adding a
format type, e.g. MY_CUSTOM_OUTPUT, linked with a tcl file and a def file. A good
starting point for these would be to copy and rename the bcl.tcl and bcl.def files, perhaps to
something like custom.tcl and custom.def.
CLSF_IDEAS_MILL and CLSF_IDEAS_MILL_TURN are formats specifically for the
IDEAS postprocessor.
Creating a CLSF
The CL Source File Manager
The CLSF exists as an independent ASCII file. You will now use the CLSF Manager to
examine CLSF file. The CLSF Manager allows you to Edit, Reorder, Delete and Replay tool
paths, and to List the CLSF.
Editing the CLSF should be avoided if possible, and will therefore be discussed only briefly.
It is always better to edit the operation and regenerate the tool path because the operation
parameters are permanently stored with your part file.
Choose Tools
CLSF in the toolbar.
You must choose the CLSF that you want to open. The file mfe_tpmgr_1.cls is the same as
the file you just created.
Select mfe_tpmgr_1.cls from the mfe directory and then OK.
The CLSF Manager dialog displays. The dialog contains a list of all the tool paths in the
current CLSF.
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Creating a CLSF
Filtering the Tool Path Names
You can restrict the list of tool paths to only those that are blanked or unblanked, or to only
those that do not have an associated operation in the part file.
A Blanked tool path is temporarily removed from the paths displayed during a tool path
replay.
An Orphan is a tool path that has no associated operation. An Orphan is also anything that can
be inserted into the CLSF ( a PPRINT, macro call, etc.) that does not have a Start-of-Path or
End-of-Path statement.
Choose Blanked from the option menu.
Notice that one tool path, CORNER5, is listed.
Set the Show option back to All.
All the tool paths are listed again.
Creating a CLSF
Reordering Tool Paths
You can use Cut and Paste to remove one or more tool paths or to reposition them in the
CLSF. You will cut the MULTI-LEVEL tool path that roughs out the pocket and paste it
before POCKET1.
Choose MULTI-LEVEL from the listing window.
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Choose Cut.
Highlight TLCHG1.
The cut tool path will be pasted after the highlighted tool path (after TLCHG1).
Choose Paste.
If you had not highlighted TLCHG1, the cut tool path would have been placed as the first tool
path in the list.
Creating a CLSF
Deleting Tool Paths
You can also permanently delete one or more tool paths from the CLSF. Remember that you
are only removing the tool path from the CLSF - the operation and the internal tool path
which are stored in the part file are not affected.
Highlight POCKET2 and choose Delete.
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A confirmation message appears listing the names of the tool paths that will be deleted. If you
delete the tool path, you will not be able to get it back using Paste. To get it back, you would
have to regenerate the tool path and create another CLSF.
OK to delete the tool path from the CLSF.
Creating a CLSF
Listing Tool Paths
You can list the text of one or more tool paths in the CLSF.
Select CORNER1 in the list box.
Be sure you do not use the List button in the CLSF Actions section - that will list the entire
CLSF.
Choose List in the Tool Path Actions section.
The selected tool path is listed in the Information Window.
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Creating a CLSF
Replaying Tool Paths
You can replay the tool paths in the CLSF. First, you will use the Filter Methods section to
display just the corner tool paths.
Key in c* in the By Name field.
Turn on the By Name button.
Only those tool paths beginning with "c" are now listed.
Choose Select All.
You can stop the display of the tool paths at any time by choosing Stop on the Work in
Progress dialog.
Choose Replay in the Tool Path Actions section.
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The tool paths display graphically on the part.
Turn off the By Name option to deselect the tool paths.
All the tool paths are listed again.
Creating a CLSF
Optimizing the CLSF
Optimization is very useful when it is time to send the program to the shop floor. It can help
with some of the tedious cleanup.
Optimization allows you to:
preselect a tool for the next tool path.
suppress duplicate tool change commands in consecutive tool paths.
remove postprocessor commands which are generated (or inserted) at the end of each
tool path.
verify that a tool change command is output when the tool parameters change.
Choose List from the CLSF Actions section.
All of the tool paths in the CLSF are listed in the Information window. Look at line 50 in the
listing. It is the first LOAD/TOOL, 1 ... command.
Look at line 160 in the listing. It is an unnecessary duplicate LOAD/TOOL , 1 ... command.

Optimizing will strip out the duplicate tool changes.
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Choose Optimize.
The CLSF CONTROL dialog displays. The default settings will remove the duplicate tool
changes.
OK to optimize the CLSF.
Creating a CLSF
Verifying the Optimization
You can verify that the duplicate tool changes have been removed.
Choose List from the CLSF Actions section.
The duplicate tool change that was located at line 160 has been removed.
Postprocessing with GPM

There are two elements necessary for postprocessing with the Graphics Postprocessor
Module:
CLSF - The tool path Cutter Location Source File.
MDF - The Machine Data File
The Graphics Postprocessor Module (GPM) uses the Machine Data File (MDF) to convert the
CLSF into a format compatible to the machine tool's controller.
The CLSF is an ASCII text file containing Standard APT commands. A CLSF is required
when using a 3rd party postprocessor or the legacy Graphics Postprocessor Module (GPM).
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The Machine Data File (MDF) describes the characteristics of a machine and the required
format for its accompanying controller. Each MDF contains data the GPM needs for
postprocessing tool paths. The MDF is an ASCII file and has an extension of .mdfa.
When you are postprocessing, the GPM does the following in this order:
Reads a specified CLSF and MDF
Formats the CLSF according to the MDF instructions
Outputs a postprocessed tool path
This sounds involved, but it actually is not. The GPM is provided by Unigraphics NX and the
MDF probably already exists at your company.

Beginning to Postprocess
You will begin postprocessing with the GPM.
Choose Postprocess in the CLSF Actions section.
First, you must specify the GPM, CL file, and MDF. You can change the GPM using the
Specify option under Postprocessor Name.
You will not need to specify a different postprocessor for this exercise because the system
defaults to the GPM program provided with the current distribution of Unigraphics NX.
You can use the Specify option under Input File Name to change the CLSF. Notice that it has
defaulted to mfe_tpmgr_1, which is the CLSF you want to postprocess.
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Specifying the MDF
You must supply the name of the MDF.
Choose Specify under MDF Name.
Choose mfe_3axis.mdfa from the mfe subdirectory and OK.
The name of the MDF file displays on the NC Postprocessing dialog.

Run Time Options
Run time options override the non-machine related options in the MDF. For example, you can
change the MDF setting for the printed format of the postprocessed tool path, or change the
output units from inches to millimeters.
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NC Output - Selects the destination for the finished machine tool program. This
program is frequently referred to as the tape image, punch file (in the past it was
usually punched out on paper tape) or M and G code file.
Listing Output - Selects the destination for the listing output. The Listing Output is a
combination of the CLSF input and the NC Output and is frequently used for
debugging and other tasks.
Input Units - Specifies the input units to be used.
Listing Format - Can be set to Column (the listing is formatted into columns), Packed
(the listing is packed without column divisions), or MDF Defined.
Listing Commentary - Controls the listing of commentary data. It can be set to Yes,
No, or MDF Defined.

Specifying the NC Output
NC Output options allow you to set the destination of the output.
File - The output is an ASCII format file having a ".ptp" extension. You can edit this
file.
Paper Tape - Outputs the file to a tape punch.
None - All postprocessor output is suppressed.
MDF Defined - Defaults to the setting in the MDF.
Set NC Output to None.
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Specifying the Listing Output
There are five Listing Output options.
File - Sends the listing to a file with the specified file name.
Line Printer - Sends the output to the system printer.
Terminal - The listing is displayed in the status window of your terminal.
None - All postprocessor output is suppressed.
MDF Defined - Defaults to the setting in the MDF.
Set Listing Output to Terminal.

Initiate Postprocessing
Postprocess initiates postprocessing on the current CLSF file.
Choose Postprocess.
The CLSF is postprocessed and the output is displayed in a window.
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If you had directed the postprocessing output to a file, machine code as below would have
been written to the file:
A Message is displayed informing you that the postprocessing is finished and instructing you
to press Return to continue.
Press the Enter key.
Cancel the NC Postprocessing dialog.
Cancel the CLSF Manager dialog.
Ordinarily, you would save the file at this time.
Cancel the Save CLSF dialog.
Shops
Shops setups are template files that utilize a Process Assistant designed to step the occasional
user (such as the shop floor machine operator) through the process of creating an
operation.This lesson provides one general example of how to use a Shops template and how
to follow the Process Assistant to create a single operation.
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Open part file mfe_shops_1.prt from the mfe subdirectory.

Choose Application
Manufacturing.
Defining the Setup

You will follow the steps provided by the Process Assistant to define the setup. You will
define the Machine Coordinate system, the clearance plane, and the blank geometry.
Defining the Setup

Defining the Machining Environment
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Because this part has not yet been saved in the Manufacturing application, the Machining
Environment dialog displays requiring you to choose a configuration and a setup.
Choose shops_diemold as the CAM Session Configuration.
If you have purchased the Shops bundle, only one Shops choice appears here.
Shops setups are templates supplied with the system. Additional setups may also be available,
depending on how your system has been customized.
Choose shops_mill_contour as the CAM Setup.
Choose Initialize.
Defining the Setup

Defining the MCS
A sequence of Process Assistant dialogs will now begin stepping you through the process of
defining the setup.
Step 1 of the Process Assistant prompts you to define the Machine Coordinate system. You
may specify new MCS parameters or accept the current MCS.
OK to accept the current MCS.
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Defining the Setup

Step 2 of the Process Assistant prompts you to define the clearance plane.
Turn on the Clearance option and choose Specify.

Choose Two Lines.
Select the two lines illustrated below.
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Defining the Setup

Step 3 of the Process Assistant prompts you to define the blank geometry.
Choose Select.
Select the blank body as illustrated below.

At this point, the setup has been created.
in the toolbar. and click on the plus (+) sign to fully
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expand the object.
The MCS_MILL and WORKPIECE objects have been created using the parameters you just
defined.
Creating the Operation

You are now ready to begin creating the operation.
Choose WORKPIECE and MB3
Insert
Operation.
Choosing WORKPIECE assures that it will the parent group of the operation.
Be sure shops_mill_contour is displayed as the Type.
The Type determines the available Subtype icons and parent groups.
Choose ZLEVEL_FOLLOW_CORE as the Subtype.
The Subtype determines parameters specific to the operation such as the cut pattern.

Specifying the Tool
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A sequence of Process Assistant dialogs will now begin stepping you through the process of
defining the operation.
The first step in creating the operation is to define the tool and the method.
Be sure Tool: None is chosen.
Choose Select.
Choose New.
Choose the MILL icon.
The tool name defaults to MILL based on the Subtype you chose.
OK to begin defining the MILL tool parameters.
Key in the following values to define the tool.
OK to finish defining the tool.

Verifying the Method
The method defines parameters such as Intol, Outtol, and part stock.
Be sure MILL_ROUGH has been specified as the Method and OK to accept it.
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Displaying the Blank Geometry
Blank geometry has been defined in the Workpiece parent group.
Choose Display to highlight the Blank geometry.

Specifying the Part Geometry
The third step in creating the operation specifies the part geometry.
Choose Select.
Choose the part body as illustrated below.
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OK to accept the part geometry.

The fourth step defines the depth of each cut level.
OK to accept the default of 6.0.

You will now generate the tool path.
Choose the Generate icon.

Turn off the Pause After Display and Refresh Before display options.
This allows you to generate all the cut levels at once and to continue viewing them after they
have generated.
OK the Display Parameters dialog.
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OK the error.
The error message simply informs you that the tool cannot cut to the bottom of the part.
At this point in the process, you are free to modify operation parameters as you choose.
OK to complete the ZLEVEL_FOLLOW_CORE operation.
Choose Edit Blank Blank in the toolbar and select the blank geometry so that only
the part geometry displays as illustrated below.

Visualizing the Uncut Material
The Show 3D option creates a faceted model of the remaining uncut material.
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Choose ZLEVEL_FOLLOW_CORE and MB3
Workpiece
Show 3D.
It will take a moment to generate the faceted model.
The faceted model graphically represents the uncut material that remains after generating the
ZLEVEL_FOLLOW_CORE operation.
Shop Documentation
In this lesson, you will learn how to create shop documentation for use by machine tool
operators.
There are two formats for shop documentation: text format and HTML (Hyper Text Markup
Language) format. The text format is standard plain text. HTML format (illustrated below) is
the type of format read by web browsers and allows you to include graphics and other visual
enhancements to your documentation.
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Creating Shop Documentation

The following is a simple example of how to create and save a tool list in text format.
Open part file mfe_shop_doc_1.prt from the mfe subdirectory.
Choose Application
Manufacturing.
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in the toolbar.
Expand the objects so you can see the operations.
You will create shop documentation for these two operations.

Creating the Tool List
Choose Information
Shop Documentation in the menu bar.
You can also use the Shop Documentation icon

Documentation.
on the toolbar to access Shop
Templates defining different formats for the output of shop documentation display in the Part
Documentation dialog.
Choose Tool List (TEXT).
Choose Browse and select a directory to which you have write access.
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The default output file name is the same as the part file, with the extension .txt.
OK to accept the default output file name.
The text file is written to the specified directory and displayed in an Information window.
This file can be sent with the N/C program to the machine operator with instructions on how
to set up the stock for machining, etc.
Creating a Tool List for a Selected Program

A tool list can be created for a selected program when postprocessing. This is useful when
you wish to create shop documentation for a single program, and not the entire part.
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To create a tool list for a program, select the program in the Operation Navigator, choose the
UG/Post Postprocess icon in the toolbar, and choose one of the Program Tool List templates
in the list box.

Opening the Part
Open part file mfe_shop_doc_2.prt from the mfe subdirectory.
Choose Application
Manufacturing.

in the toolbar.
The Operation Navigator displays three programs.

Choose PROGRAM2 so that it highlights.

Creating the Tool List
Choose the UG/Post Postprocess icon in the toolbar.
Templates defining different formats for the output of shop documentation display in the Part
Documentation dialog.
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Choose Tool List (text).
Choose Browse and select a directory to which you have write access.
The default output file name is the same as the part file, with the extension .txt.
OK to accept the default output file name.
The text file is written to the specified directory.
This file can be sent with the N/C program to the machine operator with instructions on how
to set up the stock for machining, etc.
Close the Browser.
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PLANAR AND CAVITY MILLING

Planar Milling - Profiling
This course will teach you how to create Planar and Cavity Milling operations. Planar and
Cavity Milling operations create tool paths that remove material in planar layers, by cutting
levels perpendicular to the tool axis.
Planar Milling is intended for parts with vertical walls and planar islands and floors normal to
the tool axis. Part and blank material is defined using boundaries. It is used for roughing and
finishing.
Cavity Milling is intended for parts with tapered walls and contoured floors. Part and blank
material can be defined using boundaries, faces, curves, and bodies. It is used for roughing.
Audience
The audience for this course is Unigraphics NX Manufacturing application users who want to
machine 3-axis parts containing pockets, profiles, or cavities.
Prerequisites
The prerequisite for this course is the Manufacturing Essentials CAST Online Library course.
Course Contents
Planar Milling - Profiling You will learn how to create single pass Planar Milling tool
paths that follow open boundaries to machine reference surfaces for precise placement in
fixtures.
Planar Milling - Single Level You will learn how to create a single-level Planar Milling
operation.
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Planar Milling - Multi-Level You will learn how to create multi-level Planar Milling
operations, clean up islands, and create and edit boundaries.

Planar Milling - Multi-Region You will learn how to create a multi-region Planar Milling
operation that will cut several pockets with varying depths.

Face Milling You will learn how to create a Face Milling operation that finishes the faces
of a part. You will also learn several ways to cut across open and closed voids and learn how
to create mixed and manual cut patterns.
Cavity Milling You will learn how to create Cavity Milling operations that rough out
cavities and cores. You will also learn how to use a faceted body to perform rest milling.
Z-Level Milling You will learn how to profile the part at each cut level and then constrain
the cut region using the silhouette or "shadow" of the part. You will specify a Steep Angle to
profile only the steep areas left unmachined by a previous Fixed Axis Surface Contouring
operations. You will also learn how define a Cut Area and then further constrain the cut
region using a trim boundary.
Planar and Cavity Milling Project You will create a program that roughs, semi-finishes,
and finishes a part containing multiple cavities.
Creating the Master Model Assembly

You will use the Master Model concept to setup the part. This metric part file will be the top
level assembly part file containing the machining operations. It has some predefined geometry
in it which has been modeled to allow positioning of the part in the fixture
You will enter the Manufacturing application and define the part and blank geometry in the
Workpiece parent group. Operations can then inherit the parameters defined in the Workpiece
parent group.
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Opening the Part
The first step is to open a top level assembly part.
Open part file pln_assy_1.prt from the pln subdirectory.
Choose Application
Assemblies.

Adding Components to the Assembly
You will add a component that defines the part geometry.You may have to turn on the
Assemblies toolbar under View Toolbars Customize
Choose the Add Existing Component icon
from the Assemblies toolbar.
Choose Choose Part File.

Choose pln_pmp_1.prt from the pln subdirectory and OK to accept it.
The Add Existing Part dialog displays with the Positioning set to the Absolute coordinate
system.
OK to accept this part file and positioning mode.
Make sure the values in the Base Point coordinate fields are all set to 0.000 and WCS and
OK to accept them.
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Cancel the Add Existing Part dialog.

Entering the Manufacturing Application
Choose Application
Manufacturing.
The Machining Environment dialog displays because the part file has never been saved in the
Manufacturing application.
Be sure cam_general has been chosen in the CAM Session Configuration listbox.
Choose mill_planar in the CAM Setup: listbox.
Choose Initialize.

Creating a Permanent Boundary
Planar Milling operations can use boundaries to control the tool motion.
Choose Tools
Boundary in the toolbar.
You will create an open boundary using the line extending across the top of the part. You will
make it an "On" condition boundary so that the the tool center point positions directly on the
boundary.
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Choose Create.
Set Tool Position to On and Boundary Type to Open.
Select the line at the left end as illustrated below.
OK twice to create the boundary.

The origin of a boundary (indicated by a small circle) is determined by where the curve is
selected. The origin should be at the left end. The "tick mark" displays on both sides to
indicate that it is an "On" boundary, meaning that the center of the tool will follow the
boundary.
Cancel the Boundary Manager dialog.

Editing the Workpiece
You will edit the Workpiece object so that it defines the part and blank geometry.
in the toolbar.
Expand the MCS_MILL object in the Operation Navigator.

Double-click on the WORKPIECE icon to edit the geometry group.
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Choose the Blank icon, then Select.
Select the white rectangular block as the blank geometry.
OK the Blank Geometry dialog.

Defining Part Geometry
Choose the Part icon, then Select.
Select the green solid as the part geometry.
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OK the Part Geometry dialog.

OK the MILL_GEOM dialog.

Grouping Operations
It is convenient to group operations under program objects by the type of machining they do,
by the setups they use, or other criteria particular to your manufacturing processes.
in the toolbar.
Highlight PROGRAM.
Choose MB3
Rename.
Change the program name to ROUGHING_PROG.
This program name is easy to recognize as containing all the roughing operations. Finishing
operations could be contained in another program such as FINISHING_PROG.

Creating a New Tool
The open boundary was created in order to cut the top face of the stock with a single pass. To
provide safe clearance to bring the tool to the cut depth, the boundary begins 60 mm in
negative XC from the left side of the stock. The boundary ends 60 mm in the positive XC
direction from the right side of the stock.
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in the toolbar.
You will create a 100 mm diameter tool that is 25 mm long and has 20 inserts.
Choose the T_CUTTER icon and key in TMAX100 in the Name field.
OK to begin creating the tool.

Key in 100.00 in the Diameter field.
Key in 20 in the Number of Flutes field.
The tool diameter and number of flutes are used in the calculation of the feeds and speeds
generated by using the Reset from Table option on the Feeds and Speeds dialog. The Material
for the tool is set to HSS, High Speed Steel. Choosing this option and changing the tool
material will also affect the speeds and feeds.
OK to create the tool.

in the toolbar.
The tool displays in the Operation Navigator.
Facing the Top of the Stock
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You will create a Planar Mill operation that uses a large cutter (100 mm diameter) to machine
the top face in a single pass.

in the toolbar.
Be sure mill_planar is specified as the Type.

Choose the PLANAR_MILL icon.
Key in RUFTOP100MM in the Name text field.
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Choose OK to begin creating the operation.

Displaying the Tool
Choose the Groups tab and choose Display to view the tool.
The tool will cover the entire top of the stock in one pass.
Refresh the graphics window.

Startup Post Commands
Before the part can be cut on the machine tool, the controller needs to be told to load the
milling tool, turn on the spindle, and usually to turn on the coolant to flush away chips and
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cool the tool and workpiece. You will define several beginning of path and end of path
commands.
Choose Machine.
Choose Edit below the grayed-out Startup Commands option.
The number and types of available events in the Available list is determined by the setup of
the configuration files.

Adding a Load Tool Command
Highlight the Tool Change command.
At the bottom of the dialog, the Add option is now available allowing you to add the Tool
change command to the top of the tool path.
Choose Add.
Since this is the first tool to be used in the program, you might want to have it loaded into tool
position one in the magazine.
Key in 1 in the Tool Number field and OK to accept it.
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The User Defined Events dialog displays with the Tool Change event set to
"Status=Active,Tool Number=1,Head Designation=None,Manual Tool Change-FALSE".

Adding a Spindle On Command
Highlight Spindle On and Add it.
The Spindle On dialog displays.
The RPM specified for a tool depends on the material to be cut, the cutting tool (whether it is
a tool using inserts or various kinds of tool steel), the diameter of the tool, the strength or
rigidity of the machine tool, machine tool horse power and the desired finish.
Key in 194 in the Speed field and OK to accept it.
The Spindle On user defined event displays in the Defined list listbox.

Adding a Coolant On Command
Highlight Coolant On in the Available Functions listbox and Add it.
OK to return to the User Defined Events dialog.
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Three startup events have been defined so far.
These three commands are probably the most frequently used. There are many more
commands listed under the Available list.
The postprocessor might not require these user defined events in order to output the machine
tool commands to load a tool or turn on the spindle to a given RPM. These T and S words can
be automatically output based upon the stored data in the generated tool path and the structure
of the machine tool's definition files. Highly variable commands, such as coolant, which can
be set to on, flood, mist or tap, might be most easily defined as user defined events. User
defined events might override the automatic events which would be output by UG/Post. The
output is ultimately determined by the structure of the machine tool's postprocessor.
OK to return to the Machine Control dialog.
Note that the Startup Commands option is now On.

End-Of-Path Post Commands
End-Of-Path post commands can be added to turn off the spindle and turn off the coolant after
the tool machines the top of the stock.
Choose Edit located below the grayed-out End-Of-Path Commands option.
Highlight Coolant Off in the Available Functions list and choose Add.
The user defined event Coolant Off is listed in the Defined list box.
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Highlight Spindle Off and choose Add
The Spindle Off dialog displays.
The Spindle Off event is listed in the Defined list.
OK to return to the Machine Control dialog.

Notice that the End-Of-Path Commands option is now On.
OK to return to the PLANAR_MILL dialog.
The commands you have just defined will be added to the output tool path when it is
generated.

Selecting the Open Boundary
Choose Boundary to define the Mode.
To select the boundary, you should center the cursor on the tic mark.
Select the boundary.
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OK the Boundary Geometry dialog.

Specifying a Manual Engage Move
The beginning of the engage move should be specified far enough off the part to provide a
safe movement of the tool into the stock. The retract move should adequately disengage the
part before beginning its rapid motion back to the home position.
Choose Method under Engage/Retract.
Choose Ang Ang Dist for the Initial Engage.
The Distance, Angle 1, and Angle 2 text fields are now available.
The Distance is the length of the engage move.
Angle 1 is measured from the direction of the first cut move, counterclockwise in the
plane of the part surface.
Angle 2 is measured clockwise in a plane normal to the part surface.
Specify the following Distance, Angle 1, and Angle 2 values.
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These values will create an engage move in the direction of the cut, moving down at an angle
of 45 degrees for a distance of 40 mm.

Specifying a Manual Retract Move
You will use the retract to a point method to disengage the tool from the boundary, by
selecting the right end point of the line and specifying a rectangular offset relative to the
WCS.
Choose Point for the Final Retract.
Choose Rectangular for the Offset.
Select the line end point as illustrated below.
Key in the following offset values.
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OK to return to the Engage/Retract dialog.

An asterisk displays at the calculated retract point.

Specifying the Floor
The tool should cut the top of the part which is 2 mm below the white enclosing stock. To do
this, you need to define the top of the part as the floor.
Choose the Floor icon and Select.
Change the Filter to Face.
Select the top of the part (the top of the narrow wall).
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Changing the Cut Direction
The current Cut Method is Follow Part. You will change it to Profile so that the tool can cut
along the open boundary.
Set the Cut Method to Profile.
You want the cut direction to be from left to right, so you must change the type of cut from
Climb to Forward. By setting the Cut Direction to Forward, the tool motion is from the origin
of the boundary (indicated by the small circle) to the end of the boundary in the direction
indicated by the "tic" marks on the boundary.
Choose Cutting.
Choose Follow Boundary as the Cut Direction.

Changing the Feed Rates
The default feed rates are either 0.000, which results in tool motion at the rapid rate, or
250.0000 mmpm for the cut feed rate. While the program is being proofed, a slower motion is
desirable.
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The cut feed rate depends on the spindle rpm, type of cutter being used, the type of material
being cut, and several other factors. The system will calculate these feed rate and spindle rpm
values for you from data that your system administrator can customize.
Choose Feed Rates.
Note the Reset from Table option at the bottom of the dialog. Choosing this option will
automatically set the spindle RPM and feed rates to those appropriate for the current tool and
calculated from information in a database that can be customized for your site and machine
tools.
The values for the various feeds and speeds are automatically entered into the appropriate
fields. Notice that the Spindle Speed has been calculated to be 194.0000 rpm, which you
already set.

Setting the Display Options
The display options can be set to make it easier for you to interpret the tool motion. The
direction of the tool motion is more easily seen if directional arrows are painted on the tool
path. Different types of tool motion can be painted in distinctive colors and the feed rates of
the motion also displayed. Painting the tool in a 3D wireframe display makes it easier to
visualize potential interference with clamps, and also provides a rough approximation of
machining coverage.
Choose Edit Display.
Set the Tool Display to 3-D.

This will display the tool at every GOTO point and help you to visualize the tool motion.
Another aid to visualizing the tool motion is to paint direction arrows on the tool path.
Choose Other Options.
Turn the Paint Arrows option on and OK.
OK the Display Options dialog.
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The default Part Stock is set to 1.0 mm. This value is automatically set by the selected
Method, which is MILL_ROUGH. You will change the part stock value to bring the cutter
into contact with the top of the part face selected as the floor.
Choose Cutting.
Change the Part Stock to 0.00 and OK to accept it.

All of the parameters have now been specified and you will generate the tool path.
OK to continue generating the tool path.
OK to complete the operation.
Profiling Two Sides of the Stock

You will profile the left side and front of the part geometry using the two white lines and fillet
to define the tool path. This operation will machine reference surfaces for precise placement
in the fixture.
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Choose the Create Operation icon in the toolbar.
Key in PROFILE-2SIDES in the Name field.
Choose OK to begin creating the operation.

Creating a New Tool
You will create a 40.0 mm diameter tool. Because this tool is created within the operation, it
does not display as an object in the Machine Tool view of the Operation Navigator.
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Choose Reselect with the Tool option turned on.
Choose New.
Choose the Mill icon, key in EM40 in the Name field, and OK to begin creating the tool.
Key in 40 in the Diameter field, 100 in the Length field and 8 in the Number of Flutes
field.
OK to finish creating the tool.

Setting Speeds and Feeds
Choose Feed Rates.
The Spindle Speed has been calculated to be 484.0000 rpm for this tool. Remember this
value.
Change the First Cut feed rate to 98.00.
OK to accept the feeds and speeds.

Creating a Temporary Boundary
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You will create a boundary that the operation will use to define the cut path. Unlike the part
boundaries defined in the Workpiece parent group, this boundary can only be used by this
operation.

Specifying Custom Boundary Member Data
Custom Feed Rate and other commands can be added to individual members of a boundary.
With the temporary boundary you are about to create, the tool motion through the fillet
connecting the two lines will be made without the tool contacting any material. The move can
be done at a feed rate greater than the cutting feed rate of 98.00 mmpm.
Choose Custom Boundary Data.
Set the Mode option to Curves/Edges.
Set the Type option to Open and the Tool Position option to on.
Choose MB3 and refresh the graphics window.

Select the end of the white line as illustrated below.
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Choose Custom Member Data.

Specifying Cut Feedrate
The next piece of geometry you select will be given the custom data you specify.
Turn the Cut Feedrate option on and key in 200 in the text field.
Select the fillet as illustrated below.
Key in 98 as the Cut Feedrate for the next boundary member.
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Select the end of the white line.
OK twice to complete the boundary.

Displaying the Boundary
You can display the temporary boundary you have just created.
With the Part icon chosen, choose Display.
The temporary boundary displays in magenta. Notice that the tic marks are displayed on each
side of the boundary, indicating that it is an On condition boundary.
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Choose MB3 and Refresh the graphics window.

Setting the Floor Geometry Using an Arc
The last operation you created used a face to define the floor geometry. You will use the arc
filleting the two white lines this time to define the floor.
Select the arc.
OK to define the floor.
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The tip of the tool will position to this floor plane.

Using the Standard Drive Cutting Method
The Standard Drive cut method is the only boundary cutting method which allows the tool to
cross boundary members and cut them in the order in which they were selected.
Choose Standard Drive as the cut method.

Setting the Cut Direction
The Cut Direction is currently set to Climb. You will change it to Follow Boundary.
Choose Cutting.
Set the Cut Direction option to Follow Boundary and OK the Cut Parameters dialog.
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You will set the display options to more easily visualize the tool motion.
Set the Tool Display option to 3-D.

Turn the Paint Arrows option on and OK.
Turn off the Display Cut Regions and Pause After Display options.
OK to complete the display options.

All of the parameters have now been specified and you will generate the tool path.
The tool path is generated and displayed without the pause that occurred when you generated
the first operation. You might find turning off the pause very useful for multi-level operations.
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Listing the Tool Path
Choose the List icon to list the tool path.
Note the 200.0000 mmpm feed rate between the moves at 98.0000 mmpm for the circular
move which you specified. The User Defined Events are displayed as Standard APT
commands.

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You will use Toolpath Visualization to see the material removal.
Choose the ROUGHING_PROG object in the Program Order view of the Operation
Navigator.

Choose the Dynamic tab at the top of the dialog.
The operations execute in the order of the program and material on the top and along the edge
of the part is removed.

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Planar Milling - Single Level

Planar Milling operations create tool paths that remove material in planar layers. This type of
operation is most commonly used to rough out material in preparation for finishing
operations. Planar Milling is intended for parts with vertical walls and planar islands and
floors normal to the tool axis.
In this lesson, you will learn how to create single-level Planar Milling tool paths.
Creating a Planar Mill Operation

You will create single-level Planar Milling operation.

Opening the Part
Open part file pln_pms_1.prt from the pln subdirectory.
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This is a simple part, designed to illustrate the basic procedures involved in removing material
from a pocket containing an island.
Choose Application
Manufacturing.

in the toolbar.

As a general practice, Program, Geometry, Tool, and Method parent groups should be
specified in this dialog box. These parent groups, however, may be respecified within the
operation. For this exercise, you will initially specify only the Tool parent group and the
operation name.
Key in PLNR_M_PKT_1 in the Name field.

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Displaying the Tool
With the Tool option on, choose Display.
The tool displays with its axis aligned to the ZC axis.

Specifying Boundaries
Planar Mill operations use boundaries to define the part, blank, check, and trim geometry. The
volumes defined by these boundaries result from their projection to the floor plane. The blank
geometry volume minus the part geometry volume defines the material to be removed (cut
volume).
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Be sure the Mode option is set to Face.

You must define the side of the boundary you are going to cut. Since you are going to use this
boundary to cut a pocket, you will retain the material on the Outside of the boundary.
Set the Material Side option to Outside.
When the Ignore Islands option is turned on, the system will ignore any islands that rest on
the face that you select. In this case, if Ignore Islands were turned on, the island in the middle
of the part would be cut off.
Choose Ignore Islands to turn the option off.
Select the face at the bottom of the pocket.
Both the pocket and island boundaries are created.
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OK to complete the part boundary creation.

Specifying the Floor Plane
The floor plane is the lowest or last cut level. All cut levels are generated parallel to the floor
plane.
A vector displays originating from the selected face.

OK the Plane Constructor dialog.

Changing the Tool Path Display Colors
Before you generate the tool path for this operation, look at the current settings of the tool
path display colors.
Choose the Edit Display icon.
Choose Specify Colors.
The Path Display Colors dialog shows the colors that each type of tool motion will display in.
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Changing the Step Over Color
Since the part is green, you do not want the step over moves to also be green.
Choose the Step Over color.
Set the color to Pink or a similar color.

Changing the First Cut Color
Notice that the First Cut and Cut moves are both cyan. You will change the First Cut color so
that you can distinguish these moves.
Choose the First Cut color.
Set the color to White.
OK to return to the Display Options dialog.
Changing the Retract Feed Rate
Choose Feed Rates.
Key in 99 in the Retract field.
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OK to accept the feed rate.

The cut regions display.
OK to continue processing the tool path.


Creating a Profiling Operation
Profiling creates a single or specified number of cutting passes to finish part walls.
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Choose the PLANAR_PROFILE icon.
Key in PLNR_M_PKT_2 in the Name field.

Specifying Boundaries
Choose Ignore Islands to turn the option off.
Both the pocket and island boundaries are created.
OK to complete the part boundary creation.
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A vector displays originating from the selected face.

OK the Plane Constructor dialog.

Set the Tool Display option to 2-D and OK to accept it.
Generate the new tool path.
OK twice to continue processing the tool path.
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Outputting Contact Data
You will edit the operation and change the tool path output so that it is defined by cutter
contact positions.
Output Contact Data causes the tool path to be generated from cutter contact positions along
the boundaries and walls of the part rather than from cutter end point positions.
Output Contact Data complements the traditional application of cutter compensation, which is
to compensate for the wear of the cutter. By using the contact data, the machine operator has
the flexibility of choosing a range of cutter sizes (based on the nominal cutter size specified in
the operation) with which to machine the part while maintaining the same cutting accuracy
along the tool path. This feature is only available for Planar Profile operations.
Choose Machine.
Choose Cutter Compensation.
Set the Cutcom option to Engage/Retract.
Turn the Output Contact Data option on.
OK twice to accept Output Contact Data and return you to the Planar Profile dialog.

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Specifying a Zig-Zag Cut Method
Zig-Zag machines a closed pocket in a series of parallel straight line passes. Climb or
conventional cut directions are not maintained because the cut direction changes from one
pass to the next.
Double-click the PLNR_M_PKT_1 icon to edit the operation.
Set the Cut Method to Zig-Zag.

You will generate the tool path and see the difference in cut motion due to the change in the
cut type.
Set the Tool Display option to off and OK to accept it.
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This time the tool does not follow the boundary. Instead, it makes parallel cuts back and forth
with a stepover between cuts.
Change to a Front view.
You can see that the rapid moves (dashed red) cut into the island. There are options that you
can set to avoid collisions like this, but for now you will only look at the cut types methods.
Reject
the tool path.

Specifying a Follow Part Cut Method
Set the Cut Method back to Follow Part.
Follow Part creates a tool path using concentric offsets from the part geometry. This method
computes the tool path by offsetting from the outer edges of the pocket and the island.
Climb (or Conventional) cutting is maintained throughout the tool path.
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You will generate the tool path and see the difference in cut motion due to the change in the
cut type.
The tool path is generated. The tool does not collide with the island. This cut type is better
suited for this part because the island's edges are taken into account when calculating the tool
path.
Reject the tool path.

Changing the Stepover Moves
The stepover establishes how the cutter moves from one cut pass to the next.
The stepover distance can be constant or variable. You have four options for controlling it.
Constant - A fixed distance between passes.
Scallop - The stepover is calculated based on the height of the scallops left between passes.
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Tool Diameter - The stepover is determined based on the percentage of the effective tool
diameter.
Variable - Uses a variable stepover and number of passes or a minimum and maximum.
Currently, the stepover distance is being controlled using a percent of the tool diameter. It is
actually calculated using the effective tool diameter, which is the flat bottom of the tool.
The default percent value is 50.

Changing the Diameter Percent
You will see what happens to the tool path when the stepover is increased.
Key in 70 in the Percent field.

The increased stepover causes the cutting moves to be calculated differently. Compare your
current tool path with what the tool path looked like with a 50% stepover.
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Changing the Scallop Height
You will change the stepover so that the distance between cuts is controlled by the scallop
height.
Set the Stepover option to Scallop.
The Percent option changes to Height.
The Scallop size is the height of material left by the corner radius of the tool. The stepover
taken may vary from cut to cut depending on the boundary.
1. Scallop Size
2. Calculated Stepover
3. Cutter Corner Radius
The tool makes fewer passes to cut the material while maintaining the scallop height.
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Try some different combinations of Cut Method and Stepover. After you generate each tool
path Reject it. (Do not change any defaults. Just compare the differences you get).
After your last combination, refresh the graphics screen and continue with the lesson.

Completing the Operation
Set the Stepover option to Tool Diameter.
Set the Percent value to 80.
OK the PLANAR_MILL dialog to complete the operation.
Notice that PLNR_M_PKT_1 is listed in the Operation Navigator. The exclamation point ( )
next to it indicates that the operation contains an internal tool path.
Editing a Planar Mill Operation

You will explore many of the Planar Mill parameters by editing an existing operation. Among
these will be engages and retracts, transfer moves, clearance planes, avoidance geometry,
floor planes, stock, feed rates, and trim boundaries.
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Opening the Part
Choose Application
Manufacturing from the menu bar.

Editing an Existing Operation
Choose PLNR_M_PKT_1 in the Program Order View and choose MB3
Edit.

Defining Engage and Retract Moves
Engage and Retract options determine the direction and distance that the tool moves toward or
away from the part.
In the Engage/Retract section, choose Method.
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The Engage/Retract Dialog
There are two types of Engages and Retracts. Initial Engage is the first engage of the
operation. Internal Engage is an engage move to a new cut region.
Final Retract is the last retract move of the operation. Internal Retract is a retract move prior
to moving to a new cut region.
The clearance distances are the distances the tool stays away from the machining geometry
when it moves to a cutting region.
In the following illustration, the tool begins the engage .100 away from the bottom of the part.
This distance is called the Vertical Clearance distance.
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The last option that you will look at is the Transfer Method. This option defines where the
tool will retract to when moving from one cut level or one region to another. The tool path
that you have just generated does not make any transfer moves. You will see this later in the
Planar Milling Multi-Region lesson.
All of the moves are set to automatic, meaning that they are calculated for you. The engage
and retract moves are based on the cutting condition of the operation, the geometry of the
part, and different parameters that you enter.
Cancel to return to the PLANAR_MILL dialog.

The Ramp Options
When the tool initially engages the part, it ramps at the angle set in Ramp Angle from the
Vertical Clearance distance to the workpiece.
Choose Automatic.
It is difficult to see the engage move in your tool path because the cutting tool moves are
covering up the ramp engage.
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Later you will learn how to apply a Helical Engage for the Initial Engage.
Cancel to return to the PLANAR_MILL dialog.

Circular Engage and Retract
Some of the engages and retracts in the tool paths that you generated earlier are circular. Look
at the circular engage applied when the tool engages the island boundary. Notice again, the
circular engage used when the tool engages the wall of the part.
You also have circular retracts applied when the tool leaves the part wall and on the Final
Retract.
Circular Engage and Retract does not apply to Zig-Zag or any other Zig routine.

Creating Linear Engage and Retracts
Choose Automatic.
Set the Automatic Type option to Linear.
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The tool path generates and the circular engages and retracts convert to linear moves.
Choose Reject.

The Overlap Distance
Choose Automatic.
Take a closer look at the retract move along the wall of the part
The tool cuts past the start point of the cut before it retracts. This is because of the Overlap
Distance.
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This move assures a full cleanup at the point where the engage and retract occur.
The Overlap distance is also applied to engage moves.

The Retract Clearance
Look at the final retract. The tool moves .150 past the final cut point, then ramps up from the
bottom of the part, to the .05 Retract Clearance.
This time you will change the overlap distance and the Retract Clearance and look at the
difference.
Key in 0.000 in the Overlap Distance field.
Key in .300 in the Retract Clearance field.
OK to accept the changes.

The tool path is generated. The tool does not overlap at any point in the tool path. The tool
retracts lifting .300 from the bottom of the part.
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Choose Reject.

Setting the Arc Radius Value for Circular Moves
Choose Automatic.
Set the Automatic Type to Circular.
The Arc Radius field is no longer grayed out. You will define a larger arc the tool will track
when making the internal engage and the final retract moves.
Key in .500 in the Arc Radius field.
OK to accept the change.

Your tool path shows the enlarged circular engage (orange) and retract (cyan) move.
Choose Reject.
Next you will create a helical engage for your initial engage move into the part.
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Creating Helical Engages
In all of the previous tool paths, the tool ramped into the part on the initial engage. This is
because a circular engage is only applied when engaging into a wall. You can use a Helical
engage with the Follow Part cut method to avoid ramping into the part.
Choose Method.
Choose Automatic Engage/Retract.
A helical engage move will be applied to the Initial Engage move of a Follow Pocket tool
path.
Set the Ramp Type to Helical.
OK to return to the Engage/Retract dialog.

You will change the Vertical Clearance Distance setting to engage further away from the floor
plane. This will enable you to see the helical move more clearly.
Choose Method.
Key in .300 in the Vertical field.

Your tool path is generated with a helical engage.
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Setting the Avoidance Geometry
Avoidance geometry controls the non-cutting motions of the tool. These non-cutting motions
are made to avoid clamps, set a safe approach to the part stock, or for other reasons detailed in
the technical documentation. You are going to define a Clearance Plane, a From Point, and a
Start Point.
Double-click on PLNR_M_PKT_2.
The Avoidance option lets you define clearance motions for the tool as it moves toward or
away from the part. This is different from the Engage and Retracts in that the tool moves
toward or away from points in the tool path.
Choose Avoidance.
Avoidance Options
The options are described below:

From Point - The FROM Point is a reference point only. The FROM/ command is output as
the first entry in the tool path.
Start Point - The Start Point outputs a GOTO/ command at the rapid feed rate after the
FROM/ and post commands and before the first Engage move.
Return Point - After the cutter reaches the last point of the cutter path, or the end of a Retract
move if one has been defined, the cutter moves straight up to the Clearance Plane, then moves
to the Return Point.
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GOHOME Point - The GOHOME Point defines the final tool location. The From Point is
often used as the GOHOME point. This point is a physical location that the tool moves to.
GOHOME Point outputs a GOHOME/ command as the final entry in the tool path.
Clearance Plane - The Clearance Plane defines a safe plane for the tool to move before and
after an operation and when moving from one cutting region to another.
Lower Limit Plane - The Lower Limit Plane is a plane which, when violated by the tool,
issues a warning in the CLSF. You can specify what to do with points that occur below the
lower limit plane.
Redisplay Avoidance Geometry - Displays the active Avoidance Geometry (points and plane
symbols) and the Reference Coordinate System (RCS).

The tool can move to the Clearance Plane before the Engage move, after the Retract move,
and when moving between cut regions (Transfer moves). You will specify a Clearance Plane.
Choose Clearance Plane - None.
The Clearance Plane dialog displays. You can use the Specify option to define the Clearance
Plane. Then you can use the other options to temporarily omit and then reinstate the Clearance
Plane, to verify the settings you have specified, and to graphically display the Clearance
Plane.
Choose Specify.
Choose Principal Plane.
Choose ZC Constant.
You will create a clearance plane one inch above the XC-YC plane.
Key in 1.0000 in the ZC field.
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OK to accept the value.
Notice that the ZC value for the Clearance Plane displays in the dialog and a plane symbol
displays in the graphics window at ZC=1.0000.

Defining when the Clearance Plane will be used
Notice the Use at - Start_End option. You can use the Clearance Plane at the beginning of the
tool path, at the end, or both.
Choose Use at - Start_End.
The options for the use of the Clearance Plane are displayed. These settings will cause retract
to the Clearance Plane when the tool moves from one cutting region to another. As you saw in
the previous tool paths, this is necessary to prevent the tool from crashing into the island.
OK to accept the default of Start and End.
OK again.

As you can see in the Front and Right views, the tool moves from the Clearance Plane to the
engage point (red dashed line). Then at the end of the tool path, the tool moves from the last
cut point back to the Clearance Plane (blue dashed line).
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Defining a From Point
The FROM Point is only a Reference Point. It does not cause any tool motion. It is used to
establish the directional relationship between the tool and the part and as the origin of
graphical display of the tool path.
Choose Avoidance in the Machining Parameters section.
Choose From Point- None from the dialog.
Choose Specify.
Key in the following values for the Base Point and OK to accept them.
The FROM Point displays in the graphic window. You may have to rotate the view to see the
displayed point.
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OK to accept the From Point.
The From Point is defined. Next, you will define the Start Point.

Defining a Start Point
The Start Point should be located below the Clearance Plane because the tool moves first to
the Clearance Plane and then to the Start Point.
Choose Start Point- None.
Choose Specify.
The Point Constructor dialog displays. You are going to use XC, YC, ZC coordinates again.
Key in the following values for the Base Point and OK to accept them.
The START Point displays in the graphic window.
Choose OK to accept the Start Point.

Both the From Point and the Start Point are active.
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You are ready to generate the tool path using the From and Start points.
The tool path is generated. The tool moves from the From Point to the Clearance Plane. It
then moves to the Start Point. Once it reaches the Start Point, it moves to the Engage Point.

Editing the Boundary and Boundary Members
You can make changes to an entire boundary or to individual boundary members. In this
section, you will move the boundary plane.
The tool in the previously generated tool path moved to the Clearance Plane, then to the Start
Point, and then to the Engage point .300 above the floor. Then the tool moved to the boundary
plane, which was the plane of the face you selected at the bottom of the part. This is OK for
finishing because the roughing stock has already been removed. For roughing operations you
must start cutting from the top of the stock material. To do this, you must move the boundary
Plane to the top plane of the stock material.
Double-click on the BOUND_EDIT operation.
The PLANAR_MILL dialog displays. The operation is the same as the PLM_M_PKT_2
operation. It includes the Avoidance geometry and Feed Rates changes you made previously.
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You are going to move the outermost boundary to the top of the part and the island boundary
to the top of the island.
Choose Edit in the Geometry section.
Notice that the outermost boundary highlights for editing.

Editing the Plane of the Outermost Boundary
The Plane option determines the plane in which the boundaries are created. You will move the
outermost boundary from the bottom of the part to the top of the part.
Set the Plane option to User Defined.
Choose Two Lines.

Choose any linear edge at the top of the part
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Choose a second linear edge at the top of the part.
You have defined the new boundary plane for the outermost boundary.

Editing the Plane for the Island
You will edit the boundary plane for the island.
Choose the Next arrow key at the bottom of the dialog one time.
The island boundary highlights in white. Also notice that the outermost boundary now
displays at the top of the part.
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Once again, set the Plane option to User Defined.

Choose Plane of Curve.
Choose any arc edge on the top of the island.
OK the Edit Boundary dialog.

Displaying the Boundaries
You can display the boundaries to verify that changes are correct.
Choose Display from the Geometry section.
The boundaries display.
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This time the tool moves to the Clearance Plane (ZC 1.0), down to the Start Point (ZC .4) then
to the Engage Point. Remember, you set the Vertical Clearance in a previous operation to .300
above the Engage Start Point. The tool is moving at the Engage Feed Rate the Vertical
Clearance distance into the material. It is also using the Helical engage motion.
Choose Reject.

Editing Members of a Boundary
You can edit individual members of a boundary. This time you are going to slow down the
feed rate as the tool cuts part of the island.
Choose Previous or Next icon at the bottom of the dialog until the island boundary
highlights.
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Editing the First Member
Choose Edit.
Choose the Previous or Next icon to highlight the member illustrated below.
You will slow down the feed rate inside the "U" shape.
Choose Custom Member Data.
The Edit Member dialog expands to display the custom values which can be applied to a
boundary member. You can customize each object in the boundary in many ways. You can
add Post Commands, add Stock, or even change the selected geometry to be the first member
of the boundary.
Turn the Cut Feedrate option on and key in 6.00 into the value field.
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Editing the Next Member
Choose the Previous icon to highlight the previous boundary member.

Editing the Remaining Members
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OK the Edit Member dialog.

List the tool path
FEDRAT/5.000.
and scan for the custom feedrates FEDRAT/6.000 and

Now you are going to look at a few more Display options that can be used to help display the
tool path.

More About Display Options
In this section, you will change some more of the Display options.
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In the Display Options dialog, notice that the paint speed is still set to 8, as you set it earlier in
the lesson.
Set the Tool Display option to 3-D.
Key in 5 in the Frequency field.
This specifies that the tool will be displayed at every fifth Cutter Location point.
Paint Feeds - Displays the feed rate each time it changes.
Paint Arrows - Displays an arrow at the end of each tool path segment showing its
direction.
Paint Line Numbers - Displays the CLSF line number of the first CL-point of each
tool path when you Replay an accepted tool path.
Turn the Paint Feeds and Paint Arrows options on.
OK twice to return to the PLANAR_MILL dialog.

You can see the effect of all the changes you made to the display options.
The tool displays as a wireframe at every fifth point in the tool path
There is an arrow at the end of each tool path segment
Feed rate changes are shown as "F#"
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Because the Display settings are modal, they remain in effect until they are changed.
OK to accept the tool path.
You are finished using this part file. Next you are going to learn more about blank geometry
and boundaries.

Blank geometry is the material that surrounds some or all of the part. The cut volume
(material to be removed) is the blank material minus the part material.
In this portion of the lesson, you will define blank geometry and then remove the portion that
surrounds the perimeter of the part.
Choose Application
Manufacturing.

You are going to create a Planar Mill operation that removes the blank geometry around the
perimeter of the part.
in the toolbar.

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Defining the Part Boundary
With the Part icon chosen, choose Select.
The Boundary Geometry dialog displays. The Material Side is set to Inside. This means that
the material will be retained inside the boundary.
Select the four curves in order as illustrated below.
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OK to create the boundary.

Using Side Stock for Blank Geometry
You will create Blank geometry using the Side Stock option. This creates a specified amount
of stock equally surrounding the sides of the part.
Turn the Ignore Holes option on.

Turn the Stock option on and key in1.00.
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This creates an extra inch of stock surrounding the part that will be used as the Blank
boundary. The tool will cut from the 1 inch outer edge of the Blank boundary to the Part
boundary.
Be sure the Mode is set to Face.
Select the bottom face of the part.
OK to complete the boundary geometry.

Defining the Floor
You are going to use the bottom face of the part as the Floor.
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OK to accept the face and return to the PLANAR_MILL dialog.

A plane symbol and vector display, indicating the face selected and the normal vector
direction away from its interior.


Close the part.
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Planar Milling - Multi-Level

A multi-level tool path cuts material in successively deeper levels. The tool begins at the top
level and works its way down to the floor plane.
In this lesson, you will learn how to create multi-level tool paths, clean up islands, create and
edit boundaries, and control many other aspects of multi-level planar mill operations.
Creating a Multi-Level Planar Mill Operation

You will create multi-level Planar Milling operation.
Creating a Multi-Level Planar Mill Operation

Opening the Part
Open part file pln_pmm_1.prt from the pln subdirectory.
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Choose Application
Manufacturing.
Before you start, there are two terms that you should understand.
Region - this is the area within the cut levels that can be accessed by the tool without it
having to retract from within the part. There can be multiple regions cut in one
operation.
Cut Level Planes - are planes that define the levels in the pocket where the cuts take
place.
Blank and Part Geometry Definition

Blank and part geometry have already been defined in the Workpiece object. You will
examine the blank and part geometry in the Workpiece object and then define part boundaries
and the floor plane.
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Examining the Workpiece Parent Group
Set the Operation Navigator to the Geometry View.
Expand the MILL_ORIENT and WORKPIECE objects.
Highlight WORKPIECE.
Choose MB3
Edit.
With the Part option chosen, choose Display.

Choose the Blank icon and then Display.
OK the WORKPIECE dialog.

Set the Operation Navigator to the Program Order view.
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Editing the Operation
You are going to edit an existing operation.
Double-click on the operation named PMMULTI.

Defining the Boundaries
You will create three part boundaries using the Curve/Edge mode - first the main boundary,
then two island boundaries.
With the Part icon chosen, choose the Select option.
You are cutting a pocket, so the material to remain is on the outside of the pocket boundary.
The Material Side option needs to be changed to Outside.
You are ready to select the objects for the first boundary.
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Creating the Main Boundary
You can select the boundary objects individually or by chaining.
Choose Chaining.
You will select the first segment of the boundary at the end that indicates the chain direction.
Select the linear edge at the left end as illustrated below.
Select the arc edge as shown.
All the elements are chained and highlighted.
The system will automatically bridge the gap to create a closed boundary.
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Creating the Next Boundary
The Create Next Boundary option lets you finish creating the current boundary and then start
another without leaving this dialog.
Because the Type was set to Closed, the boundary was automatically closed by extending the
first element to meet the last.

The Boundary Plane
The boundary is created in the boundary plane. The boundary plane does not necessarily have
to be in the same place as the objects that you select.
There are two boundary plane choices:
Automatic - The plane is determined by the first element selected (if it is an arc) or the first
two elements (if the first is not an arc). This is the default.
User-Defined - You define the plane using the Plane Subfunction.
Leave the Plane option set to Automatic.
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Creating an Island Boundary
You are ready to create an island boundary. This island is the mid-level face containing the
two counter bored holes. It is red in the illustration below.
You are cutting the top of an island, so the Material Side is on the inside of the boundary this
time. The material will be retained on the inside of the boundary, preventing the island from
being cut away.
Set the Material Side option to Inside.
The tool will not remove material from inside the boundary.
The plane of island boundaries should be located at the top of the island, so you can let the
system use the edges you select to automatically define the plane for this boundary.

Chaining the Elements
Choose Chaining.
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When you are chaining, the crosshair placement determines the success of the chaining
operation.The selection ball must capture the edge that you are selecting and The crosshair
must pierce the island face that contains the edges you wish to chain.
Select the first linear edge toward the right end as shown.
OK to create the chain.

All the objects around the top of the island are selected. The system used the plane defined by
the two end points of the object selected to determine the boundary plane. It then chained the
contiguous objects in that plane to form the boundary.
Make sure your Cue line says "Select object #9". This means you have successfully selected 8
objects.

Creating the Third Boundary
Again, you are defining an island and will create this boundary by chaining the edges on the
top face of the object. (You could use the face selection method, but for instructional purposes
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use the chaining method.) Material Side should be set to Inside. The material will be retained
on the inside of the boundary, preventing the island from being cut away.
Choose Chaining.
Select the linear edge toward its lower end, as shown below.
Select the arc edge as the end of the chain.
After you accept the selection, all the elements on the top of the island are selected
highlighted.
OK to create the boundary.

Establishing the Floor Plane
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The floor plane is the lowest plane in your pocket. The cut levels of the tool path will be
parallel to this plane. The default of the XC-YC plane is currently set.
With the Floor icon selected, choose Select.
Select the face on the bottom of the pocket.

The tool path is generated at one level (the floor plane). You need to set cut levels to create a
multi-level operation. Also, you can see that the engage move does not look right. This will be
corrected later.
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Refresh the graphics area.
Defining Cut Levels

In order to create a multi-level tool path, you must define cut levels. You will add stock,
define the cut depth and define engages and retracts.
Defining Cut Levels

Defining the Cut Depth
Choose Cut Depths.
You are going to define the cut depths by defining the maximum and minimum depths. First
you will define the largest amount of material to be cut at any level. If you use the default of
0, you would generate a single level tool path at the floor plane.
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Key in 1.30 in the Maximum field.
Now you will set the Minimum cut depth to 0.100. This is the smallest amount of material
that you can cut at any level.
Key in 0.10 in the Minimum Field.
If you accept the Minimum default value of 0, and specify a larger Maximum value, the tool
will cut at the Maximum value depth and,at the top of each island.
Cut Levels
There are five types of cut levels.
User Defined - You define the depths of cut. You can set the Maximum, Minimum, Initial,
and Last depths of cut
Floor Only - Generates a single cut level at the floor plane.
Floor & Island Tops - Generates one cut level at the floor plane and then generates a cleanup
cut at the top of each island.
Levels at Island Tops - Generates a cut level at the top of each island.
Fixed Depth - Generates cut levels at a constant depth, using the Maximum field.
Initial - Defines the depth of cut for the first cut level of the tool path.
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Final - Defines the depth of cut for the last cut level of the tool path.
Increment Side Stock - Adds side stock to each cut level. Cut level one will leave the
specified stock. Cut level two will leave twice the specified stock, and so on.
Top Off Islands - Causes the tool to cut the tops of the islands if they could not be cut at one
of the cut levels. Notice that this option is on by default.
When there are islands in the part file and the maximum and minimum depths of cut are
defined, the system will try to use the tops of the islands as one of the cut depths. This is
subject to the number of islands defined and the specified maximum and minimum cut depths.
OK to accept the Cut Depth and return to the PLANAR_MILL dialog.
Defining Cut Levels

Adding Stock
You can add stock to the floor and/or walls of your part.
Choose Cutting.
Key in 0.03 for the Part Stock field.
Defining Cut Levels

Stock Options
The Stock values are near the bottom of the Cut Parameters dialog.
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Part Stock - This is the remaining material on the walls at the completion of the tool path.
Final Floor Stock - This is the amount of material that is left on the floor and on top of the
islands at the completion of the tool path.
Blank Stock - This is the distance the tool will be positioned from the defined blank geometry.
Blank Distance - This is the offset distance applied to the part boundary or part geometry to
produce the blank geometry.
Check Stock - Is the distance the tool will be positioned from the check geometry.
Trim Stock - Is the distance the tool will be positioned from the trim geometry.
Defining Cut Levels

Defining a Clearance Plane
You will define the Clearance Plane for this operation.
Choose Avoidance.
Choose Clearance Plane - None.

Choose Specify.
Choose Principal Plane.
Choose ZC Constant.
Key in 0.10, then OK.
The ZC value for the Clearance Plane displays on the dialog.
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A plane symbol displays at the WCS ZC 0.0.
OK twice to return to the PLANAR_MILL dialog.

Before you generate the tool path, be sure that all 4 views are displayed, since you want to be
able to see the tool path from several directions.
Defining Cut Levels

Turn on the Refresh Before Display option.
Notice that the cut region extends out to the entire pocket, including the island on the right
end. You can see in the Front or Right view that the cut is above this island.
OK to generate the first cut level.
OK to display the second cut region.
This time, you can see that the cut is right on top of the island on the right end.
OK to generate the second cut level.
Choose OK each time this dialog displays and generate the entire tool path.
The final level cuts the bottom of the pocket and around the middle island.
Each time the tool goes from one cut level to the next, it moves back up to the Clearance
Plane, as shown below.
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You will eliminate this unnecessarily large tool move by changing the Transfer Method.
Defining Cut Levels

Calculating the Cut Levels
Choose List.
The tool path displays in the Information window. Notice that the depth of the first cut is .900. You specified 1.3.
The distance from the top of the part to the top of the first island is 1.800. You also specified
Top of Island as a cut level. Since this distance (from the top of the part to the top of the first
island is greater than the 1.300 the maximum depth you specified, the actual distance of 1.800
is divided into two equal steps of .900.
1. First Cut Level
2. Second Cut Level (top of island)
3. Top of Part
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Defining Cut Levels

Specifying the Transfer Method
Transfer Method refers to the way the tool moves from one Cut Level to the next or from one
region to another. These moves occur between the retract from one level or region and the
engage move to the next. You will set the transfer method so that the tool does not move to
the clearance plane with each internal engage/retract move or cut level.
Choose Method in the Engage/Retract parameters section.
In the Transfer Method section, choose Clearance Plane.
Transfer Methods
There are four methods available:

Clearance Plane - This is the default. The tool moves to the clearance plane for the engage
and retract moves.
Previous Plane - Uses the current completed cut level (plus the vertical clearance distance) to
position and engage to the next cut level or region.
Blank Plane - Moves the tool to the blank plane (plus the vertical clearance distance) before
moving to the next cut start point.
Direct - Makes a straight line move from the current position to the start of the engage move,
or to the cut point if no engage move is specified.
The transfer method does not affect the initial tool engage or the final tool retract moves.
Those moves are determined by your Engage/Retract settings.
Set the Transfer Method to Previous Plane.
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The default Vertical and Horizontal Clearance Distances are .1. This means that the tool will
retract .1 above the previous plane before engaging to the next cut and come no closer than .1
inch to any wall geometry.
You will change these values to ensure that the tool will not gouge the top of the island.
Key in .200 in the Horizontal value field.
Key in .200 in the Vertical value field.
OK to accept the values.
Defining Cut Levels

Changing the Feed Rates
You are going to slow down the engage moves.
Choose Feed Rates.
Change the Engage feed rate to 5 ipm and the Cut feed rate to 8 ipm.
Defining Cut Levels

Generate the tool path and OK the dialogs as needed to generate all the levels of the tool
path.
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Notice the dashed lines, indicating the move between levels at the previous plane plus the
vertical distance of .2.
Defining Cut Levels

More Cutting Options
In this section, you will change the Region Connection status and compare the differences in
the final cut levels of the tool paths.
Choose Cutting.
Cut Order - determines the order in which multiple regions are cut.
Direction - sets the cut direction so the cutting tool either climb cuts or conventional cuts.
Set the Cut Direction option to Conventional Cut.
OK to accept the cut parameters.
Defining Cut Levels

Generate the tool path and OK as needed to generate all of the cut levels.
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The tool cuts the part using the conventional cut direction. The resulting tool path is the same,
but the tool path is developed differently. When the last level is cut the tool starts on the right
side of the part rather than the left. The tool also cuts around the island in the opposite
direction.
Defining Cut Levels

Specifying a Helical Engage
With the advent of high performance cutting tools, which eliminate the need to drill relief or
start holes, tool engagement can be controlled using a helical engage to prevent cutting tool
damage.
Choose Automatic under Engage/Retract.
Set the Ramp Type option to Helical.
Notice the Helical Diameter % defaults to 90.0.

Key in 100 for the Helical Diameter %.
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Helical Diameter %
The most effective way of engagement is through the milling of a "start" hole using helical
interpolation. Associated with this method of ramping is the parameter Helical Diameter % which describes the maximum diameter path used by the tool for a Helical engage and is used
for the Helical ramp type only.
When using the helical method, there is a minimum and maximum hole diameter that can be
utilized, leaving no center or cone material at the bottom of the hole. The maximum hole
diameter is equal to:
The minimum hole diameter is equal to:
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If the hole diameter is greater than the calculated maximum hole diameter, material remains in
the center of the hole but has no effect on the tool since the material is on the outside of the
cutter.
If the hole diameter is less than the calculated minimum hole diameter, material remains in
the center of the hole, causing the tool to break.
If the hole diameter is equal to the calculated minimum hole diameter, no material remains in
the hole and the cutting tool will cut normally.
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If the hole diameter is equal to the calculated maximum hole diameter, the bottom of the hole
is completely flat. This is the preferred method for helical interpolation.
If the area is not large enough to allow the Helical Diameter, the diameter of the path will be
reduced and an attempt is made to perform the engage again.
This process will continue until either the Helical Engage is successful or the path diameter
becomes less than the Minimum Ramp Length. If the area is not large enough to allow the
path diameter that is equal to the Minimum Ramp length, the system will attempt to ramp into
the area.
OK to accept the Automatic Engage/Retract dialog.
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Defining Cut Levels

Defining Cut Levels

Specifying a Linear Ramp Engage
In cases where helical interpolation is impractical (i.e. long narrow cut areas) ramping into the
part may be more suitable.
Choose Automatic under Engage/Retract.
Set the Ramp Type option to On Lines.
Key in 80 in the Min Ramp Length-Dia % field.

Minimum Ramp Length
When using an inserted cutting tool, the ramping motion must be long enough to eliminate
any uncut material. Associated with the ramp method is the parameter Min Ramp LengthDia% - which is used by all three Ramp Types (On Lines, On Shape, Helical). For On Shape
and On Lines, the Minimum Ramp Length-Dia% represents the minimum path distance used
by the tool from the top to the bottom of the ramp. For Helical Ramp Type, the parameter
represents the minimum diameter path used by the tool. The minimum ramp length can be
calculated as follows:
2 x Tool diameter - 2 x Insert Width
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If the ramp length is less than the calculated minimum, material remains which results in tool
breakage.
If the ramp length is greater than or equal to the calculated minimum, no material remains and
the tool will cut normally.
OK to accept the linear ramp engage.

When ramping into a part, a check is made to verify that at least some portion of the region is
long enough to allow ramping motion using the Minimum Ramp Length. If this is impossible,
a warning message will be displayed.
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Defining Cut Levels

Defining Cut Levels

A shaded display of the material removal can help you to visualize the machining operation.
MB3 Expand in the TFR-ISO view so that this is the only view that appears in the
window.
Highlight PMMULTI.
Choose MB3
Toolpath

Choose Play Forward.
Verify.
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Cancel the tool path visualization.
MB3
Expand so that all four views again appear in the window.
Uncut Region Boundaries

Many times when developing a tool path you may have areas of uncut material. This may be
caused by a number of different conditions such as a tool that is too big or stock left on the
part walls or corners.
There is an option available in Planar Milling that can automatically create boundaries for the
uncut regions. You can then use these boundaries to create a tool path to clean up these areas.
In the following portion of this lesson, you are going to create a profile tool path using a tool
that will leave material in the corners while it removes the 0.030 part stock left by the
previous operation. You will save the uncut regions as boundaries and use them in a second
tool path to cleanup the corners.

Creating Uncut Region Boundaries
You are going to create a tool path using a 1 inch tool. This tool is intentionally larger than
the corner radii in order to leave behind uncut material. You will save the uncut regions as
boundaries.
There are two different ways you can create and save boundaries for uncut regions:
Under Edit Display, if the Process Display Parameters are set properly ( that is, with
Pause After Display enabled), the Display Parameters dialog will give you the options
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of displaying and saving the uncut regions. This interactive method allows you some
control over the number and location of the boundaries which will be created.
Under the Cutting section of the Planar Mill dialog, the Auto Save Boundary option
can be selected. This method will automatically create boundaries at all the locations
where uncut material is detected.
Double-click on UCUT.

Creating Boundaries for Uncut Regions by Setting Display Options
It is important that the tool path display options are set correctly. The option that you use to
save the Uncut Region Boundaries is located on the Display Options dialog. You want to
make sure that it is displayed when you need it. Pause After Display must be turned On.
Turn the following Process Display Parameters options on.
OK the settings.

You are going to generate the tool path. While the tool path is generating, you will also
display the uncut regions.
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The first cut level displays along with the Display Parameters dialog.
The Overlap Distance is an offset to be applied to the boundary into the cut region to insure
clean up.
Four uncut regions are displayed in this cut level.
You can see the material left in the corners. You could select the Save option, but you will
wait for the last cut level before saving.
The Display Parameters dialog displays. Notice that you do not have the option of saving the
uncut regions at this time.
The second cut level displays along with the Display Parameters dialog. Once again, you have
the option to Save the uncut regions but you will not.
The Display Parameters dialog displays without the Save Uncut Region option.
The third cut level displays along with the Display Parameters dialog.
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There are more boundaries displayed this time. Continue to process this tool path. You will
save on the next level.
Choose OK to continue processing the tool path.
The final cut level displays along with the Display Parameters dialog. Now there are
additional Uncut Regions displayed at the U shape near the island.

Saving the Uncut Regions as Boundaries
You are going to Save the uncut regions as boundaries.
Choose Save from the Uncut Regions section.
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At this point you will get an Uncut Boundary Output Warning message saying "Previously
saved Uncut Boundaries will be replaced. Do you want to proceed?". This means that the
boundaries you did not create at the higher levels in this operation will be overwritten by the
boundaries you are about to create. This is just an informative message and will cause no
problems.
OK the warning.
The boundaries are created and displayed in green. As you have developed this operation, you
may have noticed that some of the same boundaries are displayed at each level. Only one
boundary is saved for each location thus eliminating boundary duplication.

The final cut level is developed and the PLANAR_MILL dialog displays.
This is one method of creating the Uncut Regions as boundaries. You are going to Cancel this
tool path. If you Cancel the operation, the boundaries will not be saved.
Cancel this operation.
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Creating Boundaries for Uncut Regions Automatically
You are going to edit the same operation, only this time you will use the Automatic method of
saving the uncut regions.
Double-click on UCUT.
Choose Cutting.
The Cut Parameters dialog displays. Notice the Auto Save Boundary option in the Uncut
Regions section at the bottom of the dialog.
Choose the Auto Save Boundary option to turn it on.

Now you will edit the display options to eliminate the user interaction in creating the uncut
region boundaries.
Choose Edit Display at the bottom of the PLANAR_MILL dialog.
Turn off Pause After Display.
Turn on Refresh Before Display.
OK the settings.

Changing the Cut Method to Profile
The bulk of the interior material of the part was removed by operation PMMULTI. Part stock
of 0.030 was left for removal.
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You will set up the current operation so that it will remove the part stock. You only need to
machine the walls of the part and its island. The profile cut method will eliminate the interior
tool motion that was generated in PMMULTI.
Set the Cut Method to Profile.

Generating the Tool Path and Automatically Saving the Uncut Regions as
Boundaries
You are going to generate the tool path. While the tool path is generating, you will also be
displaying and saving the uncut region as boundaries.
The boundaries are created at each cut level as the tool path is generated.

Creating an Operation Using the Uncut Region Boundaries
Now you are going to create a tool path using the uncut region boundaries that were created
from the previous operation. You are going to copy the previous operation and make your
boundary and tool changes to the copy. Copying the operation rather than creating a new one
saves time in that you do not have to redefine many of the options you had set (i.e.,
Boundaries, Avoidance Geometry, Floor Plane).
If necessary, highlight the operation name UCUT.
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Choose MB3
Copy, then MB3
Paste.
The copied operation displays in the Operation Navigator underneath operation UCUT with
the name UCUT_COPY.

Defining Blank Boundaries
You are going to define the new uncut region boundaries as blank geometry. Remember, the
system sees blank geometry as material that needs to be removed.
Double-click on UNCUT_COPY.
Choose the Blank icon, then Select from the Geometry section.
The Material Side is set to Inside.

Set the Mode option to Boundary.
Select all 8 of the uncut region boundaries in order as illustrated below.
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OK to complete the blank geometry.

Redefining the Tool
You are going to use a smaller tool for this cleanup operation.
Choose Reselect.
Choose EM-.375-.03 and OK to accept it.

Choose Edit Display, turn on the Pause After Display option.
OK to accept the display options.
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The first cut level is displayed. The tool is only going to cut the blank boundary material and
will avoid gouging any of the part geometry.

The tool cuts the first corner at the first cut level.
Turn Off the Pause After Display option.

Choose OK to continue to process the tool path.
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The tool cuts all of the boundaries at each level, then moves down to the next level to cut all
of the boundaries at that level. This continues until all boundaries are cut to the floor plane.
You could specify that the tool cut one boundary to the finish depth before moving to the next
boundary.

Changing the Cutting Order
You can control the cutting order of the tool path to cut by Levels or by Depth. The previous
tool path cut all of the boundaries by levels. When all of the cutting at one level was
complete, then the tool moved down to the next level to start cutting.
Cutting by Depth cuts one region or boundary to the finish depth before moving to the next
region or boundary.
Choose Cutting.
Set the Cut Order option to Depth First.
OK the Cut Parameters dialog.

The first cut level displays. It looks the same as the previous tool path.
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Turn Off the Pause After Display and Refresh Before Display options.
The tool path is generated. This time the tool cuts each boundary to the finish depth before
moving to the next boundary.

window.
Highlight NC_PROGRAM.
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in the toolbar.

The colors displayed for dynamic material removal may differ from those illustrated and are
determined under Preferences
Manufacturing
Visualize.
OK the Toolpath Visualization dialog.

Using Corner Control and Slowdown

In this portion of the lesson, you will create a Profile tool path to machine a corner of the part.
You will create and edit an open boundary, add an additional roughing pass, and use the
Corner Control and Feed Rate options.
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Opening the Part
The part file is very similar to pln_pmm_1.prt.
Choose Application
Manufacturing.

Editing an Operation
You are going to edit an existing operation.
Set the Operation Navigator to Program Order View.
Double-click on operation PMOPEN.

Creating an Open Boundary
With the Part icon selected, choose the Select option in the Geometry section.
Choose Curves/Edges as the Mode.

Choose Open as the Type.
Notice the Material Side option. It now reads Material Side Left. The option settings are Left
and Right for open boundaries. The material side is determined relative to the direction in
which the boundary members are selected.
Choose the Material Side option and change it to Right.
Choose the three edges in the order shown (you may want to zoom in on the area first).
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OK to accept the edges.
OK to accept the boundary.

Defining the Cut Method
You will machine the corner with a Profile cut method.
Choose Profile as the Cut Method.

Editing the Boundary End Points
If you created your tool path now, it would cut all the way from the beginning of the first edge
in the boundary to the end of the last. But you really only need to cut a small amount from the
corner. You can do this by editing the boundary members.
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Choose Edit.
The Edit Member dialog displays. Notice that the first boundary member is highlighted.

Moving the Start Point
You are going to move the start point, which is on this boundary member at the circle which
indicates the origin.
Choose Start Point.
The Modify Boundary Start Point dialog displays and a directional arrow displays in the
graphics window to indicate the boundary direction.
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Key in 60 in the Percentage field and OK.
The start point is moved.

Moving the End Point
You will move the end point of the last segment so that the two linear boundary segments are
about the same length.
Choose the Next arrow
twice until the last boundary member is highlighted.
Choose End Point.

Using the slider bar, move the end point towards 35%.
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The shortened boundary displays. The white cone head indicates the boundary direction.
OK three times to return to the PLANAR_MILL dialog.

Adding a Roughing Pass
You will add a roughing pass to this operation .060 away from the part wall.
Set the Stepover option to Constant.
Key in .06 in the Distance field and 1 in the Additional Passes field.

You will define the floor plane at the top of the island.
Choose Floor and Reselect.
A dialog warns you that the default floor geometry (the XC-YC plane) will be removed.
OK the warning.
Select the face on the top of the island.
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The face highlights and a directional vector appears.

Setting the Cut Level
Since you only need to cut at the floor plane, you must eliminate the multi-level passes.
Remember, Floor Only generates a single cut level at the floor plane.
Choose Cut Depths.
The Depth of Cut Parameters dialog displays.
Set Type to Floor Only.
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Applying Slowdowns
Choose Corner.
The Corner and Feed Rate Control dialog displays. You can use these options to control the
machining of inside and outside corners.You will slow down the feed rate as you enter
corners and accelerate as you leave them.
Turn on the Slowdowns option.
The Length value determines how far ahead of the beginning of the corner radius you want
the tool to slow down. The default of Percent Tool determines the length using a percentage
of the current tool diameter.
Make sure the Length setting is Percent Tool.
The Length option toggles between Percent Tool and Previous Tool. The previous tool option
allows you to set the slowdown to coincide with the end of material cutting for a previous,
perhaps larger, tool.
Key in 50 in the Percent Tool field.
The Slowdown % value determines the slowest feed rate during slowdown, as a percentage of
the present feed rate.
Key in 4 in the Number of Steps field.
The Number of Steps value affects the abruptness of the slowdown. The greater the number,
the more even the slowdown. The feed rate reduction per step is:
(100% - Slowdown %) / No. of Steps
The number of acceleration steps is approximately one-half of the number of deceleration
steps.
This is a small corner - you really do not need four steps to slow the feed rate down but you
can easily see the results in the tool path.

Setting the Engage and Retract
Choose Automatic from the Engage/Retract section.
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Notice that the Automatic Type is set to Circular and the activation range is set to .100. You
will change the Activation Range to 0.
Key in 0 in the Activation Range field.
The tool path that you generate with this setting will use a circular engage on the final pass
only.

Generating and Listing the Tool Path
After the Cut Region displays, OK to generate the tool path.
Notice that the first pass is .060 away from the part wall. The tool makes a circular engage
into the wall on the final pass, then moves to cut the radius and retracts in a circular fashion
along the remaining wall.
You can also see the feed rate changes as the tool machines the corner. There are several
stacked up in the corner where the slowdown occurred.
Choose List at the bottom of the dialog.

The slowdowns are listed in the tool path is listed in the listing window.
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The feed rate changes as the tool slows down going into the corner and then accelerates as it
moves away from it. The number of acceleration moves is approximately half of the
decelerations.
Cutting the Blank Geometry and Pocket in One

Operation
In this portion of the lesson, you are going to cut the blank material and the pocket of the part
in one operation. You are going to define the blank material using the Blank Distance option.
You used this option in the previous lesson. You are also going to define a different Cut
Depth.
Cutting the Blank Geometry and Pocket in One Operation

Opening the Part
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Choose Application
Manufacturing.

You are going to define a total of 5 boundaries. Some of the boundaries have been defined as
permanent boundaries (b1 and b3) for you to speed the selection process. Even though the
boundaries are blanked, you can still select them.
Double-click on operation PMBLANK_3.
In order to cut multiple depths, you must specify:

the top of a pocket as Material Retained Outside (creating a pocket boundary)
the bottom of the pocket as Material Retained Inside (creating an island boundary).
Calling the bottom of a pocket an island may seem inconsistent, but when you specify the
Depth of Cut Type to Levels at Island Tops, the tool will cut to the "island" boundary at the
bottom of the pocket.
This allows you specify the floor plane somewhere else in your part, such as the very bottom
of the part, in order to remove blank material.
245

Defining the Blank Material
In this operation you will cut several different depths. You will cut to the very bottom of the
part to remove the blank material. You will then cut to the island tops and the bottom of the
pocket.
With the Part icon selected, choose the Select option in the Geometry section.
The Boundary Geometry dialog displays with the Material Side set to Inside. This is the
correct setting for this operation.
Turn on the Blank Distance option and key in 1.00.
This creates an extra inch of stock surrounding the part boundary that will be used as the
blank material.
You are going to use the top outer edge of the part. The boundary b1 has been created for you.
Key in b1 into the Name field.

Defining the First Part Boundary
The first boundary is going to define the inside of the pocket.
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Turn off the Blank Distance option.
You want the boundary located at the top of the part, on the inside of the pocket, with the
Material Retained Outside/Right.
Set the Material Side to Outside/Right.
Key in b3 into the name field.

Defining the Second Part Boundary
The next part boundary is going to define the top of the island step.
Change the Material Side to Inside/Left.
The Mode needs to reflect the type of object you are selecting.
Change the Mode to Face.
You are going to use the top face of the island as the boundary. You do not have to include
the hole in this boundary, so you will tell the system to ignore the holes.
Choose the Ignore Holes option and turn it on.
Select the top face of the island step as shown .
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The boundary around the island step is defined.

Defining the Third Part Boundary
The next part boundary is going to define the top of the island in the middle of the part.
The Material Side option should still be set to Inside.
The material will be retained on the inside of the boundary, preventing the island from being
cut away. Leave the Ignore Holes option On.
Select the top face of the island as shown.
The inside island boundary is defined.
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Defining the Last Part Boundary
The last part boundary is going to define the bottom of the pocket (as an island).
The Material Side should still be set to Inside.
Now you are ready to select the bottom face of the pocket.
Select the bottom face of the pocket as shown.
All of the boundaries are defined for this operation.


Displaying the Boundaries
With the Part icon selected, choose Display from the Geometry section.
The five part boundaries are displayed.
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You are going to use the bottom of the part as the floor. This ensures that the tool will cut all
of the blank material.
With the Floor icon selected, choose Reselect.
OK the Reselect dialog.

Select the very bottom face of the part.
The bottom face is defined as the floor.

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You want to specify a Cut Depth for this operation. You are going to use Floor & Island Tops
to generate one cut level at the floor plane and then generate a cleanup cut at the top of each
island.
Select Cut Depths.
Under Type, choose Floor & Island Tops.

The first cut region of the tool path displays. Note the blank material that is defined. The tool
will cut blank material to the floor plane.
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OK as needed to continue generating the tool path.

Planar Milling - Multi-Region

In this lesson, you will learn how to create a multi-region Planar Milling operation.
Creating a Multi-Region Planar Mill Operation
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You will develop a Planar Mill tool path that will cut many pockets (regions) with varying
depths. You will cut one pocket, then edit the tool path and add more pockets.

Opening the Part
Open part file pln_pmr_1.prt from the pln subdirectory.
The part has several pockets, one of which contains an island with steps and a pocket. Also
note that one of the pockets has multi levels.
Choose Application
Manufacturing.

Double-click PMREGION in the Program Order view.
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Selecting the Part Boundaries
The boundaries that you will use in this operation have been created for you (b1 through b6).
Remember, in order to cut multiple pocket depths, you must specify the top of a pocket as
Material Side Outside (creating a pocket boundary) and the bottom of the pocket as Material
Side Inside (creating an island boundary).
In review:
Material Side Outside - A boundary with Material Side Outside is a pocket boundary.
Material Side Inside - A boundary with Material Side Inside is an island boundary.
With the Part icon selected, choose Select in the Geometry section.

Defining the Top of the Pocket
You want the tool to cut the inside of this closed boundary, so the material remaining should
be outside.
Set the Material Side to Outside/Right.
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Key in b1 into the Name field and OK to accept it.

The boundary b1 is highlighted on the screen.

Defining the Bottom of the Pocket
Set the Material Side to Inside/Left.
The boundary B2 is highlighted on the screen below B1.
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You have now defined the top and bottom of the large pocket.

Selecting the Remaining Boundaries
Select the remaining boundaries b3 through b6 just as you did for b1 and b2. Use the
following Material Side settings for each boundary:
b3 . . . . . Outside/Right
b4 . . . . . Inside/Left
With boundaries b3 through b6 selected, your part should look similar to the part shown.
OK to return to the PLANAR-MILL dialog.

Changing the Cut Depth
Setting the Cut Depth Type to Levels at Island Tops will cause the tool to cut at the top of
each island. You have defined the pocket bottom as an island, therefore, the tool will cut the
pocket bottom at the proper depth.
Choose Cut Depths.
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Change User Defined to Levels at Island Tops.
The tool will cut to the tops of the islands.


Changing the Cut Order
If you were to generate the tool path now, the tool would finish each level before engaging
further down. You want to cut each pocket to full depth before moving on to the next pocket.
Choose Cutting.
Set the Cut Order option to Depth First.
This option cuts each pocket to full depth and does not leave the pocket until reaching the
bottom.

Defining the Floor
You are going to use the bottom of the part as the floor.
Choose the Floor icon, then Reselect.
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OK the Reselect dialog.


Each cut level displays as the tool path is generated.

Continue to choose OK as necessary.
The tool cuts to the bottom of the pocket.
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The error message "Tool Cannot Fit into Level 3" will display. This is because the tool cannot
reach the specified floor, which is below the bottoms of the pockets.
OK the error message to continue.
Reject the tool path and Refresh the graphics window.

Cutting a Second Pocket
You are going to add an additional pocket (a second cut region) to be cut in this operation as
shown below.
This region contains a pocket within a pocket. The top boundary of the smaller pocket will
define the lower boundary of the larger pocket.

Editing the Part Geometry
You are going to edit the part geometry by appending boundaries to the current set of
boundaries.
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Choose the Part icon, then Edit.

Appending Boundaries
Choose Append.
You are going to add boundaries b10, b13 and b14. You will set the Material Side for each
boundary.
Set Material Side to Outside/Right.
The boundary b10 is highlighted on the screen.

Set Material Side to Inside/Left.
OK twice to return to the PLANAR-MILL dialog.

Each cut level displays as the tool path is generated.
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Continue to choose OK as necessary.
OK the warning.
The tool path is generated. The tool cuts to the bottom of each pocket.

Cutting the Remaining Two Pockets
You will cut the remaining two pockets. You will need to append the additional boundaries (
b11 and b12 and b7, b8 and b9. See if you can do it by editing operation PMREGION_2
without further instruction.
Double-click on operation PMREGION_2 in the Operation Navigator and Edit
the boundaries listed above.
Append
Remember, in order to cut multiple pocket depths, you must specify the top of a pocket as
Material Retained Outside (creating a pocket boundary) and the bottom of the pocket as
Material Retained Inside (creating an island boundary).
Top of Pocket=Outside/Right B7
Top of Pocket (island)=Outside/Right B8
Bottom of Pocket-Inside/Left B9
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The pocket with the open end also requires a Closed Boundary
Top of Pocket=Outside/Right B11
Bottom of Pocket=Inside/Left B12

When you have all the boundaries correctly specified, you are ready to generate the tool path.
Turn the Display Cut Regions and Pause After Display options off.
OK to generate the tool paths.
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Cancel the tool path visualization.
Analysis Tools
The Analysis Tools are used to visually inspect the cutting areas in the tool path.
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Analysis Tools
Analyzing Tool Paths
Double-click on the PMREG_ANAL icon in the Operation Navigator.
Choose the Options icon at the bottom of the dialog.

Choose Analysis Tools.
Analysis Tools
Analyzing the Tool Path by Level
Note that the number of levels in the tool path is displayed at the top of the dialog.
This dialog acts like a replay tool. It will only display the tool path at a specified level.
Key in 4 in the Current Level field and press the Enter key.
The tool movement at level 4 is replayed in the graphics window.
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The Previous and Next arrows on the dialog select the tool path at the next level or the
previous level.
Choose the Previous or Next arrow.
The tool path at that level is replayed.
OK until you return to the PLANAR-MILL dialog.
Cancel the PLANAR-MILL dialog.
Analysis Tools
Double-click on the PMREG_ANANL_2 icon in the Operation Navigator
Choose the Options icon.

Choose Analysis Tools.
The Analysis Tools dialog displays along with the cut region for the first cut.
This dialog looks very different from the Analysis Path By Level dialog. Some of the options,
such as Current Level and Edit Display, function in the same way.
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Analysis Tools
Analysis Tools Level Option
Look at the top of the dialog and note the two settings, Region and Level.
The Level setting displays all of the offset shapes and regions at the current level.
You can use the Previous and Next arrows to cycle through the different levels. This option is
the same as the previous Analysis Tool.
Choose Show Cut.
The cut motion for the specified level (level 1) is replayed.
Analysis Tools
Displaying Blank Cut Shape
Choose Blank Cut Shape.
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Only the blank material offset shape displays.
If you use the arrows now, the system will cycle through only the Blank Shape Traces.
Choose the Previous or Next several times to cycle through the Blank Cut Shape at each
level.
Analysis Tools
Displaying Part Shape
Choose Part Shape.
You should see only part shapes displayed in the graphics window.
If you cycle through the levels now, you will only see cut levels for the part displayed.
Choose the arrow several times to cycle through the Part Shapes at each level.
Key in 2 into the Current Level field and press Enter.
Analysis Tools
Displaying Uncut Regions
Choose Uncut Regions.
The Uncut Region at level 2 displays.
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Analysis Tools
Displaying Cut Regions
Choose Cut Regions.
Analysis Tools
Using the Cycle Option
The Cycle option enables you to specify a subset of a specified shape.
A drop down menu displays three options:
All - displays all of the specified shapes within each level as you cycle from one level
to the next.
Shape - highlights each specified shape in sequence (only within the currently
displayed level) as you select the arrows.
Segment - highlights each segment of the displayed shapes in sequence (only within
the currently displayed level) as you select the arrows.
Set the Cycle option to Shape.
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The display in the graphics window is changed.
The blank shape displays.

Use the arrows to cycle through the different shapes at level 2, returning to the blank shape.
Change the Cycle option to Segment.
Use the arrows to cycle through the different segments of the blank shape.
Change the Cycle option back to All.
Analysis Tools
The Dump Level Option
This option is only available when using the Level option and when Cycle is set to All. Dump
Level allows you to write just the current level to a file so that problems occurring in that
level can be analyzed by CAM Development.
Analysis Tools
Analysis Tools Region Option
The Region setting displays each cut region individually within the operation.
Choose the Region option.
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The cut regions are displayed in the graphic window. Although you no longer have control of
the cut levels, the cut regions for level 2 are displayed. This is because you were at level 2
when you changed from Level to Region.
Use the Previous and Next arrows to cycle through the different Cut Regions.
OK two times to return to the PLANAR-MILL dialog.
Cancel the Analysis Tools dialog.
Cancel the operation.
Face Milling
Face Milling is a fixed axis milling method similar to Planar Milling, but designed
specifically to rough and finish the planar faces of a part. It allows you to specify the face
geometry simply by selecting the faces to be machined. It also allows you to define face
geometry by selecting existing curves and edges or by specifying a sequence of points in
much the same way as Planar Milling.
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The tool axis is automatically defined as the normal of the first selected face boundary plane.
Since Facing removes material in planar levels with respect to the tool axis, the normal of a
face boundary plane must be parallel to the tool axis. If it is not, the face will be ignored
during tool path generation.
In this lesson you will create a Face Milling operation that finishes the faces of a part. You
will also learn several ways to cut across open and closed voids and learn how to create mixed
and manual cut patterns.
Creating a Simple Face Milling Operation

You will create a simple Face Milling operation.

Opening the Part
Open part file pln_facing.prt from the pln subdirectory.
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Choose Application
Manufacturing.

Choose the Create Operation icon.
Choose FACE_MILLING as the subtype.

Displaying the Part Geometry
Choose the Part icon and Display to verify the part geometry.
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The part geometry has already been defined in the WORKPIECE parent group.

Defining the Faces
You will define the faces to be machined.
Choose the Face icon and Select.
With the Face Boundary icon chosen, select the six faces illustrated below.
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Face boundaries are processed as blank boundaries. The center line of the tool cuts all the way
to the boundary (where it does not gouge the part), which results in the material being
removed along the edge of the face.
Choose Follow Periphery as the Cut Method.

Turn all of the Display Parameter options off and OK to continue.
Notice that the tool path does not avoid the clamps. You will need to define the clamps as
check geometry.

Defining Check Geometry
You will define solid bodies as check geometry.
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Choose the Check Body icon and Select.
Select the three solid bodies that represent clamps.

Turn off all of the Display Parameters and OK to continue.
Notice that the tool path now avoids the clamps.

In addition, you can define multiple level cuts by specifying Blank Distance and Depth Per
Cut.
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Visualizing Material Removal
You will use Verify Toolpath to graphically simulate material removal for the program.
In the Program Order View of the Operation Navigator, choose PROGRAM.
in the toolbar.


Cutting Across Closed Voids

The cut pattern can be maintained or excluded when closed voids are encountered. This
insures that the tool will cut across rather than around voids when Zig, Zig-Zag, or Zig with
Contour is used.
An area fully enclosed inside a single cut region that is empty or devoid of material is
regarded as a closed void.
An area along the periphery of a cut region that is empty or devoid of material is regarded as
an open void. Cut patterns are not maintained across open voids. The cylindrical area
illustrated below is an open void because it crosses cut regions.
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Excluding Cut Pattern From Voids
Open part file pln_facing_1.prt from the pln subdirectory.
Choose Application
Manufacturing.
Double-click on the FACE_MILLING icon to edit the operation.
Choose Cutting.
Notice that Across Voids is set to Follow. This option excludes the cut pattern from closed
voids, causing the cut pattern to follow the shape of the cut region.
OK to accept the Cut Parameters.

Replay the tool path.
The cut pattern is excluded from the closed void.
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Cutting Across Voids
Choose Cutting.
Set the Across Voids option to Cut.
This option maintains the cut pattern across closed voids at the cut feed rate.
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Traversing Across Voids
Choose Cutting.
Set the Across Voids option to Traverse.
This option maintains the cut pattern across closed voids but uses the cut feed rate only while
the tool is in contact with material. The traversal feed rate is used when the tool is not cutting
material.
Notice the Traverse Distance is set to zero. The Traverse Distance represents the minimum
amount of empty space the tool must cut to employ a traversal feed rate inside a void. A
Traverse Distance of zero ensures that a traversal feed rate will always be used when the tool
is not cutting through material.

Editing the Blank Overhang
Blank Overhang is the distance that the cutting tool travels beyond the edge of a face. By
setting the Blank Overhang parameter to a value smaller than the cutter diameter, tool path
movement is kept to a minimum.
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Choose the Edit Display icon
under Tool Path.
Choose 2-D for the Tool Display and OK to accept it.

Notice how the tool travels beyond the edge of the face the full diameter of the tool.
Choose Cutting.
Key in 25 to define the Blank Overhang distance as a percentage of the tool diameter.
OK to accept the Blank Overhang.

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Specifying the Tool Run-Off
When using a Zig or Zig-Zag cut pattern, the Tool Run-Off parameter allows you to retract
the tool completely off the part after each cutting pass. This is often desirable when finishing
to achieve a quality finish.
Tool Run-Off
When finish milling using a Zig or Zig-Zag cut pattern, it is often desirable to retract the tool
completely off the part after each cutting pass to achieve a quality surface finish. However,
when roughing production parts, it is sometimes desirable to allow the tool to stay on the part
after each cutting pass to minimize toolpath time
The Tool Run-Off parameter satisfies both cases. Tool Run-Off is supported for Zig and ZigZag cut types in face milling, planar milling, and cavity milling operations and is only applied
to operations which employ an Automatic Retract.
When Tool Run-Off is On, the tool will automatically retract off the part after each cutting
pass by a distance equal to the horizontal clearance.
When Tool Run-Off is Off, no attempt is made to retract the tool off the part after each cutting
pass. Depending upon the amount of the Blank Overhang, the tool may or may not remain on
the part.
The tool will always engage from the safe shape for a Zig or Zig-Zag cut. The tool will retract
to the safe shape only if the Tool Run-Off option is On and and an Automatic Retract is
employed by the operation.
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Choose Method.
Notice that Tool Run-Off is On.
Also notice that the horizontal clearance is set to 0.100.
The tool will retract off the part after each cutting pass by a distance equal to the horizontal
clearance. You will increase the horizontal clearance so you can see the Tool Run-Off a little
more clearly.
Key in 0.30 in the Horizontal field and OK to accept it.
Change to a Top view.

Reject the previous tool path.
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Creating Mixed and Manual Cut Patterns

Face milling allows you to specify a different cut pattern for each region of an operation. In
addition to automatic cut patterns (Zig-Zag, Zig, Zig with Contour, Follow Periphery, Follow
Part, Profile), you can define manual cut patterns or exclude cut patterns completely.
Manual cut patterns are defined interactively, allowing you to control tool movements
individually. This is especially useful when you need to define a simplified tool path that is
independent of the shape of the cut region. When using a large tool for example, a straight
tool path across a complex shape is sometimes a more efficient way to machine the face as
illustrated below.
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Displaying the Face Boundaries
You will open a part and display the face boundaries of an existing face milling operation.
Open part file pln_facing_2.prt from the pln subdirectory.
Choose Application
Manufacturing.
In the Program Order view of the Operation Navigator, double-click on the

FACE_MILLING icon to edit the operation.
Choose the Face icon and Display.
Notice that three faces have been defined.

Specifying the Tool Path Display
A Silhouette tool display will allow you to clearly see the area the tool cuts across.
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under Tool Path.
Choose 2-D for the Tool Display and Silhouette for the Path display.
OK to accept the Display Options.

Defining Mixed Cut Methods
The Mixed cut method allows you to specify a cut pattern for each region.
Choose Mixed.
Choose Generate.
The Mixed Cut Pattern dialog displays. The current cut level being processed and the region
number at that level are displayed at the top of the dialog.
The order in which the regions are cut is determined by Region Sequencing. In this example,
the Region Sequencing is set to Standard, so the regions will be cut in the order the faces were
selected.
The first cut region is displayed.
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Turn on all three display parameters.

Specifying a Follow Periphery Cut Method
You will specify a cut method for the first region.
Choose Follow Periphery.
OK to accept the cut pattern and display the tool path.
OK to complete the cut pattern and display the next cut region.
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Notice that the follow periphery cut pattern has been added to the list box.
The most efficient tool path for this next cut region is one that cuts in straight line segments
where possible rather than following the exact shape of the region. A manual cut pattern will
allow you to do this.

Specifying a Top View
It is easier to define a manual cut pattern in a top view.
MB3
Replace View
TOP.

You should be able to see the shape of the cut region clearly.
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Defining a Manual Cut Pattern
You will define a manual cut pattern to create an optimal tool path for this cut region.
Choose Manual.
OK to begin defining the Manual cut pattern.

The Create Manual Cut Pattern dialog contains options that allow you to interactively create
specific tool motions for the current cut region and level.
Most parameters that apply to automatic cut patterns (Cutter compensation,
Engage/Retract parameters, Cutting parameters) do not apply to the Manual cut pattern.

Repositioning to a Center Point
The Reposition To Point option is automatically selected, allowing you to define a transfer
move from the previous cut region.
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Choose Arc/Ellipse/Sphere Center as the Point Method.
Select the hole illustrated below to define the center as the reposition point.

Cutting to a Center Point
The engage will be made to a center point on the face.
Choose Move To Point.
Choose Engage as the Motion Type.
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Select the small hole to define the center as the point the tool will cut to.

Cutting to a Point on the Cut Region Shape
The next cutting move will cut in a straight line to a point on the cut region shape.
Choose Move To/From Shape.
Choose Cursor Location as the Point Method.
Be sure Minimum Distance To Shape has been chosen.
These options allow you to create a point on the cut region shape close to where you indicate.
Be sure Cut Region is specified as the shape to be selected.
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Choose Cut as the Motion Type.
Indicate on or near the center of the cut region segment as illustrated below.
The indicated point projects at a minimum distance to the cut region shape where the system
defines the point the tool will cut to.
The face is cut with a simple linear move.
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Cutting Along the Shape of the Cut Region
The next several moves need to cut along the shape of the cut region. This will allow the tool
to cut the face while avoiding the boss.
Choose Move Along Shape.
Choose Minimum Distance To Vertex.
This option assures that the vertex of the cut region shape closest to where you indicate is
defined as the point the tool will cut to.
Indicate on or near the cut region vertex as illustrated below.
The tool moves along the shape in the wrong direction.
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Choose the Reverse Direction icon.
The tool should now move along the shape in the opposite direction.
Select on or near the next cut region vertex as illustrated below.
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Choose Minimum Distance To Shape.
Indicate on or near the center of the cut region segment as illustrated below.

Cutting to an End Point
The next cutting move will be made to an end point.
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Choose End Point as the Point Method.
Select the end point of the arc as the next point the tool will cut to.

Cutting to a Center Point
The last two cutting moves will be made to center points on the face.
Choose Arc/Ellipse/Sphere Center as the Point Method.
Select the small hole to define the center as the next point the tool will cut to.
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Select the small hole to define the center as the last point the tool will cut to.
OK to complete the manual cut pattern.

Notice that the manual cut pattern has been added to the list box.
Choose Format
original view.
Layout
Replace View
LAYOUT1 and OK to return to the
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Excluding a Cut Region
The next cut region displays at the center of the part. You will not cut this region.
Choose Omit as the Cut Method for this region.
OK to complete the mixed cut pattern.


Choose the Verify
icon at the bottom of the dialog.
Slow down the Animation Speed to 8.
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Choose Offset from Part and key in 0.10 for the Offset.
OK to accept the blank material and begin the visualization.

The system displays the dynamic material removal. Notice that the cut region specified as
None was not cut.
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Editing a Cut Pattern
You can go back and edit any of the cut patterns.
and turn on Pause After Display.
This will allow you to edit one cut region at a time.

Choose Generate.
The Mixed Cut Pattern dialog displays along with the first cut region.
OK to display the Follow Periphery cut pattern.
OK to display the next cut region.
OK again to display the Manual cut pattern.
OK to display the last cut region.
reg_3_lv_3_omit should be highlighted in the list box.
You will change the cut pattern for this region to Profile.
Choose Profile.
OK to accept the cut pattern.

OK to finish editing mixed cut pattern.

Choose the Verify icon at the bottom of the dialog.
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Choose Offset from Part and key in 0.10 for the Offset.
OK to accept the blank material and begin the visualization.
Material is now cut from every cut region.

Cavity Milling
Cavity Milling is designed to rough out large volumes of material from cavities and cores,
especially those with tapered walls such as dies and molds. Cavity Milling is similar to Planar
Milling in that it uses a fixed tool axis and removes the material in planar cut levels.
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In this lesson you will create Cavity Milling operations that rough out cavities and cores.You
will also learn how to use a faceted body to perform rest milling.
Machining the Body of the Bottle

You will create an operation that roughs out a cavity.

Opening the Part
Open part file pln_cavity_assy.prt from the pln subdirectory.
This part file has features commonly found in many molds. The sides have a taper angle and
the bottom has a curved face.
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Choose Application
Manufacturing.

Defining the Workpiece Using Solids
You will edit the WORKPIECE object to define the part and blank geometry. Later, you will
use this object as a parent group for the operation.
in the toolbar.
Expand the MCS_MILL object and highlight WORKPIECE.
Choose MB3
Edit.
The MILL_GEOM dialog displays.

Defining the Material Type
Before you select the part and blank geometry, you should define the type of material to cut.
The material you are cutting has a very important effect in determining the cutter speeds and
feeds.
Choose Material: CARBON STEEL.
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The Part Material listing displays in a Search Result dialog.
Highlight MATO 00266 ALUMINUM and OK to accept it.
The part material has been changed to ALUMINUM.

With the Part icon chosen, choose Select
Select the body as the part geometry.
OK to accept the Part Geometry dialog.

Defining the Blank Geometry.
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Choose the Blank icon and then Select.
Select the rectangular block as the Blank Geometry.
OK the Blank Geometry dialog.

OK the MILL_GEOM dialog.
The WORKPIECE geometry has been defined.

Be sure Type is set to mill_contour.
Choose the CAVITY_MILL icon.
in the toolbar.
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Enter RUF_BODY in the Name field.


Defining the Cut Levels
You will reduce the first cut range to the depth of the vertical cavity walls and then add an
additional range with smaller cut levels for the curvature of the bottom of the cavity.
Choose Cut Levels.
Zoom in on the corner of the part.

Defining the Level of the Bottom of the First Range
The system initially assumes that the first cut range is from the top of the blank geometry to
the bottom of the part geometry. The limits of this range are indicated by the large white plane
symbols.
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The range depth is currently indicated as 35.00 mm in the Range Depth field and on the slider
bar.
You will raise the bottom of the range.

Choose Generic Point.
Select the edge end point as illustrated below.
Use MB3
Refresh to clear the graphics window.
Choose Display to display the new cut range.

The two large plane symbols display the reduced cut range. The smaller plane symbol
indicates the first cut depth, which is set at 6.00 mm. Because the sides of the cavity have a
small draft angle, a 6.00 mm depth of cut will provide adequate material removal.
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Defining the Second Range
You will append an additional cut range below the current range and set the depth per cut to a
smaller value to provide for more material removal on the curved face.
Choose Add Ranges.
You will reference the new range from the bottom of the currently highlighted range.
Change the Reference option to Range Bottom.
Zoom in on the logo area.

Select the end point as illustrated below.
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OK the Point Constructor dialog.

MB3
Fit to display all the geometry in the graphics window.
Choose Display to display the new cut range.

The new cut range is indicated by the large plane symbols beneath the first cut range.

Specifying the Depth per Cut
You will change the depth per cut in the second range to 1.00 mm. This will remove more
material from the curved faces by creating smaller steps.
Choose Modify Ranges.
You need to modify the lowest range. It should be highlighted.

If the lowest range is not highlighted in white, you can change the range you are modifying by
choosing the Current Range arrows.
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Selecting the up or down arrow will change the range being modified.
Enter 1.00 in the Depth per Cut field and press Enter.
The graphics display indicates the new, smaller, depth per cut by displaying six plane symbols
between the large range symbols.
OK the Cut Levels dialog.

More About Cut Levels
The Cut Levels dialog allows you to adjust the planes of the cuts and the depths of the cuts.
Some definitions are in order to clarify the terminology:
A Range is a specified amount or depth of material within the cavity to be removed. You can
specify up to 10 Ranges.
A Cut Level is a specified depth of cut within a Range to be removed.
1) Use this area to add or modify the cut range.

You can also specify the maximum depth per cut
within the range.
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2) Use this area to define where the range is

measured from.
3) Use these arrow keys to select a defined range.

4) Use these icons to remove a defined range or
reset any range modifications.
The dialog displays the exact depth of this range - both in the Range Depth field and at the
end of the slider bar.
You can use one or more ranges to cut the cavity.
Assigning multiple ranges allows more control over the amount of material being removed
within the cavity.
For example, you may want to remove more material per cut in the upper portion of the cavity
and smaller amounts of material towards the bottom of the cavity. Defining several ranges
would accomplish this.
Because the first range is defined for you, you must choose Modify in order to make any
changes to the range. You must be certain the Modify Ranges icon is depressed for any
changes to be applied.
By default, the Reference option is set to Top Level. This option determines where the Range
Depth value you specify is referenced from.
Notice the graphics area, several plane symbols are displayed. The system automatically
determines the first range based on the highest and lowest points defined by the part and blank
geometry. The top and bottom of the range are indicated by the two large plane symbols.
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The smaller plane symbols indicate the depth per cut.

Here is a summary of the Reference options:
Top Level will reference the Range Depth value from the top of the first cut range.
Range Top will reference the Range Depth value from the top of the currently highlighted
range.
Range Bottom will reference the Range Depth value from the bottom of the currently
highlighted range.
WCS Origin will reference the the Range Depth value from the origin of the WCS.

Setting the Feed Rates
Tool motion speeds and feeds are set using the values stored in tables.
Choose Feed Rates.
By default, only the Cut feed rate is defined at 250.000 mmpm. The feeds and speeds can be
automatically calculated and set to values appropriate for your tool geometry and material and
your part material by selecting Reset from Table.
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An Error dialog displays.
The Error displays because there is no data in the Feeds and Speeds data file for the
combination of a ceramic tool and aluminum part material.You will change the tool material
in the next step.
OK the Error dialog.
OK the Feeds and Speeds dialog.

Changing the Tool Material
With the Tool option selected, choose Edit.
The Milling Tool-5 Parameters dialog displays.

Change the Material to High Speed Steel (HSS).
OK the Milling Tool-5 Parameters dialog.

Setting the Feed Rates
Choose Feed Rates.
The feeds and speeds are loaded into the appropriate fields.
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OK to generate the first level.
OK several more times to display the traces and tool paths at each level.
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The last cut level is generated and displayed showing how the curved face of the bottom of
the cavity has narrowed the tool path.
After the lowest cut level is generated, the Processor Error message "Tool cannot fit into level
8" displays.
This message indicates that there is still material to be removed below the lowest level cut,
but the tool cannot fit into the remaining volume. You must finish cutting this material with
either a smaller tool or a different cutting method.
OK the Warning dialog.

A shaded display of the material removal can help you to visualize the machining operation.
Choose the Play Forward icon at the bottom of the dialog.

Notice that the large tool has not removed any material from the neck of the bottle.
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Displaying Excess Material
The Compare function displays areas where excess material remains due to large scallops and
inaccessibility of the tool.
This function is useful in determining how much material remains for subsequent operations
to remove and for comparing the finished machined part to the modeled part. You can
compare the remaining material with the part geometry.
Choose Compare.
The white area indicates that further finishing is required to machine to the specified Outtol.

Machining the Neck of the Bottle
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You will create a Cavity Mill operation that uses a small tool to rough out the neck of the
bottle.

in the toolbar.
Be sure Type is set to mill_contour.

Choose the CAVITY_MILL icon.
Enter RUF_NECK in the Name field and OK to begin creating the operation.
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Defining the Trim Boundary
You will use an existing boundary to define the Trim boundary that will constrain the cut
region to the neck of the bottle.
Choose Format
Layer Settings in the menu bar.
Make Layer 4 Selectable.

OK the Layer Settings dialog.
A boundary displays surrounding the neck geometry of the bottle. You will use this boundary
to define the Trim boundary.
Choose the More Tab.

Choose Select under Boundary Geometry.
Choose Boundary as the Mode, Outside/Right as the Side Trimmed, and Trim as the
Geometry Type.
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These parameters will restrict the tool path to the inside of the inside of the selected boundary.
Choose the boundary.

Defining the Cut Method
Set the Cut Method to Follow Periphery.
The follow periphery cut method creates cut patterns using only the outside part geometry.

Defining Cut Levels
Choose Cut Levels.
Choose the Quadrant Point icon.
Select the bottom of the arc as illustrated below.
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Enter 0.500 in the Depth per Cut field and Enter.

Using Pre-Drill Engage Points
Because the bulk of the material has already been removed from the body of the bottle, the
tool can easily move to cut depth from the body area. You will define a pre-drill engage point
to position the tool close to the neck to begin the cutting motion.
Choose Points in the Control Geometry section.
Choose Edit in the Pre-Drill Engage Points section.
If the depth field is left with the 0.00 default value, the Pre-Drill Engage Point will be applied
to all cut levels.
Choose the Cursor Location icon.
Indicate a point at the approximate screen position illustrated below.
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OK the Point Constructor dialog.

OK the Pre-Drill Engage Points dialog
OK the Control Geometry dialog.

Setting the Feeds and Speeds
You need to reset the feed rates so that they are compatible with the new, smaller tool and the
high speed steel tool material.
Choose Feed Rates and Reset from Table.
The recalculated speeds and feeds are displayed in their appropriate fields.
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Turn the Pause After Display option off.
The path is generated. All of the engage motions are outside the material being cut.
OK to accept the operation and generated tool path.

Visualizing Multiple Tool Paths.
You will use Verify Toolpath to graphically simulate material removal for both operations.
In the Program Order VIew of the Operation Navigator, highlight NC_PROGRAM.
in the toolbar.
The Toolpath Visualization dialog displays.

Choose the Dynamic tab and then Play Forward.
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This cumulative display of the material removed is helpful in indicating areas requiring
further machining.
Choose Compare.
The white areas indicate the areas where further finishing is required to machine to the
specified Outtol.
Machining a Core
You will use Cavity Mill to rough out a core.
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Machining a Core
Opening the Part
Open part file pln_cavity_2.prt from the pln subdirectory.
Choose Application
Manufacturing.
Machining a Core
Choosing the Operation to Edit
You are going to edit an existing Cavity Mill operation.
Expand the WORKPIECE object in the Geometry View of the Operation Navigator.
Double-click on the operation named BLNK_GEOM.
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The CAVITY_MILL dialog displays. Some of the options that have been set for you are:
Machining a Core
Looking at the Part Geometry
The part geometry highlights.
Machining a Core
Select the white rectangular body that surrounds the part.
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Machining a Core
Defining the Cut Levels
You are going to define Cut Levels by specifying Ranges and Cut Depths.
Choose Cut Levels.
The current cut range is indicated by two plane symbols.
The blank geometry is a little more than .5 inches above the top of the part geometry. You
will move the cut range to the top of the blank geometry and set the depth of each cut level to
.25 inches.
Machining a Core
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Removing the Current Range

Choose the Remove Current Range icon to delete this range.

Choose Cut Levels again.
Machining a Core
Modifying the Range
The current range is referenced from the top of the Blank geometry and extends to the top of
the part geometry. You will extend the bottom of the range to a lower level so that it removes
more of the blank material.
Choose the Modify Ranges icon.

Select the end point of the edge illustrated below to define the bottom of the range.
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The Range Depth field will read 2.50. The range will remain associative to this face. If the
face is modified or deleted, the range is adjusted or deleted with it.
Machining a Core
Modifying the Depth per Cut
Key in 0.250 for the Depth per Cut and Apply.
Small plane symbols indicate the depth per cut for the current range.
Machining a Core
Defining the Second Range
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Choose the Add Ranges icon.
Slide the Range Depth pointer to 5.50.
Moving the slide bar to 5.50 sets the range bottom to the bottom of the Blank geometry.
Key in 1.000 for the Depth per Cut and Apply.
The cut levels should look similar to those illustrated below.
OK to accept the cut levels.
Machining a Core
Generating this tool path may take a little longer than other tool paths you have generated due
to the complexity of the part and the number of cut levels.
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The first cut region and the Display Parameters dialog are displayed.
OK once to continue processing the tool path.

The first cut level is generated. The tool removes .25 from the top of the blank material.
OK twice to generate the second cut level.

The second cut level cuts to the top of the island.
OK twice to generate the third cut level.
The third level cuts around the islands.
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OK to finish processing the tool path.
The tool path cuts around the islands to the bottom of the first range and then removes the
blank material around the outside of the part.
Machining a Core
Visualizing Material Removal for the Cavity Mill Operation
window.
The roughing operation leaves large scallops for the subsequent finishing operations to
remove.
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MB3
Expand so that all four views again appear in the window.

Next, you are going to remove blank material using an offset.
Machining a Core
Making the Blank Geometry Invisible
You are going to remove the modeled blank geometry from the display so you can later define
blank geometry by specifying a blank distance.
Choose Format
Layer Settings.
Select BLANK_GEOM_TOP in the list box and set it to Invisible.
OK to accept the layer settings.

The blank material no longer displays.
Machining a Core
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Double-click on the operation named BLNK_DIST.
Machining a Core
Defining the Blank Distance
You are going to define blank geometry uniformly to the entire part by specifying a blank
distance.
Choose Cutting.
Key in 0.250 for the Blank Distance.
Also note that there is a Blank Stock setting as well. Blank Stock is the additional stock that is
applied to blank geometry.
Machining a Core
The first cut regions are displayed.
The tool cuts around the islands taking into consideration the Blank Distance. This is a very
different tool path than the previous tool path you generated using the modeled blank
geometry.
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OK in the Cavity-Mill dialog to complete the operation.
Machining a Core
Using Blank Geometry to Isolate Areas
You can use blank geometry to isolate and cut specific areas of the part.
Choose Format
Layer Settings.
Select BLANK_ISOLATE_1 in the list box and set it to Selectable.

A white block that you will use as blank material displays.
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Machining a Core
Double-click on the operation named BLNK_ISO.
Machining a Core
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This time all of the faces have not been selected. You could have used all of the faces, but
adding unnecessary part geometry will increase the time required for the tool path to generate.
What is important is that the part geometry you wish to cut be contained within the blank
material.
Machining a Core
Choose the Blank icon and then Select.
Select the white rectangular block.
Machining a Core
Displaying the Cut Levels
Choose Cut Levels in the Control Geometry section.
The cut levels start at the top of the blank geometry and extend to the bottom of the blank
geometry
OK to return to the CAVITY-MILL dialog.
Machining a Core
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The first cut region is displayed.
The tool cuts the top of the part within the blank geometry.
The tool cuts around the island.

OK to complete processing the tool path.
In this operation, the tool begins machining each cut level in the middle of the region and cuts
outward. Usually, you should start machining from the outside of the stock and cut inward.
You can correct this by changing the pocket direction parameter.
Machining a Core
Changing the Cut Direction
You are going to change the cut direction so that the tool starts machining from the outside of
the stock and cuts inward.
Choose Cutting.
Change the pocket direction to Inward.
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OK to return to the CAVITY_MILL dialog.
Machining a Core
The first cut region displays.
The tool cuts from the outside in.
OK as necessary to complete the tool path.

Machining a Core
Using Blank Distance with Blank Geometry
You can use modeled blank geometry and Blank Distance to machine parts which are more
heavily stocked in some areas than others. The following figure illustrates rectangular blank
geometry surrounding the left top side of the part. The remaining part area has a Blank
Distance value of 0.1 specified because it was cast closer to size.
You will modify operation BLNK_ISO_DIST to generate a tool path with the stock defined
as above.
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Double-click on the operation named BLNK_ISO_DIST in the Operation Navigator.
Machining a Core
Choose Display from the Geometry section.
Machining a Core
You are going to define the blank geometry using the same rectangular block used in the
operation you just generated.
Choose the Blank icon, then Select in the Geometry section.
Select the white rectangular block that surrounds the part and then OK to accept it.
Machining a Core
Defining the Blank Distance
Choose Cutting.
Key in .25 for the Blank Distance.
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Machining a Core
Specifying the Cut Levels
Choose Cut Levels.
You will define the cut range and levels to machine the top of the part.
Choose Modify Ranges.

Select the edge of the white block as illustrated below to define the bottom of the range.
Be sure 0.25 is displayed in the Depth per Cut field.

Refresh the graphics display and choose Display.
The cut levels display.
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OK to return to the CAVITY_MILL dialog.
Machining a Core
Turn all of the Display Parameter options off.
OK to complete generating the tool path.

Tolerant Machining and Undercut Handling

Tolerant Machining is the preferred method for most milling operations. It is a reliable
algorithm to find the correct machinable regions without gouging the part. In this case it will
prevent the shank of the tool from rubbing against the part geometry by applying a horizontal
clearance.
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Opening the Part
Open part file pln_cavity_3.prt from the pln subdirectory.
Choose Application
Manufacturing.

Expand the objects in the Geometry View of the Operation Navigator.
Double-click the UNDERCUT_TOL icon to edit the operation.

Using Tolerant Machining
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Tolerant Machining uses a reliable algorithm to find the correct machinable regions without
gouging the part. In the following figure, the shank of the tool does not gouge the canted rib
when using Tolerant Machining.
Unlike Undercut Handling, it does not apply a horizontal clearance to the tool shank.
Choose Cutting.
Notice that when Tolerant Machining is turned on, Undercut Handling is not available.

You will first generate the tool path with only Tolerant Machining turned on.
Turn all of the Display Parameter options off.
OK to complete the tool path.
The tool does not collide with the canted wall of the pocket.

Turning Off Tolerant Machining and Undercut Handling
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You will now turn off both Tolerant Machining and Undercut Handling and observe the
behavior of the tool path.
Choose Cutting.
Note that Undercut Handling is grayed out. You can only turn off the Undercut Handling
option after you have turned off the Tolerant Machining option.
Turn the Tolerant Machining option off.
Turn the Undercut Handling option off.

You will now generate the tool path with Tolerant Machining and Undercut Handling turned
off.
The shank of the tool collides with the wall..
Undercut Handling
When you use the Undercut Handling option the system applies the Horizontal Clearance
(specified under Engage/Retract Method) to the shank of the tool (the portion above the
flutes) unless the Horizontal Clearance is greater than the tool radius, in which case the tool
radius is used.
As the tool progresses deeper through the cut levels, the Horizontal Clearance will keep the
shank from rubbing against the part geometry forming the undercut.
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In this operation, the Horizontal Clearance uses the default of .100. The tool radius is .120. So
the tool will be offset from the undercut face .100.

Using Undercut Handling
Undercut Handling prevents the shank of the tool from rubbing against the part geometry by
considering undercut geometry. The system applies the Horizontal Clearance (specified under
Engage/Retract Method) to the shank of the tool to clear the undercut part geometry.
Undercut Handling applies only to non-tolerant machining (i.e., the Tolerant Machining
option is toggled OFF).

Turning On Undercut Handling
Choose Cutting.
Turn the Undercut Handling option on.

You will now generate the tool path with only Undercut Handling turned on.
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Notice that the tool is offset from the wall to avoid rubbing the shank of the tool on the wall.
Select OK to accept the tool path.

Rest Milling
Cavity Milling allows you to perform rest milling by creating an associative In-Process
Workpiece (IPW) in an operation and using it as blank geometry in the next operation. It also
allows you to display the previous IPW and the resultant IPW for each operation.
To use the IPW, operations must be in the correct program sequence in the MILL_GEOM or
WORKPIECE geometry group. The tool path must be generated and accepted in all previous
operations in the sequence before the IPW can be used in the next operation.
Rest Milling
The Initial IPW is defined as the Blank in the geometry parent group MILL_GEOM or
WORKPIECE geometry parent group.
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You will define the BLANK in the MILL_GEOM parent group, activate the use of the 3D
IPW and generate the operation. You will use the subsequent IPW that was generated as the
blank for the next operation.
Open part file pln_rest_mill.prt from the pln subdirectory.
Choose Application
Manufacturing.
Display the Geometry View in the Operation Navigator and expand the objects.
Rest Milling
The part geometry has been defined in the WORKPIECE parent group.
Double-click the WORKPIECE parent group.
With the Part icon highlighted, choose Display.
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Rest Milling
You will define the blank geometry using a method that automatically creates a solid body
enclosing the part geometry.
Choose the Blank icon and Select.
Turn the Auto Block option on.
A solid body bounding the part geometry is created. The XM, YM, ZM fields allow you to
modify the size of the body by specifying offsets from each face.
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OK to accept the blank geometry with no additional offsets.

OK to accept the MILL_GEOM dialog.
Rest Milling
Creating a Roughing Operation
You will create a roughing operation that uses the blank geometry you just defined.
from the toolbar.
Be sure the Type option is set to mill_contour and choose Cavity Mill.
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Rest Milling
Generate the Tool Path.
Turn the three Display Parameter options off and OK to continue generating the tool
path.

Rest Milling
Creating a Semi-Finish Operation
You will create a semi-finish operation that uses the IPW defined by the roughing operation
as blank geometry.
Choose the Create Operation icon from the toolbar.
Be sure Cavity Mill is still chosen as the subtype.
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Rest Milling
Using the IPW as Blank Geometry in the Current Operation
You will use the IPW generated by the roughing operation as the blank geometry in this
operation.
Choose Cutting from the CAVITY_MILL dialog.
Turn the Use 3D IPW option on.
OK to accept the Cut Parameters dialog.
Rest Milling
Displaying the Previous IPW
The Previous IPW icon replaces the Blank icon at the top of the CAVITY_MILL dialog.
Choose the Previous IPW icon and Display.

The system may require some processing time to display the faceted body.
This IPW is the blank geometry that will be used by this operation.
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Rest Milling
You will generate a tool path that semi-finishes the part.
path.
Rest Milling
Displaying the Resulting IPW
You will display the resulting IPW that will be passed on to the next operation.
Choose the Display Resulting IPW icon.
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Rest Milling
Creating a Finishing Operation
You will create a finishing operation that uses the IPW defined by the semi-finish operation as
blank geometry.
Choose the Create Operation icon from the toolbar.
Be sure Cavity Mill is still chosen as the subtype.
Rest Milling
Using the IPW as Blank Geometry in the Current Operation
You will use the IPW generated by the semi-finish operation as the blank geometry in this
operation.
Choose Cutting from the CAVITY_MILL dialog.
Turn the Use 3D IPW option on.
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OK to accept the Cut Parameters dialog.
Key in 3.000 in the Depth Per Cut field.
Rest Milling
path.
Rest Milling
Displaying the Resulting IPW
Choose the Display Resulting IPW icon at the bottom of the dialog.
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Rest Milling
Displaying the IPW Column in the Operation Navigator
Turn the IPW option on.

The IPW column now displays in the Operation Navigator. The check marks indicate the
operations that contain resulting IPW's.
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If an new operation is inserted in the program sequence, if an operation is deleted, or if the
operations are reordered, clock icons indicate that the resulting IPW's are out of date. This
simply means that when generating the tool paths, the IPW's will need to be updated
internally, requiring additional processing time.
Remove the IPW column from the Operation Navigator.
Z-Level Milling
Z-Level Milling is designed to profile a part at multiple cut levels using a fixed axis. It allows
you to cut either the entire part or steep areas only.
When the Steep Angle option is toggled on, only areas with a steepness greater than or equal
to the specified Steep Angle are profiled. This allows you to profile areas left unmachined by
the Area Milling Drive Method in Fixed Axis Surface Contouring.
In this lesson, you will profile the part at each cut level and then constrain the cut region using
the silhouette or "shadow" of the part. You will then specify a Steep Angle to profile only the
steep areas left unmachined by a previous Fixed Axis Surface Contouring operation. In
addition, you will learn how to define a Cut Area and then further constrain the cut region
using a trim boundary.
Profiling the Entire Part
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You will use Z-Level Milling to profile the part. You will observe how the Trim By option
can be used to profile the entire part at each cut level or to constrain the cut region by the
silhouette or "shadow" of the part.

Opening the Part
Open part file pln_zlevel_mill.prt from the pln subdirectory.
Choose Application
Manufacturing.

In the Geometry view of the Operation Navigator, expand the MCS_MILL object.
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The WORKPIECE object does not yet define the part geometry and must be edited.
Double-click on the WORKPIECE object.
This displays the MILL_GEOM dialog so you can define Part, Blank, and Check Geometry.
Select the body as the part geometry and OK to accept it.
OK in the MILL_GEOM dialog to complete the geometry definition.

The WORKPIECE object defines the part geometry that will be inherited by the operations it
contains.

Creating a Z-Level Profile Operation
Change the Type to mill_contour.
Choose ZLEVEL_PROFILE.
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ZLEVEL_PROFILE and ZLEVEL_PROFILE_STEEP
You can choose either of the two subtypes outlined below to create a Zlevel Profile operation.
The ZLEVEL_PROFILE icon creates an operation with no Steep Angle, allowing the entire
cut region to be profiled. The Steep angle option is turned off by default.
The ZLEVEL_PROFILE_STEEP icon creates an operation that allows only areas with a
steepness greater than or equal to a specified Steep Angle to be profiled. The Steep angle
option is turned on by default.
The system automatically names the operation ZLEVEL_PROFILE.


Notice that the Select/Reselect option is blanked for defining part geometry. Part geometry is
inherited from the WORKPIECE object.
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The Trim By option can be set to None or Silhouette. None allows the tool to profile the entire
part geometry by generating a trace at each cut level.
Choose Cutting.
Choose None as the Trim By option and OK.
Notice that the Steep Angle option is turned off.
The off condition allows the entire cut region to be profiled regardless of the steepness of the
surface being cut.

You will generate a tool path that profiles the entire part.
Turn the Pause After Display option off and OK to continue generating the tool path.
The entire part is profiled at each cut level.
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Profiling the Silhouette
Now you will constrain the cut region using the silhouette or "shadow" of the part.
Choose Cutting.
When the Trim By option is set to Silhouette, the cut region is constrained by the silhouette or
"shadow" of the part projected along the tool axis. The tool profiles outward until it reaches
the silhouette of the part geometry where a single profiling cut is then generated along the
outer edge.
Choose Silhouette as the Trim By option and OK.

You will generate a tool path that is trimmed by the silhouette of the part.
Turn the Pause After Display option off and OK to continue generating the tool path.
The tool path is generated with only a single pass at the silhouette.
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Profiling Only Steep Areas

An important feature of Z-Level Milling is the ability to specify a Steep Angle to distinguish
steep from non-steep areas.
This allows you to profile only the steep areas left unmachined by previous Fixed Axis
Surface Contouring operations. When the Steep Angle option is turned on, only areas with a
steepness greater than the specified Steep Angle are profiled. The steepness of the part at any
given point is defined by the angle between the tool axis and the normal of the face.
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Opening the Part
Open part file pln_zlevel_mill_1.prt from the pln subdirectory.
Choose Application
Manufacturing.
In the Program Order view of the Operation Navigator, expand the PROGRAM object to
display the two operations.
Notice that the ZLEVEL_PROFILE operation follows the CONTOUR_AREA operation in

the program sequence. You will examine the CONTOUR_AREA operation first and then
observe how the subsequent ZLEVEL_PROFILE operation profiles the unfinished steep
areas.

Double-click on the CONTOUR_AREA icon to edit the operation.
Notice that the Select/Reselect option is blanked, indicating that the part geometry is inherited
from the WORKPIECE object.
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Choose Display to highlight the part geometry.

The part geometry is defined by a surface region.

Replaying the Tool Path
This operation uses the Area Milling Drive Method to restrict the allowable steepness of the
tool path.
Notice that the very "steep" areas are not machined. This restriction is necessary when using a
zig-zag cut pattern to prevent the tool from plunging directly down into the part material.

Examining the Steep Angle
Choose Area Milling under Drive Method.
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In the Area Milling Method dialog, notice that the Steep Containment is specified as Nonsteep and the Steep Angle is specified as 70 degrees. This allows only areas where the tool
path is less than or equal to 70 degrees to be machined by this operation. The steepness of the
part at any given point is defined by the angle between the tool axis and the normal of the
face.
Cancel twice to exit the operation.

Specifying the Steep Angle in the Second Operation
Now you will edit the ZLEVEL_PROFILE operation so that it profiles the steep areas left
uncut by the CONTOUR_AREA operation.
Double-click on ZLEVEL_PROFILE.
The ZLEVEL_PROFILE dialog displays.

Turn the Steep Angle option on and key in 70.
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This will allow only the areas with a steepness greater than or equal to 70 degrees to be
profiled.

By comparing the tool paths, you will notice that the entire part is machined by the two
operations. The CONTOUR_AREA operation zig-zags the areas where the steepness is less
than or equal to 70 degrees. The ZLEVEL_PROFILE operation profiles the areas where the
steepness is greater than or equal to 70 degrees.

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Specifying the Cut Order

Unlike Cavity Milling which orders cut traces by cut region, Z-Level Milling orders cut traces
by shape.
You may profile shapes by Depth First in which case one shape (an island, for example) is
completely profiled before profiling the next shape as illustrated below, or you may profile
shapes by Level First in which case all shapes are profiled at a particular level before cutting
the next level.

Opening the Part
Choose Application
Manufacturing.
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In the Geometry view of the Operation Navigator, expand the MCS_MILL object and the
WORKPIECE object to display the ZLEVEL_PROFILE operation.
Double-click on ZLEVEL_PROFILE to edit the operation.

With the Part icon chosen, choose Display to highlight the part geometry.
The entire solid model highlights indicating that it has been defined as the part geometry.
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Examining the Cut Order
Notice that the Cut Order is currently set to Depth First. This causes the operation to
completely finish profiling one shape (island in this example) before profiling the next shape.

The island on the left is completely profiled before profiling the island on the right.
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Respecifying the Cut Order
Change the Cut Order to Level First.
This option profiles all shapes (islands) at a given level before profiling the next level.

Turn the Pause After Display option on and OK the dialog.

The first level cut on the left island displays.

The first cut level on the right island displays.
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OK as necessary to complete the tool path.

Notice how the islands are cut alternately.
OK the ZLEVEL_PROFILE dialog to complete the operation.
Specifying a Cut Area

Unless otherwise specified, the system uses the entire defined part geometry (excluding areas
not accessible by the tool) as the cut area. You can specify cut areas by selecting Surface
Regions, Sheet Bodies, or Faces.

Specifying a Surface Region as the Cut Area
Double-click on ZLEVEL_PROFILE.
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Choose Cut Area, then Select.
In the Cut Area dialog, choose Features.
This will allow you to select surface regions (and only surface regions) to define the cut area.
You may not mix features and geometry when defining a cut area.
Select the surface region illustrated below and OK.

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The Display Parameters dialog displays.
Turn the Pause After Display option off and OK the dialog.
The tool path is generated and restricted to the feature you selected.
Specifying a Trim Boundary

A Trim boundary allows you to further constrain the cut regions.
You may define the area of the cut regions to exclude from the operation by specifying the
Trim Side as Inside or Outside. Trim boundaries are always closed and use an On condition.
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Specifying a Trim Boundary Using Control Points
Choose Trim, then Select.
In the Trim Boundary dialog, choose Outside as the Trim Side.
This will exclude all portions of the cut region falling outside of the trim boundary.
Choose Point Boundary as the Filter Type and Control Point as the Point Method.
This will allow you to create the trim boundary by specifying a sequence of points.
Specify the four control points in order as illustrated below and OK to accept them.
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Choose Display (in the Geometry section of the dialog) to display the trim boundary.

Turn off the Pause After Display option and OK the dialog.
The tool path is generated within the trim boundary and restricted to the cut region you
defined earlier.
Notice that the cutter retracts, traverses, and engages between each cut level. A more effecient
cut pattern would be to allow the cutter to remain in contact with the part between cut levels.
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Specifying a Cut Pattern for High Speed

Machining
Cut patterns for high speed machining must allow constant volume removal and eliminate
burying the cutter into material. They must also provide a smooth transition from level to
level as the cutter progresses downward or upward along the path, eliminating constant
retracting, traversing, and engaging. To maximize volume removal, the tool should always be
in contact with the part.
Specifying a Cut Pattern for High Speed Machining

Specifying the Cut Pattern
Choose Cutting.
Set the Cut Direction option to Mixed and the Level to Level option to Direct on Part.

Turn off the Pause After Display option and OK the dialog.
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Notice how the cutting tool engages the part, feeds down the wall of the part to get to the next
level, and alternates the direction of cut from one level to the next.

Another Example of High Speed Machining
Choose Application
Manufacturing.
Double-click on the ZLEVEL_PROFILE icon in the Operation Navigator to edit the

operation.
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Choose Cutting.
Set the Cut Direction option to Mixed and the Level to Level option to Direct on Part as
you did before and OK to accept the cut parameters.
Notice the reduction in engage, traverse, and retract moves.

Specifying a Merge Distance

The Merge Distance option enables you to eliminate small discontinuities or unwanted gaps in
the tool path by connecting disjointed cutting motions.
The value you enter determines the distance the tool will span to connect the end points of
cutting moves.
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Opening the Part
Notice the two 4.0 mm slots cut into the part. The Merge Distance option determines whether
the tool will retract or continue profiling when it reaches the slots.
Choose Application
Manufacturing.
Expand the objects in the Geometry view of the Operation Navigator.

Specifying the Merge Distance
Double-click on the ZLEVEL_PROFILE icon to edit the operation.

Notice that the Merge Distance is currently set to 3.0000.
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Because this value is smaller than the width of the slots, the tool will not profile across the
slots and will instead retract each time it encounters them.
Change the Merge Distance to 5.0000.
Now that the Merge Distance is greater than the width of the slots, the tool path will connect
the disjointed cutting motions and cut across the slots.

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Notice that the tool does not retract, but instead cuts directly across the slots.
Planar and Cavity Milling Project

This English units part contains several cavities that are machined from a solid block of
material. The completed machining program consists of six operations that rough, semi-finish,
and finish the part. You will create three of the operations.
To complete this project, you should be familiar with the following operation subtypes.
CONTOUR_AREA_NON-STEEP
CONTOUR_ZIGZAG
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CONTOUR_AREA_DIR_STEEP
In addition, you should know how to use Verify Toolpath to graphically simulate material
removal and compare the in-process workpiece to the part.
Functions Used to Machine the Part

In this project you will:
Create a ZLEVEL_FOLLOW_CAVITY operation to rough the part.
Create a ZLEVEL_PROFILE_STEEP operation to semi-finish the steep areas.
Create a FACE_MILLING operation that uses a manual cut pattern to finish the top
face.
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Use Verify Toolpath to graphically simulate material removal for the entire program.
Compare the in-process workpiece to the part by displaying the excess material.
Machining the Part
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The completed program must cut the finished part from a solid block of material using a
sequence of roughing, semi-finishing, and finishing operations while applying acceptable
standard machining techniques.
Machining the Part

Open the Part File
Open part file pln_proj_1.prt from the pln subdirectory.
Enter the Manufacturing Application.
Fully expand the objects in the Program Order View of the Operation Navigator.
In the Operation Navigator, click on the plus (+) sign next to the PROGRAM
object.
Replay the three operations.
In the Operation Navigator, click on the PROGRAM icon and MB3
Replay.
These Fixed Axis Surface Contouring operations semi-finish and finish the part. You will
create three more operations that rough out the initial material, semi-finish the non-steep
areas, and finish the top face of the part, and then place them in the correct program sequence
as illustrated below.
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Machining the Part

Creating a ZLEVEL_FOLLOW_CAVITY Operation
You first need to create an operation that roughs out the initial material.
Begin a ZLEVEL_FOLLOW_CAVITY operation using the following parent groups:

Choose mill_contour as the Type
Choose the ZLEVEL_FOLLOW_CAVITY icon as the subtype.
Specify the parent groups as indicated below.
Machining the Part

Displaying the Part and Blank Geometry
You need to visually verify the part and blank geometry the operation will use.
Display the part geometry.
Under Geometry, choose the Part icon and Display.
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The part geometry is inherited from the WORKPIECE object.

Display the blank geometry.
Under Geometry, choose the Blank icon and Display.
The blank geometry is also inherited from the WORKPIECE object.

Machining the Part

Specifying the Depth Per Cut and Range Depth
You need to reduce the Depth Per Cut and specify the Range Depth.
Specify a Depth Per Cut of 0.1500.
Key in 0.1500 for the Depth Per Cut.
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Specify the bottom of one of the cavities as the Range Depth.

Under Control Geometry, choose Cut Levels.
Select the bottom face of any one of the four cavities.
Machining the Part

You need to generate the tool path to see if the operation cuts the part correctly.
Notice that the tool path finishes each cut level by traversing from one region to the next
before beginning the next cut level.
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In this case, it would be more efficient to completely finish machining each region from top to
bottom before traversing to the next region.
Machining the Part

You need to specify a cut order that will machine the cavities more efficiently.
Specify Depth First as the Cut Order.
Choose Cutting.
Choose Depth First as the Cut Order.
This option will cut each pocket to full depth, as encountered.

Machining the Part

Turn the Display Cut Regions option off.
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Notice that the tool path completely machines each region from top to bottom before
traversing to the next one.

Notice that the operation is at the end of the program.
Machining the Part

Reordering the Operations
The operation you just created needs to be moved to the beginning of the program.
Reorder the operations so that ZLEVEL_FOLLOW_CAVITY is at the beginning of the
program.
In the Program Order View, choose the CONTOUR_AREA_NON_STEEP,
CONTOUR_AREA, and FLOWCUT_SINGLE operations. You will need to hold
down the Ctrl key to choose all three operations.
Choose MB3 Cut.
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The operation you choose in the next step is the object below which the pasted operations will
appear.
Choose ZLEVEL_FOLLOW_CAVITY and MB3
Paste.
The operations should appear in the order illustrated below.
Machining the Part

Creating a ZLEVEL_PROFILE_STEEP Operation
You need to create an operation that semi-finishes the steep areas.
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Begin a ZLEVEL_PROFILE_STEEP operation using the following parent groups:

Choose mill_contour as the Type.
Choose the ZLEVEL_PROFILE_STEEP icon as the subtype.
Machining the Part

Displaying the Cut Area
You need to visually verify the cut areas.
Display the cut area geometry.
Under Geometry, choose the Cut Area icon and Display.
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Each cavity is a separate cut area. The cut area geometry is inherited from the Mill_AREA
object.
Machining the Part

Specifying the Steep Angle
Specify a Steep Angle of 55.0000 degrees.
Key in 55.0000 for the Steep Angle.
profiled.
Machining the Part

Specifying the Depth Per Cut and Cut Levels
You need to reduce the Depth Per Cut and specify the Range Depth.
Specify a Depth Per Cut of 0.1000.
Key in 0.1000 for the Depth Per Cut.
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Machining the Part

Verifying the Range Depth
Verify that the Range Depth is the depth of the cavities.
Under Control Geometry, choose Cut Levels.
The current Range Depth is defined by the depth of the Cut Area geometry and should be
1.0000.
Machining the Part

Turn all of the display parameters off.
Notice that the tool path completely machines each region from top to bottom before
traversing to the next one. Only the steep areas are machined.
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Notice that the operation is at the end of the program.
Machining the Part

Reordering the Operations
The operation you just created needs to be moved to a different position in the program.
Move the ZLEVEL_PROFILE_STEEP operation to the third position in the program
In the Program Order View, choose the ZLEVEL_PROFILE_STEEP operation.
Choose MB3 Cut.
The operation you choose in the next step is the object below which the pasted operation will
appear.
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Choose CONTOUR_AREA_NON_STEEP and MB3
Paste.
The operations should appear in the order illustrated below.
Machining the Part

Displaying Material Removal
You need to visualize the tool path for the entire program and compare the in-process
workpiece to the part.
Use dynamic material removal to visualize the tool path for the entire program.
In the Program Order View of the Operation Navigator, click on the PROGRAM
icon.
Choose the Verify Toolpath icon in the toolbar.
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Compare the in-process workpiece to the part.

Choose Compare in the Toolpath Visualization dialog.
Notice that large scallops remain on the top face of the part. Next, you will create a face
milling operation that that uses a manual cut pattern to finish the top face.
Cancel to dismiss the Toolpath Visualization dialog.
Machining the Part

Creating a FACE_MILLING Operation
You need to create an operation that uses a manual cut pattern to finish the top face of the
part.
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Begin a FACE_MILLING operation using the following parent groups:

Choose the FACE_MILLING icon as the subtype.
Machining the Part

Specifying the Face Geometry
You need to specify the face the operation will finish.
Select the top of the part as the face to finish.
Under Geometry, choose the Face icon and Select.
Select the top face of the part.
OK to accept the face geometry.
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Machining the Part

Specifying a Top View
You need to change to a top view so you can see the manual cut pattern clearly.
Replace the current view with a top view.
MB3
Replace View
TOP.
Machining the Part

Specifying the Tool Path Display
You need to specify a 2-D silhouette tool path display so you can clearly see the area the tool
cuts.
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Specify a 2-D Tool display and a Silhouette Path Display.
Choose the Edit Display icon under Tool Path.
Choose 2-D for the Tool Display and Silhouette for the Path Display.
Machining the Part

Specifying a Manual Cut Pattern
You need to specify a manual cut pattern to cut along the top of the walls.
Specify that you wish to begin defining a manual cut pattern.
Choose Mixed as the Cut Method.

In the Mixed Cut Pattern dialog, be sure Manual is chosen as the Cut Method.
OK to begin defining the cut pattern.
The Create Manual Cut Pattern dialog should be displayed.
Machining the Part

Repositioning to a Point
Reposition the tool to a point in space just to the right of the corner of the part as illustrated
below.
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Be sure the Reposition to Point icon is chosen.
Indicate a point in space to the right of the corner of the part.
Machining the Part

Engaging to a Point
Engage the tool to the corner of the part.
Choose End Point as the Point Method.

Select the corner of the part as the engage point.
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Machining the Part

Cutting to a Sequence of Points
Create four linear cuts along the periphery of the top face as illustrated below.
Select the four end points in order as illustrated below to define the sequence of
linear cutting moves.
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Machining the Part

Reposition the tool to a point in space just off to one side of the part as illustrated below.
Choose Reposition To Point.

Indicate near the center of the side of the part.
Machining the Part

Engaging to a Point
Engage the tool to the center of the side of the part.
Choose Control Point as the Point Method.
Select the center of the line as the engage point.
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Machining the Part

Cutting to a Point
Cut across the center of the part to a point on the opposite side.
Select the center of the line on the opposite side of the part.
Machining the Part

Reposition the tool to a point in space just off to one side of the part as illustrated below.
Choose Reposition To Point.
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Indicate near the center of the side of the part.
Machining the Part

Engaging to a Point
Engage the tool to the center of the side of the part.
Choose Control Point as the Point Method.
Select the center of the line as the engage point.
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Machining the Part

Cutting to a Point
Cut across the center of the part to a point on the opposite side.
Select the center of the line on the opposite side of the part as illustrated below.
OK to complete the manual cut pattern.
Machining the Part

Replace the current view with a TFR-ISO view.
MB3
Replace View
TFR-ISO.
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Machining the Part

You need to visualize the tool path for the entire program and compare the in-process
workpiece to the part.
In the Program Order View of the Operation Navigator, click on the PROGRAM
icon.
Compare the in-process workpiece to the part.

Notice that the scallops have been removed from the top of the part.
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SURFACE CONTOURING
Area Milling Drive Method
The Area Milling drive method generates a fixed axis surface contouring tool path by
specifying a cut area and, if desired, adding steep containment and trim boundary constraints.
Cut areas may be defined by selecting surface regions, sheet bodies, or faces.
You can restrict cut areas based on the steepness of the tool path. By cutting non-steep areas
and then profiling steep areas, you can avoid plunging the tool directly into the material along
vertical walls.
Steep areas can be profiled with a subsequent Z-Level Milling operation or a Surface
Contouring operation that uses a Directional Steep containment.
The Area Milling drive method is similar to the Boundary drive method but has no drive
geometry and uses a more robust and automated computation of collision-free containment.
For these reasons, you should use the Area Milling drive method in place of the Boundary
drive method whenever possible.
In this lesson, you will create several fixed axis surface contouring operations using the Area
Milling drive method. You will see how the Area Milling drive method works together with
Z-Level Milling operations to machine both steep and non-steep areas of a cavity and a core.
You will also learn to graphically simulate material removal using a shaded image and display
areas where excess material remains.
Machining a Cavity
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You will first examine a program that consists of three milling operations and observe how
these three operations work together to machine the entire cavity.
Machining a Cavity
Opening the Part
Open part file srf_area_mill_1.prt from the srf subdirectory.
in the toolbar so you can clearly see the contoured surfaces.
Notice that the sides of the cavity are very steep (vertical or nearly vertical).
Choose the Visible Hidden Edges icon
to return to a wireframe display.
Machining a Cavity
Choose Application
Manufacturing.
In the Geometry View of the Operation Navigator, choose Expand All

expand the objects as illustrated below.
to fully
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The operations inherit parameters from the MILL_GEOM and MILL_ORIENT parent groups.
Machining a Cavity
Examining the MILL_GEOM Group
The MILL_GEOM parent group defines the part geometry used by all three operations.
Double-click on the MILL_GEOM icon.
Choose the Part icon and Display.
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Cancel out of the MILL_GEOM dialog.
Machining a Cavity
Replaying the Cavity Mill Tool Path
Choose the Program Order View
icon in the toolbar.
The CAVITY_MILL operation first roughs out the cavity. The

CONTOUR_AREA_NON_STEEP and ZLEVEL_PROFILE_STEEP operations then finish
the cavity.
Double-click on the CAVITY_MILL operation to display the CAVITY_MILL dialog.
Choose Replay.
Machining a Cavity
Visualizing Material Removal for the Cavity Mill Operation
The Verify option allows you to graphically simulate material removal using a shaded image.
This function requires blank material to be defined. If it is not already defined in the
Workpiece group or within the operation, it can be temporarily defined for display purposes
when performing the tool path visualization.
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Be sure Auto Block is chosen as the Blank Type.
Offsets can be added to each of the six faces by entering values in the dialog or by dragging
the handles.
OK to begin the tool path visualization.
The roughing operation leaves large scallops for the subsequent finishing operations to
remove.
Machining a Cavity
Replaying the Non-Steep Tool Path
Double-click on the CONTOUR_AREA_NON_STEEP icon in the Operation Navigator
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to display the operation dialog.
Replay
the operation.
Notice that the tool does not cut all the way to the edge of the cavity. The Steep Containment
parameters restrict the cut area, allowing the tool to cut from side to side but preventing it
from cutting downward and plunging directly into the material.
Machining a Cavity
Visualizing Material Removal for the Non-Steep Operation
Choose the Verify
icon at the bottom of the dialog.


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Machining a Cavity
Replaying the Steep Tool Path
Double-click on the ZLEVEL_PROFILE_STEEP operation.
Replay the operation.

This operation profiles the steep areas left uncut by the surface contouring operation.
Machining a Cavity
Visualizing Material Removal for the Steep Operation
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Material removal is displayed for ZLEVEL_PROFILE_STEEP.

Cutting Non-Steep Areas

You will create a fixed axis surface contouring operation that uses the Area Milling drive
method to cut only the non-steep areas of a cavity.

Opening the Part
Choose Application
Manufacturing.
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In the Geometry View of the Operation Navigator, expand the objects.

This program contains a MILL_GEOM group that defines part and blank geometry and a
CAVITY_MILL operation that roughs out the cavity.

The Type determines the subtype icons that are available and the groups that are initially
available to choose from in the dialog. You can use any one of the subtypes outlined below to
create a fixed axis surface contouring operation.
Choose CONTOUR_AREA_NON_STEEP as the subtype.
This subtype defines most of the operation parameters you will need to cut non-steep areas.
The system automatically names the operation CONTOUR_AREA_NON_STEEP.
Specify the following groups in the Create Operation dialog.
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The operation will inherit the parameters defined by these parent groups.

Notice that the Select/Reselect option is blanked for defining part geometry. Part geometry
has already been defined and is inherited from the MILL_GEOM group. It can only be
modified by editing the group.
Choose Display to highlight the part geometry.

The part geometry is defined as the entire body.
Notice that the Drive Method defaults to Area Milling.
The CONTOUR_AREA_NON_STEEP subtype that you chose earlier determined this option
as the default.

The cut area defines the area of the part the operation considers for cutting when generating
the tool path. If you do not specify a cut area, the system uses the entire Part Geometry as the
cut area.
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Choose the Cut Area icon and Select.
The Selection Options should be set by default to Geometry and Faces.
Select the face defining the cavity as illustrated below.
OK to accept the face as the cut area.

Specifying Non-Steep Containment
The Non-Steep option enables you to generate only cuts that are less than or equal to the
specified Steep Angle. This allows the tool to cut from side to side while preventing it from
plunging into the material along the vertical walls.
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Notice that the Steep Containment parameters default to non-steep with a steep angle of
65.0000 degrees. The CONTOUR_AREA_NON_STEEP subtype you chose earlier
determined these as the defaults.
Key in 55 for the Steep Angle.
The operation will now cut only the areas where the steepness of the tool path is less than or
equal to 55 degrees.
OK to accept the steep containment and return to the operation dialog.

You will generate the tool path and observe how the Cut Area and Steep Containment
parameters influence the tool path.
Only non-steep tool paths (those between 0-55 degrees) are generated.
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Notice, however, that the operation also creates small zig-zag cuts along the edge of the
cavity.
These small zig-zag cuts are non-steep tool paths that occur as a result of edge tracing.
Edge tracing occurs when the tool "rolls over" the edge of the cut area. The steepness of these
edge traces falls within the specified 0-55 degree Steep Angle as illustrated below.
Edge traces are generally undesirable and should be removed.
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Removing Edge Traces
Choose Cutting.
Turn Remove Edge Traces On.
OK to accept the cutting parameters.

You will generate the tool path and observe how the edge traces have been removed.

The CONTOUR_AREA_NON_STEEP operation now appears as the second operation in the
Program Order View of the Operation Navigator.
The Program Order View determines the order in which operations will be executed on the
machine tool.
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You will create a Z-Level Milling operation that profiles the steep areas left uncut by the
previous Area Milling operation.
For additional information on creating Z-Level Milling operations, refer to the Z-Level
Milling lesson in the Planar and Cavity Milling course.

Choose ZLEVEL_PROFILE_STEEP
in the toolbar.
as the subtype.
This subtype defines most of the operation parameters you will need to cut steep areas.
The system automatically names the operation ZLEVEL_PROFILE_STEEP.
The operation will inherit the parameters defined in these groups.

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the tool path.
The Selection Options should be set by default to Geometry and Faces.
Select the three faces defining the cavity as illustrated below.
OK to accept the faces as the cut area.

Defining the Steep Angle
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The Steep Angle determines which portions of the Cut area will be machined based on the
steepness of the area.
Notice that the Steep Angle option has already been turned on. The
ZLEVEL_PROFILE_STEEP subtype you chose earlier determined this as the default.
profiled. In other words, all the steep areas left uncut by the previous Area Milling operation
will now be profiled.
Choose Cut Levels.
Key in 0.0500 in the Depth per Cut field.
This determines the depth of each profile cut.


You will generate the tool path and observe how only the steep areas are profiled.
Turn off all of the Display Parameters options and OK.
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The ZLEVEL_PROFILE_STEEP operation now appears as the third operation in the Program
Order View of the Operation Navigator.
By comparing the Contour Area Non-Steep tool path and the Z-Level Profile Steep tool path,
you can see that the two operations finish the entire cavity.
Using a Trim Boundary

You will create a fixed axis surface contouring operation that uses a Trim boundary to
constrain the cut area and define additional finishing passes within a specific area.
You will copy and paste an existing operation and then edit the parameters.

Copying an Existing Operation
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This operation uses many of the same parameters as the existing
CONTOUR_AREA_NON_STEEP operation. It will be easier to copy and modify the
existing operation than to create a new operation.
In the Program Order View of the Operation Navigator, highlight
CONTOUR_AREA_NON_STEEP and MB3 Copy.
Highlight ZLEVEL_PROFILE_STEEP and MB3
Paste.
CONTOUR_AREA_NON_STEEP_COPY now appears as the last operation in the Program

Order View.

Reselecting the Tool
Double-click on CONTOUR_AREA_NON_STEEP_COPY to edit the operation.
First, you will change to a smaller tool.

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With Tool:T2 chosen, choose Reselect.
Choose T3 in the Reselect Tool dialog and OK.
The dialog now displays T3 as the tool the operation will use.

Editing the Steep Angle and Stepover
Choose Area Milling under Drive method.
Key in 25 for the Stepover Percent.
Decreasing the stepover size will reduce the scallop height on the machined part.
OK to accept the changes.
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Defining a Trim Boundary

You will define a Trim boundary to constrain the cut area. To assist you in defining the
boundary, you will display four points that are hidden on Layer 6.
Choose Format
Layer Settings from the menu bar.
Highlight 6 in the Layer/Status list box and choose Selectable.

Four points should be displayed.
Choose the Trim icon
and Select.
The Trim Boundary dialog displays. Notice that Outside is specified as the Trim Side.
This will exclude all areas of the cut region outside of the boundary. The tool path will only
be created inside of the boundary.
Choose the Point Boundary icon and Existing Point as the Point Method.
Select the four points in order as illustrated below.
OK to complete the boundary.
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Choose Display to verify that the boundary has been created correctly.
Trim boundaries are always Closed and always use an On condition.

You will generate the tool path and observe how the Trim boundary constrains the cut area.

You will use Verify Toolpath to graphically simulate material removal for the entire program.
In the Program Order View of the Operation Navigator, highlight NC_PROGRAM.
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on the Manufacturing Operations toolbar.

The material removed by each successive operation is displayed in a contrasting color.

Using a Tool Holder

The Area Milling and Flow Cut drive methods allow you to define a simple tool holder to
ensure a collision free tool path.
You will first replay a fixed contour operation that uses the Area Milling drive method to see
how closely a tool without a holder cuts to the check geometry. Check geometry can be
anything that you would want the tool to avoid. In this case, imagine it to be a clamp holding
the part to be machined.
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You will then create a tool with a holder and observe how the system alters the tool path to
avoid collision between the tool holder and check geometry.
Using a Tool Holder

Choose Application
Manufacturing.
Display the Machine Tool View of the Operation Navigator and expand the objects.
Using a Tool Holder

You will replay the fixed contour operation to see how closely the tool without a tool holder
cuts to the check geometry.
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In the Machine Tool View of the Operation Navigator, highlight the FIXED_CONTOUR
operation.
in the toolbar.
The operation uses a tool without a holder. Notice how closely the tool cuts to the check
geometry.
Using a Tool Holder

Creating the Tool
You will create a tool with a holder.
Be sure mill_contour is specified as the Type.

This is important because not all Types allow you to create a tool with a holder.
Choose MILL_WITH_HOLDER as the subtype.
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OK to begin defining the tool.
Using a Tool Holder

Defining the Tool and the Holder
You will specify parameters that define the tool and the holder.
Fill in the values specified below to define the tool.
Fill in the values specified below to define the holder.
OK to accept the parameters and create the tool with the holder.
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Using a Tool Holder

Applying the Tool to the Operation
You will now apply this tool to the operation.
Double-click on FIXED_CONTOUR to edit the operation.
Choose Tool:MILL and Reselect.
Choose MILL_WITH_HOLDER in the Reselect Tool dialog and OK.
Using a Tool Holder

Using the Holder With the Tool
In order for the operation to recognize the holder, the Use Tool Holder option must be turned
on.
Choose Cutting.
Check Safe Clearance defines an extended safety zone for check geometry which cannot be
violated by the tool or the tool holder.
Key in .01 for Check Safe Clearance.
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Turn Use Tool Holder on.
OK to accept the Cutting Parameters and return to the FIXED_CONTOUR dialog.
Using a Tool Holder

You will generate the tool path and observe how the system alters the tool path to avoid
collision between the tool holder and check geometry
The system has altered the tool path to avoid collision with the tool holder and the check
geometry. Notice the Tool holder Collision Warning.
OK to dismiss the warning.
Using a Tool Holder

Visualizing the Tool Holder
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Using a Tool Holder

Retrieving Tools From a Library
The Retrieve Tool option allows you to retrieve tools from a library based on search criteria.
Once retrieved, the tool groups appear in the Machine Tool View of the Operation Navigator
and become available for selection when defining operations.

Choose the Retrieve Tool icon
in the toolbar.
and OK.
This displays the Library Class Selection dialog.

Expand the Milling tools and choose End Mill (non indexable).
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Using a Tool Holder

Specifying Search Criteria
The Search Criteria Dialog allows you to narrow down the library search by specifying
parameters.
Notice that the number "64" appears next to the option. This indicates there are sixty-four
tools in the library that match the parameters you have specified so far.
You can narrow the search even further by specifying exact numeric values or a range of
values using <, >, <=, and >= signs.
Key in .50 for the Diameter.
Notice that the number "7" now appears next to the option. You have narrowed the search to
only those tools in the library with a diameter of .50.
Choose Result Info.
This displays an Information listing of all the tools matching the search criteria. It will allow
you to determine which values (Flute Length and Corner Radius for example) can be
specified to continue narrowing the list.
Key in the following expressions.
The >1 means that the flute length should be greater than 1 inch long and the >=.05 means
that the corner radius should be greater than or equal to 0.05.
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Notice that the number "3" now appears next to the option. You have narrowed the search to
the only three tools in the library with a flute length greater than 1 and a corner radius greater
than or equal to .05 .
OK to accept the search criteria.
Using a Tool Holder

Choosing Tools
The Search Result listing allows you to choose the desired tool or tools. Each tool you choose
will create a separate tool group.
Choose the tools from the list indicated below.
Use the left mouse button to choose a single tool. Use the left mouse button in combination
with the Shift key to choose a range of tools. Use the left mouse button with the Ctrl key to
selectively choose tools from the list. The Ctrl key also enables you to deselect.
OK to accept the tools.

The tools retrieved from the library now appears in the Machine Tool View of the Operation
Navigator and will be available for selection when defining operations.
Using a Tool Holder

Changing the Tool
You will drag and drop the operation so that it uses the library tool with a holder.
In the Machine Tool View of the Operation Navigator, drag and drop the
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FIXED_CONTOUR operation onto the UGTI0203_016 tool.
The operation now uses a library tool with a holder.
MB3
Generate to generate the tool path and OK to accept the tool path generation.
Using a Tool Holder

Displaying the Tool Holder Assembly
You will observe how you can graphically display a tool holder assembly when replaying a
milling operation.
Only tools retrieved from a library and containing a modeled assembly can display a tool
holder assembly. If a part file defining the tool holder does not exist or cannot be loaded, then
the Solid tool display option is used in place of the Assembly display.
Choose the Verify Toolpath icon on the Manufacturing Operations toolbar.
Choose Assembly for the Tool Display Option.
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Zoom Out if necessary to see the tool holder.

Machining a Core
You will create two fixed axis surface contouring operations that use the Area Milling drive
method to machine a core.
The first operation will use None as the Steep containment to mill the entire cut area. It will
leave large scallops on the sides.
The second operation will use Directional Steep as the Steep Containment to cross cut only
the steep areas and remove the large scallops left by the first operation.
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Machining a Core
Opening the Part
Choose Application
Manufacturing.
In the Geometry View of the Operation Navigator, expand the objects as illustrated below.
The WORKPIECE group defines the part geometry that both operations will use.
Machining a Core
the tool path. It may be specified in a geometry group and then inherited or it may be
specified within individual operations. If you do not specify a cut area, the system cuts the
entire Part Geometry.
In this example, you will define the cut area in a geometry group so that subsequent
operations can inherit the same set of cut area parameters.
Choose the Create Geometry icon.

Choose the MILL_AREA icon.
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Choose WORKPIECE as the Parent Group.
OK to begin creating the geometry group.

Turn the Features option on.

Select the surface region as illustrated below.
OK to accept the cut area.

OK to create the MILL_AREA geometry group.
More About Surface Regions
Surface Regions (Tools Prepare Geometry Surface Region) are CAM features that
contain faces on a single solid body or sheet. The ability to select a single entity makes the
specification of Part and Blank geometry very easy. Surface Regions are also easy to identify
and select as features using the Model Navigation Tool.
Surface Regions are associative to the solid. That is, when you modify the solid, the
associated Surface Regions update automatically to match the solid.
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Surface Regions are created by selecting faces of a body. All faces of a Surface Region
Feature must be on the same body. Three methods of defining Surface Regions (Seed, All
Faces, and Selected Faces) are available in the Surface Regions dialog box under Region
Type.
To summarize, the purpose of creating Surface Regions is to organize the areas to be
machined, to make the selection of Part and Blank Geometry easier by enabling you to use the
Surface Region selection method, and to establish associativity with bodies.
Machining the Entire Cut Area

The first operation in this program will machine the entire cut area.

Choose CONTOUR_ZIGZAG as the subtype.
This subtype defines most of the operation parameters you will need to mill the entire cut
area.
The system automatically names the operation CONTOUR_ZIGZAG.
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The operation will inherit the parameters defined by these groups.


Displaying Part Geometry
Choose the Part icon
and Display to highlight the part geometry.
The part geometry is defined by the entire body. This operation inherits the part geometry
from the Workpiece group.

Displaying Cut Area
Choose the Cut Area icon
and Display to highlight the cut area.
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This operation inherits the cut area from the Mill Area group you created.

Specifying None as the Containment
Specifying None as the Steep Containment imposes no steepness restrictions on the tool path
and allows the operation to mill the entire cut area.
Notice that the Drive Method defaults to Area Milling.
The CONTOUR_ZIGZAG subtype that you chose earlier determined this as the default.
Notice that the Steep Containment parameter defaults to None. The CONTOUR_ZIGZAG
subtype you chose earlier determined this as the default.
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Specifying the Cut Angle
Choose User Defined as the Cut Angle.
The Cut Angle dialog displays. The Cut Angle determines the angle of rotation of the cutting
pattern about the ZC axis with respect to the XC axis.
OK to accept 0.0000 degrees as the Cut angle.

Choose Display Cut Direction.
A vector displays indicating the cut angle direction of the zig-zag cutting moves. In this
operation, the tool will zig-zag parallel to the XC axis.
The next operation in the program must have a cut direction defined at 90 degrees to this one
in order to cross cut and remove the scallops remaining on the steep surfaces.
OK to return to the CONTOUR_ZIGZAG dialog.
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You will generate the tool path and observe how the operation mills the entire cut area.

Visualizing the Scallops
Choose the Play Forward option.
Notice the large scallops left on the sides of the part.
You will use Directional Steep in the next section to remove these scallops.
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Machining Steep Areas

The second operation in this program will machine only the steep areas left by the first
operation.

Choose CONTOUR_AREA_DIR_STEEP as the subtype.
This subtype defines most of the operation parameters you will need to mill only the steep
areas.
The system automatically names the operation CONTOUR_AREA_DIR_STEEP.
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Specifying Directional Steep as the Containment
The Directional Steep option will cross cut only the steep areas and remove the scallops left
behind by the first operation. Steep areas are determined relative to the cut direction.
Notice that the Steep Containment parameter defaults to Directional Steep. The
CONTOUR_AREA_DIR_STEEP subtype you chose earlier determined this default.
Choose Directional Steep as the Steep Containment.

Remember the Cut Angle for the previous operation was 0.000 degrees. This operation must
cross cut the steep areas to remove the large scallops. Notice that the Cut Angle for this
operation defaults to 90.0000 degrees.
OK to accept 90 degrees as the cut angle.

The Area Milling Method dialog displays.
A vector displays indicating the direction of the zig-zag cutting moves. In this operation, the
tool will zig-zag parallel to the YC axis.
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The operation will now cut only the areas where the steepness of the tool path is greater than
55 degrees.
OK to accept the parameters in the Area Milling Method dialog.

You will generate the tool path and observe how the operation machines only the steep areas.
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Notice that only the steep areas relative to the cut direction are machined.
By comparing the Area Milling operation that uses Steep Containment set to None with the
operation that uses Steep Containment set to Directional Steep, you can see that the two
operations finish the entire core.
Controlling Scallop Height

You will control the scallop height when using the Follow Periphery cut pattern to machine
steep and non-steep areas.
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By calculating the tool path directly on the part, scallop heights are consistent and both steep
and non-steep surfaces can be effectively machined in the same operation.

Open the Part File
Choose Application
Manufacturing.

You will replay the current Follow Periphery tool path and observe that the stepovers on the
steep areas are very large.
In the Program Order view of the Operation Navigator, choose the CONTOUR_FOLLOW
operation and MB3 Replay.
Currently, the drive path is calculated on the XC-YC plane at the base of the part and then
projected upward onto the part surface. This results in large stepovers relative to the part
surface on the steep areas.
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You will display the scallops using dynamic material removal.
Highlight CONTOUR_FOLLOW.

Notice the large scallops on the steep areas.
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You will control the scallop height by calculating the tool path, including the stepovers,
directly on the part.
Double-click on the CONTOUR_FOLLOW operation icon to edit the operation.
Choose Area Milling.
The Apply option is currently set to On Plane. This causes the drive path to be calculated on
XM-YM plane and then projected onto the part surface. The On Part option calculates the tool
path directly on the part.
Set the Apply option to On Part.
This option is only available for the Follow Periphery cut pattern.
OK to accept it.

You will generate the tool path and observe how the stepover is now consistent.
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Use Verify Toolpath as you did before to display dynamic material removal.
Notice the scallop height is now consistent.

Machining a Cavity
You will create four fixed axis surface contouring operations that use the Area Milling drive
method to semi-finish and finish a cavity.
The program begins with a Cavity Mill operation, ZLEVEL_FOLLOW_CAVITY, that
roughs out the cavity.
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The first operation you create, CONTOUR_FOLLOW, will semi-finish the bottom of the
cavity.
The second operation you create, CONTOUR_FOLLOW_1, will semi-finish the entire cavity.
The third operation you create, CONTOUR_ZIGZAG, will use None as the Steep
Containment to finish the entire cavity.
The fourth operation you create, CONTOUR_AREA_DIR_STEEP, will use Directional Steep
as the Steep Containment to cross cut only the steep areas and remove the scallops.
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Machining a Cavity
Opening the Part
Choose Application
Manufacturing.
Machining a Cavity
Examining the WORKPIECE Group
The WORKPIECE group defines the part and blank geometry.
Expand the objects in the Geometry View of the Operation Navigator.
The ZLEVEL_FOLLOW_CAVITY operation inherits parameters from the WORKPIECE
and MCS_MILL groups.
Highlight the WORKPIECE group.
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Choose the Display Object icon
in the toolbar.
The part and blank geometry highlight.
Machining a Cavity
Visualizing the Cavity Mill Operation
You will use Verify Toolpath to graphically simulate material removal for the existing Cavity
Mill operation.
Highlight the ZLEVEL_FOLLOW_CAVITY operation.

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Semi-Finishing the Bottom of the Cavity

You will create a new operation and use the Area Mill Drive Method to semi-finish the
bottom of the cavity.

Choose CONTOUR_FOLLOW as the subtype.
This subtype defines most of the operation parameters you will need to mill the cut area.
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the tool path. For this operation, you will select the face at the bottom of the cavity.
Select the face at the bottom of the cavity as illustrated below.
OK to accept the face.
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Specifying the Stepover
This operation uses a fairly large tool to semi-finish the bottom of the cavity. You will need to
decrease the stepover.
Key in 15.0 for the Stepover Percent.
OK to accept the stepover.

You will generate the tool path and observe how the operation machines the cut area at the
bottom of the cavity.
Notice that the tool path does not cover the entire cut area. Part of the cut area is left uncut
because the tool movement is limited by the sides of the cavity.
Choose the Edit Display icon under Tool Path and choose 3-D for the Tool Display.
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OK to accept the tool display.
Change to a Front view and Replay the tool path.
The tool comes close to the sides of the cavity, but does not gouge the part. The operation
machines as much of the cut area as possible without violating the part geometry.
The distance between the tool and the part is defined by the Part Stock in the
MILL_SEMI_FINISH Method group. This is the material that is left for the finishing
operations to remove.
Change to a TFR-ISO view.
Semi-Finishing the Entire Cavity

This operation will use the Area Mill Drive Method to semi-finish the entire cavity. By using
a smaller tool and a smaller stepover, large scallops will be removed and the entire bottom of
the cavity will be semi-finished.
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Choose CONTOUR_FOLLOW as the subtype.
This subtype defines most of the operation parameters you will need.

If you do not explicitly define the cut area in the operation or in a geometry group, the system
uses the entire defined Part Geometry (excluding areas not accessible by the tool) as the cut
area. In other words, the system uses the silhouette of the part as the cut area.
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Cut Areas require additional processing time when generating a tool path. It is therefore a
good idea to not define a cut area unless it is necessary.
For this operation, you will not define the cut area.

You will need to decrease the stepover to produce smaller scallops.
The Area Milling Method dialog displays.

OK to accept the stepover.

You will generate the tool path and observe how the operation machines the entire cavity.
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Notice that the tool rolls over the outer edge of the part. This occurs as a result of edge
tracing. In this case, because a cut area was not defined, edge tracing cannot be removed by
simply turning on the Remove Edge Traces option.
Choose Cutting.
Note that the Part Stock is set at 0.25 mm and the part tolerance is set at +/- 0.03. These
values were determined when the MILL_SEMI_FINISH method was chosen.
Turn the Remove Edge Traces option on and OK to accept it.

The edge traces remain. In cases like this where edge tracing occurs because a cut area has not
been specified, you must use a Trim boundary to remove the edge tracing.

You will define a Trim boundary in a Mill Area geometry group. By doing this, you will
define the boundary just once and then apply it to as many operations as needed.
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Choose the MILL_AREA icon and WORKPIECE as the Parent group.
OK to begin creating the geometry group.

Choose the Trim icon and Select.
ChooseOutside as the Trim Side.

This will insure that the tool path is created inside of the boundary and will exclude all areas
outside of the boundary.
With the Face Boundary icon
chosen, select the bottom face of the part.

OK to create the MILL_AREA geometry group.
This geometry group contains the Trim boundary and can be used as a parent to as many
operations as needed.
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Applying the Trim Boundary
You will now make the MILL_AREA geometry group a parent of the
CONTOUR_FOLLOW_1 operation so that the Trim boundary is applied to the operation.
In the Geometry view of the Operation Navigator, double-click on the
CONTOUR_FOLLOW_1 to display the CONTOUR_FOLLOW dialog.
Choose the Geometry tab.

Turn the Geometry option on and choose Reselect.
Choose MILL_AREA in the Reselect Geometry dialog and OK.

The Geometry view of the Operation Navigator now shows the MILL_AREA group as a
parent of the CONTOUR_FOLLOW_1 operation.
This operation will now inherit the parameters defined in the MCS_MILL, WORKPIECE,
and the MILL_AREA groups.
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You will generate the tool path and observe how the operation no longer generates edge
tracing.
In the Operation Navigator, highlight CONTOUR_FOLLOW_1 and MB3
Generate
Notice that the tool path no longer rolls over the outer edge of the part.
The remaining operations you create will also require the Trim boundary defined in the
MILL_AREA group.
OK the tool path Generation dialog.
Finishing the Entire Cavity

This operation will use the Area Mill Drive Method to finish the entire cavity with a zig-zag
cut pattern.
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Choose CONTOUR_ZIGZAG as the subtype.

Notice that the Steep Containment parameter defaults to None. The CONTOUR_ZIGZAG
subtype you chose earlier determined this option as the default.

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The Cut Angle determines the angle of rotation of the cutting pattern about the ZC axis with
respect to the XC axis.
Choose User Defined as the Cut Angle.
OK to accept 0.0000 degrees as the Cut angle.

A vector displays indicating the direction of the zig-zag cutting moves. In this operation, the
tool will zig-zag parallel to the XC axis.
The next operation must have a cut direction defined at 90 degrees to this one in order to
remove the scallops left on the steep surfaces.

OK to return to the CONTOUR_ZIGZAG dialog.

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You will generate the tool path and observe how the operation finishes the entire cavity.
Finishing the Steep Areas

This operation will use Directional Steep as the Steep Containment to cross cut only the steep
areas and remove the scallops.

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Choose CONTOUR_AREA_DIR_STEEP as the subtype.

Specifying Directional Steep as the Containment
The Directional Steep option will allow you to cross cut only the steep areas. Steep areas are
determined in relation to the cut direction.
Notice that the Steep Containment defaults to Directional Steep.
Choose Directional Steep as the Steep Containment.
Remember that the Cut Angle for the previous operation was 0.000 degrees. This operation
must cross cut the steep areas to remove the large scallops. Notice that the Cut Angle defaults
to 90.0000 degrees.
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OK to accept the cut angle.

Key in 60 degrees for the Steep Angle.
The operation will only cut areas where the steepness of the tool path is greater than 60
degrees.

OK to accept the parameters in the Area Milling Method dialog.
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You will generate the tool path and observe how the operation finishes the steep areas

You will use Verify Toolpath to graphically simulate material removal for the entire program.
In the Program Order View of the Operation Navigator, highlight PROGRAM.
This chooses all of the operations in the program.

Choose the Verify Toolpath icon in the toolbar
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The material removed by each successive operation displays in a contrasting color.

Comparing to the Original Model
You can compare the machined part to the original model. White areas, if any, indicate the
areas where further finishing is required to machine to the specified Outtol.
Choose Compare.
OK to dismiss the Toolpath Visualization dialog.


The Show Excess function allows you to display areas where excess material remains due to
large scallops and inaccessibility of the tool. This function is useful in determining how much
material remains for subsequent operations to remove and for comparing the finished
machined part to the modeled part.
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You will first use the Show 3D option to create a faceted model of the uncut material that
remains after generating a specific operation or sequence of operations.
You will then use the Show Excess option to compare the faceted model to the specified
Excess Material. Excess Material is an offset value that defines the allowable material
measured from the part. Areas of the faceted model that exceed this offset are graphically
displayed as excess material when you choose Show Excess.

Opening the Part
Choose Application
Manufacturing.
to display the part as a shaded solid.

Changing Object Color Preference
You should display the faceted model in a color that contrasts the part.
Choose Preferences
Object from the menu bar.
Choose Orange (or a similar color) and OK to accept it.
OK to accept the Object Preferences.
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Creating a Roughing Faceted Model
You will use a roughing operation to create a faceted model representing the uncut material.
In the Program Order View, highlight the ZLEVEL_FOLLOW_CAVITY icon.

Choose the Static tab.
Choose Create to create the faceted model.

The faceted model displays in orange and represents graphically the uncut material that
remains after generating the ZLEVEL_FOLLOW_CAVITY operation.
The faceted model was created from a roughing operation that uses a 0.1200 mm Outtol and a
1.0000 mm Part Stock. Therefore, any uncut material within a 1.1200 mm offset of the part is
allowed by the operation. Any uncut material beyond the 1.1200 mm offset is excess material.
Choose Delete to remove the currently displayed faceted model.

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In the Toolpath Visualization dialog, choose Excess and key in 1.1200 for the Excess
Material.
Choose Create.
The excess material graphically represents the uncut material outside of the specified 1.1200
mm Excess Material offset. This is the material that must be removed by subsequent
operations in the program.
The color of the Excess Material is determined under Preferences

Visualize in the menu bar.
Manufacturing
The thickness of the excess material can determine whether or not the subsequent operations
are appropriate. If it is too thick, additional roughing operations may need to be added.
Choose Delete to remove the displayed excess material.

Determining Excess Material Thickness
You can get an idea of the thickness of the excess material by increasing the specified Excess
Material value. Any excess material that continues to display is thicker than the specified
increase.
Key in 1.5200 for the Excess Material.
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This increases the Excess Material value by 0.4000 mm.

Choose Create.
Excess material continues to display, although there is now less of it. The displayed excess
material is thicker than 0.4000 mm.
Choose Delete to remove the currently displayed excess material.

Creating a Finishing Faceted Model
You will use the two finishing operations to create a faceted model representing the finished
machined part. You will then compare the finished machined part to the modeled part to
determine whether or not the finish meets the design specifications.
Choose Preferences
Object from the menu bar.
Choose Red (or a similar color) and OK to accept it.

This is the color in which the faceted model will display.
OK to accept the Object Preferences.
In the Program Order View of the Operation Navigator, highlight CONTOUR_ZIGZAG
and CONTOUR_AREA_DIR_STEEP. You will need to use the Ctrl key to select the
second operation.
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The faceted model displays in red. It graphically represents the uncut material that remains
after finishing the part.
The finishing operations use a 0.0300 mm Outtol and a 0.0300 mm Intol. Any uncut material
within 0.0300 mm offset of the part is allowed by the program. Any uncut material outside of
the 0.0300 mm offset is excess material.

Material.
Choose Create.
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Notice that there is quite a bit of excess material remaining on the finished part. You can
reduce the amount of excess material by reducing the stepover to create smaller scallops and
also by changing the part Intol and Outtol smaller values. Making these values smaller will
increase the size of the calculated tool path and also increase the time required for its
calculation.
Choose Delete to remove the currently displayed excess material.

Modifying the Operations
You will decrease the stepover in the two operations to finish the part more accurately.
CONTOUR_ZIGZAG icon.
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Repeat these steps for the CONTOUR_AREA_DIR_STEEP operation.

Creating a Finishing Faceted Model
You will create a new faceted model representing the machined part with the smaller finishing
stepovers.
In the Program Order View of the Operation Navigator, highlight CONTOUR_ZIGZAG
and CONTOUR_AREA_DIR_STEEP.

The faceted model displays in red.
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Material.
This accounts for the Outtol in the finishing operations.

Choose Create.
Notice that there is less excess material remaining on the finished part.
Flow Cut Drive Method

The Flow Cut drive method generates fixed axis surface contouring tool paths that machine
concave corners and valleys formed by part surfaces. The system determines where to apply
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flow cutting based on bi-tangency contact points and the angle between part surfaces. You can
create single pass or multiple pass operations.
The resulting tool path is optimized in such a way that the tool remains in contact with the
part as much as possible and minimizes non-cutting moves.
The Flow Cut drive method, like the Area Milling drive method, allows you to define a
simple tool holder to ensure a collision free tool path.
It is recommended that only Ball Nose tools be used in flow cut operations. Unsatisfactory
results in the tool path can occur if Bull Nose or Flat Nose tools are used.
In this lesson, you will create Single Pass, Multiple Pass, and Reference Tool Flow Cut
operations.
Machining a Cavity
In this section, you will examine the geometry groups and the sequence of operations. You
will observe how the rough, semi-finish, and finish operations inherit parameters and work in
sequence to machine the entire cavity.
Machining a Cavity
Opening the Part
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Open part file srf_flow_cut_1.prt from the srf subdirectory.

Notice the concave corners and valleys formed between part surfaces. These are the areas the
system will recognize when determining flow cuts.
Choose the Invisible Hidden Edges icon

Choose Application
to display a wireframe.
Manufacturing.
Machining a Cavity
Examining the WORKPIECE Group
The WORKPIECE group defines the part geometry used by all of the operations.
In the Geometry View of the Operation Navigator, fully expand the objects and doubleclick on the WORKPIECE icon to edit the group.
Choose the Part icon and Display.
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Cancel out of the MILL_GEOM dialog.
Machining a Cavity
Examining the MILL_AREA Group
The MILL_AREA group defines the cut area used by the CONTOUR_AREA_NON_STEEP,
CONTOUR_FOLLOW, ZLEVEL_PROFILE_STEEP, and FLOWCUT_SINGLE operations.
Double-click on the MILL_AREA icon to edit the group.
Choose the Cut Area icon and Display.
The cut area geometry highlights.
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Cancel out of the MILL_AREA dialog.
Machining a Cavity
Visualizing Material Removal for the Program
You will graphically simulate material removal for the program.
In the Program Order View of the Operation Navigator, fully expand the objects.
Notice the sequence of operations. The ZLEVEL_FOLLOW_CAVITY operation first roughs
out the cavity. The CONTOUR_AREA_NON_STEEP and ZLEVEL_PROFILE_STEEP
operations then semi-finish the cavity. The CONTOUR_FOLLOW and FLOWCUT_SINGLE
operations finish the cavity.
Highlight the PROGRAM group.
in the toolbar.

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In the following section, you will create a Single Pass Flow Cut operation similar to the one in
this program.
Creating a Single Pass Flow Cut Operation

You will create a Single Pass Flow Cut operation that finishes the concave corners and valleys
formed by the part surfaces.

Opening the Part
Choose Application
Manufacturing.
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available to choose from in the dialog.
You can use any one of the subtypes outlined below to create a flow cut operation.
Choose FLOWCUT_SINGLE as the subtype.
This subtype defines most of the operation parameters you will need to create a Single Pass
Flow Cut operation.
The system automatically names the operation FLOWCUT_SINGLE.
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Displaying the Cut Area
Choose the Cut Area icon and Display.
Notice that the Select/Reselect option is blanked for defining the cut area. The cut area cannot
be defined within the operation because it is inherited from the MILL_AREA group.
The cut area has been defined as all the interior faces of the cavity.

You will observe how the operation generates the tool path along corners and valleys formed
between part surfaces.
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Removing Short Tool Path Segments
Minimum Cut Length enables you to eliminate short cutting moves that may occur in isolated
areas of the part.
You will eliminate the short cutting moves that occur at the intersection of the fillets.
Choose the More tab.

Key in 0.8000 for the Min. Cut Length.
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Cutting moves shorter than 0.8000 will not be generated.

Reject the previous tool path and Generate a new one.

Restricting the Maximum Concavity
Maximum Concavity enables you to determine where flow cuts are created based on the angle
of concave corners and valleys formed by part surfaces. Flow cuts are created where the angle
between surfaces is less than or equal to the specified Maximum Concavity angle.
The Maximum Concavity is currently specified as 179.0000 degrees. Because of this, the tool
does not cut across the top of the part where the angle between surfaces is very flat. The angle
between the surfaces in this area exceeds 179.000 degrees, so the tool retracts.
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Watch what happens when you restrict the Maximum Concavity.

Key in 100 for the Maximum Concavity.

Notice that some of the flow cuts have been eliminated. The angles formed between part
surfaces in these areas exceeds the Maximum Concavity of 100.0000 degrees. The areas of
the cylindrical intersections that have a concavity less that 120 are not cut because the length
of the cut is less than 0.80.

Increasing the Maximum Concavity
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You will now increase the Maximum Concavity so that the tool cuts as much of the flat area
on the top of the part as possible. The value you enter must be positive and must be less than
or equal to 179.0000 degrees.
Key in 179 for the Maximum Concavity.

Flow cuts are created where the angles formed between adjacent part surfaces are less than or
equal to the 179.000 degrees.
A closer look reveals that the tool path still does not cut all the way across the top of the part.
This is an area where the angle between part surfaces is very large (between 179 and 180
degrees) and is nearly flat.
You cannot specify a Maximum Concavity greater than 179.0000 degrees. You can, however,
increase the Hookup Distance to eliminate unwanted gaps in the tool path.
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Eliminating Unwanted Gaps in the Tool Path
Hookup Distance enables you to eliminate small discontinuities or unwanted gaps in the tool
path. These discontinuities occur where the tool retracts from the part and are sometimes
caused by gaps between surfaces or variations in the angle of concavity that exceed the
specified Maximum Concavity angle.
The value you enter determines the distance the tool will span to connect the end points of
cutting moves. The system will connect the two ends by linearly extending the two paths and
will not gouge the part.
Key in 0.2500 for the Hookup Distance.

The tool no longer retracts and now continues cutting across the top of the part.

Flow Cutting Along the Fillets
As stated earlier, the system determines where to apply flow cutting based on bi-tangency
contact points. To generate a flow cut, the tool must contact two part surfaces at two distinct
points. Single pass flow cutting will not occur in areas where the curvature of the surface is
larger than the corner radius of the tool as illustrated below. It will occur, however, in areas
where the curvature of the surface is equal to or less than the corner radius of the tool,
allowing bi-tangency contact points.
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In your part, the fillet that surrounds the cavity on three sides has a radius of 0.5000 inch. The
tool you have been using (MILL_2) has a diameter of only 0.2000 inch. This is why flow
cutting has not occurred along the fillet.
You will change to a larger tool and observe how flow cutting is generated along the fillets as
a result bi-tangency contact points between two surfaces.
Choose Tool: MILL_2 and Reselect.
Choose MILL_3 in the Reselect Tool dialog and OK.

MILL_3 is a 1.0000 inch diameter ball end mill. Because this tool has the same radius as the
fillet, it contacts the surfaces on both sides of the fillet.
Notice that flow cutting now occurs along the fillets.
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Creating a Multiple Pass Flow Cut Operation

You will create a Multiple Pass Flow Cut operation to finish the concave corners and valleys
formed by the part surfaces.

Opening the Part
Open part file srf_flow_cut_2.prt from the srf subdirectory again. This is the same part
you used for creating the single pass operation.
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Choose Application
Manufacturing.

Choose the Create Operation icon in the CAM Create toolbar.
Choose FLOWCUT_MULTIPLE as the subtype.
This subtype defines most of the operation parameters you will need to create a Multiple Pass
Flow Cut operation.
The system automatically names the operation FLOWCUT_MULTIPLE.

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You will use the default operation parameters to generate the multiple pass tool path.
You will now make some changes to improve the tool path.

You will eliminate the short cutting moves at the intersections of the fillets as you did
previously for the single pass operation.
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Key in 0.8000 for the Minimum Cut Length.
Choose the Main tab

Specifying the Cut Sequence
Sequencing enables you to determine the order in which the multiple Zig or Zig-Zag cut
passes are executed.
Inside-Out causes the cutter to start at the center pass and move toward one of the outside
passes. The tool then moves back to the center cut and works its way toward the other side.
Outside-In does just the opposite.
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Unidirection causes the cutter to move from one outside cut to the other, traversing through
the center.
Be sure Inside-Out is specified for the Sequencing.

Specifying the Number of Offsets
Number of Offsets enables you to determine the number of passes to generate on each side of
the center flow cut.
Key in 4 for the Number of Offsets.

Specifying the Cut Direction
While a Mixed cut direction will provide the least amount of tool motion, it is frequently
desirable to cut from high to low. Cutting from High to Low tends to keep the tool forced into
the tool holder.
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Set the Cut Direction to High to Low.

You will generate the tool path and observe how the short cutting moves have been
eliminated.
Notice that the short cutting moves at the intersections of the fillets have been eliminated.

In the Program Order view of the Operation Navigator, highlight PROGRAM.
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Choose the Verify Toolpath icon on the CAM toolbar.


Creating a Reference Tool Flow Cut Operation

You will create a Reference Tool Flow Cut operation that uses multiple passes to finish the
concave corners and valleys formed by the part surfaces.
Reference Tool Diameter enables you to specify the width of the finishing cut region based on
the diameter of the roughing (reference) tool. The reference tool is typically the tool used to
previously rough out the area. The system calculates the bi-tangency contact points from the
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specified Reference Tool Diameter and then uses these points to define the cut region for the
finishing operation.
1.
2.
3.
4.
Reference Tool Diameter

Finishing Tool
Bi-Tangency Contact Pts. of Reference Tool
Cut Region Defined by Contact Pts. of Reference Tool
Because the reference tool determines the bi-tangency contact points rather than the actual
cutting tool, this type of flow cut operation can finish large fillets using multiple passes of a
small tool.

Opening the Part
Choose Application
Manufacturing.

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Choose FLOWCUT_REF_TOOL as the subtype.
This subtype defines most of the operation parameters you will need to create a Reference
Tool Flow Cut operation.
The system automatically names the operation FLOWCUT_REF_TOOL.


You will eliminate the short cutting moves that occur at the intersection of the fillets as you
did for the single and multiple pass operations.
Key in 0.8000 for the Minimum Cut Length.
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Specifying the Reference Tool Diameter

The system calculates the bi-tangency contact points from the specified Reference Tool
Diameter and then uses these points to define the cut region for the finishing operation. You
must key in a diameter for the reference tool that is larger than that of the current tool in use.
The current tool in use (MILL_2) has a diameter of 0.2000.
Key in 1.0 for the Reference Tool Diameter. You might need to scroll down in the dialog
to see this option.
Because the reference tool has the same radius as the fillet (.5000), it contacts the surfaces on
each side of the fillet, establishing the necessary bi-tangency contact points.
Overlap Distance enables you to extend the width of the area defined by the Reference Tool
Diameter along the tangent surfaces.

You will generate the tool path and observe how the concave corners, valleys, and fillets are
finished with multiple passes.

505

Highlight the PROGRAM group.


Radial Cut Drive Method

The Radial Cut drive method generates a fixed axis surface contouring tool path normal to
and along a boundary.
506
Radial cuts allow hand finishing of concave corners and valleys across scallops rather than
along scallops. It is often used as a follow-up to flow cutting.
In this lesson, you will create a fixed axis surface contouring operation that uses the Radial
Cut drive method to finish the concave corner the part.
Creating a Radial Cut Operation

You will create a fixed axis surface contouring operation that uses the Radial Cut drive
method. You will then Animate the program to graphically simulate material removal.
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Opening the Part

Open part file srf_radial_1.prt from the srf subdirectory.
Choose Application
Manufacturing.

in the toolbar.

Choose FIXED_CONTOUR as the subtype.
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The WORKPIECE geometry group defines the part geometry and the blank geometry. Blank
geometry is required by the Verify function to graphically simulate material removal.

Defining the Drive Method
The Radial Cut drive method allows you to define a tool path normal to and along a boundary.
Choose Radial Cut under Drive method.
A Warning dialog is displayed, cautioning you that previously defined drive parameters will
be deleted.
OK the warning.

Defining the Drive Geometry
Drive geometry allows you to define the boundaries along which the tool will zig or zig-zag.
Choose Select under Drive Geometry.
Choose Open as the Type.
Select the five edges in sequence as illustrated below.
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Specifying a Tool Diameter Percent Stepover
Stepover allows you to specify the distances between successive cutting passes. The stepover
is a straight line distance measured either at the widest point between successive passes (A-B)
or at the boundary intersection (C-D), depending on the Stepover method used.
The % of Tool option allows you to define the stepover in terms of a percentage the effective
tool diameter. This distance is measured at the boundary (between points C and D).
Turn the Stepover option on.
% of Tool should already be specified as the Stepover.
Key in 20 for the Percent.
OK to complete the drive geometry.

A single temporary boundary is created.
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If multiple boundaries are defined, a lift is applied allowing the tool to traverse from one
boundary to the next.
OK to complete the Radial Cut drive method.

You will generate the tool path and observe how the tool path zig-zags along the boundary.
Notice how far apart the stepovers are at the corners. You may control this by specifying a
maximum stepover value.
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Specifying a Maximum Stepover
The Maximum option requires you to key in a value defining the Maximum allowable
distance between Stepovers. This value is applied at the widest point of the cut pass (between
points A and B).
Choose Radial Cut under Drive method.

Choose Maximum as the Stepover.
Key in .05 for the Value.
OK to complete the Radial Cut Drive Method.

You will generate the tool path and observe how the modified Stepover effects the tool path.
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Notice how the tool path crosses over itself at the corners and how it cuts all the way to the
outside edge of the part. This can be corrected by adjusting the Bandwidth.

Modifying the Bandwidth
Bandwidth defines the total width of the machined area measured in the plane of the
boundary. The bandwidth is the sum of the Material Side and Opposite Side offset values.
1. Band Width
2. Opposite Side
3. Material Side
Choose Radial Cut under Drive Method.
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Key in .25 for Material Side and .74 for Opposite Side.
OK to complete the Radial Cut Drive Method.

You will generate the tool path and observe how the modified Bandwidth effects the tool
path.
The tool path no longer crosses over itself at the corners and no longer cuts all the way to the
outside edge of the part.

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In the Program Order View of the Operation Navigator, highlight the PROGRAM icon.


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Curve/Point Drive Method

The Curve/Point drive method generates a fixed axis surface contouring tool path that follows
selected points and curves. This drive method is sometimes used for engraving on contoured
surfaces.
The drive path is generated from points and curves and projected onto the part surfaces where
the tool path is created. The curves may be open or closed, contiguous or noncontiguous,
planar or nonplanar.
In this lesson, you will create a fixed axis surface contouring operation that uses the
Curve/Point drive method.
Creating a Curve/Point Operation

You will create a fixed axis surface contouring operation that uses the Curve/Point drive
method to engrave the number "1471" on the part. You will then animate the program to
graphically simulate material removal.
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Opening the Part
Open part file srf_curve_1.prt from the srf subdirectory.
Choose Application
Manufacturing.

in the toolbar.

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The WORKPIECE geometry group defines the part geometry and the blank geometry. Blank
geometry is required by the Verify function to graphically simulate material removal.
Key in engrave for the operation name.

The Curve/Point drive method allows you to define a tool path that follows curves projected
onto contoured surfaces.
Choose Curve/Point under Drive method.
OK the warning.
The Curve/Point Drive Method dialog displays.

The Drive Geometry options allow you to select and edit points and curves that will be used
to define the tool path. They also allow you to specify parameters such as feed rates, lifts, and
cut direction.
Drive geometry is projected onto part surfaces along the projection vector.
1. Drive Curves
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2. Projection Direction
3. Tool Path
4. Part Surface

The order in which the curves are selected determines the sequence in which they are cut. The
proximity in which each curve is selected determines the cut direction. The selected end of the
curve defines the start point of the cut for that curve.
1. Selected End of Curve
2. Cut Direction of Tool

Selecting the First Curve
The tool should retract at the end of the first curve (the first "1" in 1471) and engage at
beginning of the second curve.
Turn the Local Lift at End option on.
Select the first curve at the upper end as illustrated below.
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A vector indicates the cut direction.

Selecting the Second Curve
The tool should not retract at the end of the second curve, but should cut continuously to the
end of the third curve.
Turn the Local Lift at End option off.
Select the second curve at the upper end so the cut direction vector displays as illustrated
below.
You may choose Back at any time to deselect the curves one at a time if you make a mistake.
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Selecting the Third Curve
The tool should retract at the end of the third curve and engage at beginning of the fourth
curve.
Turn the Local Lift at End option on.
Select the third curve so the vector displays as illustrated below.

Selecting the Fourth Thru Seventh Curves
The tool should retract at the end of the fourth curve and engage at beginning of the fifth
curve.
Local Lift at End should remain turned on.
Select the fourth curve so the vector displays as illustrated below.
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The tool should not retract at the end of the fifth curve, but should cut continuously to the end
of the sixth curve.
Turn the Local Lift at End option off.
Select the fifth curve so the vector displays as illustrated below.
Turn the Local Lift at End option on and select the sixth and seventh curves.

Selecting the Last Four Curves
The tool should cut the last four curves continuously.
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Turn the Local Lift at End option off and select curves eight through eleven at the
positions indicated below so they are cut in a counterclockwise direction.
OK to complete the selections.

Defining the Projection Vector
The projection vector determines how the drive path projects from the drive geometry to the
part surface.
Choose Display Drive Path.
Choose Tool Axis for the Projection Vector.
OK to complete the Curve/Point drive method.
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Specifying a Negative Part Stock
A negative stock allows you to cut below the part surface, creating a groove.
Choose Cutting.
Key in -.035 for the Part Stock.
This value is the same as the radius of the tool.

OK to accept the Part Stock
Defining Non-Cutting Moves

Non-Cutting moves allow you to specify movements that position the tool before, after, and
between cutting moves.
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This section describes the non-cutting moves that apply to this particular operation. Refer to
the non-cutting moves lesson at the end of this course for a complete discussion.

Choose Non-Cutting.
You will first define non-cutting moves for engages. You will then define non-cutting moves
for retracts by specifying that they will use the same non-cutting moves as defined for
engages.

Defining Engages
Choose the Engage icon.
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The Case options determine whether the motion parameters will apply to all engages or only
to specific types of engages. By specifying Default as the Case, all types of engages will use
the same motion parameters.
Be sure the Case is specified as Default.
The Status option determines the available motion parameters. For this operation, all engages
will move a specified distance to the part along the tool axis.
Be sure the Status is specified as Manual.
The Distance option determines the length of the engage.

Turn the Distance option on and key in 0.25 .
The Movement options determine the shape of the engage.

Choose Linear for the Movement.
The Direction options determine the orientation of the engage.

Choose Tool Axis for the direction.
Here is how you would read the Non-Cutting Moves dialog; "Unless otherwise specified, all
engages will move .25 inches in a linear direction defined by the orientation of the current
tool axis".
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Next, you will define retracts by specifying that they will use the same motion parameters as
defined for engages.

Defining Retracts
Choose the Retract icon.
Notice that the Case is set to Default and the Status is set to Use Engage. All retracts (by
default) will use the same parameters as defined for engages. In other words, all retracts (by
default) will move from the part to the clearance plane in a linear path along the tool axis.

Defining Departures and Approaches
In this example, Approach and Departure moves are not necessary.
Choose the Departure icon.
Choose None for the Departure Status.
Choose the Approach icon.
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Choose None for the Approach Status.

OK to accept the Non-Cutting Moves.

You will generate the tool path and observe how the tool path follows the drive geometry and
incorporates the specified local lifts.

Blanking the Drive Geometry
You will blank the drive geometry so you can clearly observe the dynamic material removal.
In the tool bar, choose Edit
Blank
Blank.
Set the Rectangle/Polygon Method to Inside and drag a rectangle around the drive
geometry.
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OK to accept the selection and blank the drive geometry.

In the Program Order View of the Operation Navigator, highlight the PROGRAM icon.

in the toolbar.
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Spiral Drive Method

The Spiral drive method generates a fixed axis surface contouring tool path that spirals
outward from a specified center point.
Unlike other drive methods which require an abrupt change in direction to Stepover to the
next cutting pass, the Spiral drive method Stepovers are a smooth, constant transition
outward. Because this drive method maintains a constant cutting speed and smooth motion, it
is useful for high speed machining applications.
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In this lesson, you will create a fixed axis surface contouring operation that uses the Spiral
drive method to finish the part. You will then Animate the operation to graphically simulate
material removal.
Creating a Spiral Drive Operation

You will create a fixed axis surface contouring operation that uses the Spiral drive method to
finish the part. You will then Animate to graphically simulate material removal.

Open part file srf_spiral_1.prt from the srf subdirectory.
Choose Application
Manufacturing.
in the toolbar.

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The WORKPIECE geometry group defines the blank geometry required by the Verify
function to graphically simulate material removal.
Key in spiral for the operation name.

The WORKPIECE group does not currently define the part geometry. You will define the part
geometry within the operation.
and Select.
Select the body as illustrated below.
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OK to accept the body as the part geometry.

The Spiral drive method allows you to define a tool path that spirals outward from a specified
center point.
Choose Spiral under Drive method.
OK the warning.
The Spiral Drive Method dialog is displayed.

Defining the Center Point
The center point defines the center of the spiral and it is where the tool begins cutting. If you
do not specify a center point, the system uses 0,0,0 of the Absolute Coordinate System. If the
center point is not directly on the part surface, the point follows the projection vector to the
part surface.
Choose Select under Spiral Center Point.
Choose the Arc/Ellipse/Sphere Center icon.
Select the arc on top of the part as illustrated below.
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Defining the Stepover
Stepover allows you to specify the distances between successive cut passes.
Spiral drive method stepovers are a smooth, constant transition outward and do not require an
abrupt change of direction.
Tool Diameter allows you to define the stepover in terms of a percentage of the effective tool
diameter.
Choose Tool Diameter as the Stepover.
Key in 20 for the Percent.
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Defining the Maximum Spiral Radius
Maximum Spiral Radius allows you to limit the area to be machined. This constraint reduces
processing time by limiting the number of drive points created. The radius is measured in the
plane normal to the projection vector.
1. Maximum Spiral Radius
2. Part Surface
Key in 8.25 for the Max(imum) Spiral Radius.
This value is the same as the radius of the part.

The projection vector determines how the drive path projects from the plane of the center
point to the part surface. The drive path you are using is much more dense than the one shown
below.
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Choose Specify Vector.
The Vector Constructor dialog displays and the current projection vector displays on the part.
OK to accept this projection vector.
OK to complete the Spiral drive method.

You will generate the tool path and observe how the tool path spirals outward from a
specified center point.
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Visualizing Material Removal for the Operation
You will graphically simulate material removal for the operation.
In the Program Order View of the Operation Navigator, highlight the SPIRAL operation.

in the toolbar.
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Surface Area Drive Method

The Surface Area drive method creates a wide variety of fixed and variable tool axis
operations. Variable axis operations generate tool paths that can follow the contours of very
complex surfaces by providing control of both the tool axis and the projection vector.
The Surface Area drive method creates an array of drive points on the drive surface and then
projects them to the part surface along a specified projection vector. The tool path is created
as the tool moves across the part surface from one contact point to the next. A tool path may
also be created directly on the drive surface when there is no part geometry defined.
In this lesson, you will create variable axis surface contouring operations using the Surface
Area drive method and a variety of tool axis controls.
Examining a Program
You will first examine a program consisting of operations that rough and semi-finish a part.
You will then add a variable axis surface contouring operation that finishes the contoured
surfaces.
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Examining a Program
Opening the Part
Open part file srf_srf_area_1.prt from the srf subdirectory.
Choose the Wireframe icon
to return to a wireframe display.
Examining a Program
Choose Application
Manufacturing.
In the Geometry View of the Operation Navigator, fully expand the objects as illustrated
below.
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These operations rough and semi-finish the part. They inherit parameters from the MCS and
WORKPIECE groups.
Examining a Program
Examining the Workpiece Group
The WORKPIECE group defines the part geometry.
Highlight WORKPIECE.
Choose the Display Object icon.

Examining a Program
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Animating the Program

You will animate the program to display material removal for the roughing and semi-finishing
operations.
In the Program Order View of the Operation Navigator, highlight PROGRAM.

in the toolbar.

Temporary blank geometry must be defined for the system to display dynamic material
removal. Auto Block creates a solid body aligned with the MCS and enclosing the part
geometry. Offset from Part defines blank geometry based on a specified offset distance.
OK to accept Auto Block and the default values of 0.0000.
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Away From Line Tool Axis

You will create a variable axis surface contouring operation that uses the Surface Area drive
method and the Away From Line tool axis to finish the contoured surfaces.
Away From Line defines a tool axis that diverges away from a focal line, allowing the axis to
follow the general convex shape of the part geometry while not undulating excessively.

Choose mill_multi-axis as the Type.
Choose VARIABLE_CONTOUR as the subtype.
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This option is the most generic of the multi-axis subtypes and will allow you to create a wide
variety of operations.
The system automatically names the operation VARIABLE_CONTOUR.


This operation does not inherit part geometry from the WORKPIECE group. You will define
the part geometry within the operation.
and Select.
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More About Surface Regions
Surface Regions (Tools Prepare Geometry Surface Region) are CAM features that
contain faces on a single solid body or sheet. The ability to select a single entity makes the
specification of Part and Blank geometry very easy. Surface Regions are also easy to identify
and select as features using the Model Navigation Tool.
Surface Regions are associative to the solid. That is, when you modify the solid, the
associated Surface Regions update automatically to match the solid.
Surface Regions are created by selecting faces of a body. All faces of a Surface Region
Feature must be on the same body. Three methods of defining Surface Regions (Seed, All
Faces, and Selected Faces) are available in the Surface Regions dialog box under Region
Type.
To summarize, the purpose of creating Surface Regions is to organize the areas to be
machined, to make the selection of Part and Blank Geometry easier by enabling you to use the
Surface Region selection method, and to establish associativity with bodies.
OK to accept the surface region as the part geometry.

Check geometry will prevent the tool from gouging the planar face.
Choose the Check icon
and Select.
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Choose Faces as the Filter Method.
Select the planar face as illustrated below.
OK to accept the face as the check geometry.

When Gouging Check Geometry
The When Gouging option allows you to specify how the system will respond when the tool
gouges Check geometry during cutting moves.
Choose Cutting.
Choose Skip for When Gouging.
Warning causes the system to issue only a warning message and does not alter the tool path
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Skip causes the tool to omit the tool positions which gouge the Check Geometry.
Retract causes the tool to avoid gouging the Check Geometry by using the Check Engage and
Retract parameters defined in Non-Cutting moves.
Be sure a value of 0.1000 is specified for Check Safe Clearance.

OK to accept the Cutting Parameters.

The Surface Area drive method allows you to define a variable tool axis.
Choose Surface Area under Drive Method.
OK the warning.
The Surface Drive Method dialog displays.

You will select the bottom face of the part as the drive geometry. This is the face on which the
array of drive points will be created.
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Select the planar face on the bottom of the part.
OK to accept the drive geometry.

Two vectors display, one defining the default drive direction and other defining the Material
Side of the drive geometry.
When machining part surfaces as in this example, the Projection Vector (which you have not
yet defined) determines which side of the surface the tool contacts and the Material Side
vector has no effect.

Defining the Cut Direction
Cut Direction allows you to specify the direction of the first cut and the quadrant where the
first cut will begin.
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Choose Cut Direction.
Select the vector illustrated below.

Stepover controls the distance between successive Cut Passes.
Choose Scallop as the Stepover.
Scallop Height is the maximum allowable height measured normal to the Drive Surface.
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Key in 0.0100 for the Scallop Height.
Choose Display Drive Path to verify that drive points and a zig-zag drive path are defined
on the drive geometry.

More About Stepover
Stepover controls the distance between successive Cut Passes. You may specify the Stepover
in terms of the scallop size or the total number of Stepovers. The Stepover options vary
depending on the Cut Type used.
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Scallop allows you to specify the maximum allowable size of Scallops by specifying values
for height, horizontal, and vertical distances. This method is useful for good Scallop Height
Control when the Drive Surface is also used as the Part Surface. The system limits the size of
the stepover to roughly less than two-thirds of the tool diameter regardless of what you
specify as the scallop size.
Horizontal Limit allows you to restrict the distance a tool may move in a direction normal to
the Projection Vector. This option helps you avoid leaving wide ridges on near vertical
surfaces by limiting the horizontal distance of the Stepover.
Vertical Limit allows you to restrict the distance a tool may move in a direction parallel to the
Projection Vector. This option helps you avoid leaving wide ridges on near vertical surfaces
by limiting the vertical distance of the Stepover.
Horizontal Limit and Vertical Limit may be used together, separately, or not at all. If the
values are set to zero, then they are not used.
Number allows you to specify the total number of Stepovers for the Tool Path.
If the Cut Type you select is Follow Pocket, enter the Number of Stepovers for the First
Direction (i.e., cut direction) and for the Second Direction (i.e., Stepover direction).

The projection vector determines how the drive points project to the part geometry and the
side of the part geometry the tool contacts.
Choose Specify Vector under Projection Vector.
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The Vector Constructor dialog is displayed.

OK to accept the default I,J,K values of 0,0,-1.
A vector pointing in the negative ZM direction displays.
Drive points always project from the drive geometry to the part geometry. The angle of the
vector determines the path along which the drive points project. For this part, the drive points
project upward from the drive geometry (bottom face of the part) to the part geometry along
the ZM axis. The positive vs. negative direction of the arrowhead does not matter.
The side of the part geometry the tool contacts is determined by the direction of the projection
vector. The tool always positions to the part geometry on the side the Projection Vector
approaches. For this part, the arrowhead must point downward (as it currently does) so that
the tool approaches and positions on the part geometry from the top.
More About Projection Vector
Projection Vector enables you to define how the Drive Points project to the Part Surface, and
the side of the Part Surface the tool contacts.
The Drive Points project along the Projection Vector to the Part Surface. Sometimes, as
illustrated below, Drive Point project in the opposite direction of the Projection Vector (but
still along the vector axis) as they move from the Drive Surface to the Part Surface.
The direction of the Projection Vector determines the side of the Part Surface the tool
contacts. The tool always positions to the Part Surface from the side the Projection Vector
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approaches. In the following figure, drive point p1 projects to the Part Surface in the opposite
direction of the Projection Vector to create p2.
1. Projection Vector
2. Part Surface
3. Drive Surface
The types of Projection Vectors available depend upon the Drive Method. The Projection
Vector option is common to all Drive Methods except Flow Cut.
The following figure illustrates another example of how the Drive Points project to the Part
Surface. In this example, the Projection Vector is defined as Fixed. The vector is parallel to
the ZM axis at any given point on the Part Surface. To reach the Part Surface, the Drive
Points must project from the Boundary Plane in the same direction as the Projection Vector
arrowhead.
1.
2.
3.
4.
Drive Boundary
Projection Vector
Part Surface
Drive Path Projection
The direction of the Projection Vector determines the side of the Part Surfaces the tool
contacts.
1. Projection Vector
2. Part Surface
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3. Drive Surface
4. Tool Side of Part Surface
The following figures illustrate how the direction of the Projection Vector determines which
side of the Part Surfaces the tool contacts. In each figure, the tool contacts the same Part
Surface (inside the cylinder), but the contact side differs depending on the direction of the
Projection Vector.
The Projection Vector illustrated below, Towards Line, yields undesirable results. The tool
follows the direction of the Projection Vector and approaches the Part Surface from the
outside of the cylinder and gouges the part.
1.
2.
3.
4.
Part Surface
Drive Surface
Projection Vector
Tool Gouges Part
The Projection Vector illustrated below, Away From Line, yields the desired results. The tool
follows the direction of the Projection Vector and approaches the Part Surface from the inside
of the cylinder and does not gouge the part.
1.
2.
3.
4.
Part Surface
Drive Surface
Projection Vector
Tool Does Not Gouge Part
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When using Away From Point or Away From Line as the Projection vector, the minimum
distance from the Part Surface to the vector focal point or line must be greater than the radius
of the tool as illustrated below. The tool end must be allowed to position to the projection
vector focal point or anywhere along the projection vector focal line without gouging the Part
Surface.
1.
2.
3.
4.
5.
6.
Tool Path
Part Surface
Drive Surface
Distance Greater than Tool Radius
Projection Vector Away from Line
Projection Vector Focal Line
If the tool gouges the Part Surface when the tool end is positioned at the focal point or
anywhere along the focal line as illustrated below, the system cannot guarantee a good tool
path.
1.
2.
3.
4.
5.
6.
Gouge
Part Surface
Drive Surface
Distance Less than Tool Radius
Projection Vector Away from Line
Projection Vector Focal Line
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Defining the Away From Line Tool Axis
The Tool Axis is a vector that points away from the tip of the tool and toward the tool holder.
A variable tool axis constantly changes orientation as it moves along the tool path. The
method you use to control the orientation of the tool axis depends to a large extent on the
shape of the part you are machining.
For this part, a fixed tool axis would cause the tool to plunge straight down along the vertical
sides.
By contrast, a tool axis that is normal to the part surface would cause excessive tool
undulations.
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This part requires a tool axis that follows the general convex shape of the part geometry while
not undulating excessively. Away From Line defines a variable tool axis that diverges away
from a focal line. The tool axis hinges on the line as it travels along the length and remains
normal to the line.
Choose Away From Line under Tool Axis. You might need to scroll up in the dialog to
see this option.
The Line Definition dialog is displayed.

Choose Two Points.
Choose the Control Point icon.
Select the two control points illustrated below.
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OK to accept the line definition.

OK to complete the Surface Area drive method.

You will generate the tool path and then replay it to observe how the tool axis follows the
general convex shape of the part while preventing excessive tool undulations.

surfaces.
in the toolbar so you can clearly see the contoured part
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Normal to Drive Tool Axis

method and the Normal to Drive tool axis to finish the contoured part surfaces.
Normal to Drive defines a tool axis perpendicular to the drive surface, allowing the axis to
follow the general convex shape of the part geometry while not undulating excessively.

Opening the Part
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This part is the same as the one used in the previous section with the addition of a surface that
will be used as drive geometry.
Choose Application
Manufacturing.

In the Create Operation dialog, choose mill_multi-axis as the Type.


This operation does not inherit part geometry from the WORKPIECE group. You will define
the part geometry within the operation.
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and Select.

OK to accept the surface region as the part geometry.

The VARIABLE_CONTOUR dialog displays.

Choose Surface Area under Drive method.
OK the warning.

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The drive geometry will define the drive points and will control the tool axis.
Select the curved surface above the part.

Two vectors display, one defining the default drive direction and other defining the Material

Projection Vector determines how the drive points project to the part geometry and the side of
the part surface the tool contacts.
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Choose Normal to Drive under Projection Vector.
Normal to Drive allows you to define the projection vector relative to the drive surface
normals.
vector. The tool always positions to the part geometry on the side of the part geometry the
projection vector approaches. For this part, the projection vector must point inward toward the
part geometry as illustrated below for the tool to position correctly.
When using Normal to Drive, the projection vector is calculated as the inverse of the material
side vector. This means that the projection vector currently points outward away from the part
geometry and not inward as it should.
Refresh the graphics display to remove the vectors.
Choose Flip Material.
This reverses the direction of the material side vector.
The projection vector, calculated as the inverse of the material side vector, now points inward
toward the part geometry as it should. The tool will therefore position to the part geometry
along the projection vector.
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A set of vectors is displayed, showing all possible vectors tangent to the drive surface edges.
Choose the vector illustrated below.

Choose Number as the Stepover.
Number of Steps defines the total number of stepovers for the tool path.
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Key in 50 for the Number of Steps.

Defining the Normal to Drive Tool Axis
This part requires a tool axis that follows the general convex shape of the part geometry while
not undulating excessively. Normal to Drive defines a variable tool axis perpendicular to the
drive surface at each the drive point.
1. Tool Axis
2. Drive Surface
3. Part Surface
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Choose Normal to Drive under Tool Axis.

You will generate the tool path and observe how the tool axis follows the drive geometry.
Choose the Shaded icon in the toolbar so you can clearly see the contoured part surfaces.
If the drive geometry does not appear translucent as illustrated below, choose
Preferences Visualization Visual (tab) and turn on Translucency.
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It is difficult to tell by looking at the tool path whether or not the tool gouges the part.
Defining check geometry can help.

Check Geometry can be defined and warnings generated if the tool violates the check
geometry.
and Select.
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gouges check geometry during cutting moves.
Choose Cutting.
Choose Warning for When Gouging.
Warning causes the system to issue only a warning message and does not alter the tool path.
When the tool path is complete, the following message displays warning you that the check
geometry is violated by the tool.
OK to dismiss the message.

If you wish, you may specify Skip for the When Gouging option to omit the tool positions
that gouge the check geometry and then regenerate the tool path.
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method and the Normal to Drive tool axis to finish the contoured surface while avoiding the
blades.
Normal to Drive defines a tool axis perpendicular to the drive geometry. In this operation, you
will define only the drive geometry. You will not define part geometry. As a result, the tool
path will be created directly on the drive geometry and definition of a projection vector will
not be necessary.

Opening the Part
Choose Application
Manufacturing.

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ChooseSurface Area under Drive Method.
OK the warning.

You will define the drive geometry by selecting a single drive surface.
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Select the face illustrated below.

Two vectors display; one defining the default drive direction and other defining the material
side of the drive geometry.
Rotate the view so you can see these arrows clearly.
1. Drive Direction
2. Material Side
The material side vector determines the side the tool will contact when cutting directly on the
drive surface. This vector should point towards the material to be removed (away from the
part). It currently points away from the material to be removed and must be reversed.
Choose Flip Material.
This reverses the direction of the material side vector.
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Refresh the graphics display and then MB3
Restore to change back to a TFR-ISO view.


Stepover controls the distance between successive cut passes.
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Defining the Normal to Drive Tool Axis
This part requires a tool axis that follows the contour of the drive geometry. Normal to Drive
defines a variable tool axis perpendicular to the drive surface at each drive point.
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Choose Normal to Drive under Tool Axis.

When Gouging Drive Surfaces
gouges drive surfaces during cutting moves. These options apply only when you are cutting
directly on drive surfaces and not when you are cutting on part surfaces.
When Gouging also appears in the Cutting Parameters dialog. In that dialog, the options
determine how the system responds when the tool gouges check geometry.
Warning causes the system to issue only a warning message and does not alter the tool path
Skip causes the system to alter the tool path by removing only the drive points that cause the
gouging to occur.
Retract causes the tool to avoid gouging the Drive Surface by using the parameters defined in
Non-Cutting Moves.
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More About When Gouging Drive Surfaces
gouges the Drive Surface during cutting moves. These options only apply when you are
cutting to Drive Surfaces and not when you are cutting to Part Surfaces.
None causes the system to ignore Drive Surface gouging. It will generate the same unaltered
tool path as the Warning option, but will not issue a warning message to the tool path or
CLSF.
Skip causes the system to alter the tool path by removing only the Drive Points that cause
gouging to occur. The result is a straight tool movement from the last position before gouging
to the first position which is no longer gouging.
When generating tool paths directly from Drive Surface, the tool does not violate the Drive
Surface at convex corners, and does not gouge concave regions when using Skip as illustrated
below.
In some cases where the drive surface is smoothly concave, the Skip option may not clean up
the tool path as well as illustrated in the concave corner case above.
Non-Cutting Moves.

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Check geometry will prevent the tool from gouging the blades. You will define the check
geometry by selecting the three faces on each blade.
and Select.
The Check Geometry dialog displays.

Select the three faces that define the first blade as illustrated below.
Select the three faces that define the second blade as illustrated below.
OK to accept the faces as check geometry.
575
The Variable Contour dialog displays.

Choose Cutting.
Choose Retract for When Gouging.
Retract causes the tool to avoid gouging the check geometry by using the Check, Engage, and
Retract parameters defined in Non-Cutting moves.
Be sure a value of 0.1000 is specified for Check Safe Clearance.


Non-Cutting moves allow you to specify movements that position the tool before, after, and
between cutting moves.
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This section describes the non-cutting moves that apply to this particular operation. Refer to
the non-cutting moves lesson at the end of this course for a complete discussion.
Choose Non-Cutting.
You will first define non-cutting moves for engages. You will then define non-cutting moves
for retracts by specifying that they will use the same non-cutting moves as defined for
engages.

Defining Engages
Choose the Engage icon.
The Case options determine whether the motion parameters will apply to all engages or only
to specific types of engages. By specifying Default as the Case, all types of engages will use
the same motion parameters.
Be sure the Case is specified as Default.
The Status option determines the available motion parameters. For this operation, all engages
will move a specified distance to the part along the tool axis.
Choose Manual for the Status.
The Distance option determines the length of the engage.

Turn the Distance option on and key in 1.5.
577
The Movement options determine the shape of the engage.

Choose Linear for the Movement.
The Direction options determine the orientation of the engage.

Choose Tool Axis for the direction.
Here is how you would read the Non-Cutting Moves dialog; "Unless otherwise specified, all
engages will move 1.5 inches in a linear direction defined by the orientation of the current
tool axis".
Next, you will define retracts by specifying that they will use the same motion parameters as
defined for engages.

Defining Retracts
Choose the Retract icon.
Notice that the Case is set to Default and the Status is set to Use Engage. All retracts (by
default) will use the same parameters as defined for engages. In other words, all retracts (by
default) will move from the part to the clearance plane in a linear path along the tool axis.
OK to accept the Non-Cutting Moves.
578

You will generate the tool path and observe how the tool axis follows the contours of the
drive geometry while avoiding the check geometry.

Swarf Drive Tool Axis

You will create two variable axis surface contouring operations that uses the Surface Area
drive method and the Swarf Drive tool axis to finish the blades.
579
You will create the first operation by specifying all the necessary parameters to finish the first
blade.
You will create the second operation by copying the first operation and then respecifying the
drive geometry to finish the second blade.
Swarf Drive defines a tool axis that follows the swarf rulings of drive surfaces. The side of the
tool cuts along the drive surfaces and the tip of the tool cuts along the part surfaces.

Opening the Part
Choose Application
Manufacturing.

580

Key in swarf for the operation name.

OK the warning.

You will define the drive geometry by selecting the three faces on the first blade.
The Drive Geometry dialog displays.
Select the three faces that define the blade in order as illustrated below.
581
Drive surfaces must be selected in order and must be edge-to-edge.

Two vectors display; one defining the material side of the drive geometry and other defining
the default drive direction.
The material side vector determines the side the tool will contact when cutting directly on the
drive surface. This vector should point towards the material to be removed (away from the
part) as it currently does.
The currently displayed drive direction vector will cause the tool to cut along the drive
surfaces in the direction indicated below.
582

Defining the Swarf Drive Tool Axis
This part requires a tool axis that cuts along the sides of the blades. Swarf Drive defines a
variable tool axis that allows the side of the tool to cut along the drive surfaces by following
the swarf rulings. The tip of the tool cuts along the part surfaces.
1. Part Surface
2. Drive Surface
3. Swarf Ruling Direction
Choose Swarf Drive under Tool Axis.
583
Four directional vectors appear relative to the first drive surface you selected. The vector you
select defines the swarf ruling direction that the tool axis will follow. The vector you select
should point toward the tool holder.
Rotate the view so you can see these vectors clearly.
Refresh the graphics display and change back to a TFR-ISO view.

The projection vector determines how the drive points project to the part geometry.
Choose Tool Axis under Projection Vector.
584

The cut type (Zig-Zag, Zig, Follow Pocket, etc.) has no effect on the Swarf Drive tool axis.
To produce a single pass, the number of stepovers must be set to zero. If the number of
stepovers is greater than zero, the system will produce multiple passes.
Choose Number as the Stepover.
Key in 0 for the Number of Steps.

gouges drive surfaces during cutting moves.
gouging to occur.

More About When Gouging Driving Surfaces
585
CLSF.
below.
Non-Cutting Moves.

The part geometry guides the tip of the tool.
and Select.

Select the face as illustrated below.
586
OK to accept the face as the part geometry.

You will generate the tool path and observe how the SWARF operation finishes the first
blade.
587

Choose the Wireframe icon to return to a wireframe display.

Copying the Operation
You will finish the second blade by copying the existing SWARF operation and respecifying
the drive geometry. This will be easier than creating a new operation.
In the Program Order View of the Operation Navigator, highlight the SWARF operation
and MB3 Copy.
MB3
Paste to copy the operation.
SWARF_COPY now appears as the last operation in the Program Order View.
588

Editing the Drive Geometry
You will respecify the drive geometry so that this operation machines the second blade.
Double-click on the SWARF_COPY icon to edit the operation.
You will define the drive geometry by selecting the three faces on the second blade.
Choose Reselect under Drive Geometry.
OK the warning
Select the three faces that define the second blade as illustrated below.
Drive surfaces must be selected in order and must be edge-to-edge.


You will generate the tool path and observe how the SWARF_COPY operation finishes the
second blade.
589

Instancing an Operation
Instancing allows you to make multiple copies of the tool path while maintaining a link to the
original operation. Editing one instance automatically updates all instances.
590
This is especially useful when the part has not been fully modeled and uses a callout to
specify that certain features are repeated.
Opening the Part
You will create five instances of an operation that finishes one of the blades.
Choose Application
Manufacturing.
You will replay the tool path and observe how the SWARF operation finishes the blade.
591
and MB3 Replay.
Creating Instances
You will create five instances of the operation by rotating it about the centerline in 60 degree
increments.
icon and MB3 Object Transform.
Choose Rotate About Line.
Choose Existing Line.
Select the centerline of the part.
Key in 60 for the Angle and OK to accept it.

Choose Multiple Instances.
Key in 5 for the Number and OK to accept it.
592
The instances display temporarily for visual verification.
Choose Accept to complete the instances.

Notice that five additional operations named "Instance" are created.
Each instance is linked to the original operation. Unlike copies, modifying any instance will
automatically update all associated instances.
Editing an Instance
You will edit one of the instances and observe how all five associated instances automatically
update.
Double-click on the SWARF_INSTANCE_2 icon to edit the operation.
A warning displays informing you that all associated instances will be edited.
OK the warning.
593
Choose Method:MILL_FINISH and Reselect.
Set the Method option to MILL_SEMI_FINISH and OK.

Notice that all of the instances as well as the original operation have been edited and must
now be regenerated.
You will generate the sequence of operations and then visualize the tool paths.
Highlight the Program icon and MB3
Generate.
OK for each operation.

Choose the Shaded icon in the toolbar.
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Normal to Part Tool Axis

method and the Normal to Part tool axis to finish the contoured surfaces.
Normal to Part defines a tool axis that is normal to the part geometry.

Opening the Part
595
Choose Application
Manufacturing.



This operation inherits the part geometry from the WORKPIECE group.
and Display.
Part surfaces (unlike drive surfaces) do not need to be arranged in an orderly grid of rows and
columns.
596

Choose Surface Area under Drive method.
OK the warning.

Drive geometry defines the drive points that are projected to the part surfaces.
597

Two vectors display, one defining the default drive direction and other defining the material
side of the drive geometry.
The material side vector determines which side of the surface the tool contacts only when
machining directly on drive surfaces. When machining on part surfaces as in this example, the
projection vector (not the material side vector) determines the side of the surface the tool
contacts. The material side vector therefore has no effect on this operation.

Projection Vector determines how the drive points project to the part geometry and the side of
the part geometry the tool contacts.
598
Choose Specify Vector under Projection Vector.
vector. The tool always positions to the part geometry on the side that the projection vector
approaches. For this part, the projection vector must point in a downward direction so that the
tool positions to the part geometry from the top.
Be sure that the I,J,K values in the Vector Constructor dialog are 0,0,-1.
Drive points always project along the vector to the part geometry. In this case, the points
project along the vertical vector but up from the bottom of the part in the opposite direction of
the arrowhead.
OK to accept the projection vector.

599

Be sure the Scallop Height is 0.0050.
600

Defining the Normal to Part Tool Axis
Normal to Part defines a tool axis perpendicular to the part surfaces, allowing the axis to
follow the contours of the part geometry.
Choose Normal to Part under Tool Axis.
OK to complete the Surface Drive Method.
601

You will generate the tool path and observe how the tool axis follows the contours of the part
geometry.

602
Relative to Part Tool Axis

You will define a Relative to Part tool axis by editing a Variable Contour operation containing
a Normal to Part tool axis.
Relative to Part defines a tool axis leaning forward or backward, or tilting to the right or left
of an otherwise normal tool axis relative to the part surfaces.
The Lead angle leans the tool forward or backward relative to the cut direction.

Choose Application
Manufacturing.

VARIABLE_CONTOUR icon to edit the operation.
This operation uses Normal to Part as the tool axis and is similar to the operation you created
in the previous section.

Defining the Relative to Part Tool Axis
Relative To Part defines a tool axis leaning forward or backward, or tilting to the right or left
of an otherwise normal tool axis relative to the part surfaces.
603
Lead Angle defines the angle of the tool forward or backward along the tool path. Tilt Angle
defines the angle of the tool side to side.
1.
2.
3.
4.
Negative Tilt
Positive Tilt
Lead (positive)
Lag (negative)
Choose Relative to Part under Tool Axis.

Defining the Lead
A positive lead angle leans the tool forward from the normal axis orientation based on the
direction of the tool path. A negative lead angle (lag) leans the tool backward based on the
direction of the tool path.
The minimum and maximum lead values define how far the tool can deviate from the
specified lead angle.
1. 20 Degree Lead (forward angle)
2. Max Lead (25 degrees)
3. Min Lead (15 degrees)
604
Key in the following values for Lead, Minimum Lead, and Maximum Lead.
Leave the Tilt values set to zero for now.


You will generate the tool path and observe how the Relative to Part tool axis maintains the
specified lead angle.
605

Reorient to a Front view (MB3
Orient View
Front).
A positive lead angle leans the tool forward based on the direction of the cutting pass. This is
why the lead flips direction as the tool alternates between zig and zag cuts.

4-Axis Normal to Part Tool Axis

You will define a 4-Axis Normal to Part tool axis by editing a Variable Contour operation
containing a Normal to Part tool axis.
4-Axis Normal to Part defines a tool axis that uses a rotation angle and a rotation axis. The
rotation angle allows the tool to rotate about the rotation axis while remaining normal to the
606
axis. Unlike a lead angle, a rotation angle leans the tool to the same side of the normal tool
axis regardless of the zig or zag cut direction.
1. Rotation Angle
2. Tilt

Choose Application
Manufacturing.

This operation uses Normal to Part as the tool axis. You will change this to a 4-Axis Normal
to Part tool axis.

Defining the 4-Axis Normal to Part Tool Axis
4-Axis Normal to Part defines a tool axis that uses a rotation angle and a rotation axis.
In the left view illustrated below, the rotation angle causes the tool axis to lean to the right of
the normal tool axis in both the zig and zag moves. The tool moves within parallel planes
normal to the rotation axis.
1. Part Surface Normal
2. Rotation Angle
607
3. Plane Normal to Rotation Axis
4. Axis Parallel to Plane
Choose 4-Axis Normal to Part under Tool Axis.
The 4-Axis Normal to Part dialog displays.

Key in 15 degrees for the Rotation Angle.
Choose 2 Points for the Rotation Axis.
Select line end points 1 and 2 as illustrated below to define the Rotation Axis.
608
The Rotation Axis vector displays.

OK to accept the tool axis definition.

You will generate the tool path and observe the 4-Axis Normal to Part tool axis.

Orient View
Front).
609
The tool consistently leans to the right (by 15 degrees) of a tool axis that is otherwise normal
to the part surface during both zig and zag moves.
Change to a Right view.

Choose the Play Backward icon.
The tool moves within parallel planes normal to the rotation axis.

610
4-Axis Relative to Part Tool Axis

You will define a 4-Axis Relative to Part tool axis by editing a Variable Contour operation
containing a 4-Axis Normal to Part tool axis.
4-Axis Relative to Part works in much the same way as 4-Axis Normal to Part. In addition,
you may define a lead and a tilt angle allowing the tool axis to lean forward or backward or
tilt to the right or left of an otherwise 4-Axis Normal to Part tool axis.
1.
2.
3.
4.
5.
Part Surface Normal

Positive Lead Angle
Rotation Angle
Plane Normal to Rotation Axis
Axis Parallel to Plane. Tilt of 0 Degrees

Choose Application
Manufacturing.

611
This operation uses 4-Axis Normal to Part as the tool axis. You will change this to a 4-Axis
Relative to Part tool axis.

Defining the 4-Axis Relative to Part Tool Axis
4-Axis Relative to Part defines a tool axis that uses a lead, tilt, rotation angle, and rotation
axis.
A positive lead leans the tool forward from the normal tool axis based on the direction of the
tool path.
The rotation angle leans the tool forward or back in relation to the lead angle. It always leans
to the same side of the lead angle and is not dependent on the cut direction.
1. Part Surface Normal
2. Positive Lead Angle
3. Rotation Angle
The rotation axis defines the plane that the tilt is referenced from.
A tilt angle defines the angle of the tool axis from side to side and is referenced from the
plane normal to the rotation axis. 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. Plane Normal to Rotation Axis
2. Rotation Axis
3. Axis Parallel to Plane. Tilt of 0 Degrees
612
Choose 4-Axis Relative to Part under Tool Axis.
The 4-Axis Relative to Part dialog displays. The Rotation Angle and Rotation Axis are
retained from the 4-Axis Normal to Part tool axis.
Key in 5.0 degrees for the Lead.
Leave the Tilt set to 0.0000.

OK to accept the tool axis definition.

613

Orient View
Front).

The rotation angle consistently remains 15 degrees to the right of the lead. The lead reverses 5
degrees to either side of the normal tool axis depending on the zig or zag cut direction.
1. Lead
2. Rotation Angle
Change to a Right view.

Choose the Play Backward icon.
The tool moves within parallel planes normal to the rotation axis (zero degree tilt).
614

Interpolate Tool Axis

method and the Interpolate tool axis to finish the contoured surfaces.
Interpolate controls the tool axis at specific points by allowing you to add, delete, and edit
tool axis vectors.
615
In this operation, you will define only the drive geometry. You will not define part geometry.
As a result, the tool path will be created directly on the drive geometry and definition of a
projection vector will not be necessary.

Opening the Part
Choose Application
Manufacturing.

in the toolbar.

616

The Surface Area drive method allows you to define a variable tool axis and to cut directly on
the drive geometry.
OK the warning.

You will define the drive geometry by selecting an array of faces.
When selecting more than one face, the faces must be arranged in an orderly grid of rows and
columns.
617
Faces must be selected in an orderly sequence. They may not be selected randomly. The
sequence in which you select the first adjacent faces defines a row. When you finish selecting
the first row, you must specify that you wish to begin selecting the second row. Each
subsequent row must then contain the same number of adjacent faces.

Selecting the First Row
Select the first face as illustrated below.
Select the second face. You may need to rotate the model.
618
Select the third and fourth faces.
You must now specify that you wish to begin the next row.

Selecting the Second Row
Choose Select Next Row.
619
By choosing this option, you have specified that every row will contain four faces. You will
no longer need to choose Select Next Row when beginning a new row.
Select the fifth through eighth faces.

Selecting the Remaining Faces
Select the ninth through twelfth faces.
Continue selecting faces in the same orderly sequence until all twenty-eight faces have
been selected.
620

Defining the Material Side
Two vectors display; one defining the default drive direction and other defining the Material
The material side vector determines which side the tool contacts when cutting on the drive
surfaces. The material side vector should point towards the material to be removed (away
from the part) as illustrated above. If it does not, Flip Material can be used to reverse the
direction.
Choose Display under Drive Geometry to verify that the drive geometry has been correctly
defined.
621

622

623

Defining the Interpolate Tool Axis
This part requires a tool axis that follows the general shape of the drive surfaces while
avoiding excessive tool axis change.
Interpolate controls the tool axis at specific points using vectors. It allows you to control
excessive change of the tool axis caused by very complex drive or part geometry without
requiring the construction of additional tool axis control geometry (ex: points, lines, vectors,
smoother drive surface).
You may define as many vectors extending from specified positions on the drive geometry as
needed to create a smooth tool axis movement. The more vectors you specify, the more
control you have over the tool axis.
624
Choose Interpolate under Tool Axis.
An array of default tool axis vectors displays. These vectors are normal to the drive surfaces
and define the current Interpolate tool axis. Using all of these vectors would cause excessive
change in the tool axis.
You may remove, add, and edit vectors to achieve the necessary tool axis control. To edit or
remove a vector, you must first highlight the desired vector by using the Previous or Next
arrow options or by selecting the desired vector directly from the screen and then choose Edit
or Remove. Display refreshes the screen and updates the currently defined vectors for visual
reference.

Removing Tool Axis Vectors
You will remove the vectors that cause unnecessary tool axis change.
625
Choose the Next arrow until the vector illustrated below highlights.
Choose Remove to delete the highlighted vector.

The next vector in the sequence highlights.
Choose Remove to delete the highlighted vector.
626
Continue using Next and choosing Remove to delete vectors until only the vectors
illustrated below remain. remember, you can choose Display at any time to update the
currently defined vectors for visual reference.
OK to complete the Interpolated tool axis.


You will generate the tool path and observe how the tool axis follows the vectors.
Choose the Edit Display icon under Toolpath and choose 3-D for the Tool Display.
Key in 40 for the Frequency.
OK to accept the tool display.
627

Orient View
Front).

The tool axis rotates 180 degrees as the tool zig-zags from one side of the part to the other.
You can reduce the change in the tool axis by editing the tool axis vectors.
628

Editing Tool Axis Vectors
You will edit the vectors so that there is less change in the tool axis as the tool zig-zags from
one side of the part to the other.
Change to a TFR-ISO view.
To aid you in editing the vectors, you will display two lines that are currently hidden on Layer
3 and use them to edit the vectors.
Choose Format
Layer Settings from the menu bar.
The Layer Settings dialog is displayed.

Highlight 3 in the Layer/Status list box and choose Selectable.
Two yellow angled lines display.
Choose Interpolate under Tool Axis.
Use the Next arrow icon to highlight the vector illustrated below.
Choose Edit under Data Point to modify the highlighted vector.

Choose the Inferred Vector icon.
629
Choose the upper end of the angled line as illustrated below.
A temporary vector displays at the end of the line.

OK to complete editing the vector.
The edited vector is highlighted.
630
Choose Display to refresh the screen.
The currently defined tool axis vectors are displayed.
Continue using Previous or Next, choosing Edit, choosing the Inferred Vector icon, and
selecting the top end of the appropriate angled line to edit the remaining five vectors at the
bottom of the part.
Choose Display to refresh the screen.
OK to complete the Interpolated tool axis.
631

You will generate the tool path and observe how the tool axis follows the edited vectors
Orient View
Front).
Reject the previous tool path.


632
The tool axis rotates 180 degrees as the tool zig-zags from one side of the part to the other.
You can reduce the change in the tool axis by editing the tool axis vectors.
Toward Point Tool Axis

method and the Toward Point tool axis to finish the vertical walls of a cavity.
Toward Point defines a tool axis that converges toward a focal point, allowing the tool to cut
with the tip in a confined space.
633

Opening the Part
Choose Application
Manufacturing.
634



the drive geometry.
OK the warning.
635

You will define the drive geometry by selecting an array of surfaces as you did when defining
the Interpolate tool axis.
When selecting more than one drive surface, the surfaces must be selected by row in an
orderly sequence.
Select the first surface as illustrated below.
Select the second and third surfaces.
636

Selecting the Second Row
You must now specify that you wish to begin the next row.
Choose Select Next Row.
By choosing this option, you have specified that you will begin a new row and that every row
will contain three surfaces.
Select the fourth, fifth, and sixth surfaces.
637

Selecting the Third Row
Select the seventh through ninth surfaces.

Selecting the Remaining Surfaces
Continue selecting drive surfaces in the same orderly sequence until all twenty-four
638
surfaces have been selected. You may need to rotate the model.

Choose Display under Drive Geometry to verify that the drive geometry has been correctly
defined.

Defining the Material Side
639
from the part) as illustrated above. If it does not, Flip Material can be used to reverse the
direction.

640

Defining the Cut Type
A Zig cut type will allow the tool to cut the cavity in one direction.
Choose Zig for the Cut Type.

Choose Display Drive Path to verify that drive points and zig drive path are defined on the
drive geometry.
641

Defining the Toward Point Tool Axis
This part requires a tool axis that can reach into the cavity and cut along the vertical walls
with the tip of the tool.
Toward Point defines a tool axis that converges at a focal point.
Choose Toward Point under Tool Axis.
Select the point above the part.
642

gouges drive surfaces during cutting moves. These options apply only when you are cutting
directly on drive surfaces and not when you are cutting on part surfaces.
gouging to occur.

More About When Gouging Driving Surfaces
643
CLSF.
below.
Non-Cutting Moves.

You will generate the tool path and observe how the tool finishes the sides of the cavity.
644

645
Away From Point Tool Axis

method and the Away From Point tool axis to finish the sides of a core.
Away From Point defines a tool axis that diverges away from a focal point, allowing the tool
to cut the vertical walls with the tip.

Opening the Part
646
Choose Application
Manufacturing.



the drive geometry.
OK the warning.
647

You will define the drive geometry by selecting a single drive surface.
Select the surface as illustrated below.

from the part) as illustrated below. If it does not, Flip Material can be used to reverse the
direction.
648


Defining the Cut Type
A Zig cut type will allow the tool to continually cut around the core in one direction.
Choose Zig for the Cut Type.
649

Scallop Heights the maximum allowable height measured normal to the Drive Surface.
Be sure the Scallop Height is 0.0050.

Defining the Away From Point Tool Axis
This part requires a tool axis that can finish the vertical sides of a core with the tip of the tool.
Away From Point defines a tool axis that diverges away from a focal point.
650
Choose Away from Point under Tool Axis.
Select the point below the part.


Defining the Check Geometry
Check geometry will prevent the tool from gouging the planar face.
and Select.
651

The VARIABLE_CONTOUR dialog displays.

Choose Cutting.
Skip causes the tool to omit the tool positions which gouge the check geometry.
652
Key in 0.05 for the Check Safe Clearance.


You will generate the tool path and observe how the tool finishes the sides of the core.
653

Surface Contouring Projects

These two projects require you to finish a core and a cavity. You will create programs
consisting of Surface Contouring operations that machine the parts using standard machining
techniques. You will then check each program by dynamically displaying material removal
and comparing the finished machined part to the original model.
654
Using Area Mill to Machine a Core

This metric part is a core machined from a solid block of material. The completed machining
program consists of six operations that rough, semi-finish, and finish the part. You will create
the last four operations using the Area Mill drive method to semi-finish and finish the part.
To complete this project, you should be familiar with the following types of operations.
CONTOUR_AREA_NON-STEEP
CONTOUR_ZIGZAG
CONTOUR_AREA_DIR_STEEP
In addition, you should know how to create a Mill Area parent group and how to define a
Trim Boundary and a Cut Area.
You will also Animate the tool path and use Show Excess to graphically display the excess
material left by the roughing operations.
655

Create a CONTOUR_AREA_NON_STEEP operation to semi-finish the part.
Create a MILL_AREA parent group containing a Trim Boundary.
Apply the MILL_AREA geometry group as a parent to the

CONTOUR_AREA_NON_STEEP operation to eliminate edge tracing.
656
Create a CONTOUR_ZIGZAG operation using the MILL_AREA geometry group to
finish the part.
Create a CONTOUR_AREA_DIR_STEEP operation that finishes only the steep areas.
Create a CONTOUR_ZIGZAG operation using a Cut Area to finish the core with a
very small stepover.
657
Compare the finished machined part to the original model.

Design Intent
The completed program must cut the finished part from a solid block of material using a
sequence of roughing, semi-finishing, and finishing operations while applying acceptable
standard machining techniques.

Open the Part File
658
Open part file srf_proj_1.prt from the srf subdirectory.
Fully expand the objects in the Geometry View of the Operation Navigator.
Choose the Geometry View icon in the Toolbar.
In the Operation Navigator, select the plus (+) signs next to the MCS_MILL and
WORKPIECE groups.
Replay the two operations.
In the Operation Navigator, highlight the WORKPIECE icon and MB3
Replay.
These two Z-Level Milling operations perform the initial rough cuts. You will create four
Fixed Axis Surface Contouring operations that use the Area Mill drive method to semi-finish
and finish the part.

Creating a Contour Area Non-Steep Semi-Finish Operation
You need to create an operation that semi-finishes only the non-steep areas.
659
Create a CONTOUR_AREA_NON_STEEP operation using the following parent groups:

Choose the CONTOUR_AREA_NON_STEEP icon as the subtype.

Specify a Steep Angle of 35 degrees and a Stepover of 25 percent of the tool diameter.
Under Drive Method, choose Area Milling.
Key in 35.0000 for the Steep Angle and 25.0000 for the Stepover Percent.
OK to accept the parameters.
Notice the edge tracing.
660

You need to remove the edge tracing. In this case, you will define a Trim boundary in a
geometry group.
Create a MILL_AREA geometry group using WORKPIECE as the parent.

Choose the MILL_AREA icon.
Choose WORKPIECE as the Parent group.
OK to begin creating the Group.
Define a trim boundary on the bottom face of the part.
Choose the Trim icon and Select.
Turn on the Outside option.
OK to complete the trim boundary.
OK to complete the MILL_AREA geometry group.
The MILL_AREA geometry group should now appear in the Geometry View of the
Operation Navigator.
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Applying the Trim Boundary
You need to apply the geometry group to the operation so that the edge tracing is removed.
Edit the CONTOUR_AREA_NON_STEEP operation so that MILL_AREA is specified
as the parent geometry group.
In the Operation Navigator, double-click on the
CONTOUR_AREA_NON_STEEP icon to display the operation parameters
dialog.
Turn on the Geometry:WORKPIECE option.
Choose Reselect.
Choose MILL_AREA in the Reselect Geometry dialog.
OK to complete editing the operation.
The MILL_AREA geometry group should appear as a parent of the

CONTOUR_AREA_NON_STEEP operation.

In the Operation Navigator, highlight the CONTOUR_AREA_NON_STEEP
operation and MB3 Generate.
OK the Tool Path Generation dialog.
Notice the edge tracing has been removed.
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Creating a Contour Zig Zag Finish Operation
You need to create an operation that finishes the entire part.
Create a CONTOUR_ZIGZAG operation using the following parent groups:

Choose the CONTOUR_ZIGZAG icon as the subtype.

Specify a Cut angle of 0.0000 degrees and a Stepover of 25 percent of the tool diameter.
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Choose User Defined as the Cut Angle and OK to accept 0.0000 degrees.
Key 25.0000 for the Stepover Percent.

Creating a Contour Area Directional Steep Finish Operation
You need to create an operation that finishes only the steep areas.
Create a CONTOUR_AREA_DIR_STEEP operation using the following parent groups:

Choose the CONTOUR_AREA_DIR_STEEP icon as the subtype.
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Verify that the Steep Containment is defined as Directional Steep and that Steep Angle is
35 degrees.
Specify a Cut angle of 90 degrees and a Stepover of 25 percent of the tool diameter.

Creating a Contour Zig Zag Finish Operation
You need to create an operation that finishes the core with a very small stepover.
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Create a CONTOUR_ZIGZAG operation using the following parent groups:

Choose the CONTOUR_ZIGZAG icon as the subtype.

Specify a Cut angle of 0.0000 degrees and a Stepover of 10 percent of the tool diameter.
Define the core as the cut area.
Under Geometry, choose the Cut Area icon and Select.
Turn on the Features selection option and choose the surface region illustrated
below.
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OK to accept the Cut Area.


The operations and groups should now appear in the Geometry View of the Operation
Navigator.
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You need to visualize the tool path for the entire program and compare the finished machined
part to the original solid model.
In the Program Order View of the Operation Navigator, highlight the PROGRAM
icon.
Choose the Verify Toolpath icon in the Toolbar.
Choose the Dynamic Tab.
Compare the machined part to the original model.


Close the part.
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Using Flow Cut to Finish a Cavity

This part contains a cavity machined from a solid block of material. The completed machining
program consists of six operations that rough, semi-finish, and finish the part. You will create
the last two operations of the program using Flow Cut to finish the corners and fillets.
To complete this project, you should be familiar with the following types of operations.
FLOWCUT_SINGLE
FLOWCUT_REF_TOOL
You will also Animate the tool paths to graphically simulate material removal.

Create a FLOWCUT_REF_TOOL operation to finish the corners and fillets using
multiple passes.
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Create a FLOWCUT_SINGLE operation to finish the corners using a single pass and a
small tool.
Compare the finished machined part to the original model.

Design Intent
The completed program must be able to cut the part from a solid block of material, using flow
cuts to finish the corners and fillets.
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Open the Part File
Open part file srf_proj_2.prt from the srf subdirectory.
Fully expand the objects in the Program Order View of the Operation Navigator.
Choose the Program Order View icon in the Toolbar.
In the Operation Navigator, select the plus (+) signs next to the PROGRAM group.

icon.
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The white areas indicate that further finishing is required to machine to the specified Outtol.
You will create two Flow Cut operations to finish the corners and fillets.

Creating a Reference Tool Flow Cut
You need to create an operation that finishes the corners and fillets with multiple passes.
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Create a FLOWCUT_REF_TOOL operation using the following parent groups:
Choose the FLOWCUT_REF_TOOL icon as the subtype.

Key in a Stepover Distance of 0.05.
Specify the sequence of cuts to start at the center flow cut and move toward the outside
passes.
Choose Inside-Out for Sequencing.
Define the cut region so that it covers at least the width of the 0.1500 radius fillets.
Key in 0.375 for the Reference Tool Diameter to establish a cut region that is a
little wider than the fillets.

Creating a Single Pass Flow Cut
You need to create an operation that finishes just the corners with a single pass.
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Create a FLOWCUT_SINGLE operation using the following parent groups:

Choose the FLOWCUT_SINGLE icon as the subtype.

Specify that the tool should cut along as flat an angle as possible.
Key in a Maximum Concavity of 179.0.
Be sure the tool cuts all the way across the top of the part in a continuous motion and does
not retract.
Key in 0.25 for the Hookup Distance.
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icon.

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Close the part.

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program containing a predefined sequence of operations.

for use by machine tool operators.

Parent Groups and Operations

Parent Groups and Operations

Parent Groups and Operations

Parent Groups and Operations

Parent Groups and Operations

Parent Groups and Operations

Turn the Tool Description option on.

OK to accept the Operation Navigator Properties dialog.

Parent Groups and Operations

Parent Groups and Operations

Choose the Machine Tool View icon

Click on the plus (+) signs to fully expand the objects.

Parent Groups and Operations

Choose the Program Order View icon

Parent Groups and Operations

Choose the Geometry View icon

Click on the plus (+) signs to fully expand the objects.

Parent Groups and Operations

Choose the Machining Method View icon

Click on the plus (+) signs to fully expand the objects.

Cutting and Pasting Operations

Cutting and Pasting Operations

Choose the Program Order View icon

Choose the CONTOUR_ZIGZAG icon and MB3

CONTOUR_ZIGZAG is now the last operation in the program sequence.

Cutting and Pasting Operations

Choose the Machine Tool View icon

CONTOUR_FOLLOW_1 now uses MILL_2 as the cutting tool.

Operation Status Symbols

indicates a complete status

indicates a regenerate status

indicates repost status

Cutting and Pasting Operations

OK the Tool Path Generation dialog.

Cutting and Pasting Operations

Choose the Program Order View icon

Cutting and Pasting Operations

Cutting and Pasting Operations

Choose the Shaded icon

in the toolbar to display the part as a shaded solid.

Choose the Play Forward icon.

Cutting and Pasting Operations

Redefining the Machining Environment

Redefining the Machining Environment

Delete Setup from the main menu bar.

More About Machining Environment

Redefining the Machining Environment

Redefining the Machining Environment

Redefining the Machining Environment

Choose the Geometry View icon

Choose the Machining Method View icon

Creating Tool Objects

Creating Tool Objects

Creating Tool Objects

Choose the Create Tool icon

Creating Tool Objects

Highlight TMCO_00001 HSS and OK.

OK to create the FACE_MILL tool object.

Creating Tool Objects

The FACE_MILLING operation now uses FACE_MILL as the cutting tool.

Creating Tool Objects