UGS NX 3 CAM: Observations

A CIMdata Review

UGS NX 3 CAM: Observations

August 2004

Prepared by CIMdata
Alan Christman

http://www.CIMdata.com
Copyright 2004 by UGS and CIMdata, Inc. CIMdata is a registered trademark of CIMdata, Inc. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical photocopying, Recording, or otherwise, without prior written permission of UGS and CIMdata.

UGS NX 3 CAM: Observations

The capabilities provided by the suite of products under the NX 3 CAM umbrella, including manufacturing modeling, mold design, and progressive die design, combined with the information management functionality contained in Teamcenter Manufacturing results in a comprehensive, distinctive, and industry leading offering. In addition, the Efactory digital manufacturing capability, along with the interface to manufacturing execution systems, provides a broad and strong offering that encompasses an exceptionally wide range of needs in manufacturing engineering. CIMdata is favorably impressed by the UGS CAM program The new CAM capabilities introduced in NX 3 are substantial. In machining these include feature recognition, synchronization support for multi-function machines, use of an automatic trochoidal cut in high-speed milling, support of variable axes profiling, and major enhancements in usability, feature-based machining, integrated simulation and verification. In tool design there are enhancements for mold design and for progressive die design. Over the years, UGS has established a strong and positive market presence in CAM. In 2003 UGS was positioned by CIMdata as the largest CAM software vendor on the basis of revenue received. CIMdata projects that UGS will continue to be ranked as the largest CAM software vendor in 2004. The breadth and depth of functionality, data integration, and knowledge-based orientation of the NX CAM offering is impressive. NX includes robust capabilities across the entire CAM spectrum. The strengths of the UGS CAM offering include market presence, industry reputation in CAM, integration from design through manufacturing, and being among the industry leaders in mold base design, progressive die design, high-speed machining, and 5-axis machining of complex components. CIMdata is also favorably impressed that UGS continues to develop standalone solutions for specific industry application areas within manufacturing. Full internal development of the modeling capability, toolpath generation, post-processing, visualization and simulation, and information management, as compared to the use of third-party products, is unique. It provides for a complete machining solution within NX. Common data is shared by all applications.

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This facilitates a single user interface, enhances data integration among all components in the NX Machining solution, and provides the user with a single point of contact.

User Productivity
UGS continues to make NX Machining easier to learn and use. The new graphical content in the user dialogues clearly indicate required user interaction. The NX Machining Wizard leads a user The Feature Manager in NX Allows Control of Machining Features step-by-step through a task from A new Feature Manager was introduced in setup through a complete process. A MachinNX 3 to create and recognize manufacturing ing Wizard Builder provides a visual develfeatures, organize and prepare manufacturing opment environment to create a Wizard withfeatures, assign selected manufacturing feaout writing code. tures to CAM geometry groups for processing, remove unwanted features by Feature-Based Machining selecting from a list, display manufacturing Significant progress is being made in featurestatus, and provide overall management of the based machining (FBM), including a new features to be machined. Feature groups can feature recognition capability. In NX 2, FBM be created from selected features. With the was only employed in hole making, as this Feature Manager the user can view the full was an essential first step. In NX 3, a broader feature content and be assured that the feature-based milling capability is being profeatures are being machined with the vided to support fixed tool axis, planar-cut appropriate process. features. This permits the use of FBM in cavAn internally developed rules-based and ity milling and face milling. Features for Knowledge Fusion-enabled feature recognimilling can come from CAD, tagged geometion capability is available in NX 3. It autotry, feature recognition, direct user selection, matically detects holes, open and closed slots or as a user-defined feature. The model to be and pockets, any flat area, fillets on walls or employed can be from any design system, as the floor, islands, and peninsulas. At this an NX (i.e., formerly known as Unigraphics) point, a planar floor is required. User defined model is not required as a starting point. The features can also be generated so that one can software utilizes the NX Knowledge Fusion pick any area and define it as a feature. Feafunctionality. ture recognition is an important and essential

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component of feature-based machining and programming automation.

Multi-Functional Machining
In NX 3 major strides have been made in multi-functional machining. Integrated millturn and support of balanced turning for 4axis lathes is now provided by employing the new synchronization function in NX 3. Complex machines are supported such that multiple devices can move simultaneously. Milling and turning can be accomplished on the same spindle. A Synchronization Manager calculates machining times, allows the insertion and editing of wait and sync marks, permits rearranging operations and events into the proper time sequence, and provides a time bar for visualizing the machining process. These changes are a significant step forward in support production machining operations. Multiple spindles and turrets are each programmed individually. The data is then postprocessed to create the time elements, and the results are passed to the Sync Manager where

the sync and wait marks are added to obtain the desired concurrent operation. The software knows where each tool is mounted on the turret. There is no limit on the number of turrets or spindles. Currently, the synchronization is done manually, as users select the parameters. In the future, rules will be established to further optimize the process.

Fixed-Axis Milling
Cutting enhancements are included in NX 3 fixed-axis milling. A manual cut pattern now provides added flexibility in toolpath definition. It supports both vector and point moves. Automatic cut levels can also be established at critical depths. Z-level adds additional cuts as required to reduce the gaps left by Z-level machining in non-steep areas. This can eliminate a follow-up operation to remove the excess material left behind. A level-based inprocess workpiece is provided in cavity milling to simplify the visualization and provide for a faster and cleaner toolpath. The in-process workpiece is updated at each cut level. This in-process workpiece can be used with holder collision avoidance in a series of operations with various tool lengths for automatic rest milling. In addition, part material, tool material, cut method, tool diameter and length, and machine rigidity data are now being used to establish feed rates, spindle speed, depth of cut, and stepover distance.

The Synchronization Manager in NX Provides a Graphical UI for Setting Up Multi-Function Machining Tasks

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Enhancements to High-Speed Milling

High-speed milling enhancements introduced in NX 3 include a corner cleanout feature, an automatic trochoidal cut, and a routine that automatically adds additional tool passes to maintain a constant uncut material depth. UGS also provides a library of speeds and feeds for high-speed milling of P20 steel, and a methodology for users to assess the performance of their own machine and tool combinations, and add their optimal machining data to the library. The trochoidal strategy is initiated automatically when heavy material is present and/or when the distance between cutting paths exceeds a given amount, which is likely to occur in corners. With these improvements, UGS will re-enforce its position as one of the industry leaders in support of high-speed milling.

matically generate a toolpath to machine the walls of a cavity or a region bounded by floors and walls, with the side of a cutter. Geometry is selected by part, floors, and walls. After selecting the floor, the system will automatically find all the walls that bound the floor. Multiple regions of a part can be processed simultaneously. The tool axis is constantly adjusted to obtain a smooth path. The swarf cutting is automatic. This strategy is appropriate for machining pockets with canted walls, such as those found in aerospace parts.

Tool Axis Interpolation

Tool axis interpolation is another strategy for contour profiling in 5-axis. In this case, the tool axis is controlled within multiple vectors. The vectors are picked by the user. A flat floor is not required. This technique is appropriate for twisted surfaces. A new smoothing option is available for tool axis interpolation in NX 3. It is ideal for complex situations where full control of the tool axis is mandatory to avoid collisions with the part. These new advanced cutting strategies strengthen the UGS position as the premier CAM software supplier for performing 5-axis milling on complex components.

Visualization and Simulation

Unlike most NC software vendors that utilize third-party products, the visualization and simulation software is internally developed by UGS. This permits greater integration with toolpath generation and post-processing, which are also internally developed by UGS. UGS offers three levels of visualization and simulation; replay of toolpath, material

The Trochoidal Toolpath In NX is Automatically Inserted when User-Defined Conditions are Met

Variable Axis Contour Profiling

This is a new module in NX 3. It is a swarf cutting technique that allows a user to auto-

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removal visualization, and complete simulation of a machining operation with the kinematics of a machine tool being considered. Visualize includes the basic toolpath verification capability and ISV provides full machine tool simulation, including recognition of the fixtures and kinematics of the tool. The inprocess workpiece functionality in Visualize and ISV has been upgraded in NX 3 to include a 3D dynamic option for creation of the in-process workpiece, translucency of the in-process workpiece, a measurement capability, and pan, zoom and rotate viewing control during playback.

management engine for all NX 3 manufacturing applications. The integrated combination of CAM, digital manufacturing, and tool design utilizing Teamcenter Manufacturing as the core component, provides a solution that is unmatched in the industry. CIMdata is also favorably impressed by the introduction of the Part Planner application within Teamcenter Manufacturing. The acceptance of process planning software is beginning to accelerate in the industry. UGS is in a position to become a market leader in support of this application area.

NX Offers Advanced Machine Tool Simulation that Runs in the NX Programming Environment

Teamcenter Manufacturing
Teamcenter Manufacturing is a powerful and unique product. No other product offers such extensive and distinctive information management functionality that is focused on manufacturing. It serves as the information

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