NX Manufacturing Fundamentals

Workbook April 2007 MT11021 NX 5

Publication Number mt11021_w NX 5

Manual History

Manual Revision

Unigraphics Version Version 16.0 Version 17.0 Version 17.0 Version 18.0 Unigraphics NX Unigraphics NX 2 NX 3 NX 4 NX 5

Publication Date March 1999 January 2001 June 2001 September 2001 September 2002 September 2003 November 2004 January 2006 April 2007

This edition obsoletes all previous editions. Proprietary & Restricted Rights Notice This software and related documentation are proprietary to UGS Corp. 2007 UGS Corp. All Rights Reserved. All trademarks belong to their respective holders.

NX Manufacturing Fundamentals

mt11021_w NX 5

Contents

The Manufacturing Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Create a Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fixture Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Create a Setup Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Set the Machining Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Set the MCS, Part, Blank, Check Geometry and Mill Method . . . . . 6-1 Create a Cavity Milling operation. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Visualize and Verify. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Face Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Drilling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 Post Processing and Shop Documentation. . . . . . . . . . . . . . . . . . . 11-1

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Lesson

The Manufacturing Process

The workbook project consists of various aspects of designing and machining a part of a manufacturing assembly. The manufacturing assembly is comprised of the work holding device, blank material, and the piece part, in this case a bracket. The bracket part is considered to be the Master Model and the work holding device and blank material are considered component parts of the assembly.

The manufacturing processes or methods that you will use, in this workbook, may or may not be the same approach, in order or content, that you would use at your company. The end result, the nal part, is the same. What is more important, in this class, is gaining an understanding of the methodology and application of using the various manufacturing options of NX, allowing you to customize tool path generation to methods or processes that you have become familiar with.

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1-1

The Manufacturing Process

The following owchart illustrates the Manufacturing process steps that you will use when creating and processing tool paths in NX.

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Lesson

Create a Clamp

In this section, you will create a clamp. Later, you will nish the setup assembly and create a setup sheet. You will then begin the process of programming the part to completion. Step 1: Step 2: Open the part seedpart_in and save it as ***_clamp_1 where *** represents your initials. Create a rectangular shape extrusion as shown below. Enter the entire expression as the value in the length elds (i.e. BLLG=5.25). Locate the block at WCS of 0,0,0. Note Expression names used will aid you in referencing the values used later in this project. BLLG=5.25 BLHT=0.75 BLWD=2.0

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Create a Clamp

2
Step 3:

The extrusionis created and is positioned in the location specied. Note the orientation of the extrusion with respect to the WCS. Expressions are also stored for the three equations that were keyed in. These expressions store the parameters used for the extrusion creation and allow the ability to modify the extrusion, if so required, with minimal effort. Change the work layer to 61. Create three datums that pass through the center of the part, based on width, length and height as shown.

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Create a Clamp

Step 4:

Create a slot 2.0 long by 0.625 wide by 1.0 deep. Position the slot to center it on the datums as shown.

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Create a Clamp

Step 5:

Create a boss on one end of the clamp. Make the boss .5 diameter by .5 tall. Center it on the end of the clamp.

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Create a Clamp

Step 6:

Create a slot on the under side of the clamp. Create the slot .375 wide, .1875 deep and centered on the datum plane.

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Create a Clamp

Step 7:

Blend the four outside corners, with .25 radius as shown.

Step 8:

Save and Close the part

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Lesson

Fixture Assembly
3

In this section, you will complete the assembly for the machining setup. Most of the setup has already been completed for you. Your task is to add two locating pins to accurately position the raw stock. Step 1: Open the assembly workbook_mfg and save it as ***_workbook_mfg where *** represents your initials. The current setup consists of the following: a tooling plate with multiple mounting holes (workbook_tooling_plate)

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Fixture Assembly

the designed part which is to be machined

the raw stock the part is being manufactured from

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Fixture Assembly

a window frame designed to hold the part in place while machining. The frame is the remains of the raw stock, designed with small holding tabs that attach to the part. After machining, the tabs are removed.

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Fixture Assembly

a set of clamps, holding the stock in place during the machining process

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Fixture Assembly

Your task is to add two locator pins at the location indicated.

Step 2:

Add the workbook_locator_pin to the assembly using the BODY reference set. Note The workbook_locator_pin is owned by another user and is write-protected. It may not be modied or saved. The assembly le is owned by you and may be modied and saved.

Step 3:

Mate the locator pin to the tooling plate by applying the proper mating conditions between the appropriate faces (A to A and B to B).

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Fixture Assembly

Tip Use the mating conditions of Mate (B) and Center (A). Step 4: Step 5: Add the last locator pin at the other designated location. Save and Close the part

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Lesson

Create a Setup Sheet

In this section, you will create a setup sheet showing the location of locator pins, clamps, stock and the MCS of 0,0,0. Step 1: Open the seedpart_in part and save it as ***_workbook_dwg where *** represents your initials. Add the ***_workbook_mfg to the assembly using the BODY reference set. Save the part. In the Assembly Navigator, turn off the display of the workbook_stock le. This will all the designed part to display in the drawing view. Enter the Drafting application and specify a drawing sheet where the units are inches, the scale is 1/8, the drawing size is A and the drawing name is SETUP1.

Step 2:

Step 3: Step 4:

Step 5:

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Create a Setup Sheet

Step 6:

Under Preferences, turn off Centerlines.

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Create a Setup Sheet

Step 7:

Add views to the drawing as shown. The TFR-TRI view is 1/12 scale (8.0833).

Step 8:

Save the part.

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Create a Setup Sheet

Step 9:

Dimension the part as shown.

Step 10: Save and close the part.

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Lesson

Set the Machining Environment

In this section, you will create a Machining Environment and dene numerous tools. Step 1: Step 2: Open the manufacturing assembly ***_workbook_mfg. Start the Manufacturing application and set the Conguration (1) to cam_general and the CAM Setup (2) to mill_planar. Initialize (3) the Machining Environment.

Step 3:

In the Machine Tool view of the Operation Navigator, create a Carrier and 15 pockets. Number the pockets 115.
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Set the Machining Environment

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Set the Machining Environment

Step 4:

Create the following tools: Pocket 1 2 3 4 5 Tool Flute Tip # of Diameter Length Material Type Length Flutes Angle End 0.75 2 1.25 3 Carbide mill End 0.5 2 1.25 3 Carbide mill Spot 0.5 2 0.75 2 90 HSS drill HSS0.6875 3 2.0 2 135 Drill Coated Boring Bar 0.75 3 0.125 1 Carbide Tipped

Step 5:

Save and Close the part.

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Lesson

Set the MCS, Part, Blank, Check Geometry and Mill Method

In this section, you will set the MCS, select the Part, Blank and Check geometry and then choose the Mill Method. Step 1: Set the MCS and an associative clearance plane, .5 above the blank geometry. Open the Workpiece object and set the Part (1), Blank (2) and Check (3) geometry as shown.

Step 2:

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Set the MCS, Part, Blank, Check Geometry and Mill Method

Step 3:

Set the Part material to aluminum.

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Set the MCS, Part, Blank, Check Geometry and Mill Method

Step 4:

Change the Program name to workbook_project.

Step 5:

Change the amount of Part stock in the mill_rough Machining method object to 0.05. Save and Close the part.

Step 6:

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Lesson

Create a Cavity Milling operation.

In this section, you will create a Cavity Milling operation. Step 1: Create a Cavity Mill operation as shown. Program Tool Geometry Method WORKBOOK_PROJECT EM-.75-0 WORKPIECE MILL_ROUGH

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Create a Cavity Milling operation.

Step 2:

Set the Cut Levels so the lowest cut level is at the face as shown.

Step 3: Step 4: Step 5: Step 6:

Set the Check Stock to 0.05. Generate the operation. Save the part. In the Program Order view, copy the CM_ROUGH_1 operation and rename it to CM_ROUGH_2.

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Create a Cavity Milling operation.

Step 7:

Edit the CM_ROUGH_2 operation, change the tool to .500 end mill, turn on Use 3D IPW, set the Global Depth of Cut to .1. Generate the operation. Save and Close the part.

Step 8: Step 9:

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Lesson

Visualize and Verify.

In this section, you will visually inspect and verify the previous tool paths that were created. Step 1: Step 2: Visualize and Verify the operations created in the previous section. Save and Close the part.

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Lesson

Face Milling

In this section, you will create a Face Milling operation. Step 1: Create a Face Milling operation to nish the faces. Program Tool Geometry Method WORKBOOK_PROJECT EM-.5-0 WORKPIECE MILL_FINISH

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Face Milling

Step 2:

Select all the faces, parallel in the XY plane as shown (dark areas).

Step 3: Step 4: Step 5:

Generate the operation. Verify the results. Save and close the part.

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Lesson

10 Drilling.

In this section, you will create drilling type operations. Step 1: Create a spot drilling operation. Program Tool Geometry Method Step 2: Step 3: Step 4: Step 5: Step 6: Step 7: Step 8: WORKBOOK_PROJECT SPOT_DRILL WORKPIECE METHOD

Spot drill the hole to a tip depth of .125. Create a drilling operation. Drill to model depth. Create a boring operation. Bore the hole to model depth. Verify the results Save and close the part.

10
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Lesson

11

11 Post Processing and Shop Documentation.

In this section, you will post process your tool paths and generate shop documentation. Step 1: Step 2: Post Process the workbook_project nc program. Create shop documentation for the workbook_project nc program.

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