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If needed, when defining the MCS you can set a cylindrical clearance.
Step 2 – Process design
Decide if:
1. More than one roughing operation is needed. If so, you must define and use a blank in order to do efficient re-
roughing in a second step. If not, you don’t need to define blank - it impacts the performance of generating the
roughing operation. The fact that only ball tools are supported in this version may influence this decision. (note: NX
9 can rough turbo components with flat and bull-nosed tools.)
2. Blades should be finished all around or leave edge(s) to be milled by a separate edge finish operation. The fact that
the current version does not contain a dedicated edge finish operation may influence this decision.
Step 3 – Workpiece
In the workpiece define the following:
• Part – the geometry in the “zone of interest”. Hub, blade, blend and splitters must be subset of Part. Selecting too
many faces (i.e. – on the other side of the impeller) will impact the performance.
• Check - any geometry that may interfere with the expected toolpath. Selecting geometry clearly outside the milling
zone will impact performance. Blade, blend, hub and splitters in the milling area are considered. No need to define
them as Check.
Check geometry is not instanced. In case there are Check geometry faces / bodies attached to each blade / splitter, you
must select them all.
If the trailing edge of the blade is part of one rotary face all around, this face is not part of the blade geometry, so it is
recommended that you select it as a check. In some rare cases the top of the blade also needs to be selected
as Check (when the shroud is not part of the blade geometry).
In some rare cases the tool needs to tilt so much that interferes with a blade beyond the milling zone (not the one bounding
the milling zone). In this case it needs to be explicitly selected as Check.
Other cases where using Check is required.
In the case when Check geometry is needed locally for one operation but interferes with other operations, it should be
selected from within the operation dialog.
• Blank – required only if an In-Process Workpiece (IPW) consideration is needed (see step 2 above). If required,
select the geometry used for turning.
• Blade – select Blade faces without blend and top. These faces can span to the Hub, can go below it or leave a gap
from it (as long as the gap between the Hub and the Blade / blend is larger than tool radius).
Note: the area to be rough milled is to the right side of the selected Blade (CCW around rotary axis).
Usually, the trailing edge is not included in the Blade definition. But in case the trailing edge needs to be selected as part of
the Blade, but is actually part of a rotary face around the Blade as shown here...
...then you need to extract that face (if it is a solid body) and trim it so that the applicable portion of it could be selected:
• Blade Blend – specify Blend geometry. This is not a required input in the case when the geometry does not contain
it, yet it is required that the radius of the used tool is larger than the expected Blend radius.
• Splitters – through the Define Splitters dialog you can define up to 5 different Splitters.
Each Splitter is a combination of wall faces and blend faces. The selected Splitter should be next to the selected
main Blade on its right (CCW about the axis). In the case where there are multiple Splitters between two
main Blades, select them in sequence from left to right. Each Splitter should be selected separately, even if
two Splitters share identical geometry to their surrounding (otherwise this can slow down tool path generation).
• Number of Blades – Number of main Blades on the impeller.
Step 5 – Operation creation
Create each operation using an appropriate template.
Make sure that the operation Geometry is set properly as the defined BLADE_GEOM.
Based on the specified Blade Stock, Tilt Angle, Allowance for gouge prevention, and compensation for smoothing, the
system attempts to use the defined tool to mill the entire part. You can specify tools that are too large to mill the whole
volume, but it may be easier to use a smaller / longer tool than to specify additional operations.
TITLE
Turbomachinery Milling with NX CAM Part 2, Roughing
URL NAME
turbomachinery-milling-with-nx-cam-part-2-roughing
LANGUAGE
English
SUMMARY
Briefly describe the article. The summary is used in search results to help users find relevant articles. You can improve the
accuracy of search results by including phrases that your customers use to describe this issue or topic.
DETAILS
Article description
Overview
This is article 2 of a 3 part series that describes the steps and considerations for milling a multi-bladed part using NX CAM
Turbomachinery Milling.
Part 1 - Setup
Part 2 - Roughing
Part 3 - Finishing
To avoid that you may want to do one or more of the following changes:
• Tool Axis dialog – change “Rotate about” option “Part axis” to “Blade” and / or decrease the tilt clearance angle.
• Cutting Parameters dialog – decrease Blade Stock, decrease Part Safe Clearance, change the Axis
Smoothing % and the Max Blade Roll Angle.
• Change tool and / or cut levels.
“Crossing paths” are not necessarily bad. Remember that the tool path displays tool tips, but the contact point moves around
depending on tool tilting. The tool tip locations may cross each other while the contact points with the hub are as expected.
Based on the blank material knowledge set the Tangential Extensions and Radial Extensions to provide full coverage.
Tangential Extension = 50%Tool; Radial Extension = 0% tool
• Offsets from shroud - each cut level is created on constant offset surface patch from the shroud. In this case the
depth of cut is constant as the lower cut levels reach the hub, the passes are not trimmed, but rather extended along
the hub to perform passes connections outside the impeller.
• Interpolate from shroud to hub – The hub level and the shroud level are interpolated to determine intermediate
cut levels. In this case the depth of cut varies along the pass.
Set the Range Depth.
• Automatic would span the cut levels across the whole depth to be milled, while Specify allows you to determine
the number of cuts to be milled.
• For Offsets From Hub or Offsets From Shroud the system will generate the specified number of cuts spaced by
the depth per cut distance, while for Interpolate From Shroud to Hub the given number of cuts is equally spaced
across the whole depth to be milled.
• For interpolate from shroud to hub the user can limit the cut volume by changing the Start % (highest cut level)
and the End % (Lowest cut level).
Press the Display button to generate the preview. The preview here shows the cut levels as distributed along the blades and
splitter(s). Change parameters as needed to get proper results previewed. Note that this preview also shows the passes
extensions on the higher cut levels, so you may want to switch to the drive method dialog to fine tune some parameters
there.
Step 4 – Specify the tool axis orientation
The tool axis orientation is controlled by the settings in the Automatic Tool Axis Orientation dialog and the Tool Axis
Control tab of the cutting parameters.
In the Automatic Tool Axis Orientation dialog:
Tilt Clearance Angle - controls the minimal allowed deviation between the tool and the blades / splitters:
Path Smoothing %= 30
Blank Stock– inflates the blank or the IPW.
Shroud Stock – offsets the shroud to control the higher cut levels. Negative value causes the highest cut level to start
deeper below the shroud. Positive values are not supported initially, but when implemented will add cut levels above the
shroud.
Blade Stock and Hub Stock– minimum allowed remaining stocks on the blade and hub respectively. Blade Stock value is
used for all blades, blade blends, splitters, blend splitters and check geometries. In some cases where the outer passes are
hazy set Blade Stock ≠ Hub Stock.
Part Safe Clearance – set additional clearance from the holder to the part and check geometries. Note the in case of tight
geometries this value should be minimized. This is especially true for cases where a portion of the tool is described as holder
(i.e. the cylindrical portion of a taper tool).
Step 6 – Blank consideration
If blank was defined in one of the geometry groups the operation inherits from it will be considered. That means the same
motions are initially calculated, but all motions where the tool is not touching the blank are trimmed. Non-Cutting Moves
(NCMs) are used to connect across the gaps. In the Cutting Parameters dialog user can select to consider 3D
IPW instead of Initial Blank. That means that an internal simulation is used to calculate the IPW state after all previous
operations milled the initial blank. In this case the user can further control: Minimum Material Removed, Hookup
Distance, and Minimum Cut Length – a cutting motion smaller than this values is neglected
This is also the order these parameters are considered (so small gaps are hooked up before removing small segments).
Blank consideration is optional. In the classic case where the blank is initially turned to the shroud level, having the blank
defined will increase the generation time without changing the result. Blank is needed only if one of the next operations
uses 3D IPW consideration. IPW calculation is time consuming. To save time on next regenerations it is recommended to set
“Save IPW Model” in the Manufacturing Preferences / Geometry / In Process Porkpiece menu.
Step 7 – Non Cutting Motions (NCMs)
All Non Cutting Motions options and controls are identical to rest of the operations. Every connection between leading and
trailing edges is considered “Between Region.” Connections from one cut level to the next is controlled by the Region
Distance as long as it is done on the same edge. A new option “Smooth” traverse type was added in NX 7.5. Though
available for all operations, it is very effective using it with the family of these of operations.
Step 8 – First cut feed rate First pass at each cut level is a slotting pass.
In the Feeds and Speeds dialog the user can set a slower First Cut feed rate for this slotting motion. In case one or more
splitters exist, the first pass at each segment is controlled by the First Cut feed rate. Visualize these first cuts using the Edit
Display / Path Display Colors and set the color of the First Cut motions to be different than the Cut motions.
Step 9 - Generation results assessment
After generation use the Verify Tool Path to assess the results. Being a cut level-based operation it is
recommended to use the ‘Current Level’ display, and to check the ‘Pause at Each Level’.
This way you can navigate between levels using the buttons.
Visualize the tool path to see if all levels are completely cut, if changes to the extensions or other controls need to be
done. Visualize the tool motions to see if tool axis control parameters are set properly. Additionally, the Operation
Navigator provides Gouge Check capabilities as a MB3 option for the operation.
Step 10 - Instancing
Programmers are expected to program the these cuts just once, for a single blade/splitter sequence. Tool paths are then re-
used, or "instanced" around the hub as needed. There are a few ways to accomplish this:
• Using the Operation Navigator, Object / Transform for this operation
• Let the post processor process the operations as Macros. NX outputs the macro code needed for this as part of
these operation types, so the post can make the "define as Macro" code, followed by the several "use Macro" codes.
• Output the G-code once and then manipulate instances using the controller. For example the operator could simply
index a rotary axis and rerun the cuts as needed. This is the most manual method.
In the case that the machinists desire to cut in a sequence that roughs, then finishes one level at a time before roughing
deeper (sometimes a requirement for thin blades), the instancing of these operations needs to account for this sequence
preference. These operations are level-based, and so have a level marker at each level. This enables the post to process
these where N levels are cut at once, than in the next instance same N levels are cut and so on till N levels are cut all
around. Than next N levels are cut in the first instance and so on. (Note that NX 9 includes specific support for cutting these
kinds of rough/finish sequences without resorting to such post processor gymnastics.)
Hub Finish
Hub Finish is actually the lowest cut level out of the rouging operation, so all steps described for the roughing are identical
for the Hub Finish excepting step 3 – cut levels and step 6 – blank consideration. Also, Hub Finish does not require shroud
geometry as input. Hub Finish covers only the hub and not the blends. In case opposing blends touch (overlap) each not
leaving space for the hub, this portion will not be finished and non-cutting moves (NCMs) will connect the gap.
TITLE
Turbomachinery Milling with NX CAM Part 3, Blade Finishing
URL NAME
turbomachinery-milling-with-nx-cam-part-3-blade-finishing
LANGUAGE
English
SUMMARY
Briefly describe the article. The summary is used in search results to help users find relevant articles. You can improve the
accuracy of search results by including phrases that your customers use to describe this issue or topic.
DETAILS
Article description
Overview
This is article 3 of a 3 part series that describes the steps and considerations for milling a multi-bladed part using NX CAM
Turbomachinery Milling.
Part 1 - Setup
Part 2 - Roughing
Part 3 - Finishing
The system will spend some time to generate the lower rail along which you can define the orientations and the system
points defined by a yellow arrow:
In case the geometry is not contiguous or tool not defined you may get some warnings / error messages same as during tool
path generation.
You will also get the Interpolated Vector dialog:
There are a few activities you can do at this stage:
Display preview of tools along lower rail
• Click the display Preview button:
• You will get tools displayed at interpolated locations and orientations according to settings in the list:
• Those tools are colored green for safe positions or red for gouging positions. Those settings are controlled by User
preferences.
• To clear those images – refresh the screen (use refresh command or F5)
Change orientation of that tool at system points
• Select one of the arrows on the screen or from the list in the dialog. You will get the tool displayed at that point and a
dynamic CSYS.
• Grab one of the rotary handles and rotate the tool to the required position:
• You can also enter the angle or change the dynamic snap angle from the GUIF (key-in box that accompanies
interactive handles)
• In order to copy the initial orientation from another point right click on the other point and select “Use This
Orientation”
• The point was added to the list and you can change its orientation using all options described for system points.
• User points can be moved to any other point along the rail. Any attempt to place it off the rail will snap it to the
closest point on the rail.
• To remove a user point select it and either press the X button near the list or right click on the arrow and select
“Remove”.
While rotating a vector, system can dynamically show the impact of the action on closest locations (including
gouge check).
• To do so check the Preview checkbox in the dialog:
• Result:
To clear those vectors – refresh the screen (use refresh command or F5).
Tilt Clearance Angle is not active in NX7.5.2.
In NX8 it will provide same safety clearance from the part as in Automatic tool axis.
Reset to Default from the dialog will delete all user points and will reset all system points to the default orientation.
When copying an operation to another file or copying it to be used for a different blade / splitter in the current file it is
recommended to use it to avoid applying irrelevant settings.
The list in the dialog contains all points. For each point it shows: