Introduction to Generative Machining

I-DEAS Tutorials: Milling Projects and Turning Projects

I-DEAS Generative Machining generates NC toolpaths

for 2-, 2 1/2-, and 3-axis milling operations, 5-axis
positioning, 2-axis turning, and the most commonly used
hole-making operations. The software includes tools for
planning all the manufacturing steps that result in a
finished part.
In this tutorial, youll learn the basic process for planning
a job.
Learn how to:

create an NC job
create an operation
define critical depths
create a finish operation
view all the toolpaths
1

Before you begin...

Prerequisite tutorials:

all tutorials under the Modeling Fundamentals

menu

Setup

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The file you need for this tutorial is distributed with the
product. You must copy it into your local directory.
Move to the local directory where you want to copy the
file. Then:
In UNIX:
cp $SDRC_INSTL/examples/nc/tut_nc_intro.arc .
In Windows use:
copy %SDRC_INSTL%\examples\nc\
tut_nc_intro.arc .
If you cant copy the file, you may have to set up the
variable needed to copy from the I--DEAS installation.
. sdrc_oadev
If you cant access the file, contact your system
administrator. The file may not be installed.

Setup

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If you didnt start I-DEAS with a new (empty) model file,

open a new one and name it ncstart.
File
Open
Open Model File form
Model File name: ncstart
OK
Make sure youre in the following application and task:
Application: Manufacturing
Task: Generative Machining
Set your units to inches.
Options
Units
Inch (pound f)

Setup

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Import the archive file that contains the parts and tools
that you need to complete this tutorial. Importing an
archive file can take several minutes. Be patient.
File
Import
Import Selections form
I--DEAS Archive File
OK
File Name Input form
Archive file name: tut_nc_intro.arc
OK
The Manufacturing application quits, an informational
message is displayed (the message will dismiss
automatically), and the archive file is imported.
Import Archive File Status
Check I-DEAS List.
Be sure to check the List region to be sure that the parts
imported properly.
Dismiss
A second informational message is displayed (the
message will dismiss automatically) and the
Manufacturing application starts.

Setup

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Recovery Point
File
Save
Warning!
If youre prompted by I-DEAS to save your model file,
respond:
No
Save only when the tutorial instructions tell you tonot
when I-DEAS prompts for a save.
If you make a mistake at any time between saves and
cannot recover, reopen your model file to the last save
and start over from that point.
Hint
To reopen your model file to the previous save, press
Control-Z.

Create an NC job

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An NC job represents your entire job plan. Its the

collection of setups, opgroups, and operations required
to machine a part.
A setup represents one fixtured configuration of
the stock, fixture, and clamps on the machine
table.
An opgroup is a container for grouping related
operations.
An operation contains all the information needed to
create the toolpath used to generate a standard CL
file.
When you create a job, the software creates the first
setup and opgroup. You will add the operations to fill the
opgroup and any additional opgroups and setups
necessary to complete the job.
When you delete the job, all the setups, opgroups,
operations, and other job entities are deleted too.

In this section youll create an NC job and use the

softwares tools to check the contents of your model file.
Youll also add a part instance to the setup and use the
softwares tools to check the setup assembly.

Create an NC job

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What: Create an NC job and check what is added to

your model file.
How:

NC Job Create form

Job Name: Block Job
OK

Manage Bins form

View: All
Things to notice
The following entities were added to the model file when
the NC job was created:
Block Jobthe NC job.
Setup-1_Assemblythe NC Setup. Later, this will
include the first configuration of part instances
representing the machine table, stock, clamps, and
other fixtures.
The other elements in the list were added when
the archive file was imported.
Dismiss
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Create an NC job

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What: Add a part instance to the setup.

How:

Get
From Bin/Library
Select Part/Assembly form
tut_block
OK

Create an NC job

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What: Check the contents of the setup assembly.

How:

Setup Specification form

Things to notice
The box on the right side of the form lists the part
instance you added to the setup.
Dismiss
Recovery Point
File
Save

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Create an NC job

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What: Move the part to the global space coordinate

system. The global space coordinate system acts as the
origin, or program zero, of the job. In later tutorials, youll
learn how to define a machine instance and specify
indexing.
How:

1 anywhere on the part

Move To

1
2
2 V4
Key In
Check I-DEAS Prompt.
Enter 0, 0, 0.
(accept)
(done)
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Create an NC job

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What: Bring up the NC Job Planning form to see the job

you created.
How:

Things to notice
The form contains a Setup--1 and an indented
OpGroup--1. This happens automatically when the NC
job is created.
For more complex jobs, youll need to create any
additional setups or opgroups on your own.
Dont close the NC Job Planning form.

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Create an operation

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An operation contains the information needed to

generate toolpaths. For a basic operation, you can
define the following:
the surfaces to be machined
the machining coordinate system (covered in later
tutorials)
bounding sections (covered in later tutorials)
the tool
machining parameters that specify how to cut the
part
the toolpath itself
The icons for completing these tasks are located on the
Operation Specification form.
In the next steps, youll create a face mill operation to
machine the face of the part. When creating the
operation, youll define a bi--directional cut pattern and a
cut type of Climb First.

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Create an operation

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What: Modify the opgroup by adding an operation to

machine the top of the part.
How:
NC Job Planning form
OpGroup--1

OpGroup Specification form

Operation Selection form

Category: Milling
Type: Face Mill
Create
Dont close the Operation Specification form.

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Create an operation

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What: Name the facing operation and select the surface

to be machined.
How:
Operation Specification form
Name: Face Mill Top of Part

Hint Use F1, F2, or F3 to position the part for easier

selection.
Dont close the Stock Specification form.

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Create an operation

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What: Define the stock. Youll learn more about

techniques for defining stock in later tutorials.
How:
Stock Specification form
System Defined Stock: On
With XY Offset of: 50
Stock Top: 0.25
Stock Top
The stock top is already selected, so just accept.

OK
Dont close the Operation Specification form.

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Create an operation

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What: Create a tool for the facing operation.

How:
Operation Specification form

Cutting Tool SpecificationMill form

Identifier: 1.5 inch Face Mill
Press the Tab key to advance to the next field.
I-DEAS Warning
OK
Style: Face Mill
Shank Diameter: 1
Holder to Tip Distance: 2.5
Max Depth of Cut: 2
Cutter Diameter: 1.5
Nose Radius: 0
Things to notice
The shape of the tool on the form changes as you define
its parameters.
OK
Dont close the Operation Specification form.

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Create an operation

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What: Define a bi--directional cut pattern and the cut

type as Climb First.
How:
Operation Specification

Machining Parameters: Cut form

Cut Pattern: Bi--Directional
Cut Type: Climb First
OK
Dont close the Operation Specification form.

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Create an operation

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What: Create and animate the toolpath.

How:
Operation Specification form

Animate Tool form

Things to notice
Because of the bi--directional cut pattern and the cut type
of Climb First, the tool stays in contact with the surface.
Also, notice that the tool goes past the edge of the
surface by 50 percent of its diameter because With XY
Offset Of is set to 50%.
Dismiss
Recovery Point
File
Save
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Define critical depths

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In the next few steps, youll define critical depths for an

operation. When generating a toolpath, the software
creates a series of axial depths of cut. An axial depth
that contacts a selected planar surface, whose angle to
the tool is less than the critical depth angle, is a critical
depth.
You can control the number of critical depths by which
surfaces you select. First, youll select the surfaces
composing the cavityexcept for the tops of the
bossesand generate a toolpath. Thus, youll have only
one critical depth for the bottom surface of the cavity.
Then youll modify the operation and pick the tops of the
bosses. These surfaces will add two critical depths to
your toolpath.

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Define critical depths

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What: Create an opgroup.

How:

NC Job Planning form

Deselect Face Mill Top of Part by
pressing the Control key and selecting
Face Mill Top of Part.

Things to notice Notice on the OpGroup Specification

form, OpGroup--2 is created. Because you deselected
the operation and opgroup on the NC Job Planning form,
the new OpGroup--2 is placed at the end of the Setup--1.
Dont close the OpGroup Specification form.

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Define critical depths

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What: Create a volume clear operation. This operation

will remove most of the material from the cavity.
How:
OpGroup Specification form

Operation Selection form

Category: Milling
Type: Volume Clear
Create
Dont close the Operation Specification form.

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Define critical depths

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What: Name the volume clear operation and select the

surface to be machined.
How:
Operation Specification form
Name: Cavity Milling

1 double--click on the face to select the cavity

Things to notice Although all the surfaces composing

the cavity appear to be selected, the sides and tops of
the bosses arent. The software will avoid the boss
surfaces and wont recognize the tops as critical
surfaces.
Dont close the Stock Specification form.

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Define critical depths

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What: Define the stock.

How:
Stock Specification form
Stock Top: 2.5
Stock Bottom: .5
OK
Dont close the Operation Specification form.

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Define critical depths

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What: Create a tool for the volume clear operation.

How:
Operation Specification form

Cutting Tool Specification form

Identifier: .5 inch Flat End Mill
Press the Tab key to advance to the next field.
I-DEAS Warning
OK
Style: End Mill
Shank Diameter: .75
Holder to Tip Distance: 4
Max Depth of Cut: 3.5
Cutter Diameter: .5
Nose Radius: 0
OK
Dont close the Operation Specification form.

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Define critical depths

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What: Set the machining parameters to machine the

cavity. Typically, you use a Spiral Out cut pattern to mill a
cavity so the slotting cut is in the middle of the cavity and
the last pass is along the walls.
Youll use an axial entry only because the selected
surfaces compose a closed volume. You define an Along
Path so that the tool enters by following the cutting
portion of the toolpath while sinking to the cut depth.
How:
Operation Specification form

Machining Parameters: Cut form

Cut Pattern
Cut Type: Climb
Axial Depths...
Axial Depths form
Maximum Depth of Cut: 0.5
1

(next to Maximum Depth of Cut)

OK

Dont close the Machining Parameters form.

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Define critical depths

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Machining Parameters: Cut form

Cut...
Axial Entry...
Machining Parameters: Entry form
Entry Type: Along Path
Sink Angle: 60
Axial Entry...
Planar Entry...
Machining Parameters: Entry form
Entry Type: Do Not Use
OK
Dont close the Operation Specification form.

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Define critical depths

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What: Create the toolpath.

How:
Operation Specification form

Recovery Point
File
Save

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Define critical depths

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What: View the second depth of the toolpath. Then

return to the full view of the toolpath.
How:

Things to notice
Because you didnt select the tops of the bosses, the
software didnt recognize them as critical depths. The
tool machined around them. Tool transition moves
between each machining region are displayed as
separate toolpath regions.

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Define critical depths

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What: Modify the operation to machine the tops of the

bosses.
How:

NC Job Planning form

Dont close the Operation Specification form.

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Define critical depths

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What: Pick the tops of the bosses to be machined.

How: When selecting the tops of the bosses, dont
deselect the rest of the cavity.
Operation Specification form

Stock Specification form

Hide Toolpath
1 shift double--click on surface to select boss
2 shift double--click on surface to select boss

Show Toolpath

OK
Dont close the Operation Specification form.
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Define critical depths

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What: Create the toolpath.

How:
Operation Specification form

I-DEAS Warning
OK

If your toolpath appears drastically different, modify

the operation, pick the surfaces again, and
regenerate the toolpath.
Recovery Point
File
Save

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Define critical depths

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What: View the first and second depths of the toolpath.

Then return to the full view of the toolpath.
How:

Things to notice
Notice that the toolpath now contacts the tops of the
bosses. You now have three critical depthstwo on the
tops of the bosses and one at the bottom of the cavity.
Notice as you cycle through the depths, the software
makes a pass around the bosses after roughing.

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Create a finish operation

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In the previous operation, you removed all the stock from

the floors of the part, but left .03 inches of material along
the walls. Now youll create a profile operation to clean
up the walls. (You can check the amount of material left
by the volume clear operation by modifying it and
checking the Machining ParametersAllowances and
Tolerances form.)
Youll also learn how to generate axial depths. Then,
youll delete two critical depths so the tool creates a
finish pass along the bottom surface of the cavity.

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Create a finish operation

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What: Create a profile operation to finish the cavity and

bosses.
How:

NC Job Planning form

OpGroup--2

OpGroup Specification form

Deselect Cavity Milling by pressing the
Control key and selecting Cavity
Milling.

Operation Selection form

Category: Milling
Type: Profile
Create
Dont close the Operation Specification form.

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Create a finish operation

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What: Name the profile operation and verify that the

surfaces are still selected from the previous operation.
How:
Operation Specification form
Name: Profile Walls and Bosses

Surface Selection form

Dismiss
Dont close the Operation Specification form.

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Create a finish operation

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What: Create a tool for the profile operation.

How:
Operation Specification form

Cutting Tool SpecificationMill form

Identifier: .375 inch Flat End Mill
Press the Tab key to advance to the next field.
I-DEAS Warning
OK
Style: End Mill
Cutter Diameter: 0.375
Nose Radius: 0
OK
Dont close the Operation Specification form.

37

Create a finish operation

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What: Set the depth of cut manually rather than allowing

the software to calculate it.
How:
Operation Specification form

Machining Parameters: Cut form

Axial Depths...
Axial Depths form
Maximum Depth of Cut: 2.5
1

(next to Maximum Depth of Cut)

Generate Depths

Things to notice
Notice that three critical depths are generated. The
depths still represent the tops of the two bosses and the
bottom of the cavity.
Dont close the Axial Depths form.

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Create a finish operation

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What: Delete the first two critical depths. When you

generate the toolpath, the software will create a finish
pass on the bottom surface only.
Then define the start point for the entry. Note that 2.5
inches is half the length of the part.
How:
Axial Depths form
2.000000 critical depth

1.500000 critical depth

OK
Machining Parameters form
Cut...
Entry...
Start Near: 2.5,0,0
OK
Dont close the Operation Specification form.

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Create a finish operation

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What: Create the toolpath. Animate the toolpath, if

desired.
How:
Operation Specification form

Things to notice
The toolpath has only one depth of cut along the bottom
surface of the part.
If you animate the toolpath, notice the small axes box
located in the upper left corner of the screen displays the
exact position of the tool tip as its shown on the screen.
You can use this display to check the actual tool position
at points between CL data points.
Recovery Point
File
Save

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View all the toolpaths

1 of 1

What: Scroll through the toolpaths. You can use these

commands to view the toolpaths in your setup quickly or
to find an operation to modify.
How:

Recovery Point
File
Save

41

Tutorial wrap-up
Youve completed the Introduction to Generative
Machining tutorial.
Warning!
Dont delete this model file once youre finished. Youll
use this model file and job in a later tutorial.

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