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NX CAM post processing errors: Machine data file generator vs. Post Builder

Article  in  FME Transactions · January 2016

DOI: 10.5937/fmet1602159Z

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 NX CAM Post Processing Errors:
Machine Data File Generator vs.
Post Builder
Replacing or upgrading software packages requires a detailed analysis
and testing.This is especially important for software modules that are part
Srđan Živković of the production process. Machining of free-form surfaces always
Head of Section requires using of a five-axis milling machine. Tool path post-processing
Military Technical Institute Belgrade, Serbia for these machines allways attracts special attention. The most important
Experimental Aerodynamics Division
Prototype Production Department
part of the postprocessor is implemented IKS (Inverse Kinematic Solver).
Implemented IKS in the postprocessor must accurately describe the
kinematics of milling machine in the production plant. Military Technical
Institute performed parallel testing of two postprocessing modules of
CAD/CAM system Siemens PLM NX: and old GPM (Graphics
Postprocessor Module and a new module MOM (Manufacturing Output
Manager). Complete analysis was sent to the NX support center and
application engineers confirmed that the old and new postprocessors do
not behave identically. The paper describes in detail the analysis and
explains the solution of the presented problem.

Keywords: Five-Axis Milling, Post processing, CAD/CAM

1. INTRODUCTION software in everyday engineering work.

Such a comparative analysis is made in the MTI
Any replacement of software, especially that on which (Military Technical Institute). It was concluded that for
directly depend on the flow and quality of the the same settings GPM and MOM do not generate the
production process requires a detailed analysis and same output NC (Numerical Control) code. It is
testing. In the manufacturing process there is no "Undo" concluded that there are differences in the applied
command. Errors produced on the machined parts will kinematic model in GPM and MOM modules for five
inevitably lead to the re-manufacturing work. It is clear axis milling machines with dual rotary heads.
that in such cases costs are multiplied. Siemens NX product support application engineers
The new version of Siemens PLM NX, starting from confirmed all the allegations MTI.
NX8, completely abandoned the concept of GPM post
processing, which has been in operation for more than 2. FIVE-AXIS MILLING MACHINES
20 years.
GPM (Graphics Postprocessor Module) is replaced Five-axis milling machines are classified according to
by a new, improved, MOM (Manufacturing Output the combination of linear (T) and rotary (R) axes. Even
Manager) module, which is based on the TCL (Tool though a large number of possible combinations, in
Command Language) programming language. practice five-axis milling machining are reduced to
Post-processing of tool path for five-axis milling three different types [1]:
machines, generated by the CAD/CAM system is a 1. RRTTT: Dual rotary tables type 5-axis machine
critical activity in engineering work. Kinematic model, 2. TTTRR: Dual rotary heads type 5-axis machine
implemented in the postprocessor must accurately
3. RTTTR: Rotary Table and Head 5-axis machine
describe the kinematics of milling machine in the For the five-axis milling of the second type
production plant.
(TTTRR), the analysis was performed by generating NC
Software upgrades or new modules must provide the
code with two different post processing module.
continuity of the production process. It is expected that
for the same settings MOM module generates identical 2.1 Dual Rotary Heads type 5-Axis Milling Machine
machining program as the old GPM module, whose
validity was confirmed in multiannual production. The 5-axis milling machine STARRAG NTV 225 is
The above reasons explain why such testing is shown in figure 1. It is a five-axis milling machine of
necessary before a complete transition to the new the second type (TTTRR) with three linear (X, Y, Z)
and two rotary axes (A, B) of the following technical
Received: September 2014, Accepted: September 2015 characteristics:
Correspondence to: Dr Srdjan Živković, Mech.Eng. • X-Axis: 1870mm
Military Technical Institute Belgrade, • Y-Axis: 900mm
Ratka Resanovića 1, 11030 Belgrade, Serbia • Z-Axis: 850mm
E-mail: [email protected] • A-Axis: ±20º, plane of rotation: YZ
doi:10.5937/fmet1602159Z
© Faculty of Mechanical Engineering, Belgrade. All rights reserved FME Transactions (2016) 44, 159-164 159
• B-Axis: ±20º, plane of rotation: XZ
• Pivot distance: varying in the range of 370 to 470
mm; manually adjustable pulling in/out of main
spindle.

Figure 2. Pivot distance measurement

Pivot distance measurement procedure requires

cylindrical mandrel, which is the top cut off exactly
halfway (maximum diameter), figure 2.
• First, the spindle of the machine is placed in a
vertical position (A = 0 and B = 0).
• Second, measure the distance from the working table
to the top of the mandrel. In figure 2 this distance is
marked as “N”.
• Third, the machine spindle (axis A or B, anyway) is
rotated for a known angle, for example 20°. In
Figure 2 this angle is marked by “α”.
• Fourth, measure the distance from the edge of the
rotated mandrel to the working table. In the figure 2
this distance is marked with “M”.
Figure 1. TTTRR - Starrag NTV 225 The distance of pivot point (pivot length), in figure 2
The control unit of the machine is Allen Bradley denoted as “L”, is calculated from the eq. (1).
OSAI 8600 CNC [2]. NC control unit is connected via (M − N )
DNC (Distributed Numerical Control) connection with a L= (1)
host computer. This connection is realized through a
(1 − cos α )
serial RS-232 interface. If the angle of rotation is 90 degrees, the obtained
Setting pivot distance on the five-axis machine tools equations are presented in the [3] and [4]. Calculated
is the most critical phase in the whole, otherwise a very pivot distance is compared with the value defined in the
complicated procedure milling complex spatial forms. postprocessor. If necessary, the spindle (manually by
Most of the errors occur at this stage. That is why setting handle) pull-out or retract to obtain a distance defined
the pivot distance requires special attention. Adjustment by the postprocessor, figure 3.
procedure is described in detail in the next chapter.

2.2 Pivot distance measurement procedure

In figure 1 are indicated the key elements for the pivot

distance measurement: machine zero, pivot point and
axis of the spindle.
In order to obtain accurate machining, it is necessary
that the distance from the tool tip to the pivot point of
the machine is exactly the same as the value defined in
the postprocessor.
Pivot distance (pivot length) measurement Figure 3. Different lengths of the cutting tool relative to the
pivot point; Pivot distance adjustment.
procedures are explained in the book [3] and webinar
[4] cannot be applied to all five-axis machines with Auxiliary cylindrical mandrel is removed from the
double rotating head. In cases where the five axis tool holders and in its place the cutting tool is put. Tool
milling machine does not have the technical capabilities tip relative to the pivot point at an unknown distance, in
to rotate the spindle for 90 degrees, such as the case figure 3 is marked as length "E". The spindle is pulled
with the five axis milling machine in figure 1, these out or retracted so that the tool tip comes at the same
procedures are not usable. position where it was previously cylindrical mandrel, in
Pivot distance measurement procedure presented in figure 3 marked as length "L".
[5] is applicable to all five-axis milling machines with After all the above steps, five-axis milling machine
dual rotating head. This procedure is more general; is ready for operation. For proper operation, it is
procedures presented in the [3] and [4] are just a special necessary that the distance of the pivot is always
case of the procedure presented in the [5]. accurately measured.

160 ▪ VOL. 44, No 2, 2016 FME Transactions

3. GPM AND MOM POSTPROCESSORS Figure 4 shows these steps [6]. The main drawback
of this concept is the multiplication of files on the same
Next, a very sensitive step is post-processing the tool path.
generated tool path for the appropriate combination of MDF (Machine Data File) contains a detailed
machine tool and its control unit. Postprocessor is a description of the machine tool and its control unit.
software product which translates the input APT Machine Data are defined using a special generator
(Automated Programming Tool) code in the NC MDFG (Machine Data File Generator). MDFG module
machining program. provides a summary listing of the generated post-
CAM module generates source code with the processor for a specific machine tool. Figure 5 shows a
appropriate data, and for the five-axis machining portion of the MDF listing, which shows the equations
processing has the following form: of conversion programmed part coordinates to machine
GOTO/x,y,z,i,j,k coordinates for five-axis milling machine with dual
GOHOME/x,y,z,i,j,k rotating head. Users are not able to change the equation
FROM/x,y,z,i,j,k of kinematic transformations.
GODLTA/x,y,z,i,j,k
The first three numbers are the position vector of the 3.2 Siemens NX MOM postprocessor
tool tip (x, y, z), the last three are components of the
vector axis of the cutting tool (i, j, k). Based on the GPM post processing module was replaced by a new,
kinematic model defined in the postprocessor, the improved, module MOM (Manufacturing Output
generated tool path is transformed into movement Manager). Both modules existed in parallel, including
commands of five axis milling machine for three linear version NX7.
axes (X, Y, Z) and two rotational (A, B).

3.1 Siemens NX GPM postprocessor

GPM postprocessor (CAD/CAM system Siemens NX

formerly Unigraphics), was developed in the 80s and 90s
of the last century, according to the needs and
requirements of ISO 6983 standard. Starting from the
source code of the tool path CLS (Cutter Location
Figure 6. MOM post processing procedure
Source) through intermediate steps BCL (Binary Cutter
Location) post-processing gives a final NC machining Similar to the concept of GPM, MOM module
program. requires several components [6], shown in figure 6:
• Events Generator is the basic module on the
CAD/CAM system level.
• Event Handler is a file that contains a set of
instructions that determine how each of the events is
to be processed.
• Definition File contains static information about a
specific combination of machine tool control unit.
Figure 4. CLS file is post processed according to MDF
instructions

Figure 7. Post Builder module: Rotary Axis settings; 5-Axis

milling machine, Dual Rotary Heads

Tool path is post processed using instructions from

the Event Handler and the formats in the Definition File.
Users can use Post Builder (PB) module to create a
Figure 5. Machine Data File Generator: Postprocessor postprocessor for its own needs [7].
summary listing; 5-Axis milling machine; Tool path Figure 7 shows the settings of the rotary axis in PB
coordinate transformation. module for five-axis milling machine shown in figure 1.

FME Transactions VOL. 44, No 2, 2016 ▪ 161

4. POSTPROCESSORS TESTING Tool path in figure 8 is quite short: there are exactly
40 lines with GOTO commands. For clarity, table 1
For testing purposes, using the PB module generated shows only 4 lines of tool path. It is enough to display
postprocessor with identical setting such as the post- the differences between GPM and MOM post-
processor generated using MDFG module. For the processor. Rows (x, y, z, i, j, k) are parameters of
machine shown in figure 1, the five-axes milling GOTO commands. The columns are labeled as sequence
machine with dual rotating head, set the following number to compare the calculated NC coordinates.
kinematic parameters:
• Three linear axes: X,Y,Z 4.1 GPM post processing
• Fourth Axis (Head)
For post-processing tool path, in the GPM module was
o Plane of rotation: YZ
used postprocessor StarS.MDFA (the name is an
o Word leader: A abbreviation of Starrag Srdjan), which was generated 15
o Axis limits: ±20º years ago using MDFG module. The validity of this
• Fifth Axis (Head) postprocessor has been confirmed multiple times during
o Plane of rotation: XZ a decade of its use. Milling machine in figure 1 is a key
o Word leader: B issue in the production of the model`s for wind tunnel
o Axis limits: ±20º testing. All parts are manufactured at the five-axis
• Machine Zero to 4th axis center: milling machine going full control of the geometry in
o X Offset: 0mm CMM (Coordinate Measuring Machine) [8].
o Y Offset: 0mm Table 2 shows the NC program generated by GPM
module for the CLS from Table 1. Rows are calculated
o Z Offset: -400mm
coordinate for linear motion of five axes (X, Y, Z, A, B).
o Angular Offset: 0º
o Pivot Distance: 400mm Table 2: NC code generated using GPM postprocessor

• 4 Axis Center to 5th Axis Center:

th
GPM: S T A R S . MDFA
o X Offset: 0mm N15 N20 N30 N40
o Y Offset: 0mm X 30.000 70.261 136.833 81.106
o Z Offset: 0mm Y 0.000 16.339 101.614 103.889
Z 25.800 17.886 -4.170 7.481
o Angular Offset: 0º
A 0.000 -1.302 -11.499 -11.014
o Pivot Distance: 400mm B 0.000 5.609 15.899 8.740
After generating the tool path in version NX6, it is
post processed using GPM and MOM postprocessor. 4.2 MOM post processing – 1st settings
Figure 8 shows the path: variable axis contouring, tool
axis normal to part, end-mill cutter diameter 14mm, The same tool path post-processed using NX/post
corner radius 0mm. Machining part is the fourth of the module. Post-processor StarS401.PUI is generated by PB
torus. The start and end position of the cutting tool is module. This post-processor has the identical settings as
vertical. StarS.MDFA. These settings are listed at the beginning of
this chapter. Table 3 shows the generated NC program.
Table 3: NC code generated using MOM postprocessor, 1st
settings

MOM: S T A R S 4 0 1 . PUI
N15 N20 N30 N40
X 30,000 70,264 136,835 81,107
Y 0,000 7,207 18,835 26,605
Z 25,800 17,990 4,489 15,018
A 0,000 -1,308 -11,943 -11,141
B 0,000 5,608 15,572 8,578

It is obvious, that the NC program in table 3,

completely different from the NC program in the table
Figure 8. Variable axes tool path prepared for post– 2. It is clear that the applied equations of kinematic
processor testing
transformation for five axis milling machine with dual
Table 1: Cutter Location Source Code, generated tool path rotating head are not correct. They should be the same
Tool Path: CLS
as the listing in figure 5.
N15 N20 N30 N40
4.3 MOM post processing – 2nd settings
x 30.0000 31.1750 29.4556 21.4447
y 0.0000 7.2502 21.8737 27.4694
z 25.8000 19.9040 18.8535 19.4085 To correct identified errors in the post-processor were
i 0.00000 0.09771 0.26845 0.14915 replaced of axes. "B" axis is declared as a fourth axis
j 0.00000 0.02273 0.19935 0.19106 and "A" as a fifth axis:
k 1.00000 0.99496 0.94244 0.97018 • Fourth Axis (Head)

162 ▪ VOL. 44, No 2, 2016 FME Transactions

 o Plane of rotation: XZ machining with dual rotating head inside MOM
o Word leader: B postprocessors are not correct.
• Fifth Axis (Head)
4.5 Solution of the problem
o Plane of rotation: YZ
o Word leader: A
The quickest and easiest solution of described
Such a setting is not in accordance with the standard problem is a modification custom command
EIA RS-267 (Axis and Motion Nomenclature for “before_motion“. It is necessary a variable that refers to
Numerically Controlled Machines), but takes into the Z axis reduce for the Z offset value of “Machine
account the independent and dependent rotational axes. Zero to 4th axis center”. Listing of the Post Builder
Other settings are retained. Version of postprocessors procedure is given below (TCL programming) [9]:
with this setting named StarS402.PUI. Table 4 shows
proc PB_CMD_before_motion {}{
the generated NC program. global mom_pos
Table 4: NC code generated using MOM postprocessor, 2nd mom_kin_pivot_gauge_offset
settings #Only manipulate Z output
Set mom_pos(2) [expr $mom_pos(2) -
MOM: S T A R S 4 0 2 . PUI $mom_kin_pivot_gauge_offset] }
N15 N20 N30 N40
X 30.000 31.165 27.256 20.325 In addition, it is necessary to disable a new IKS
Y 0.000 16.339 101.614 103.889 (Inverse Kinematics Solver). Listing of the Post Builder
Z 25.800 19.801 11.132 12.126 procedure is given below:
B 0.000 5.609 15.899 8.740 proc PB_CMD_revise_new_iks {}{
A 0.000 -1.302 -11.499 -11.014 global mom_kin_iks_usage
global mom_kin_rotary_axis_method
Table 4 shows the correct coordinates for the axis of global mom_kin_spindle_axis
rotation obtained by the post-processing (axes A and B). global mom_kin_4th_axis_vector
Obtained are identical to the values in table 2. When global mom_kin_5th_axis_vector
#Disable new IKS
comparing the linear axis, shows that the only Y-axis set mom_kin_iks_usage 0
correctly calculated, X & Z are not. MOM_reload_kinematics }
All other Post Builder settings must remain as
4.4 MOM post processing – 3rd settings
described in section 4.4. After all specified settings and
writing two procedures in the PB module, the generated
The third setting is changed only by the parameter NC program is correct. Just now, postprocessor for five
“Machine Zero to 4th axis center”: axis milling machines with dual rotary heads generated
o X Offset: 0mm using a PB module can be applied in everyday work
o Y Offset: 0mm without fear that machining parts will be defective.
o Z Offset: 0mm
Instead value minus 400mm, Z offset is set to 0mm. 5. CONCLUSION
Version of postprocessors with this setting named
StarS403.PUI. Table 5 shows the generated NC program. All presented considerations have been transferred to
Table 5: NC code generated using MOM postprocessor, 3rd NX product support engineers [10]. They confirmed that
settings the PB and MDFG behave differently. The reason is as
MOM: S T A R S 4 0 3 . PUI follows:
N15 N20 N30 N40 • In the Post Builder the offset is applied along the
X 30.000 70.261 136.833 81.106 tool axis.
Y 0.000 16.339 101.614 103.889 • In the Machine Data File Generator the offset is
Z 425.800 417.886 395.830 407.481 applied along the coordinate axes.
B 0.000 5.609 15.899 8.740 In their response explained [10]: “The reversal of 4th
A 0.000 -1.302 -11.499 -11.014 & 5th axes assignment is actually a bug with the early
stage of NX/Post, where the old IKS (Inverse
Table 5 shows the correct coordinates for the axis of Kinematics Solver) was implemented incorrectly”.
rotation (axes A and B) and two linear (axes X and Y) There’s no explanation as to whether this refers to the
obtained by the post-processing. Linear Z axis is still IKS within module MDFG.
not correctly calculated but noted that the 400mm It is obvious that the variables relating to “Machine
greater than it should be. Zero to 4th axis center” and “4th Axis Center to 5th Axis
This setting gave the closest results. Z coordinate Center” are incorrectly implemented in IKS. It is shown
value which is increased by 400mm (there is such the by the analysis presented. All postprocessors at GTAC
value of Z offset for the machine of figure 1) cannot be [10] have this variables are set equal zero. Clearly, they
corrected by setting inside the PB module. As shown in have not been tested with real values. If they did, the
the previous settings, by entering an appropriate value error would have been detected.
for the Z offset of „Machine Zero to 4th axis center" gets Unfortunately, none of the explained above is not in
totally incorrect NC program. NX documentations. Inexperienced users cannot find a
The final conclusion is that the equations of solution of described problem only by reading Post
kinematic transformations for five-axis milling Builder documentation.

FME Transactions VOL. 44, No 2, 2016 ▪ 163

 REFERENCES 2014.] (correspodence by a representative of
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tornih oblika metodama koordinatne metrologije), Војнотехничком институту у Београду извршена су
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