PBT mt11060 W

Post Building Techniques
Workbook
[Date]
MT11060 Post Builder 3.5
Publication Number
mt11060_w NX 5
Manual History
Manual
Revision
Unigraphics
Version
Version 17.0
Version 18.0
Unigraphics NX
Unigraphics NX 2
NX 3
NX 4
Publication
Date
February 2001
May 2002
February 2003
March 2004
May 2005
July 2006
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.
Post Building Techniques Workbook
mt11060_w NX 5
Contents
Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Collecting Data for Post Processor Creation . . . . . . . . . . . . . . . . . . 2-1
Building a Post Processor with Post Builder . . . . . . . . . . . . . . . . . . 3-1
Post Builder: Program and Tool Path Functions . . . . . . . . . . . . . . . 4-1
Post Builder: Custom Command Functions . . . . . . . . . . . . . . . . . . . 5-1
Post Builder: N/C Data Definition Functions . . . . . . . . . . . . . . . . . . 6-1
Post Builder: Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Advanced Customization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Checklist of Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Supermill Technical Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
UGS Supermill . . . . . . . . . . . . . .
Milling Options . . . . . . . . . . . . .
Tool Length pre-setting options .
Chip Conveyor . . . . . . . . . . . . . .
Dust removal system (vacuum) . .
Measurement options . . . . . . . . .
Specialized Application Software
Supermill CNC options . . . . . . . .
Programming Functions . . . . . . .
MILLING ACCESSORIES . . . . .
Services . . . . . . . . . . . . . . . . . . .
UGS Corp., All Rights Reserved
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. B-3
. B-6
B-10
B-11
B-12
B-13
B-14
B-15
B-16
B-20
B-21
Lesson
Project Description
The Post Processor Development project is an ongoing activity that

incorporates the skills required to build a post processor. During the course of
working through this workbook, you will be asked to build a post processor
for a fictitious 3-axis machining center with some specialized codes. After you
finish this post processor, you will be asked to customize this particular post,
using the techniques presented in the customization and modification lesson.
You will begin this project by following the normal steps of researching
an operator/programmer manual to obtain the various axis limits, word
addresses, and functionality codes needed to operate the machine tool. As
an aid, a checklist will take you through the various steps necessary to
collect this information. This will assist you in the process of building a post
processor using the Post Builder. It also allows for a convenient method of
keeping a record of this data for future use.
NOTE: Due to time constraints, most of the information necessary to build
your post processor will be provided on a preprinted checklist.
You will debug the post processor, using the tool paths from the provided
part file.
The Post Processor Development project will provide general direction as
what to do but will not give explicit button pushes. You will see in this project
how the Post Builder will expedite the process of building a NX/POST post
processor.
It is the intent of this activity to allow you to apply the skills taught in this
course. However, the time constraint of this course is a factor, at any point
when progress is not being made, ask for the help of your instructor.
1-1
Project Description
The following flowchart indicates the process steps to follow for building a
post processor. You will use this flowchart as a guide throughout this project.
1-2
mt11060_w NX 5
Lesson
Collecting Data for Post

Processor Creation
2-1
Collecting Data for Post Processor Creation
One of the first steps in development or modification of a post processor is the

collection of data that is necessary for generation of the proper output.
An excellent source for this data is usually the programmer/operators manual
and or technical manual supplied by the machine tool builder. These manuals
are usually large and sometimes cumbersome to use when building a post
processor interactively.
An easier approach to collating the data would be filling out a checklist that
would suffice for the majority of the information needed without having to
leaf through the various manuals numerous times. A checklist that can be
used as an aid to post processor development can be found in Appendix A
of this manual.
In this section of the workbook project, you will collect the necessary data
needed to build a post processor for a 3-axis machining center.
Step 1:
Quickly glance through the UGS Supermill Technical Manual,

located in Appendix B of this workbook. Notice the location of
various tables and parameters which are needed for post processor
development.
Machine technical specifications, operator and programmer
manuals are excellent sources of information for the development
of post processors.
Step 2:
Using the checklist provided (also located in Appendix A), collect

information from the UGS Supermill Technical Manual applicable
for generation of a post processor.
NOTE: Due to time constraints, most of the information needed has been
collected. Please fill in areas that are blanked.
The checklist allows you to collect information needed for post processor
development in an orderly and concise manner and can be used as a quick
reference when modifying or checking parameters at some future date.
2-2
mt11060_w NX 5
Lesson
Building a Post Processor

with Post Builder
3
The Post Builder can currently create post processors for 3-axis, multi-axis
milling type machines, 2-axis lathes, Wire EDM and mill-turn centers.
Post processors for special type machines must be created manually by the
creation and or customization of Event Handlers and Definition files.
3-1
Building a Post Processor with Post Builder
3-2
mt11060_w NX 5
Building a Post Processor with Post Builder
Post processors currently created by the Post Builder can be further

customized, for specialized machines or machines not handled in their
entirety by the Post Builder, by modification of the Event Handler and
Definition files.
You will now use the Post Builder to create a post processor for the UGS
Supermill machining center.
Step 1:
If necessary, start the Post Builder module.
Step 2:
Create a new post processor with the name ***_supermill_3ax,

where *** represents your initials.
Step 3:
Save your post to the home post processor directory.
Note
The file post_commands_test will be used for testing your
post processor.
Step 4:
Using the checklist created from the previous lesson, specify the
units for output and type of machine.
Note
Currently, Post Builder supports 3-axis mills, 4 and 5-axis
machining centers, 2-axis lathes, Wire EDM and mill-turn
centers.
Step 5:
Specify axis travel limits, linear motion step size and traversal
feed rate.
Step 6:
Save the contents of the post processor.
Step 7:
Include your new post in the template_post.dat file.
Step 8:
Start a NX session, retrieve the part post_commands_test, and

enter the Manufacturing application.
3-3
Lesson
Post Builder: Program and

Tool Path Functions
The Program and Tool Path section of the Post Builder allows for creation,
modification and customization of the Event Handlers for all Events which
occur by the use of five functions. These functions, are:
Program allows for the addition, modification and customization of Program
Start Sequences, Operation Start Sequences, Tool Path Sequence including
Machine Control, Motion and Canned Cycle sequences, Operation End
Sequences and Program End Sequences.
G Codes allow for the modification of the actual G code. M Codes allow for
the modification of the actual M code.
Word summary provides a summary of all word addresses and allows the
individual modification of the various elements used in data definition of
the address.
Word sequencing allows the customization of the order of output of words
which comprise a block of N/C data.
Custom Command allows for the addition of user created commands.
4-1
Post Builder: Program and Tool Path Functions
You will now use the Program and Tool Path section of the Post Builder
to modify program start and end, operation start and end and tool path
sequences.
4-2
Step 1:
If necessary, retrieve your post processor, ***_supermill_3ax.
Step 2:
Examine and if necessary, modify the Program Start Sequence,

Operation Start Sequence, Tool Path Sequence, Operation End
Sequence and Program End Sequence.
Step 3:
If necessary, modify or add preparatory functions.
Step 4:
mt11060_w NX 5
Lesson
Post Builder: Custom Command

Functions
TheCustom Command section of the Post Builder allows for creation,

modification of custom commands.
You will now use the Program and Tool Path section of the Post Builder to
create and or modify custom commands.
Step 1:
Step 2:
Using the custom commands feature, add the required proc,

from pb_cmd_tape_utils giving you the length of the file at
the end of the program. Also add pb_cmd_path_header and
pb_cmd_program_header. These two programs can be found in
your workbook subdirectory.
Step 3:
Step 4:
Use the tool paths from the part post_commands_test to test and
verify the accuracy of the output.
Step 5:
Using the Custom Commands feature, add the custom command,

pb_cmd_tool_list, which will output tool information.
NOTE: Only the tools used in the program being post processed
will be listed. In order to create the tool list, you MUST add the
command PB_CMD_create_tool_list to either the Start of Program
or the End of Program event marker depending on where the tool
list is to be output in your program. The Shop Doc template file
pb_post_tool_list.tpl residing in the postbuild/pblib/misc directory
is required for this to function.
Step 6:
5-1
Lesson
Post Builder: N/C Data

Definition Functions
The N/C Data Definitions section allows for the definition of output formats
for N/C data. Data definitions are broken down into four sub classes. These
sub classes are:
Block which defines the format of the instruction data that appears as output.
Blocks are made up of word elements, each being defined by an address and
variable.
Address which defines the output format and the structure of the words that
comprise the instructions. Parameters associated with address are format,
maximum and minimum values, modality and leading and trailing characters.
Format for data output can be defined as real, integer or character string.
Parameters for Format vary according to the data type selected. Real numbers
are generally used for co-ordinate values; integers are used for registers and
character strings are used for commentary messages and special output.
Other Data Elements allow for the control of sequence number output, the
use of special characters for word separation, end of block and message
start and end codes.
6-1
Post Builder: N/C Data Definition Functions
You will now modify addresses and formats for the UGS Supermill.
Step 1:
Step 2:
Create any special functions, modify addresses and formats as

required.
Tip
Compare the defaults provided by Post Builder with the
specifications detailed in the UGS Supermill Technical
Manual. Make any modifications as required.
6-2
Step 3:
Specify the sequence number start and increment, and any special
characters needed for word separator, end of block, comment start
and end, and decimal points if required.
Step 4:
Step 5:
mt11060_w NX 5
Lesson
Post Builder: Output Settings
The Output Settings section allows for the generation and control of output
used in a listing file. Items considered for output are X, Y and Z co-ordinates,
4th and 5th-axis angle and feeds and speeds. You can also control appearance
by specifying page length and width as well as specify the listing file
extension.
7-1
Post Builder: Output Settings
You will now set your listing file output preferences for the UGS Supermill.
Step 1:
Step 2:
Specify the various list options, on the tabbed menu (Property

page) provided, that you will want in your listing file output.
Step 3:
Step 4:
Use the tool paths from the part post_commands_test to test the
output of the listing file.
7-2
mt11060_w NX 5
Lesson
Advanced Customization
In a previous section of this workbook (Section 5) you were able to customize

your post processor to obtain tape length and tool information by the use of
the Custom Commands feature of the Post Builder. Most customization of
your post can be performed by this method.
In this section you will create both UDEs and the related Custom Commands
for the additional features of the UGS SuperMill.
In this section of the workbook, you will modify, by use of the Post Builder,
your 3-axis post processor by creating a User Defined Event for the spindle
speed fluctuation detection G code and add a rigid tapping G code cycle.
Step 1:
Step 2:
Create a new User Defined Event for the following:

Load spindle speed fluctuation detection OFF-G25
Load spindle speed fluctuation detection ON -G26
Hint: add the following to the ude.cdl file
8-1
EVENT spindle_fluctuation
{
UI_LABEL "Spindle Speed Fluctuation"
CATEGORY Mill Drill Lathe
PARAM spindle_speed_detect
{
TYPE o
DEFVAL "Inactive"
OPTIONS "Active","Inactive"
UI_LABEL "Detection Status"
}
}
Add the following custom command:
# custom command to activate the G26 and G25
# spindle speed fluctuation detection mode
#
uplevel #0 {
proc MOM_spindle_fluctuation {} {
global mom_spindle_speed_detect
MOM_set_seq_off
if {$mom_spindle_speed_detect == "ACTIVE" } {
MOM_output_literal "## SPINDLE FLUCTUATION ON ##"
MOM_set_seq_on
MOM_output_literal "G26"
} else {
MOM_output_literal "## SPINDLE FLUCTUATION OFF ##"
MOM_set_seq_on
MOM_output_literal "G25"
}
}
}
Add to the Start_of_Program event.

Step 3:
Save your post processor as a new post, use the name

***_supermill_mod.
Step 4:
Tip
Remember to modify an operation and include the User
Defined Event which you just created. Add the new UDE to
both the Start and End post command.
Step 5:
8-2
Create a new G code cycle (G84.1) for rigid tapping.
mt11060_w NX 5
Note
Create a new format in NC DATA definitions.
Create a new 2.1 format
Create a new word for G_rigid_tap
Change the format for the new word to the new 2.1 format
Copy the existing cycle tap block and rename the copy to
cycle_tap_rigid
Change the G84 block to the new G_rigid_tap address
Enter 84.1 in the expression dialog.
Add the following in a custom command called rigid_tap

to the Start of Program event.
uplevel #0 {
proc MOM_drill_text_move {} {
global mom_cycle_text
if {[info exists mom_cycle_text]==1 &&/
$mom_cycle_text == "RIGID_TAP"} {
MOM_do_template cycle_tap_rigid
}
}
}
Step 6:
Add the custom command to the Start_of_Program event
In the part file, add a tapping cycle, Select Standard Tap

and then select Standard Text, Enter Rigid_tap, post
process the operation to verify the G84.1 output.
Create and add the following UDE which sets the various options
for coolant thru the spindle.
Add the following Tcl code to the ude.cdl file
# the following code sets the mom_coolant_mode for
# three levels of thru the spindle coolant.
# The special M code is in the format of:
# Low pressure M51 M100
# Medium pressure M51 M101
# High pressure M51 M103
# This M code is adding to the rapid spindle move
#
EVENT coolant_thru_spindle
{
UI_LABEL "Coolant Thru Spindle"
CATEGORY MILL DRILL
8-3
PARAM command_status
{
TYPE o
DEFVAL "Active"
OPTIONS "Active","Inactive"
UI_LABEL "Status"
}
PARAM thru_pressure
{
TYPE o
DEFVAL "Low"
OPTIONS "Low","Medium","High"
UI_LABEL "Thru Spindle Pressure"
}
}
In Post Builder, in the NC DATA DEFINITIONS area, copy

the existing M_coolant word
Rename the new word to M_coolant_thru
Change the Format to Digit_4
Change the maximum value to 999
Change the leader to "M51 M"
Add the new address

Tip
Navigate to Program & Tool Path tab, Program Tab,
Motion event Click on Rapid Move component Using
the pull down menu, select M_coolant_thru and
M-User Defined expression Add the new address after
the last block In the Expression Entry field, Enter the
following $my_coolant_thru($mom_thru_pressure)
Right click on the new M address and Select Optional
Create a new custom command in the Start_of_Program

event
Add the following:

uplevel #0 {
set my_coolant_thru(LOW) "100"
set my_coolant_thru(MEDIUM) "101"
set my_coolant_thru(HIGH) "103"
}
8-4
mt11060_w NX 5
Appendix
A Checklist of Information
This portion of the Appendix contains a checklist that can be used to record
information needed to create a postprocessor.
The checklist which follows has been partially completed to save time. You
will notice that a checkmark precedes some of the boxes. This indicates that
the particular option does exist.
Checklist of information used to create a post processor
Machine Tool Type
Description of machine: UGS Supermill
3-axis mill
4-axis mill
5-axis mill
2-axis lathe
4-axis lathe
Mill / turn center
Wire EDM
Other type
If 4-axis mill 4th axis is;
Positioning
Contouring
Maximum Axis Travels:
X-axis: 39.37 Y-axis: 39.37 Z-axis 19.685
Other:___________________________________________
Word Formats
XYZ:___________
IJK:____________
UVW:___________
R: ____________F: _____________S: ____________N: _____5_______

A-1
Checklist of Information
Decimal Point :
Yes
No
Drop leading zeros:
Yes
No
Drop trailing zeros:
Yes
No
Minimum resolution for output: .0001 inches
Maximum allowable Sequence Number: 99999
Miscellaneous Defaults
Inch
Metric
Absolute
Incremental
Rapid Position Feed Rate Value: 1575"/min X,Y; 1575"/min Z
Circular Interpolation Parameters
Quadrant Limited
Full Circle
Maximum radius for circular interpolation: 999.9999 inches
Minimum radius for circular interpolation: .010 inches
A-2
mt11060_w NX 5
Arc center offset designation:

I,J,K is a signed vector, arc start to circle center Inch
I,J,K is a signed vector, circle center to arc start
I,J,K is an unsigned vector, arc start to circle center.
I,J,K is absolute circle center co-ordinates
radius value
Other
Preparatory Functions (G Functions)
G00 Positioning
G01 Linear interpolation
G02 Circular/Helical Interpolation CW
G03 Circular/Helical Interpolation CCW
G02.2, G03.2Involute Interpolation
G04 Dwell
G05 High Speed Machining
G07.1 Cylindrical Interpolation
G12.1 Polar coordinate interpolation
G13.1 Polar coordinate interpolation cancel
G15 Polar coordinate command cancel
G16 Polar coordinate command
G17 XY plane selection
G18 XZ plane selection
G19 YZ plane selection
G20 XY Inch input

G21XY Metric input
G25 Spindle speed fluctuation detection off
G26 Spindle speed fluctuation detection on
A-3
G27 Reference position return check

G28 Return to reference position
G29 Return from reference position
G33 Thread cutting
G40 Cutter compensation cancel
G41 Cutter compensation left
G42 Cutter compensation right
G43 Tool length compensation +
G44 Tool length compensation G49 Tool length compensation cancel
G50 Scaling cancel
G51 Scaling
G54-G59 Workpiece coordinate selection
G65 Macro call
G66 Macro modal call
G67 Macro modal call cancel
G80 Canned cycle cancel
G81 Canned drilling cycle
G82 Canned counterboring cycle
G83 Canned peck drilling cycle
G84 Canned tapping cycle
G84.1 Rigid tapping cycle
G85 Canned boring cycle
G87 Canned back boring cycle
G90 Absolute mode

G91 Incremental mode
G92 Setting for work coordinate system
G94Feed per minute
A-4
mt11060_w NX 5
G95 Feed per revolution

G96Constant surface speed
G97Constant surface speed cancel
G98 Return to initial point in canned cycle
G99Return to R point in canned cycle
Auxiliary Functions (M Functions)
Number of M codes per block:_____3
M00 Program stop
M01 Optional stop
M02 End of program
M03 Spindle on CLW
M04 Spindle on CCLW
M05 Spindle off
M06 Tool change
M07 Coolant on flood
M08 Coolant on, mist
M09 Coolant off
M30 Rewind
M5 1Thru Spindle Coolant System
M100 Low Pressure Thru Spindle Coolant
M101 Medium Pressure Thru Spindle Coolant
M103 High Pressure Thru Spindle Coolant
Character for Rewind Stop Code: "#"
Tool / Head parameters
Maximum number of tools: 120
Is pre selection of tool allowed Yes

Tool diameter compensation code:________D
Minimum compensation code:_______0
Maximum compensation code:____999
A-5
Tool length compensation code:___________H

Minimum compensation code:_______0
Maximum compensation code:____999
Should adjust code be held for "Z" motion?
Yes
No
Spindle parameters
Maximum spindle RPM: 24000
Minimum spindle RPM: 15
Is spindle off code required to change spindle direction
Yes
No
Feed rate parameters
Maximum feed rate: 1575 ipm
Minimum feed rate: .0010 ipm
A-6
mt11060_w NX 5
Checklist of information needed for post processor development

Machine Tool Type
Description of machine: UGS Supermill
3-axis mill
4-axis mill
5-axis mill
2-axis lathe
4-axis lathe
Mill / turn center
Wire EDM
Other type
If 4-axis mill 4th axis is;
Positioning
Contouring
Maximum Axis Travels:
X-axis: _________ Y-axis: __________ Z-axis ____________
Other:___________________________________________
Word Formats:
XYZ:___________
IJK:____________
UVW:___________
R: ____________F: _____________S: ____________ N: _____5_______

Decimal Point :
Yes
No
Drop leading zeros:
Yes
No
Drop trailing zeros:
Yes
No
Minimum resolution for output: ____________ inches

Maximum allowable Sequence Number: ____________
Miscellaneous Defaults
A-7
Inch
Metric
Absolute
Incremental
Rapid Position Feed Rate Value: _________ X,Y; ___________ Z
Circular Interpolation Parameters
Quadrant Limited
Full Circle
Maximum radius for circular interpolation: _________inches
Minimum radius for circular interpolation: _________inches
Arc center offset designation:
I,J,K is a signed vector, arc start to circle center Inch
I,J,K is a signed vector, circle center to arc start
I,J,K is an unsigned vector, arc start to circle center.
I,J,K is absolute circle center co-ordinates
radius value
Other
Preparatory Functions (G Functions)
G00 Positioning
G01 Linear interpolation
G02 Circular/Helical Interpolation CW
G03 Circular/Helical Interpolation CCW
G02.2, G03.2Involute Interpolation

G04 Dwell
G05 High Speed Machining
G07.1 Cylindrical Interpolation
A-8
mt11060_w NX 5
G12.1 Polar coordinate interpolation

G13.1 Polar coordinate interpolation cancel
G15 Polar coordinate command cancel
G16 Polar coordinate command
G20 XY Inch input
G21XY Metric input
G27 Reference position return check
G33 Thread cutting
G44 Tool length compensation G49 Tool length compensation cancel
G50 Scaling cancel
G51 Scaling
G54-G59 Workpiece coordinate selection
G65 Macro call

G66 Macro modal call
G67 Macro modal call cancel
A-9

G82 Canned counterboring cycle
G84.1 Rigid tapping cycle
G90 Absolute mode
G91 Incremental mode
G92 Setting for work coordinate system
G94Feed per minute
G95Feed per revolution
G96Constant surface speed
G97Constant surface speed cancel
G99Return to R point in canned cycle
Auxiliary Functions (M Functions)
Number of M codes per block:______
M00 Program stop
M01 Optional stop
M02 End of program
M03 Spindle on CLW
M04 Spindle on CCLW
M05 Spindle off
M06 Tool change

M07 Coolant on flood
M08 Coolant on, mist
M09 Coolant off
A-10
mt11060_w NX 5
M30 Rewind
M5 1Thru Spindle Coolant System
M100 Low Pressure Thru Spindle Coolant
M101 Medium Pressure Thru Spindle Coolant
M103 High Pressure Thru Spindle Coolant
Character for Rewind Stop Code: _________
A-11
Tool / Head parameters

Maximum number of tools: _________
Is pre selection of tool allowed _________
Tool diameter compensation code:________
Minimum compensation code:_______
Maximum compensation code:__________
Tool length compensation code:___________
Minimum compensation code:_______________
Maximum compensation code:____________
Should adjust code be held for "Z" motion?
Yes
No
Spindle parameters
Maximum spindle RPM: _________
Minimum spindle RPM: _________
Is spindle off code required to change spindle direction
Yes
No
Feed rate parameters
Maximum feed rate: _________ ipm
Minimum feed rate: ________ ipm
A-12
mt11060_w NX 5
Appendix
B Supermill Technical Document
This portion of the Appendix contains a the technical specification for the
UGS Supermill Machining Center. These specifications will be used to create
the post processor for the project exercises.
The UGS Supermill is a high performance, high speed 3-axis vertical
machining center with an optional indexable head. A 5-axis version for
complex molds and impellers is also available.
The design of the Supermill incorporates a rigid frame and self cooling high
speed spindle that aids in high speed machining applications. The Supermills
modular concept enables its use in numerous applications.
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Supermill Technical Document
UGS Supermill
Technical Description
Machine Structure
The Supermill is a standard "bed" type machine, which allows for machine
rigidity and stability. The design of the Supermill allows for excellent
visibility of the actual working area. The bed, table, vertical walls and guides
of the X-axis are comprised of cast iron. The Y and Z guides are manufactured
from precision ground steel.
Machine bed and X, Y, Z axis slides
The machine bed is built from fixed box-shaped structures designed with
transverse baffles for rigidity. This adds to the general stability of the
machine. The machine guideways incorporate rolling bearing mechanisms.
Axis movements are accomplished with recirculating ball screws, driven by
brushless dc motors. The X and Y-axis have direct motor screw couplings;
the Z-axis is belt driven. Glass scales are used for accurate positioning. All
transducers are metal clad and are protected against dust and coolant. They
are also connected to a filtered compressed air system to further aid in the
reduction of contaminants.
Machine temperature control system
In order to minimize thermal drifts and maintain accuracy when machining
for extended periods, heat exchangers are placed in strategic locations. These
heat exchangers dissipate heat to a continuously circulating liquid controlled
by a standalone refrigeration unit.
Machining work area
The machining work area, or work piece table, is made of cast iron, for
thermal stability, and is equipped with T-slots for work piece clamping.
Automatic tool changer
The automatic tool changer is a chain operated device that can store up to 180
tools. Tool selection is bi-directional, that is, the chain will move clockwise or
counterclockwise to the next tool selected, which ever direction is shorter. The
tool changer will automatically detect a tool in a pocket and will also monitor
tool life through software incorporated in the CNC.
Lubrication systems
Key components including slides and spindle are constantly lubricated by
means on an automatic lubricating system regulated by a timing mechanism.
These components are monitored by sensors, which will activate alarms when
lubrication is low.
B-3
Coolant System
The coolant system dissipates heat generated by cutting through a mixture
of air and non-toxic vegetable oil. The air/oil mixture is regulated by control
valves and a nozzle system which can be directed to the cutting tool and
or work piece. Coolant on and off is controlled by the use of M functions or
manual intervention by the operator.
Drives and axis motors
All drive motors are AC and are brushless. The electronic interface between
the drives and CNC is digital.
Electrical cabinet
The electrical cabinet is self contained and mounted on the left side of the
machine and is equipped with a forced ventilation cooling system. The
cabinet meets all NEMA regulations. The cabinet is also equipped with
meters to monitor total service hours, total spindle hours, contains internal
service lighting and is provided with a 120V AC outlet.
Safety guards
The machine is completely enclosed by safety guards. Two front side sliding
doors allow for easy loading and unloading of work pieces. The doors are
equipped with electromechanical safety locks. The doors can be opened only
after the machine spindle comes to a complete stop. Inspection cycles, such as
probing can be performed with the doors open. Any operation involving the
rotation of the spindle prevents the doors from being opened.
Chip Removal
The design of the machine allows chips to move towards the front of the
machine into a removable chip container. The chip container can be removed
while the machine is operating.
UGS Supermill Computer Numerical Control
Includes the following:
XP Professional operating system
CPU Pentium I 3.500 GHz
19" graphic video terminal
512 MB RAM memory
800 GB hard disk memory
1.44 MB floppy disk drive
Alphanumeric keyboard
Operator remote pushbutton pendent including hand wheel and displays
Ethernet board
Multi-processor CPU architecture
Digital controls for axis drives
Diagnostics and help-on-line.
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TECHNICAL DATA
Linear axes
Movement
:X
Supermill
1000 mm (39.37")
1000 mm (39.37")
500 mm (19.685")
Z
Positioning accuracy
Max. rapid speed X - Y
Z
Number of tool pockets in changer
Work piece table
Standard table dimensions
Max load on table
Longitudinal T-slots: number
width
Installation requirements
0.005 mm (.0002")
40 m/min (1575"/min)
40 m/min (1575"/min)
180 Maximum
1500 x 1500 mm (59" x 59")
2500 Kg. ( 1140 lbs.)
5
18 mm (.708")
440 V 60 Hz
Power supply
20 psi + 10%
Air supply
Machine weight
12000 kg (5454 lbs.)
Floor space (excluding command panel
3.9 x 3.9 m (12.8 x 12.8 ft)
and spindle cooling device)
Overall height
3.2 m (10.5 ft)
Environmental conditions
from 10 to 40 5C
Temperature
Relative humidity
from 10% to 80%
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Milling Options
The following three milling options are available for the Supermill.
3-Axis Milling 24000 RPM
High frequency spindle, 220-mm. dia. with air/oil lubricated ceramic ball
bearings and automatic tool clamping/unclamping system.
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The tool holder clamping on the spindle consists of a mechanical device with
Belleville washers; a pneumatic piston unclamps the tool holder. The spindle
is housed on the vertical slide (Z-axis).
Spindle drive.
Cooling system.
Air/oil lubrication of ball bearings with recirculating oil.
TECHNICAL DATA
Max. spindle rotation speed
Continuous power
Constant power range
Spindle lubrication
Tool holder
Spindle nose-table max distance
Spindle axis machine bed minimum
3-axis milling
24000 RPM
2.4 kW
6000 - 24000 RPM
air-oil
CAT 50
760 mm
230 mm.
B
B-7
3-Axis milling with indexable head (4th and 5th axis) 30000 RPM
This option allows for tool orientation, which will increase the work area,
reduce tool lengths and increase cutting speeds with spherical tools.
Bi-directional indexable head with integrated spindle, housed on the

vertical slide.
High frequency spindle, 150 mm. dia. with air/oil lubricated ceramic ball
bearings and automatic tool clamping /unclamping system.
The tool holder clamping on the spindle consists of a mechanical system with
Belleville washers; a pneumatic piston unclamps the tool holder.
Motor and drive for C-axis movement.
Hydraulic unit for clamping/unclamping table, B-axis movement and

tool unclamping.
Automatic tool center compensation when changing head angle.

Spindle cooling system.
TECHNICAL DATA
C-axis movement
C-axis pitch
B-axis movement
B-axis pitch
Max. spindle rotation speed
Continuous power
Spindle lubrication
Tool holder
Spindle nose-table max distance (spindle
in vertical position)
3-Axis milling with indexable head

+ 180, -177
3
25, +25
5
30.000 RPM
2.7 kW
24000 - 30000 RPM
air/oil
Cat 50
687 mm.
280 -380 mm *
Spindle axis - machine bed min. distance
(*distance differs along with
(spindle in vertical position)
C-axis position)
5-Axis Continuous Milling Option 28000 RPM
This option enables continuous orientation of the tool in the space which
allows for undercut machining, surface contouring, convex surface machining
with standard end mills, tool length reduction and increased cutting speeds
with spherical tools.

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Bi-directional milling with continuous B and C axis movements with

integrated spindle.
High frequency spindle 120 mm. dia. with air/oil lubricated ceramic ball
bearings and automatic tool clamping /unclamping system. The tool
holder clamping on the spindle consists of a mechanical system with
Belleville washers; a pneumatic piston unclamps the tool holder.
Brushless motor and drives for B and C axis.
Direct positional transducers.
Internal calculation of tool motion with reference to the tool center.
Spindle refrigerated cooling system.
TECHNICAL DATA
B axis movement
C axis movement
B and C axis max. rotating speed
Max. acceleration
Max. spindle rotating speed
Continuous power
Tool holder
Max. tool dia. in milling
Spindle nose table max. distance
Spindle axis - machine bed min. distance
5-Axis continuous milling

+/ 110
+/ 361
5000/min
10005/sec
28000 RPM
5 kW
16000 - 28000 RPM
CAT 40
16 mm
562 mm
245 mm
B
B-9
Tool Length pre-setting options

Manual tool length pre-setting
The manual tool length pre-setting option consists of an analog measuring
device that is positioned and referenced from the work piece table.
Automatic Tool Length pre-setting
This option consists of a device that is fixed to the machine table. It includes
a digital probe for gauging, an air-blow system for probe cleaning, interface
boards, wiring and software to automatically pre-set tool lengths.
Laser probe pre-setting
The laser probe pre-setting option consists of a laser measuring system
that will check the diameter, length and shape of the tools according to
preprogrammed measuring cycles. Included in this option are all connecting
cables, interface boards and measuring software.
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Chip Conveyor
CC SM2004
The automatic chip conveyor option allows the continuous removal of chips
and is operated directly by the CNC. This option replaces the standard chip
conveyor.
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B-11
Dust removal system (vacuum)

VDRS SM2004 graphite dust removal option
The graphite dust removal option consists of an externally supplied suction
unit complete with a container and self-cleaning filter. The filter device
is connected through pipes to a suction manifold mounted along the table
of the machine.
Technical data for the VDRS SM2005 dust removal system
Fan power:5.5 kW
Air volume:1500 cubic ft/ minute
Overall dimensions:1.2 x 1.4 m.
Height:3 m.
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Measurement options
DPM SM2005 Digital probe measuring system
Included in this option are the following:
Universal digital inspection probe
Standard 50 mm. stylus
Interface board and wiring
Adapter for digital probe
UGS 2005M Software for fixed probing cycles.

This software allows:
Error calculation with respect to pre-set values
3-D measurements
Recording all data in standard file formats for later analysis
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B-13
Specialized Application Software

Supermill uses the standard MicroSoft Windows XP operating system. This
allows for ease of use with a standard interface and the simple integration
of NX at the shop floor level.
Supermill SHOPS CAM SOFTWARE optional
SHOPS is integrated with the CNC controller which allows the interactive
generation of 3D tool paths. Functions included are:
Import of IGES models.
Roughing and finishing cycles with ball and flat end-mills.
Semi-finishing and finishing cycles for high-speed milling.
High-resolution display of models and stock material.
Options available specifically for the die/mold industry.
Data transfer
High speed data transmissions via ethernet and TCP/IP protocol.
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Supermill CNC options

Scale factor
Scale factor assigns a different scale to each individual axis. This option is
applicable in the manufacturing of molds, where shrink factors are different
along the various individual axis.
Polynomial interpolation with Nurbs format
Nurbs format allows for better surface finishes when finishing with the high
speed machining option.
21" High resolution video
Upgrade with 21" video terminal instead of 19" video.
Remote push button operator pendant
This option allows the operator to independently move each axis for set-up
purposes as well as to monitor and change various functions.
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Programming Functions
The following programming functions are standard with the Supermill 2004
CNC controller.
Preparatory Functions (G Function)
Up to three multiple G functions can be included in the same block of
information.
The following G functions are recognized by the Supermill:
G00Rapid Positioning
G01Linear positioning (interpolation) at programmed feed rate
G02Circular/Helical interpolation CW
G03Circular/Helical interpolation CCW
Circular interpolation can be performed in the XY, XZ or YZ plane.
Along with X, Y, Z departures, parallel axis used for interpolation
are I, J, and K. I represents the X axis signed distance from the
start point to the center of the arc; J represents the Y axis
signed distance from the start point to the center of the arc; and K
represents the Z axis signed distance from the start point to the
center of the arc. I, J and K are always the incremental distance.
In place of I, J, or K, R with the appropriate radius value can also
be used. When the arc specified is greater than 180 degrees, the
radius value R is specified with a negative value.
G04 Dwell
G05 High speed machining cycle (optional)
G12.1 Polar co-ordinate interpolation mode (optional)
G13.1 Polar co-ordinate interpolation mode, cancel (optional)
G20 Input in inch
G21 Input in metric

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G27 Reference position return check (optional)

G44 Tool length compensation
G49 Tool length compensation cancel
G50 Scaling cancel (optional)
G51 Scaling (optional)
G54-G59 Workpiece Co-ordinate selection register
G82 Canned counter boring cycle
G84.1 Canned rigid tapping cycle
G90 Absolute co-ordinate programming
G91 Incremental co-ordinate programming
G92 Set work co-ordinate system
G99 Return to R point in canned cycle
Auxiliary Functions (M functions)
Up to three multiple M functions can be included in the same block of
information.
M00 Stop
M01Optional Stop
M02End of Program
M03Spindle On CLW
B-17
M04Spindle On CCLW
M05Spindle Off
M06Tool change
M07Coolant On, Flood
M08Coolant On, Mist
M09Coolant Off
M51Thru Spindle Coolant System
M100Low Pressure Thru Spindle
M101Medium Pressure Thru Spindle
M103High Pressure Thru Spindle
M30Rewind
Spindle Speed Function (S function)
The spindle speed can be controlled by specifying a value following the
address S. Maximum number of digits is five. Spindle speed range is based on
spindle option package. See individual specifications for speed range.
Tool Selection Function (T function)
Tools can be selected on the machine by specifying a 4-digit numerical value
following the T address code. When a move command and a T code are
specified in the same block, simultaneous execution of the move command
and the tool change occurs. Codes specifying tool offset values are grouped
with H codes for tool length offset and D codes for cutter compensation
offset. Maximum values for H codes and D codes are 999. An M06 command
performs the actual tool change.
Feed Functions
The feed function controls the feed rate of the cutting tool.
The Rapid Traverse feed function moves the tool at a rapid traverse rate
when command to position by G00.
The Cutting feed function moves the tool at a programmed cutting feed rate.
Acceleration and deceleration are automatically applied when the tool starts
and ends its movement.
Cutting feed rate is applied by a number following the F word address.
Word Address and decimal point programming
Numerical values can be entered with a decimal point. Decimal points can be
specified for the following addresses:
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mt11060_w NX 5
X, Y, Z, I, J, K, U, V, W, B, C, R and F.
Some G codes allow for decimals (Polar co-ordinate interpolation)
Fixed word lengths are as follows:
Inch 3.4 for X, Y, Z, I, J, K, U, V, W, B, C, R
Metric 4.3 for X, Y, Z, I, J, K ,U, V, W, B, C, R
Spindle 5 digits
Feed rate:
Inch 3.4
Metric 4.3
B
B-19
MILLING ACCESSORIES
Accessories for CAT 50 Tool Holder
balanced tool holder enabling the clamping of tools with cylindrical shanks.
extended balanced tool holder, enabling the clamping of tools with extended
length cylindrical shanks.
tool holder for Weldon type tools.
Sets of 7 collets (diam. 4 mm, 6 mm, 8 mm, 10 mm, 12 mm, 16 mm, 20 mm).
Sets of 4 collets (diam. 1 mm, 2 mm, 4 mm, 6 mm).
Spanner wrenches for various collets.
Tool holder support for tool assemblies.
Optional Spindles
UGSSM2005/24-24
24 kW- 24000 RPM high frequency spare spindle for 3-axis option.
UGSSM2005/20-30
20 kW - 30000 RPM high frequency spare spindle for indexable head option.
UGSSM2005/6-28
6/7,5 kW - 28.000 RPM high frequency spare spindle for 5-axis option.
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Services
Installation
Includes machine installation and acceptance at purchasers facilities.
The Supermill requires special foundations per drawing number
SM2005HS-01. These foundations to be built at purchasers expense
according to aforementioned drawing specifications.
Installation of the Supermill can be performed 4 weeks after the foundation
has been poured.
Purchaser provides all necessary pneumatic, power and water supplies.
Training
UGS will provide 40 hours of training, at the Customers site, on the use and
programming of the UGS Supermill CNC controller.
For custom training courses, please contact UGS.
Shops training
Please check Educational Services schedules for the nearest location and
dates Shops classes. Special classes can be arranged on site.
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Post Building Techniques

This edition obsoletes all previous editions.

Post Building Techniques Workbook

Project Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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Post Building Techniques Workbook

The Post Processor Development project is an ongoing activity that

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Post Building Techniques Workbook

Post Building Techniques Workbook

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Collecting Data for Post

UGS Corp., All Rights Reserved

Post Building Techniques Workbook

Collecting Data for Post Processor Creation

One of the first steps in development or modification of a post processor is the

Quickly glance through the UGS Supermill Technical Manual,

Using the checklist provided (also located in Appendix A), collect

Post Building Techniques Workbook

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Building a Post Processor

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Post Building Techniques Workbook

Building a Post Processor with Post Builder

Post Building Techniques Workbook

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Building a Post Processor with Post Builder

Post processors currently created by the Post Builder can be further

If necessary, start the Post Builder module.

Create a new post processor with the name ***_supermill_3ax,

Save your post to the home post processor directory.

Save the contents of the post processor.

Include your new post in the template_post.dat file.

Start a NX session, retrieve the part post_commands_test, and

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Post Building Techniques Workbook

Post Builder: Program and

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Post Building Techniques Workbook

Post Builder: Program and Tool Path Functions

If necessary, retrieve your post processor, ***_supermill_3ax.

Examine and if necessary, modify the Program Start Sequence,

If necessary, modify or add preparatory functions.

Save the contents of the post processor.

Post Building Techniques Workbook

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Post Builder: Custom Command

TheCustom Command section of the Post Builder allows for creation,

If necessary, retrieve your post processor, ***_supermill_3ax.

Using the custom commands feature, add the required proc,

Save the contents of the post processor.

Using the Custom Commands feature, add the custom command,

Save the contents of the post processor.

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Post Building Techniques Workbook

Post Builder: N/C Data

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Post Building Techniques Workbook

Post Builder: N/C Data Definition Functions

If necessary, retrieve your post processor, ***_supermill_3ax.

Create any special functions, modify addresses and formats as

Save the contents of the post processor.

Post Building Techniques Workbook

R: ______F: _S: ____N: _5_____

R: ______F: _S: ____ N: _5_____