Flex3D Tubes Manufacturing Manual 081208

Flex3D
Tubes Plus
Module
Lantek Sheet Metal Solutions S.L.

Parque Tecnológico de Alava
Albert Einstein, Edificio Lantek
Flex3D
Tubes Plus
01510 Miñano (Alava)
Spain
Tel: +34 945 298705
Fax: +34 945 298714
Web: www.lanteksms.com
Contents
1
Tubes Manufacturing – Flex3D Tubes Plus....................................................3
Design of Tube Part ......................................................................................3
1. Tube Creation .......................................................................................3
2. Chamfer Tube .......................................................................................7
3. Perforation Properties(Drill Tube) .........................................................8
4. Limit Tube ........................................................................................10
5. View (hide backlines)..........................................................................12
6. Dimension/Measurement Note.............................................................12
7. Section tube.........................................................................................13
8. Surface Map .......................................................................................14
9. Cut Tube .............................................................................................15
10. Modify technology .............................................................................17
11. Modify Order ....................................................................................17
12. Cutting Sense and Compensation ...................................................18
13. Lead In .............................................................................................18
14. Micro-Joints ........................................................................................20
15. Modify Clearance ..............................................................................21
16. Simulate Cut .....................................................................................22
17. Settings..............................................................................................23
a. Position the axes ...........................................................................23
b. Tube cut machines configuration......................................................23
c. System graphic configuration dialogue.............................................27
18. New (to go to Fabrication module) ....................................................29
Fabrication Order (OF module) ...................................................................29
19. Import tubes part .............................................................................30
20. Make nestings ..................................................................................31
21. Generate CNC Program......................................................................32
22. Common Cut setting (default) and Non Common Cut setting............34
23. Inverse and Rotate setting.................................................................36
Nestings for tube parts ...............................................................................38
1. Machining of cut nesting ....................................................................38
2. Saving to generate CNC .....................................................................39
3. Return to Fabrication Order ................................................................39
Appendix 2 - Tutorial of a Tube module.......................................................42
1. Creating a tube....................................................................................42
Appendix 3 - SAT file handling.....................................................................60
2
Lantek Flex3D Tubes Plus
Tubes Manufacturing – Flex3D Tubes

Plus
Tubes Plus module provides a manufacturing process to produce parts from tube
materials. The 2-steps approach of design and nesting/machining allows the maximum
material utilization and flexible automation of this manufacturing process.
Design of Tube Part

This is the CAD module for the tube part. It consists of an intuitive environment and a
great number of functionality that helps in the design process. It is totally parametric and
at any moment of the process, one can change whatever parameter of the previous
operations without redoing the whole steps again. At any moment, it can also show the
tool that is acting on the operation. The menu option is made available by placing the
mouse cursor over the said operation and right clicks the mouse button.
The user should start with the Tube toolbar and 2D Draw toolbar .
Now you could start design the tube part…
1. Tube Creation
It should begin to define the tube base (material, format) and the machine (the showed
options are the existing ones in Expert's database) in order that ultimately the software
could generate CNC's program correctly.
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In term of tube types, there are 5 types of predefined pipe formats, as shown below for
information.
4
The user could do the Operations on Tubes
Quick Note on Tube Cut Machine – tubes module settings and install machines
Additional note on the Web and Flange which affect the extremes of the tube part (Web is
for top-down or vertical and Flange is for left-right or horizontal).
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The example with Web

End as 30 degree and
Flange Start with 45
degree. They will create
the chamfer on the tube
part but the chamfers are
only used for nesting and
will be machined in the
Nesting module. On the
tube part design, the
user cannot machine the
extreme ends.
Note the left extreme end

is the Web End of 30
degree and the right
extreme end is the
Flange End of 45 degree.
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2. Chamfer Tube
Chamfers the tube based on the parameters entered in the chamfer properties dialogue.
The chamfer can be done from an attack angle or a partial chamfer can be done from two
values.
The chamfer parameters can be modified subsequently by means of the properties

command of the tube tree that appears on the left of the work area.
Chamfer Partial Chamfer

Chamfer properties dialogue
This dialogue enables you to create a new chamfer or modify the parameters of an
existing one.
Operation parameters
• Operation ID: chamfer operation identifier in the tube tree.

• Fibre: specifies the part, within the tube thickness, which serves as a reference to
do the chamfer, either to define the attack angle in the normal chamfer or to specify
the two values that make up the partial chamfer. GO
• Start/End: if this option is active, the chamfer is done at the start of the tube.
Chamfer definition
A chamfer can be done from an attack angle or a partial chamfer can be done from two
values. In both cases, the parameters take the model coordinate system as the reference.
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• Chamfer: you have to specify the attack angle of the plane that forms the chamfer
in respect of the XY plane. as well as the rotation angle of that plane in respct of
the X axis.
• Partial chamfer: the chamfer is defined from the values assigned to the
parameters Dist. X and Dist. Z as well as the rotation angle on the X axis.
To create a new chamfer press the button add. The operation ID cannot exist in the tube
operations tree. To modify the parameters of a previously created chamfer press the
button apply.
Fibre
Specifies the part, inside the tube thickness, that serves as a reference for the creation of
the tube or to define other operations
There are three possibilities:
• Inner: the reference point is included in the tube thickness. The position of this
point is determined by means of the parameter average position relative to
interior that indicates, in percentage terms, the relative position of the point in
respect of the inner edge of the tube.
• Inside: reference point in respect of the inner edge of the tube.
• Outside: reference point in respect of the outer edge of the tube.
3. Perforation Properties(Drill Tube)

Makes a hole in the tube based on the parameters entered in the perforation properties
dialogue
The perforation may be round, rectangular or obround in shape. You can also perforate
with 2D geometries imported from MEC files and with projected geometries.
The perforation parameters can be subsequently modified using the command properties
in the tube tree that appears on the left of the work area.
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Perforation properties dialogue

This dialogue enables you to make a hole in a tube or modify the parameters of a
previously created one.
• Operation ID: perforation operation identifier in the tube tree.

• Translate in X and Y: position of the perforation on the tube surface in respect of
the XY plane of the model coordinate system.
In the case of round, rectangular or obround perforations they determine the central
axis of the tool.
In the case of imported geometries they determine the displacements on X and Y

to be added to the original poition of the geometries.
• Rotation about X, Y and Z: rotation angle of the perforation in respect of the three
axes.
• Transpierce: if this option is active, the perforation transpierces the tube.
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Drill definition
• Round: defined by means of a diameter.

• Square: indicate the width (length X) and the height (length Y).
• Obround: indicate the width (length X) and the height (length Y).
• Import 2D Geo: enables you to make a perforation by importing a 2D geometry in
MEC format and taking as reference the model coordinate system.
• Projected: makes a perforation from the 2D geometry previously selected and that
will be projected on the tube surface. The XY plane of the working coordinate
system is taken as a reference.
To create a new perforation press the button add. The operation ID cannot exist in the
tube operations tree. To modify the parameters of previously created perforation press the
button apply.
4. Limit Tube
Limits the current tube with another tube based on the parameters entered in the limit
properties dialogue.
The limiting tube may be cylindrical or rectangular.
The parameters of the operation may be modified later using the command properties in
the tube tree that appears on the left of the work area.
Limit properties dialogue

This dialogue enables you to limit the current tube with another tube or modify a
previously limited tube.
• Operation ID: limit operation identifier in the tube tree.

• Fibre: specifies the part, within the tube thickness, which serves as a reference to
determine the diameter (when limiting with a cylindrical tube) or to determine the
height and base (when limiting with a block). GO
• Start/End: if this option is active, the tube is limited from the start.
Cylinder/block definition
The limiting tube can be a cylinder or a block. In both cases:
• Dist. X, Dist. Z: position of the tube axis in respect of the XZ plane.

• Rotation: rotation angle in respect of the X axis.
• Attack angle: angle in respect of the XY plane.
• Cylinder
o Diameter: diameter of limiting tube. (*)
• Block
o X length: width of limiting tube. (*)
o Z length: height of limiting block. (*)
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o Corner radius: radius of the rounded corner that forms the rectangular base
of the block.
o Rotation: rotation angle in respect of the Y axis.
(*) The reference for determining these parameters depends on the fibre selected. The
thickness of the limiting tube is considered to be the same as that of the original tube.
To create a new limitation press the button add. The operation ID cannot exist in the tube
operations tree. To modify the parameters of a previously created limitation press the
button apply
The type of cut can be customized to grain of the tube (e.g. Outside, Inside and Inner)
There are two types of Limit Tube (cylinder or rectangular). The parameters of the
positioning are the same, except in cylinder cut requires diameter and rectangular cut
requires X/Y and corner radius.
Cylinder limit tube: The cylinder diameter determines the curve at limit tube.
Rectangular Limit Tube: The dimension and the corner radius determine the shape at limit
tube. The block rotation parameter will also determine the end result of the limit tube.
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5. View (hide backlines)

The view menu provides 3 functions.
Show back lines

Hide back lines
2D
The Hide back line is especially important when they are varies holes and display the
holes on the reverse facing side will mix up and complicate the view. It is especially so
when try to make adjustments to hole such as the lead-ins etc.
The 2D view is to provide a static view of the tube part when it is in 2 dimension. The
combination of 3D view and then 2D view could provide user an added way to verify that
the operations on tubes are according to his requirements and design.
6. Dimension/Measurement Note
To measure and show Dimension note on the tube part to ensure precise placements and
positioning.
Dimension from edge
Dimension of 2 points
Angle Dimension 2 edges
Angle Dimension 2 points
Arc Dimension
Point Dimension
Delete
Show/Hide Dimension Note
Configure Dimension
Example: Dimension or measurement between two points.
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7. Section tube
This feature will cut a section of the tube.
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8. Surface Map
Projects the 2D geometry selected on the XY plane of the working coordinate system on
the tube.
The parameters for this operation are defined using the surface map properties dialogue
--------
Surface map properties dialogue

This dialogue enables a 2D geometry to be projected on the surface of the tube, taking as
a reference the XY plane of the working coordinate system. To do this, the 2D geometry
must have been selected.
Moreover, in the case of rectangular tubes the Z axis of the working coordinate system
must be perpendicular to one of the faces.
It presents the following parameters:
• Operation ID: map operation identifier in the tube tree.
Geometry
• Discretisation value: length of the discretisation segment in the projection and in

the cut operation. The default value for this parameter corresponds to the value
assigned to the surface map operation discretisation value parameter in the cut
parameter dialogue. GO
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Note: if the XY plane of the working CS coincides with the XY plane of the model CS, the
projection is done by following the positive direction of the Z axis of the model CS.
The position of the geometry depends on the active system of coordinates in every
moment. Only it is necessary to introduce the parameter of discretisation (this is due to
the fact that all the geometries that pass of 2D to 3D are represented by means of small
segments)
9. Cut Tube
Defines the cutting operation on the tube based on the machine selected.
The cutting parameters for that machine are shown in the cut properties dialogue. These
parameters can be modified subsequently by means of the properties command of the
tube tree that appears on the left of the work area.
By default Flex3D shows the cut parameters stored in the dependent materials list for the
machine selected, that is to say, the material/thickness dependent configuration.
If it cannot find the right values on the list (material and thickness of the current tube), then
it shows the parameters specified in the cut technology configuration for that machine.
Once the cut operation has been defined use the save command on the file menu, which
stores the information about the operation in a file with the extension M3D. The name of
the cut file will be the same as that of the tube modeling.
Moreover, if the post-processor is installed for the active machine, a numerical control file
is generated with the extension dependent on the machine used and which will be stored
in the directory \Flex3D\CNC.
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Up to this moment, all the operations that we have done are operations on the design of
the pipe, that is to say still not real cut that has been generated on the pipe. With this
operation the cut will be simulated and the paths of the same will be generated.
Once executed, the application will mark in red the contours, and that is the machining of
the cuts would be realized in the pipe.
Until the user does not save the file, the application will not generate the program CNC for
the chosen machine. This will be done in transparent form to the user.
A series of sub-functions exist inside this operation:
Cut properties dialogue

This dialogue shows and enables you to modify the cut parameters for the machine
selected:
• Cutting edge: determines if the cut is done on the outer or inner edge of the tube.
• Chamfer: determines if the material that forms the thickness of the tube is
chamfered.
• Technology type: cut or mark.
• Cut order: enables you to specify the cut order to be followed by the machine :
o From: starts on the contour closest to the starting point, continues to the
right and returns from the left. Always leaves for the end any cut on the left
edge of the tube.
o Left to right
o Right to left
• Stating point: coordinates of the initial location of the cutting head.
• Technology values :
o Speed: of the cutter (metric_units/minute).
o The compensation can be indicated wither by a radius or compensation
value, or by a compensation index.
• Lead-in values : the lead-ins can be set automatically using the following
parameters:
o Lead-in position: point on corner or middle point of of the discretised
segment.
o Lead-in length
• Other parameters :
o Clearance for rapid motions: rapid displacement distance.
o Cut discretisation value: length of the cut segments.
o Operation identifier: identifier that defines the cut operation in the tube
tree.
Note: Once the cut operation has been defined, if any changes are made to the tube
properties or to any of its operations it will be necessary to delete the cut operation and
define it again.
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10. Modify technology

This command enables you to configure and modify the technology type to be applied to
each cut and mark contour, as well as tool compensation using the cut values modification
dialogue.
To activate this dialogue you just have to click on the contour required.
Cut value modification dialogue

This dialogue enables you to specify the following parameters for the contour selected:
• Technology type: this option indicates the technology type to be used on the
contour, it can be:
o Standard cut
o Standard mark
o Laser pulse cut
o User technology (n)
• Cutter compensation: determines whether there is compensation and its
parameters:
o Deactivated: no cutter compensation carried out (by default).
o Left/right: compensation will be carried out on the side of the contour
specified.
Index: compensation index for the contour selected.
Value: radius or value for compensation for the contour selected.
• Speed: cutter speed in the contour selected (metric_units/minute).
The default values for the parameters index, value and speed are those specified in the
command cut tube.
11. Modify Order

This command enables you to view or modify the specified contour cut order in the tube
cutting operation.
To modify the order, click on the contour you want to cut first and then successively on all
the contours, until you have established a new cutting order.
It modifies the order in which the different geometries are going to be cut in the pipe. The
system provides a default order chosen in the settings. It always begins for the geometry
more to the left side (nearer to the origin of coordinates) except the last one, then it moves
towards the right and ultimately it returns back to the first one (the left most).
Choose the first one and then proceed with the rest. Whenever we want to begin again, it
is necessary to return to choose the Modify Order option.
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12. Cutting Sense and Compensation

It could modify the cutting direction sense. It could also modify the compensation settings
(off, left or right).
13. Lead In
This operation enables you to insert new lead-ins as well as view, modify or delete those
created earlier. The lead-ins are always parallel to the X axis of the model CS.
To insert a lead-in just click on the contour at the point you want to make the insertion.
To delete a lead-in you have to click on the contour containing it.
The configuration of the lead-ins (length and position) can be modified by clicking the
right button of the mouse on the work area using the cut lead-in values dialogue
To indicate the entry point of cut of the laser. The placement of lead-in is flexible and
intuitive.
Cut lead-in values dialogue
This dialogue enables you to configure the following parameters:
• Auxiliary operations: these operations affect all the contours.

o Modify defined lead-ins length: this option establishes a new length for all
the lead-ins that are already defined, assigning them as a new value the
parameter lead-in length.
o Delete defined lead-ins: deletes all the lead-ins defined up to now.
o Create outstanding lead-ins automatically: automatically creates lead-ins
for those contours in which they still have not been defined.
• Lead-in length: length of lead-in segment.
• Lead-in position
o Picked point
o Near corner point: lead-in on corner of discredited point.
o Middle point: lead-in on middle point of discredited segment.
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Therefore I mark with the mouse the place and then with the right mouse button, I modify
the default parameters. It can create them automatically as they have been defined in the
Settings.
There is also the automatic lead-in.
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Please note that the second option (‘Also in projected’) should be checked when the
geometry is to be imposed upon the tube part via the Surface Map function – then the
automatic lead-in would be applied in that situation as well.
14. Micro-Joints
This command enables you to add micro-joints to the cut or mark contours.
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To do this, you have to click the left button of the mouse on the micro-joint insertion point
inside a contour.
You can modify the size of the micro-joint segment as well as carry out other operations
by clicking the right mouse button on the work area using the micro-joint values dialogue
Micro-joint values dialogue

This dialogue enables you to modify the size of the micro-joint segment using the micro-
joint length parameter.
Moreover, the following auxiliary options can be carried out:
• Delete defined micro-joints: deletes the existing micro-joints on all the contours.
• Show micro-joints: shows the ends of each micro-joint.
We can define zones in the contour that are not going to be cut.
With the right mouse button, we modify the length. It is used especially when the pipe is
going to be cut at different zones, in order that the scrap parts do not break.
15. Modify Clearance

It serves to detect collisions. They are in use for controlling the lead-in that is not on
cylindrical pipe. When the machine turns the pipe to cut another geometry, if the cut head
does not have sufficient clearance from the surface, it may hit against the pipe.
21
With the right button of the mouse, we will be able to choose the distance of lead-in and
that of the lead-out of the laser head.
16. Simulate Cut

This command simulates the tube cutting operation.
The type of simulation is configured using the cut simulation dialogue
Cut simulation dialogue

This dialogue presents the following buttons, which show the different steps of the
simulation:
Goes to initial contour.
Undoes the simulation of the last contour.
Simulates the next contour in the order specified.
Simulates from the current contour to the end.
You can also configure the type of simulation using the parameters button that activates
the cut simulation parameters dialogue
It allows the simulation the cut of the different geometries. We can go forward and
backward.
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In addition, we can choose the type of simulation.
Cut simulation parameters dialogue

This dialogue enables you to set the cut and mark simulation mode:
• Only edges : the simulation is limited to cuts or marks.

• Edges and axes : the simulation includes in addition to the cut marks, the axes
that represent the position of the cutting head.
• Head simulation : makes the cut with a simulation of the head and its movements
over the part.
Finally, the check box Simulate rapid enables you to view the rapid displacements
between different operations carried out on the tube.
17. Settings
a. Position the axes
This is a functionality that is used to facilitate the generation of more complex cutting. It
allows the axes to be place at various points of the part and allows subsequent changes
as the need arises.
It has different options:

Axes on one of the faces of the piece.
Transformation of the axes.
Axes in the center of the model.
Position of the axes in the minimal box that contains the pipe.
4 predefined views of the pipe.
b. Tube cut machines configuration

This dialogue enables you to establish the configuration of the tube cut machine selected
from the list, as well as to install a new one.
• If you select to install a new machine, the machines dialogue will be initiated.
• Once you have selected a machine, the following buttons are activated to establish
your configuration:
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o Cut technology configuration

o Cut simulation configuration
o Material /thickness dependent configuration
You select the cutting machine you are going to use when you create the tube.
By default, Flex3D tries to make the cut using the values stored in the list of dependent
materials for that machine, that is to say, material/thickness dependent configuration.
If it cannot find the right values in the list (material and thickness of current tube), then it
makes use of the parameters specified in the cut technology configuration for that
machine.
Machines dialogue
This dialogue enables you to add new machines to those currently installed as well as
uninstall machines installed earlier.
To do this, just select from the list of Machines available the one you want to install and
establish its configuration, or select from the list of Machines installed the one you want
to uninstall (unless it is the active machine, in which case it cannot be uninstalled).
Cut parameters dialogue

This dialogue enables you to determine the following parameters for the machine
selected:
• Cutting edge : determines if the cut is made on the outer or inner edge of the
tube.
• Chamfer : determines whether the material that forms the thickness of the tube is
chamfered.
• Technology type : cut or mark.
• Cut order : enables you to specify the cut order to be followed by the machine,
with the following possibilities :
o From : starts on the contour closest to the starting point, continues to the
right and comes back from the left. Always leaves for the end any cut on the
left edge of the tube.
o Left to right
o Right to left
• Starting point : co-ordinates of the initial location of the cutting head.

• Technology values :
o Feed rate : of the cutting tool (metric units/minute).
o The compensation can be indicated either by means of a radius or
compensation value, or by means of a compensation index.
• Lead-in values : the lead-ins can be defined automatically using the following
parameters:
o Lead position: point on corner or middle point of discredited segment.
o Lead-in length
• Other parameters :
o Clearance for rapid motions : rapid displacement distance.
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o Cut discretization value : length of cut segments.

o Surface Map operation discretization value : length of segments
discretized in 2D geometry map.
Compensation
Once you have configured a machine in Flex3D Tubes, the corresponding CP file is
copied from the base. The name could be “PSFHKW02_1.CP1”.
The compensation value would be applied to the tube cutting.
To illustrate more clearly the result, I have set the compensation radius value as “15”.
The result on the following hole is shown.
It shows that now the defined “compensation” value for Tube machine is now being
applied to the cutting compensation and cutting path.
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Now I also show the whole tubes (hole, two extremes).
To move on to nesting, the result is also evident on the system compensation.
On the Material Thickness Dependent Data, the compensation data works in similar way.
Material/thickness dependent parameters dialogue

This dialogue enables you to establish the configuration of the cut parameters on the
basis of the material used, as well as the thickness of the tube for the machine selected.
To do this, it presents a material/thickness list in which you can carry out a number of
operations :
• New : presents the cut parameters dialogue, which enables you to add a new
configuration depending on the material and thickness selected.
• Modify : initiates the cut parameters dialogue, which enables you to modify the cut
parameters of the material/thickness pair selected.
• Delete : deletes the material/thickness pair selected.
• Copy : makes a copy of the material/thickness pair selected.
• Order : puts the list in alphabetical order.
Note: The wild card character * indicates any material.
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c. System graphic configuration dialogue

This dialogue enables the following parameters to be configured:
• Automatic orientation when WCS changed : when this option is active, each
time you change the CS you automatically get a view of the model corresponding
to the XY plane of the new CS.
• Automatic view mode when changing module : this option changes from render
mode to only 2D mode when you change from the box or tube module to the 2D
drawing module.
• Highlight current solid : in the box module this option enables you to highlight the
face of the module you select in the box tree .
It also enables you to determine the colors for the different elements that may appear in
the work area:
• WCS and Grid color : working coordinate system and grid color if grid mode is
active.
• Highlight 2D color : color of 2D entities selected on any plane.
• 2D entities in XY plane color: color of 2D entities on active plane.
• 2D entities in other planes color : color of 2D entities on another plane that is not
the active one.
• Option color : color of 2D entities from which you have to select one. These
entities are the result of 2D operations in which two solutions are possible, as in the
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case of Segment or Straight line from parallel line and distance, Circumference
from 2 points and radius and Modify edges.
• Background color : work area background color.
• Background color for printing
• 2D special entities color : color of the 2D entities used in the tube module to carry
out surface map.
• Cut simulation color : if you use cutting technology.
• Mark simulation color : if you use marking technology.
• Highlight solid color : in the box module, color of the face of the model selected in
the box tree.
• Cutting head color
• Rapid color : in the tube module, color of the panning of the tool between different
cuts or marks.
• Drag punches color : in the box module, color of the punches and press punches
when dragged on the face of the model until their location is determined.
The default colors can also be restored.
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18. New (to go to Fabrication module)

Use ‘New’ to allow access to all module. Then choose ‘Fabrication Order (OF module)’ .
Here you could import the tube parts designed in this section of Design of Tube Part.
Fabrication Order (OF module)

The user will base on project or customer order to create a Fabrication Order for tubes
parts.
This could be consider the main work environment to gather all the relevant tube parts,
and get them nested on the tube material and finally to generate the corresponding CNC
program for the specific tube cutting machine.
First step is to select and then New or Open to proceed…
a. Start a new job b. Pick job from job list
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19. Import tubes part

From the selection list, the user could pick the tube parts relevant for the current
fabrication. The list of tube parts will be shown on the Part List for user to enquire for
additional information.
See in Appendix A the first time usage
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20. Make nestings

After a tube material (profile bases) is selected and displayed,
the system will do the automatic make nesting of tube parts of the whole Fabrication
Order on the tube material.
Once the tube part is nested in the Fabrication Order, it could move on to Nesting for
Tube Parts to can handle multiple types of tube-parts (with different profile bases).
Square tube
type with its
individual
tube-part
Status of tube operations could be
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The tube parts are nested
21. Generate CNC Program

The CNC Program is generated for the specific tube cutting machine.
As the above step of make nesting is done, then move on to Nesting for Tube Parts
module to generate the CNC (right mouse click on the nest-tube icon)…
After ensuring the machining is done via Cut Nesting , the save button will help to
generate the CNC.
Notepad is a common software that can be used to open the generated CNC file.
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The operator will place the designated tube material correctly and then the cutter will
follow the CNC instructions to machine on the tube material.
Note: when you open tube-nest from Fabrication Order, then when you close the window
, the system will go back to Fabrication Order.
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22. Common Cut setting (default) and Non

Common Cut setting
By default, the tube part has been set with common cut – that means there is no distance
to the prior and subsequent tube parts in the nest.
On the Part List, with right mouse click will show a submenu, allowing user to choose the
Common Cut settings.
The following setting means not using common cut and thus will apply the ‘offset between
Parts’
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The result could be as shown below.
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23. Inverse and Rotate setting

While designing tube part, there are two configurable properties – ‘Rotatable’ and
‘Reversible’.
Then when in Tube Nesting, at Part List, there will be available the Rotation menu (when
the tube part is defined as Rotatable and Reversible).
The definitions are as follow:

Rotate = 180º about z axis
Inverse = 180º about x axis
Reverse or inverse means the same thing here.
An example given here to show difference in Automatic Nesting with Rotate/Revert

settings and when the Rotate/Revert settings are unchecked (not used).
a. With Rotate/Revert settings
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b. Without Rotate/Revert settings
By right mouse click on the part tree, there is also an option to manually rotate or inverse
a particular tube part in the nest.
The effect is only on that individual tube part.
37
Nestings for tube parts

The Nesting for tube parts could be considered a step in Fabrication Order or could also
be used as a standalone function to do nesting and machine for a single tube type
(Fabrication Order gives options for multiple tube types). The following will just describe
the nesting and machining as part of the Fabrication Order process.
Note: There is a manual nesting option as well ( ) to move individual tube part up
and down the tree structure and then rebuild the nesting .
1. Machining of cut nesting

The user could proceed to generate the cutting tube operations via the Cut Nesting option
. Once the machining is done, the simulation options – simulate nesting cut option
and simulate cut head option – would be made available.
The reload tube parts option allows for the machining of tube parts to be removed so
that another machining could be done. If require, the automatic nesting option could
also be done again.
38
Simulate Cut
It allows the simulation the cut of the different geometries. We can go forward and
backward.
In addition, we can choose the type of simulation.
2. Saving to generate CNC

As describe above in the Fabrication Order section, the save option will initiate the
generation of the CNC program. I.e.
After ensuring the machining is done via Cut Nesting , the save button will help to
generate the CNC. (refer to item 3 of Fabrication Order section).
3. Return to Fabrication Order

Note: when you open tube-nest (Nestings of tube parts ) from Fabrication Order, then
when you close the window , the system will go back to Fabrication Order.
39
Appendix 1 - First time usage (relevant steps)

Start with Formats creation
Build the Bases

40
Build the Profile bases inventory
41
Appendix 2 - Tutorial of a Tube module

1. Creating a tube
First, we click on this button:
Image1.-Tubes module button
A side bar will be opened at the right of the screen. Then we click the first button of that
bar, the “Create tube” button.
It will appear a dialog like this:
Image 2.-“Create tube” dialog
We have to choose a reference name, a base tube, a machine and a length.
For example, in this case we don’t have any base tube selected, so we push the “…”
button.
It will appear a dialog like this:
42
Image 3.-Tube bases saved on the database at the moment
We are going to suppose that we do not have any base saved on the database. So we
must create a new base. We click on the “New” button and it will appear a new dialog like
this:
Image 4.-“New” tube base dialog
For this new base we will need:
-A reference name
-A format
-A material
We will suppose we have neither of them.
43
First, we will choose the format. So we click the button “…” and a new dialog will appear:
Image 5.-Tube formats saved on the database at the moment
Once again, we will suppose we don’t have any format saved on our database. So we will
create a new one. Then we click on “New” and this dialog will be shown:
Image 6.-Edit format dialog
On this window we can select between different types of tubes, rounded, squared,
triangular… or we can create our own type drawing and selecting a 2D geometry and
pushing the last button, the one that has a pencil on it.
44
In our case we have chosen a rounded tube, selected its dimensions and write a name for
it. Then we push “Save”. So we return to the last window. Now we can see that this
format is now saved on the database.
So we have a format, then we’re going to select it. So we click “Select”.
We go back to this window:
Image 7.- “New” tube base dialog
We have no material, so we are going to create one. For that we select <new> from the
“Material” combo box. It will appear a dialog like this:
Image 8.-New material
45
We add a new material with the ID “Steel”. Select its parameters and then select it. So
now, we have all that we need to create a profile base:
Image 9.-“New” tube base dialog
We select a reference name and then press “Ok”.
Image 10.- Tube bases saved on the database at the moment
46
Now we have a base saved on the database. So we select it and then go back to this
window:
Image 11.-“Create tube” dialog
Then we select a machine for cutting the tube, the length of the tube and a reference
name for it. So we click “Ok”. This is the result:
Image 12.-A simple tube
47
If you go to the operation tree, right click on the first item and then go to “Properties”, it will
be open a dialog like this:
Image 13.-Tube properties
In this dialog we have a button with “CC” on it. This button is for selecting common cut
options. This, and the “Rotatable” and “Reversible” check boxes, will be very useful later
to make the nesting and optimize a base tube, if we want to let it.
For our example we have selected both check boxes and all the common cut options will
be true. Then we save the tube on the database just clicking on “Save” button.
Now we are going to make a simple drilling operation on the tube. For that, we select the
forth right side bar button. Select “Round drill”, diameter 7, 100 mm on “X Translation” and
“Entire solid” on “Drill depth” button. Then we add the drill. Result is like this:
Image 14.-Round drill on tube
We have many options for cutting the tube, make drillings, chamfers, etc. In
our case we save the tube again for later try the tube nesting.
48
2. Nesting tubes
For making nesting for tubes first click “New” on the main window. Then click this button:
Image 18.-Nesting tubes module
A new right bar will appear. Now, we click on the first button of this bar: “Create Nesting
Tube” button. It will appear a new dialog window like this:
Image 15.-A new tube nesting creation
On this dialog we have, as usual, to put a reference for the tube nesting we are going to
create, select the machine to cut it and the base tube.
Here we have two options, create a new tube just for this nesting or select it from an
inventory base. We are going to select this second option, so we click on “…” button. It will
appear a dialog like this:
49
Image 16.-Tube bases inventory
We suppose we do not want to use any of the profile bases stored on the database and
we will create a new one. So we click on button “New”. A dialog like this will be shown:
Image 17.-Creating new tube bases in the inventory
We just have to fill three fields:
-Profile: Here we select the profile base we created at first for the tube.
-Length: This is the length of our base tube, from which the tube will be cut.
-Quantity: This is the number of tubes of that type and length that we have on the
inventory.
50
Then press “Ok” and “Select” our material from the inventory. Then press “Ok” again and
our base tube will be shown:
Image 18.-A tube base for nesting
51
The pink part symbolizes the rotatory axis. This is configurable for this nesting, on the last
button of the right bar and for the machine, on the machine options.
Image 19.-Rotatory axis configuration for the piece
Image 20.-Rotatory axis configuration for the machine
52
Now, we are going to import a part to nest. For that we click on the third button of the right
bar. A window like this will be shown:
Image 21.-Import part to nesting
On this window, we can see the entire piece which has the same base as the base
nesting and a graphical representation of them. For our case we select the only part we
have, put 7 on the “Quantity” field and then click “+”. Then click “Ok”.
If we now click on the second button of the right bar we can see all the pieces we have to
nesting, in our case:
Image 22.-Pieces for nesting
53
On this window, if we make right double clicking we have useful information as tube
properties, quantity, common cut properties and the possibility of delete or block the tube
and a list view for the pieces.
If we click on the forth button of the right bar we can configure the offsets of the nesting.
Image 23.-Nesting configuration
54
If we click on “Automatic nesting” button on the right bar we will obtain something like this:
Image 24.-A single tube nesting
A useful option for distinguish between tubes is to do on menu ToolsSystem

settingsGraphicsMain viewer buttonSelect another color on “Part secondary”.
We can configure the order of the pieces manually using these buttons:
Image 25.-Buttons for putting in order the pieces
Using the first and the second one we can move the selected piece up or down through
the tree until have the piece on the position we want to.
The third button is for rebuilding the nesting and so to see graphically the changes.
Save this and it will be stored on the database.
55
Now, if you click on the “Cut nesting” button you will do this to the nesting. Then the button
on the bottom of this one will be activated and clicking on it you could see the cutting
simulation:
Image 26.-Cut simulation
56
Suppose a more complicated nesting. Let’s create another tube of length 250 of the same
base as first. Once we have the tube, we go to the operation tree and right click on the
only icon and then click on “Properties”.
Then check both “Rotatable” and “Reversible” check boxes and on the graphical “Cutting
extreme” icon a web start angle of 20. Also check all the options for common cutting.
Image 27.-Cutting the extreme of a tube
Then click on “Ok” and save all.
57
Now create a new nesting as we did last time and on “Import part” dialog just select the
two pieces with distinct quantities for them:
Image 28.-Importing parts for a tube nesting
Then press “Ok”. If we click on “Part list” button on the right bar we will see this:
Image 29.-A tube nesting part list
58
Now we make the “Automating nesting” and this is the result:
Image 30.-A tube nesting with two kinds of tubes
As you can see, we have introduce 5 tubes with a hole at the first of the nesting and 3
tubes with a gradual cut and the nesting have placed it at the best position.
This is what would be happen if we would not check the gradually cut tube as rotatable
and reversible and haven’t check the common cut options.
Image 31.-A tube nesting with two kinds of tubes without using common cut
59
Appendix 3 - SAT file handling

a. The Tube Part could be saved as SAT file.
This allows user to keep

a backup copy of the
Tube Part.
b. The SAT file containing a Tube Part could also be imported into the software
The Body type should be

‘Tube’.
The file select window

allows user to choose the
required Tube Part SAT
file.
60
The Tube Part is loaded

in its raw format as
follow:
Then the next step is to

analyse the Tube Part
properties (using Select
Base Face option ).
The proper tube material

thickness is then
detected and thus able to
recognise the tube
properties.
61
The end result is the

loaded Tube Part –
where all the machining
could be achieved based
all holes and the two
extreme ends. Since the
Tube Part was not
created from scratch in
the software (it is read in
from SAT file), the
operations information
such as perforation and
chamfer operations are
not recorded or created.
62

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Tubes Manufacturing – Flex3D Tubes

Design of Tube Part

Now you could start design the tube part…

The user could do the Operations on Tubes

The example with Web

Note the left extreme end

The chamfer parameters can be modified subsequently by means of the properties

Chamfer Partial Chamfer

• Operation ID: chamfer operation identifier in the tube tree.

There are three possibilities:

3. Perforation Properties(Drill Tube)

Perforation properties dialogue

• Operation ID: perforation operation identifier in the tube tree.

In the case of imported geometries they determine the displacements on X and Y

• Round: defined by means of a diameter.

The limiting tube may be cylindrical or rectangular.

Limit properties dialogue

• Operation ID: limit operation identifier in the tube tree.

The limiting tube can be a cylinder or a block. In both cases:

• Dist. X, Dist. Z: position of the tube axis in respect of the XZ plane.

5. View (hide backlines)

Show back lines

Angle Dimension 2 edges

Angle Dimension 2 points

Show/Hide Dimension Note

Example: Dimension or measurement between two points.

Surface map properties dialogue

It presents the following parameters:

• Operation ID: map operation identifier in the tube tree.

• Discretisation value: length of the discretisation segment in the projection and in

Cut properties dialogue

10. Modify technology

Cut value modification dialogue

Index: compensation index for the contour selected.

Value: radius or value for compensation for the contour selected.

• Speed: cutter speed in the contour selected (metric_units/minute).

11. Modify Order

12. Cutting Sense and Compensation

To delete a lead-in you have to click on the contour containing it.

• Auxiliary operations: these operations affect all the contours.

There is also the automatic lead-in.

Micro-joint values dialogue

Moreover, the following auxiliary options can be carried out:

15. Modify Clearance

16. Simulate Cut

The type of simulation is configured using the cut simulation dialogue

Cut simulation dialogue

Goes to initial contour.

Undoes the simulation of the last contour.

Simulates the next contour in the order specified.

Simulates from the current contour to the end.

In addition, we can choose the type of simulation.

Cut simulation parameters dialogue

• Only edges : the simulation is limited to cuts or marks.

It has different options:

b. Tube cut machines configuration

o Cut technology configuration

Cut parameters dialogue

• Starting point : co-ordinates of the initial location of the cutting head.

o Cut discretization value : length of cut segments.

The compensation value would be applied to the tube cutting.