X4 File stability question for techie types-Long

[Shotout]

I've got a frustrating file stability problem and I was hoping someone might have an idea on what it could be from. Sorry for the novella but I don't know what may or may not be pertinent. 1st thanks for reading it, second I appreciate any help, thoughts or ideas.

I have an intermittent file stability issue in X4. I will open a converted file, customer provided model, and after cleaning up any un-needed entities I manipulate it, rotation; position in space, so that it will fit into the stock I will be using. I will run No History c-hook and name the model on level 1. I copy the model to level 2 and this is the model I work from, drive or check surfaces etc. Level 3 will be a wire frame representation of my stock. Level 4 is a solid model of my stock if needed, in this most recent case which is from customer provided extrusion. From here I start creating levels for geometry to be used in machining the part, surfaces to aid in machining, vise jaws, fixtures, prints for jaws and fixtures, print for the part if required etc. I then start creating toolpaths.

In my most recent case the extrusion is something of a H shape, think a T with a small horizontal bar at the bottom. As I will be using custom jaws to hold the extrusion for the 1st op I created a solid of it for verify and to visually verify my jaw dimensions. I used Right Gview/Tool/Cplane, drew the stock end view then created a solid from this single chain extending it the length of the provided material. I ran nohistory and deleted the wireframe as I wouldn't need it. Now every time I generate or regenerate a tool path I get a grey ghost of the stock solid (level is off) that looks like an imported stl file, option lines. Also the tool path display that normally flashes and disappears when you have the display set to off will stay on the screen. Any manipulation of the view (zoom/pan/rotation) clears these off. Also if you use X-form Project the entities complete disappear until you manipulate the view. The file regularly crashes when in the tool path parameter page mostly or during a verify session using a solid for verify stock, Unexpected Handling error. I send an error report with my work email and needed files. This behavior is typical on hinky files but not to all files. File size is not associated with the problem. My config is set to disable front buffer and use open gl, basically all the setting the reseller has recommended. I am also having to regenerate the display list frequently. At the 1st sign of instability I will save my file, close MC and then reopen the file. Problem is it doesn't always give warning. I have also noticed that the color shading will be off, like color #168 will look like #199, also it looks like the lighting properties have been severely dimmed and it also looks like a translucent shaded solid except it isn't translucent to wire frame or tool path displays but only to itself and that will vary as you manipulate your view or if you auto highlight a face by moving the cursor over it then they shift from translucent to solid. This requires a reboot to correct. It all sounds like graphics to me but I exceed the system recommendations. If you try and print it will do one of two things. Either generate an error telling you to select a lower dpi, or if it does print say a solid for a set up sheet the solid will have a mix of solid and translucent faces. This also requires a reboot to clear then it will be fine for awhile

File is subject to confidentiality so I can't upload it.

Background
Dell T3500, new
1.5gig video memory on a separate card, nvidia FX4800 added
2 gig ram
1333 MHZ dual core
approx 100 gig free hard drive space
XP Pro
Dual flat panel monitors

X4 with current update
Local USB Hasp
Working from my hard drive
No other programs open
Printer and logitech background monitor programs active in task bar
McAfee anti-virus active in task bar

The only observable commonalities are:
File is imported unigraphics prt file
Model was part of a larger assembly file prior to export
Files often contains blanked (associated?) entities
No History C-hook ran on solid model by me
Unblanked entities deleted and empty levels purged
I have created additional solids in the file for jaws; fixtures; stock; or for a Highspeed surface Core roughing cycle to create tabs or leave stock above my max z depth for part location in the next op.

[Mike Mattera]

WOW! Lets start with the No History. If you loaded in a model from an outside source, It will have no history. You you should be able to eliminate that step. Had to look up No History, Never used that one. Did someone tell you to do that?

You have the model on Level 1 and you have a copy of the same model on Level2? Is that right? Why have 2 copies of the same model?

What system are you bringing it in from?
Are you bringing it in as a Solid, or as surfaces?

Ah Ha "Unblanked entities deleted and empty levels purged"
Sometimes those surfaces are the Base surface used to create a trimmed surface. There's a reason their Blanked. Dont delete those. That could be a problem.

It's late. I'll wait for your replay and read you posting again in the morning.

Mike Mattera

[Shotout]

No History, I have to create a lot of solid models so to eliminate un-needed geo (read clutter) I use it so I can delete defining wire frame. I tried it just as a hope and a prayer as on occasion when trying to delete blanked entities it has thrown up a warning asking me if I wanted to delete associated entities when they only thing not selected was the solid model. So I just started making a habit of it.

Models, Level 1 is considered the "master" model, used by quality etc. After another person in engineering decided to alter his model to make it easier to machine and used the wrong tolerances to do it which caused a shipment of parts to be rejected. The material was over $40K so a policy was put in place that we must keep a copy of the customer provided model in the file. If I create the model then level 1 is empty and unnamed as the print is the master.

Import, They are brought in through master cam with the converter we have associated with one seat's hasp. It comes in as a solid entity. The majority of files we receive are prt files. I've never had a surface model come in bad outside of improper tolerances leaving gaps, but the surface model files will be stable and I don't unblank or delete anything when I have surfaces because of the associativity. As to the native system I can't say with certainty. Everything is military aircraft so unless it is a catalina file I'd guess unigraphics was the native format as they are usually prt files. Some have _sup something in the file name if that helps.

Deleting. I thought running the no history c-hook would delete all associations for a solid. I think the documentation refers to it as a brick with no associations or history tree. It has been awhile since I read it though so I could be mistaken. I won't delete any blank entities on my future files and see if that helps. A lot of what I delete is actually geometry for where to mate the part; print notes; sometimes mating parts; location x,y,z and vector data.

I appreciate you reading through this. I know it is very long. We are going to have our reseller in early next year and I was going to ask him to go through my config files and system setup but I am hoping someone can help me in the interim. If it wasn't for the auto back up every 20 minutes I'd be toast on some files.

Originally Posted by Mike Mattera WOW! Lets start with the No History. If you loaded in a model from an outside source, It will have no history. You you should be able to eliminate that step. Had to look up No History, Never used that one. Did someone tell you to do that? You have the model on Level 1 and you have a copy of the same model on Level2? Is that right? Why have 2 copies of the same model? What system are you bringing it in from? Are you bringing it in as a Solid, or as surfaces? Ah Ha "Unblanked entities deleted and empty levels purged" Sometimes those surfaces are the Base surface used to create a trimmed surface. There's a reason their Blanked. Dont delete those. That could be a problem. It's late. I'll wait for your replay and read you posting again in the morning. Mike Mattera