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Creo Parametric Basic Turning - Jouni Ahola PDF
Creo Parametric Basic Turning - Jouni Ahola PDF
2
Creo Parametric Basic Turning
Jouni Ahola
ISBN 978-952-7074-32-9
February 2015
www.klaava.com
book@klaava.com
All rights reserved. This book may not be reproduced in any form, in whole
or in
Table of contents
.............................................................................................................. 15
3
1.3 INTRODUCTION TO TURNING MANUFACTURING
.............................................................................................. 21
1.4 STARTING
.................................................................................................................................................
24
1.5.1
MANUFACTURING CONFIGURATIONS
..........................................................................................................31
1.10
CUTTING PARAMETERS
................................................................................................................................44
1.10.1
1.10.2
4
FEED AND DEPTH OF CUT
......................................................................................................................106
1.10.3
SURFACE ROUGHNESS
.....................................................................................................................108 9
1.10.4
1.11
2.2 REFERENCE
MODEL...................................................................................................119 ...
2.3 WORKPIECE
.................................................................................................................................................
2.4 FIXTURE
.................................................................................................................................................
2.5 WORKCELL
.................................................................................................................................................
2.5.1
5
LATHE MACHINE TOOL
SIMULATION............................................................................................................74
2.6 OPERATION
.................................................................................................................................................
2.7.1
2.7.2
2.7.3
2.7.4
2.7.5
2.7.6
6
2.7.7
2.8.1
ROUGHING TOOL
.......................................................................................................... 211 ...........96
2.8.2
2.8.3
FINISHING TOOL
..........................................................................................................222 ...........
2.8.4
HOLEMAKING TOOLS
............................................................................................................. ...
101
2.8.4.1
TOOL ATTACHMENT
..............................................................................................................................
102
7
2.8.4.2
2.8.4.3
2.8.4.4
2.8.4.5
2.9.1
2.9.2
TURNING SEQUENCES
................................................................................................................................
112
2.9.3
TURNING CUT
GEOMETRY...................................................................................................................
.112
8
3
3.1.1
3.1.2
AREA REMOVAL
.........................................................................................................................................
120
3.1.3
3.1.4
3.1.5
FACE AREA
.................................................................................................................................................
134
9
138
3.2.1
3.3.1
3.4.1
COUNTERSINK SEQUENCE
..........................................................................................................................
159
3.4.1.1
3.4.2
3.4.2.1
10
TAPPING SEQUENCE
..............................................................................................................................
174
3.4.2.2
3.5 NEW
OPERATION........................................................................................................................
183
3.5.1
3.5.2
3.5.3
3.5.4
11
................................................................................................................ 213
4.1 NC OR CNC
.................................................................................................................................................
215
4.2 STRUCTURE OF AN NC
PROGRAM...................................................................................................................
216
4.3.1
4.3.2
4.3.3
12
4.3.4
4.3.5
MAPKEY
.................................................................................................................................................
224
4.3.6
CUSTOMIZING MENUS
...............................................................................................................................
226
4.3.7
4.3.8
4.4.1
POST PROCESSING
..................................................................................................................................
13
248
5.2 CL DATA
.................................................................................................................................................
251
5.2.1
5.2.2
APPENDIX
.................................................................................................................................................
259
INDEX
.........................................................................572 ...................
14
1
1.1
This book
This book is a follow-up to the books Creo Parametric Modeling and Creo
Para-
metric Basic Milling. If you already know the basis of the Creo Parametric
and
If you are using the software first time, and want to go straight to the CAM
module,
· The downloaded models are in the native Creo Parametric 2-format (.prt),
understand the complete manufacturing process and the steps involved in this
pro-
facturing models.
15
Download site: http://www.gold-cam.fi/en/download
Or inquire: gold-cam@dlc.fi
1.2
16
Chapters and Tasks
This book consists of several chapters each dealing with a primary theme of
Creo
Parametric and are meant to be used alongside the running Creo Parametric.
You will learn the material best if you take time along the way to read the
text care-
fully and think about what you are doing and observing what happens.
Usually, first is the theory and then is the Task. Tasks are marked as chapter
num-
17
18
19
1.3
20
Introduction to Turning Manufacturing
The turning manufacturing process can be divided into different main-level
steps;
1. Manufacturing Template
2. Reference Model
3. Workpiece
5. Fixture
7. Simulation
ing model includes default datum planes and a default coordinate system. 2.
21
and
edges are selected from the reference model and are used as references when
cre-
ating NC steps. The reference model can be also imported from the other
CAD-
5. Fixtures are parts or assemblies that can be used to hold the component
being
machined. For example, you can create chuck assemblies and use them as
fix-
tures.
22
The
· Cut motions, that is, tool motions while actually cutting the workpiece
material
7. Toolpaths and machine simulations are one of the most important stages
in the
step, or multiple steps. You can also display tool path and machine
simulation to-
and simulation have been completed, you can create ASCII format cutter
location
(CL) data files for operations or selected NC steps. This CL data file will then
codes.
23
1.4
Starting
24
25
26
1.5
You can access the Creo Parametric Options dialog box by clicking File
-Options.
27
Configuration Editor – Location for the config.pro editor.
28
Default settings:
Save settings:
29
30
1.5.1 Manufacturing Configurations
There are a few useful configurations for manufacturing, for example you
can de-
fine where cutting tools and NC machines locates. Before that you need to
create
folders and put your solid tools and machine assemblies and so on to them.
For ex-
ample:
31
First, select pro_mf_workcell_dir:
Select Browse and give the full path to the folder where are NC Machine
assem-
blies:
32
OK.
Add/Change.
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34
35
When options are defined – OK. Save options – Yes.
Give the path to the installation folder where the original config.pro locates
(if you
36
Next time you can find and change options easily if needed.
37
1.6
ers of the company has the same way to start the work. The model contains
the same
38
· Parameters
· Layers
· Units
Manufacturing template:
39
40
41
42
When you start the new model and give the name and clear Use default
template
box, you get the New File Options window. Here you can select or browse
template.
Sometimes may happen, that you can´t open templates or there is no template
what
you need. You can create customized templates that can be used to create
new parts
and assemblies.
43
Manufactur-
Start new:
Select Empty.
44
45
Create planes by selecting Plane tool. Show plane Tags:
If the you can´t see the plane names in the model tree, select settings and
Tree
Filters:
coordinate system.
46
47
Select planes in order. Select Orientation page. You can change the
orientation if
needed.
Your coordinate system is shown in to the same direction as the spin center.
Red
means X-axis, Green means Y-axis and blue is the Z-axis. (RGB).
You can also rename the planes. First we need to think how the lathe
coordinate sys-
tem locates.
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You have to create the coordinate system of the template match to the
machine axis.
Usually in lathes, Z-axis is horizontal and pointing away from the chuck and
it is
You can define the plane as XZ-plane and create view for it. Rotate the
50
template so
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Template rotates to the direction. Give the name and Save. OK.
Create one Isometric (3D-view) more. Rotate the template just about as
below:
54
55
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Select Reorient again, give the name and Save the view:
You can make as many views as you want. Save the template.
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58
Select new:
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61
non-solid
like parts, you can add components to layers in an assembly. If you add
compo-
nents to a layer and then hide layer, the component geometry hides.
Select Layers:
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Give the name and Layer id. Select planes from the template:
OK.
Planes are hided from the template and you can see the name of the layer
dimmed.
Click Layers again and you can see the model tree. Planes are hided.
63
Make new layer for Coordinate systems.
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65
If you hide or unhide layers, you need to Save Status. (Right lick)
Now, unhide both layers and Save Status. Save the template.
you to add important additional information into part and assembly models.
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Or
Parameters window:
67
68
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Click plus button and give the parameters. You can select: Integer, Real
Number,
OK. Save the template. Now the template is ready enough for testing. Make
new
Task1.6 is ready.
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1.7
Working directory
ü From the Folder Tree or Web browser- Right click the folder and select: Set
Working Directory.
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74
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1.8
extension is . STP
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77
Crerate Working Directory first!
Open STEP-type model and create Datum Planes and Coordinate Systems:
Selec Type: STEP – Select File from the window. From Import New Model
window: Use Part as Type, Check Use Templates – Select Details – Select
Options
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Model opens:
You can see the Datum Planes which comes from the template. The datum
planes are
You can also see the datum plane and axis names. In the Ribbon – View –
Show or
hide tags:
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Ok.
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Make one datum more, angle 90, use axis and the new plane:
The new datum planes are in relation to the camshaft cam angle. You can see
the
new features also in the model tree and rename them if wanted. DTM1 will
be the
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84
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Select plane from the model as below and the new datum planes with Ctrl
pressed.
Select Orientation page. Change surface from the model to determine Z-axis
and
Task1.8 is ready.
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1.9
Model properties
useful information. For example if you want to change units or material for
strength
Note! If you use templates for start modeling or importing, the units comes
from the
template. Material can also be defined in the template. However, you can
change
89
Task 1.9: Material – change:
Select material from the list and move it to the Materials in Model window.
90
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Select material and make Copy. Select copied material and Properties:
You can give the new name for the material and properties:
93
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The new material is in the Materials in Model window and the original
remain on
the list. So you can use any material for template when creating a new one.
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Select Info.. Now the Mass is tonne. If you want for example grams, you can
96
create a
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Now you can calculate Mass Properties with new unit_system. Expand Mass
Prop-
erties and you can see Calculation source and origin and density:
Select change for Mass Properties. Press Calculate. Mass Properties are
98
calculated
and a lot of more information. OK. Close the Model Properties Window.
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You should know the Basics about Metal Cutting Parameters before creating
toolpaths.
or difficult it is to cut. The material’s hardness is one factor that has a strong
3. Cutting speed: Cutting speed is the relative speed at which the tool passes
through the work material and removes metal. It is normally expressed in me-
ters per minute (or feet per inch in British units). It has to do with the speed
of rotation of the workpiece or the tool, as the case may be. The higher the
cutting speed, the better the productivity. For every work material and tool
material combo, there is always an ideal cutting speed available, and the tool
99
manufacturers generally give the guidelines for it.
It is derived based on the cutting speed and the work diameter cut (in case of
turning/ boring) or tool diameter (in case of drilling/ milling etc.). If V is the
cutting speed and D is the diameter of cutting, then Spindle speed N = V /(Pi
x D)
5. Depth of cut: It indicates how much the tool digs into the component (in
6. Feed rate: The relative speed at which the tool is linearly traversed over
the
workpiece to remove the material. In case of rotating tools with multiple cut-
ting teeth (like a milling cutter), the feed rate is first reckoned in terms of
In case of lathe operations, it is feed per revolution that states how much a
revolution is nothing but feed per tooth multiplied by the number of teeth in
the cutter.
To actually calculate the time taken for cutting a job, it is “feed per minute”
(in mm/min) that is useful. Feed per minute is nothing but feed per revolution
100
multiplied by RPM of the spindle.
7. Tool geometry: For the tool to effectively dig into the component to
remove
material most efficiently without rubbing, the cutting tool tip is normally
ground to different angles (known as rake angle, clearance angles, relief an-
gle, approach angle, etc.). The role played by these angles in tool geometry is
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8. Coolant: To take away the heat produced in cutting and also to act as a
lubri-
cant in cutting to reduce tool wear, coolants are used in metal-cutting. Cool-
ants can range from cutting oils, water-soluble oils, oil-water spray, and so
on.
should be available to provide the drives to the spindles and also to provide
feed movement to the tool to remove the material. The power required for
cutting is based on the metal removal rate – the rate of metal removed in a
given time, generally expressed in cubic centimeters per minute, which de-
pends on work material, tool material, the cutting speed, depth of cut, and
feed rate.
101
10. Rigidity of machine: The rigidity of the machine is based on the design
and
construction of the machine, the age and extent of usage of the machine, the
types of bearings used, the type of construction of slide ways, and the type of
drive provided to the slides. All play a role in the machining of components
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dle. Cutting speeds are usually given in feet or meters per minute and these
speeds
102
chine. Conversion is accomplished by use of the following formulas:
in feet per minute (fpm) for U.S. units and meters per minute (m/min) for
metric
and other operations that use a rotating tool, D is the cutter diameter in inches
for
Example: The cutting speed for turning a 4-inch (102-mm) diameter bar has
been
found to be 575 fpm (175.3 m/min). Using both the inch and metric formulas,
calcu-
When the cutting tool or workpiece diameter and the spindle speed in rpm are
Feed (F): In the CNC Lathe work the feedrate is not measured in terms of
time but,
as the actual distance the tool travels in one spindle revolution (rotation).
Two
103
· Inches per revolution
in/rev (IPR)
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The axial (or in face turning the radial) tool movement is called feed, fn, and
is
rpm will increase, until it reaches the rpm limit of the machine spindle. When
this
limitation is passed, the cutting speed, vc, will decrease until it reaches 0
m/min at
the component centre. The feed (f) in mm/rev is the movement of the tool in
relation
106
the sur-
face being machined and for ensuring that the chip formation is within the
scope of
the tool geometry. This value influences, not only how thick the chip is, but
also how
The cutting depth (ap) in mm is the difference between un-cut and cut
surface. It is
half of the difference between the un-cut and cut diameter of the workpiece.
The cut-
ting depth is always measured at right angles to the feed direction of the tool.
The cutting edge approach to the workpiece is expressed through the entering
angle
(κr). This is the angle between the cutting edge and the direction of feed and
is an
important angle in the basic selection of a turning tool for an operation. The
entering
er entering angles are useful. The entering angle can be selected for
accessibility and
to enable the tool to machine in several feed directions, giving versatility and
reduc-
Feed and depth of the cut are chosen together. The ratio (f : ap) is important
107
factor as
Recommended ratio for the feed and depth of the cut in turning is:
f: ap = 1:6 – 1:10
For example if the depth of the cut is 3mm, the feed can be 0.5 – 0.3mm.
Guiding
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The surface quality of the machined parts is one of the most important
product quali-
108
The perfect surface quality in turning would not be achieved even in the
absence of
fects. There are various parameters used to evaluate the surface roughness. In
the
face roughness.
· Cutting speed
· Feed rate
· Depth of cut
· Nose Radius
Surface roughness is decreasing with decreasing of the feed rate. High nose
radius
produce better surface finish than small nose radius because of the maximum
uncut
109
Small nose radius:
· Reduces vibration
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· Stronger edge
The radial forces that push the insert away from the cutting surface become
more ax-
The nose radius also affects the chip formation. Generally, chip breaking
improves
110
with a smaller radius.
As a general rule of thumb, the depth of cut should be greater than or equal to
2/3 of
the nose radius, or 1/2 of the nose radius in the feed direction.
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111
To maintain a constant rate of material removal as the cutting diameter
decreases,
most CNC machines automatically speed up the spindle, based on how far the
tool
When the tool moves down the face of the part, the diameter where the
cutting edge
When invoked, you will hear the lathe spindle increase as the tool moves
from the
perimeter of the cut to the part center. The G50 command is important
because it
CSS does not apply where the tool does not change its position along X. For
exam-
ple, don't use CSS mode for drilling or tapping on part centerline.
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ers choose to make the camshaft from steel billet. In this case the material of
the
plied in the hardened and tempered condition, which offers high wear
resistance to-
triding, which can give a hard wear resistant core in the range of 61-65Rc.
The rela-
113
tively low temperature of the nitriding process produces components with a
scale
Yield Stress Re
= 650 N/mm²
Hardness HB
= 248/302
Cutting speed (V) for High Speed Steel (HSS) tools is 60 foot per minute
(ft/min) =
18m/min.
Cutting speed (V) for Carbide tools is 300 foot per minute (ft/min) =
90m/min.
rameters.
For example: The diameter of the bar is 50mm and when using carbide
inserts the
114
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2.1
· Operation information
· Workcells
· Reference models
· Workpiece models
· Fixtures
· NC Machines
· NC Sequence information
If you check out the Use default template, you can select or browse the
Template
116
from the list. Template manufacturing models enables you to standardize on
the ini-
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The new manufacturing model is created by using template. You can see
three de-
2.2
Reference model
model represents the final machined component. Surfaces and edges and the
other
features are selected from the reference model and are used as references
when creat-
ing NC sequences.
119
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121
Toggle all display filters on and show datum plane tags. Select Assemble
Reference
model:
Select model:
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You can hide the other coordinate systems from model tree so that only
visible is
Select View from the Ribbon and from Named Views - ISO_1
Note! If you are using different template, you can Reorient the model and
save
123
Task 2.2 is ready.
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2.3
Workpiece
They are optional components, but if used, you can simulate the material
removing
when creating and running NC Sequences. There are different methods how
to create
tangular or round workpiece. You can also create workpieces using the
Inherited
Features option. As well you can select the model as workpiece. Picture
below the
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No you need round bar for workpiece. Select Create round workpiece-icon:
Select Coordinate System for the direction of the round bar. System creates
bar from
126
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Change as below:
Now the reference model is inside the workpiece. All green color means the
material
128
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2.4
Fixture
Fixtures are parts or assemblies that can be used to hold the component being
130
ma-
chined.
fixture locates:
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Select Distance constraint and surface from the jaw and surface from the
reference
model as below.
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Status is now Fully constrained, but you can add one constraint more, Angle
Offset.
Set Datum Planes visible and select datum plane from the jaw:
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Give value 0 for Offset and Flip. The orientation should be as below.
Coordinate
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Fixture setup is almost ready. Give the name for the fixture setup. Select
Properties
136
page:
Adjust the jaws. Select jaw number 1.from the fixture. Select Edit
Definition, Give
137
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Now you can see the Fixture Setup and in this case it will be better if you add
more
139
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Task2.4 is ready.
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2.5
Workcell
example, mill, lathe, or mill/turn. You must specify a workcell before you
can create
NC sequences.
142
capabilities of
Workcell Configuration:
· Name
or Wire EDM
· Number of Axes
· Post-Processor
· Probing Option
- Parameters
- Properties
- CL Command Output
- Milling Capability
- Cutter Compensation
· Tools Tab
· Travel Tab
143
· Cycles Tab
· Assembly Tab
Workcell Configuration
You configure a workcell within the Machine Tool Setup dialog box. You
can speci-
must specify the workcell name and the workcell type. This can be Mill,
Lathe,
Mill/Turn, or Wire EDM. The number of axes you can specify is dependent
on the
workcell type.
You can also specify a number of other items including the controller name.
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The Setup: Work Center dialog box has a number of tabs that enable you to
config-
144
ure different optional elements of a machine tool.
- Cutter location (CL) Command Output Options – You can specify how
- Multiple Axis Output Options – These options are only accessible for a
mill type machine tool when you set the number of axes to 4 axis.
ü Use Rotation – When you select this option, the system outputs
ü Rotation Output Mode – Only available when you select Use Ro-
tion. Enables you to specify the direction of rotation. You can al-
- Cutter Compensation – When you expand this field, the following output
145
ü Tool Center – Cutter location (CL) data is output with respect to
ü Tool Edge – Cutter location (CL) data is output with respect to the
· Parameters Tab – Specifies the maximum spindle speed, and the spindle
horsepower. As well as the rapid feed rate units and the rapid feed rate.
· Tools Tab – Specifies the time needed to change a tool, in seconds. You can
also access the Tool Setup dialog box to configure tools associated with the
machine tool.
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· Travel Tab – Specifies the travel limits and the stroke for the machine tool
along the X-, Y-, and Z-axes. Note, values for the travel limits along the axes
should be the actual dimensions that indicate the extent of the machine tool
146
workspace relative to the Program Zero coordinate system. If you output CL
data that exceeds the defined limits, an information window appears, listing
the values of the limits that have been exceeded and their corresponding val-
ues.
· Properties Tab – Enables you to specify the location of the machine, and
type
Cutter Location (CL) Command Output Options – You can specify how the
FROM,
– Cutter Compensation – When you expand this field, the following output
cutter
· Tool Edge – CL data is output with respect to the cutting edge of the tool.
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Tools tab:
Specifies the time needed to change a tool, in seconds. You can also access
148
the Tool
Setup dialog box to configure tools associated with the machine tool. Turret
1:
Parameters tab specifies the maximum spindle speed, and the spindle
horsepower
and the rapid feed rate units and the rapid feed rate.
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tion on the machine tool. You need to give full path to the location in
config.pro.
Travel tab specifies the travel limits and the stroke for the machine tool
along the
X-, Y-, and Z-axes. Note, values for the travel limits along the axes should be
the ac-
tual dimensions that indicate the extent of the machine tool workspace
relative to the
Program Zero coordinate system. If you output CL data that exceeds the
150
defined lim-
its, an information window appears, listing the values of the limits that have
been ex-
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Properties tab enables you to specify the location of the machine, and type
com-
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152
After needed information, you should have work center in the Model Tree
and you
153
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Within Creo Parametric you can simulate the CNC machine running the
various NC
sequences you created. The Lathe machine assembly is selected within the
Assembly
tab of the Lathe Work Center dialog box. This machine assembly can be
edited to
155
should be
the same location as the machine zero coordinate system for the operation.
Once the machine has been properly defined, the simulation of the operation
with the
machine can be reviewed. The system displays the machine tool simulation in
a new
window. You can then use typical play commands from the Animate dialog
box.
Some commands include controlling the speed of the simulation, stopping the
simu-
plays you can zoom and rotate the machine to any desired view. When you
close the
machine tool simulation display, the system returns you to the manufacturing
model.
156
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· Entire Operation.
· Individual NC Sequences.
You can select machine assembly files from the following locations:
158
· Current working directory.
pro_mf_workcell_dir.
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2.6
Operation
be created.
159
Manufacturing operations contain:
· Fixtures (Optional)
· Retract Plane
· NC Sequences
fixtures.
This also specifies the direction of the X- and Z-axes on the machine tool.
o A retract plane (or surface) which the tool retracts to between NC steps.
· When these items have been specified, you can create NC steps to machine
ence the machine tool and the machine zero position. You cannot create NC
steps until you configure the manufacturing operation and configure a ma-
160
chine tool.
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Select the Options tab from the dashboard and click the New button. Type
EN40B
in the Stock Material text box and press Enter. Click Accept Changes.
When the material is saved the system creates the workpiece material list
named:
<MfgWpMaterialList>
<MfgWpMaterial Name="EN40B"/>
</MfgWpMaterialList>
You can manually add more materials to the mfg_wp_material_list. xml file
163
as re-
quired. This enables you to select from more than one workpiece material.
For example:
<MfgWpMaterialList>
<MfgWpMaterial Name="EN40B"/>
<MfgWpMaterial Name="Steel"/>
<MfgWpMaterial Name="Aluminium"/>
</MfgWpMaterialList>
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Then you can select the new materials from the Stock Material drop-down
list.
Fixture Setup: Select Fixture Setup from the pull down list:
Select Properties tab and give the name for the operation and Comments:
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2.7
Cutting Tools
Tools are an essential step in the manufacturing process. You must configure
a tool
169
for each NC sequence you create. You can create tools when the workcell is
created
Once you configure a tool, you can store the information and use it again.
There are
three different tool types: standard, solid, and sketched. Each type of tool is
created
stand the differences between each type of tool and when you should use
them.
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You create standard tools by configuring tool parameters within the Tools
Setup dia-
log box. The type of tool, for example turning or drilling, determines the tool
cross-
section and therefore which parameters are available for configuration. The
tool pa-
171
rameter values control the tool shape, for example:
· Length
· Nose_Radius
Note, when playing a toolpath, the tool is displayed based on the parameter
values.
A number of tabs are available within the dialog box that enables you to
configure
General – In the General tab, a graphic image of the tool appears during
configura-
tion. You can configure the tool name and tool type. Many different standard
tool
types are available for selection. The selected tool type determines the
displayed tool
shape.
- When the tool type has been specified, you can then configure the tool
geometry
- When configuring the tool geometry, you can also configure tool holder
dimen-
sions. This provides you with a visual representation of the tool holder when
you
review a toolpath. Tool holder dimensions are also used for automatic gouge
avoidance.
172
Note! The same numbers of tabs are also available when using solid
tools!
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Settings:
You can specify a number of items relating to the tool table, including:
- Tool Number – This corresponds to the number field in a tool table, which
speci-
174
- Offset Number – This corresponds to the offset field in a tool table, which
sup-
Cut Data:
You can create cutting data for tools, enabling you to configure optimum feed
rates,
spindle speeds, and depth-of-cut. This data can then be passed into NC steps.
The
cutting data is based on the material that you are machining, the specific tool
you are
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You can use solid model turning tools to enhance CL data display and check
for in-
176
use solid models as tools when creating NC steps.
· Create a coordinate system in the model, and name it TIP. For holemaking
tools,
the Z-axis of the coordinate system must point to the tool. This coordinate
sys-
tem represents the tool tip (often referred to as the control point). This point
specifies the X-, Y-, and Z-positions for the tool in NC steps.
· Add parameters to the model with the names corresponding exactly with the
tool
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· Ptc.com
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181
Understanding a coordinate system in the solid tool model is very important.
There
are different coordinate system for tools and holders. For Turning, the axes of
the
tool coordinate system must be oriented so that they coincide with the
direction of
TIP-coordinate system represents the tool tip (often referred to as the control
point).
This point specifies the X-, Y-, and Z-positions for the tool in NC steps. The
other
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When simulating tool path with Machine Play you can see there is a many
coordinate
If you want use Vericut-software for simulations, you need one coordinate
system more named INSERT.
Vericut-simulation:
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In this case the tool is assembly, which has three parts, two holders and one
insert. If
186
you don´t want to make all by yourself, you may need to find supplier who
offer 3D-
Parametric.
Imported STEP-model.
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188
189
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Create a new Creo Parametric model of type Assembly, give it the name of
the tool.
192
named TOOL_POINT. This coordinate system is used to assemble the solid
tool
model.
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For Turning, the axes of the tool coordinate system must be oriented so that
they co-
incide with the direction of the NC sequence coordinate system’s axes when
the tool
In the picture above is RIGHT_HAND tool. The same (left side picture) tool
is from
196
back side when it is in the machine. Notice the coordinate system directions!
Nose
profile and the position of the INSERT_CSYS to assemble the insert on the
tool in
Vericut. The profile of the tool and the rotation and translation information to
define
In part level, activate insert, and create coordinate system to the center of the
insert
named INSERT:
The axes of the INSERT coordinate system must be oriented so that they
coincide
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tool model, the system will search the assembly first, and then all the
component
parts in the same order as they were assembled (that is, the first component
will be
searched first), for the tool parameters and origin data. Once a parameter is
set, all
values for the same parameter found later will be ignored. In other words, the
top-
If, after all components are searched, some of the tool parameters are
200
missing, an er-
ror message will appear and you will be asked to select another tool.
If you are using your own made tool or PTC standard solid tools, you can
find pa-
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You can toggle between dimension values and names using Switch Symbols:
If you give symbolic name for the dimension, for example length, it is
also pa-
rameter!
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If you are using solid tools from the supplier and download model for
example in
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You can notice that all assembly parameters are shown in General tab.
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Turning Tool Orientation: The area, profile, groove, and thread steps
enable you to
rameter enables you to set the tool angle to any value between 0 and 360
degrees.
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The default, 90 degrees, sets the tool to match the display in the Tools Setup
dialog
box (that is, with the holder held parallel to the X-axis). For outside and face
steps,
you would normally position the tool to match this display (at the default of
90 de-
grees). For inside NC steps, you would normally position the tool to 0
degrees (ro-
tated clockwise).
The HOLDER: option in the Tools Setup dialog box automatically mirrors
the tool
to the proper orientation depending upon whether you are using a left or right
side
tool holder.
You can mirror the tool about its vertical axis by setting the Holder_Type
parameter
210
to Right or Left. This allows you to perform back turning of diameters behind
the
shoulders of parts.
1. Holder_Type: Left
2. Holder_Type: Right
In the case above the tool is Right Hand Tool (DWLNR 2020K06 ), but when
it is
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2.8
211
Tools for Camshaft
The camshaft part needs different type of tools for outside and inside areas.
There
are numerous types of tools available for both. It is not so easy to find out
which is
the best one. There are also numerous suppliers as well as different type of
machines
and holders for them. You can ask from suppliers to help you and ask if there
are
3D-models of the tools. The 3D-models what are used in this book can be
found
The tool for roughing is defined previously and you can return to that
information
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The tool is imported from the supplier, so you need to define parameters. The
needed
215
parameters for the Turn Groove tool are listed below:
The red cross shown in the picture above left indicates the default tool control
point,
that is, the point for which the tool path will be calculated.
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Some of the parameters come from the relations and some are written.
Relations (al-
bolic dimensions and parameters. Relations let you capture design intent by
defining
217
relationships within features or parts, or among assembly components.
You can see and set Local Parameters under the Relations window:
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The picture below show all needed parameters for TURN-GROOVING tool:
218
219
220
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The tool is Right Hand Holder type, but in this case when mounted to the
machine it
is HOLDER_TYPE: Left.
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223
In the picture below, you can see different type of holes of the model. Youĺl
need
different types of tool for countersink, drilling, and tapping. Also you need
tools for
3. Drill 12
4. M10 Tap
5. Inside tool
For the holemaking you need different types of holders as well. In the picture
below
are a few holemaking tools and holders. The tool in front is called Tool
Attachment.
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2.8.4.1
Tool Attachment
Tool attachment is an assembly of a tool and an attachment. The tool and the
attach-
ment can be part models or subassemblies. You can define a tool attachment,
such as
226
cutting tool in a fixed, non-vertical position, to extend the capabilities of a
3-axis
tachment:
When you specify a tool attachment at the time of NC sequence setup, you
select a
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be used for the CL file output as an identification of the holder. The possible
values
for the TOOL_ATTCHMENT parameter are YES and NO. For the
attachment part
or assembly the value must be set to YES. When an attachment is used, the
tool path
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2.8.4.2
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2.8.4.3
231
Basic drills dia 12 and 8.5
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2.8.4.4
Tapping.
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2.8.4.5
Because the tool and tool holder are inside the part, you have to think
carefully the
The diameter of the hole after drilling is 12mm so the tool has to fit inside the
hole.
A few of the needed parameters are shown on the picture below right.
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239
Notice the coordinate system directions of the tool tip!
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2.9
type.
· Preview - Display the tool path for the NC sequence prior to comple-
tion of the NC sequence. Available after all elements have been de-
fined.
240
confirmation.
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241
generated.
You can specify and edit parameter values as needed. You can configure and
store
can retrieve these files, enabling you to quickly and easily set suitable
parameter val-
manufacturing parameters!
· Some parameters such as feed rate and spindle speed are present in all NC
sequence types.
242
NC sequences, only the relevant parameters are available for configuration.
Edit Parameters dialog box, then it is a required parameter. You must specify
a value
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rameter. –You can leave this type of parameter unchanged if required. For
example,
APPROACH_FEED = -.
– You can change these parameters to other specific values if desired. You
can select
243
the available values from a drop-down list.
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Turning sequences allow you to create 2 axis and 4 axis tool paths to machine
parts
· Area
· Profile
· Groove
· Thread
· Holemaking
Each of these types (except holemaking) can be used for either Outside,
Inside, or
244
Facing NC Sequences.
Tool Orientation and the part boundary determine whether the system
processes the
which you can define either at setup time or when you define an NC
Sequence. You
can then reference the Turn Profile in more than one Turning NC Sequence.
This
functionality enables you to define the cut references once, and then use this
defini-
The Turn Profile is the shape of the material after the cut is applied.
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1. Turning Envelopes are intended for use primarily when machining parts
with
rotating the reference part or the workpiece around the turning axis (that is,
about the z-axis of the Turning Envelope coordinate system), and then inter-
246
secting the outside perimeter of the rotated shape with the XZ plane of this
Turn Profile.
sign model to be machined from inside the Turn Profile dashboard. The area
boundary. If you use the Select Surface option, you must pick a start surface
and an end surface on the reference part. All the surfaces in between the se-
lected start and end surfaces are automatically selected. This option is par-
ticularly useful when defining an area with several surfaces (such as fillets
and chamfers) in between the start and end surfaces. If you desire to machine
only one surface in a particular step, then only select the surface once, not
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3. When sketching a Turn Profile, keep in mind that the sketch must lie in the
of the x-axis (either positive or negative). The default orientation of the mod-
249
· If the workcell is defined as Vertical (with the z-axis pointing up and x-
The tool follows this profile based on a Start Point. The Start Point is defined
in the sketch and can be moved to any curve endpoint in the sketch.
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250
4. If a reference part for turning has a complex contour, the process of
defining
the cut by selecting edges, or sketching and aligning, can be time consuming.
You can accelerate this process by using the cross section option.
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3.1
Because of the final product you need to think machining order and fixtures.
For the premachined camshaft (left side) you need basic lathe and for the
final prod-
uct, mill-turn machine. Now the premachined part needs two operations –
two fixing.
Now it could be the best way, if first fix is 74mm bar out from jaws and the
253
workpiece length about 110mm. For the second operation you need soft jaws
and fix
as shown below:
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Task 3.1: Change the length of the workpiece and the bar length from jaws.
Change Length Total to 110m and Length (+) 1.0 and Length (-) 16.4.
255
Edit fixture and give the new value 36mm:
Regenerate:
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By selecting the start and end surfaces, the system automatically selects all
the sur-
faces in between. If doing a Face cut, for example, you only have to select the
single
While holding the control key, select the two surfaces shown below:
257
Click Apply Changes from the dashboard.
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Create next turn profile for a Face cut. Select the face surface as below:
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Area Turning NC Sequences are utilized when you need to remove of a large
volume
of material (requires multiple cuts). The tool path for area sequences are
automatical-
260
1. Outside Area Removal
2. Face Area
3. Inside Area
In this case the first area to be removed lies outside the part, so the system
generates
outside turning sequence. The Area option enables you to rough material
from the
outside of the part. When the profile and orientation are set up properly, this
option
enables the tool to machine stock from the OD toward the centerline in a
series of
parallel passes.
of the toolpath.
ROUGH_STOCK_ALLOW parameter.
261
dinate system. A value of 0 creates cuts along the z-axis.
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263
Select Edit Tools:
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Notice EN40B is selected from the Stock Material drop-down list. Type the
values
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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Note, the saved 14020dwlnr2020k06.xml file now contains feed and speed
infor-
mation, as shown:
You can use the cutting data to specify optimum speed and feed parameters
when us-
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268
· Edit STEP_DEPTH to 2.
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270
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You can slide the Display Speed arrow right or left to speed up or slow down
the
toolpath display.
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In the most cases the Required Parameters are not enough for the best
toolpath.
274
Select material Removal icon:
The Vericut NC simulating software opens and you can simulate the path:
Press Play.
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You can slide the Animation Speed right or left to speed up or slow down the
toolpath display.
The red color means that you have Gouge violation in the model. Also you
get the
Error messages:
Error: Maximum Allowable Gouge violation for tool "1" and Cut Stock of
"Stock 1"
Error: Maximum Allowable Gouge violation for tool "1" and Cut Stock of
"Stock 1"
276
Error: Maximum Allowable Gouge violation for tool "1" and Cut Stock of
"Stock 1"
Close the Vericut. Select Play Path icon and Pick a location on the tool path
as
above:
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Select: Parameters Basic/All – You can view either the basic set of
parameters or all
parameters for a specific category. All parameters give you much more
options how
to change tool path. You can select All Categories or you can select one of
279
the six
different type.
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left after the rough cut for the finish cut. You can select this parameter from
the Cut
profiling is done. The tool cuts by horizontal rough passes for Area turning
and by
vertical passes for Groove turning. Accept changes and Play path.
Now there is 1mm working allowance for the finishing. If you look at the
path, the
tool is going in the air before taking chip. To avoid air machining you can
change
282
one parameter: TRIM_TO_WORKPIECE and set it YES.
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Play path:
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284
Manufacturing provides two methods of generating material removal
simulation:
on the geometric references specified for the NC sequence. When you create
an automatic material removal feature, the system lets you specify whether or
not the feature should be visible at part level (that is, when you retrieve a
(Cut, Hole).
The purpose of this feature is to reshape the workpiece so the part looks just
as it will
during the actual machining process at the completion of that NC step. The
easiest
system creates it based on the information it has. Sometimes the system does
not
have sufficient information. The system then provides the option of manually
constructing a material removal feature (except for Thread steps). The means
for
285
When the cut geometry for Area and Groove turning has been defined by
sketching,
the system enables you to create the material removal feature automatically.
Since
Model without a Material Removal Feature on the left side and Model with a
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The Area option enables you to rough material from the faces (surfaces which
are
perpendicular to the Z-axis) of the part. This option causes the tool to
machine stock
Many materials and/or tools require a specific tool for facing operations. In
other
words, roughing and finishing tools for facing can only be used on faces that
are ei-
operations are not required, you may be able to rely only on profiling (or
outside) us-
ing the SCAN_TYPE set to TYPE_1. Facing operations are also utilized for
remov-
ing a large area of material which is not very long, but lies along a large
diameter.
289
The key parameters used by Area Face Turning:
You do not need to select a tool for this step; the system is using the last tool
speci-
fied.
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Required parameters:
Select the Tool Motions tab, Select Area Turning Cut from inside the Tool
Motions tab:
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295
· Set the Start Extension to Positive X.
Play Path:
Vericut simulation shows that there is material left after the Face Area:
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Create Material Removal Cut for the Face Area and save the manufacturing
model.
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3.2
Groove Turning
299
removing it in step increments.
In practical terms, the toolpath needs to be created vertically for outside and
inside
sequences and horizontally for face sequences. In Creo Parametric, you drive
the tool
parallel (in and out of the groove), parallel to the tool orientation angle.
One of the biggest differences between Groove and Area sequences is that
groove
tools have cutting edges on both sides which enable them to cut in either
direction
For Groove turning, the tool always cuts normal to the groove bottom. The
distance
300
of retract between the cuts (the system start level) is set to CLEAR_DIST.
The final
tape file. Tip & Center are the most often used options.
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302
working al-
In the dashboard, select the drop-down arrow next to the No Tool box and
select Edit
Tools:
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304
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Select New-icon and check the settings tab to ensure there is a new number.
Select
Select the Cut Data tab and give the values as below:
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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· Edit STEP_OVER to 2.
· Edit CLEAR_DIST to 5.
Select the Tool Motions tab and Select Groove Turning Cut from inside the
Tool
Motions tab:
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To change the start or end point of the turn profile, drag the start or end point
to the
desired location along the turn profile. Select the directional arrow in the
graphics
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Play Path.
Click Apply Changes from the dashboard. Save the manufacturing model.
313
Select the Parameters tab and Edit Machining Parameters:
314
315
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Edit parameters as below left. You can also change CUT_DIRECTION from
To make NC Sequence more effective, you can adjust Feeds and Speeds.
Play Path
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Now the model should look like below. Next step is Profile Turning.
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3.3
320
Profile Turning
Profiling enables you to follow a series of edges or sketched curves with the
tool. As
with Area, you can extend the edges to force the tool to enter and exit the part
be-
ly on the location of the surfaces you select or the machining geometry you
sketch
(and the material side you select). If the surfaces you select are located on the
outside
of the part, the system assumes you want to generate an Outside Profiling
sequence.
This means that the tool moves along the side of the surface which faces
away from
the centerline (Z Axis). If the boundary or faces are vertical, the system
generates a
Face Profiling sequence. If the faces are on the inside of the part, or the
material side
of a sketch boundary faces away from the centerline, the system generates an
Inside
Profiling sequence.
The Profile option enables you to remove material leftover from an Area cut.
321
When
the profile and orientation are setup properly, this option creates a finishing
toolpath.
surfaces.
322
323
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Click Profile Turning from the Turning Group. In the dashboard, select the
drop-
down arrow next to the No Tool box and select Edit Tools:
Select New-icon and check the settings tab to ensure there is a new number.
Select
Select the Cut Data tab and give the values as below:
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
325
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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Select the Parameters tab. Edit required parameters and select the Tool
Motions tab:
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Play Path. You can see the tool is gouging the part.
Actually, the groove is ready from the previous NC Sequence, so you can
Edit Pro-
file Turning Cut in such a way that the tool is not gouging the part.
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You can edit the Start and End using drag handles, or double clicking the
value.
Edit the values as above and in the Profile Turning Cut dialog box, click
Apply
Changes.
331
You can add another Profile Turning Cut by activating Insert Here from the
Tool
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334
Material removal simulation:
Profile Turning Cut is ready. In the Profile Turning Cut dialog box, click
Apply
In this case the Automatic Material Removal feature fails. The reason is
because the
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You can Construct material removal; it means that you Cut the part by solid
feature.
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339
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Apply Revolve:
341
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Select Profile Turning from the model tree and Edit Definition. Select Tool
Motions
tab and the first Profile Turning Cut from the list, right click – Edit
343
Definition:
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Edit SHARP to CHAMFER and set the value to 0.5. In the Profile Turning
Cut dia-
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3.4
The process for creating these features in a lathe workcell is identical to the
methods
the Z-axis.
345
Note!
The order of the different sequences is very important as well as what kinds
of tools
are available. The following pages are for basic tools and purpose is
describing dif-
If you are using Solid Carbide Drills or Indexable Head Drills with Coolant
Holes
3. Tap M10
Second operation:
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tool along the center axis until a countersink to a specified diameter or depth
is creat-
ed. You define the hole and start surface in the same manner as a drill. You
enter a
countersink diameter and the system drives the tool to the depth required to
create
You can define the diameter for countersink using the following:
347
· Start Surface – The surface the required diameter is defined on.
tem will calculate the depth required from the tool defined.
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Select the Turn tab and click Countersink from the Holemaking Cycles
group.
In the dashboard, select the drop-down arrow next to the No Tool and Edit
Tools. Se-
CSS does not apply where the tool does not change its position along X.
So you
349
can't use CSS mode for drilling or tapping on part centerline!
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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Select references tab and select axis from the model for the Holes and select
end sur-
face of the model for Start. Edit value 10 for Countersink diameter:
Select the Clearance tab and select Reference surface from the model and edit
value
5.
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352
Select the Attachment:
Click Close from the PLAY PATH dialog box. Click Apply Changes from
the dash-
board.
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353
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3.4.1.1
The Breakchip holemaking cycle is similar to the Deep cycle except that the
retrac-
355
tion at each increment does not come all the way out of the hole.
Select the Turn tab and click Breakchip from the Holemaking Cycles group.
In the dashboard, select the drop-down arrow next to the No Tool and Edit
Tools. Se-
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Next, configure cutting data for a Basic Drill tool by selecting the Cut Data
tab.
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
357
Select axis for Holes and Start Surface and End depth: 25
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You can see how the tool is going in 3mm depth for each pass but does not
come all
359
the way out of the hole.
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Click Close from the PLAY PATH dialog box. Click Apply Changes from
the dash-
360
board. Create Material Removal Cut.
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The Deep Drilling holemaking cycle means that the retraction at each
increment
You can define the hole to drill by selecting either an axis, or selecting a rule-
based
method. The depth of the hole is controlled with several different options.
When you
define a depth, you can cause the tip of the tool or the shoulder of the tool to
drill to
that depth.
You can define the depth for holemaking in one of four ways:
· AUTO – The hole is drilled to the actual depth represented by the hole fea-
as measured from the start surface, for the end of the drilling.
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Select the Turn tab and click Deep from the Holemaking Cycles group.
In the dashboard, select the drop-down arrow next to the No Tool and Edit
Tools. Se-
Select as below:
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Next, configure cutting data for a Basic Drill tool by selecting the Cut Data
tab.
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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Select axis for Holes and Start Surface and End depth: 65
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370
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You can see how the tool is going in 3mm depth for each pass.
Click Close from the PLAY PATH dialog box. Click Apply Changes from
the dash-
So far the first operation looks as below. There are two NC Sequences to
define,
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3.4.2.1
Tapping Sequence
Many times the hole diameter that needs threading is too small for
conventional
threading tools used for internal threads. If this is the case, you can program
tapping
cycles, just like in milling. You must specify a start surface and a depth for
the tap. If
the tap has a chamfer on its end, the system will actually drive the tap beyond
the end
of the threads until the OD of the tap reaches the end of the required thread. If
you
are not using a bottom tap, you must enable relief behind the bottom of the
thread so
Select the Turn tab and click Tapping from the Holemaking Cycles group.
In the dashboard, select the drop-down arrow next to the No Tool and Edit
Tools. Se-
instance M10.
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Check the geometry. Next, configure cutting data for a Tap M10 tool by
selecting the
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
Select axis for Holes and Start Surface and End depth: 52
378
pitch of M10 thread is 1.5. So if the SPINDLE_SPEED is 200, the FEED will
be
300.
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Play Path:
Click Close from the PLAY PATH dialog box. Click Apply Changes from
the dash-
board.
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3.4.2.2
383
Inside Area Turning
The Area option enables you to rough material from the interior faces of the
part.
This option causes the tool to machine stock in a series of passes which are
parallel
with the centerline of the machine tool. The inside area is basically the same
as the
outside area and facing toolpaths, except that it steps away from the
centerline in-
cause the tool and tool holder are actually inside the part), you may find it is
useful
to utilize the position option to visually check for tool holder interference at
selected
tool positions. You can also use Sections with Play Path:
of the toolpath.
parameter.
384
· CUT_ANGLE – Changes the angle of cuts relative to the NC Sequence
coor-
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Press Ctrl and select the two surfaces shown above. Select the inside surface
first and
Select Area Turning from the Turning group. Select Edit Tools:
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Select New-icon and check the settings tab to ensure there is a new number.
Select
Select the Cut Data tab and give the values as below:
Click the Apply button and Yes to save the changes to the tool. In the Tools
Setup
dialog box, click Save to save the tool information. Click OK to close the
Tools Set-
up.
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Click Area Turning Cut and select Turn Profile 4 from the model:
Set the Start Extension to Positive Z. and the End Extension to Negative X.
Set Op-
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Click Close from the PLAY PATH dialog box. Click Apply Changes from
the dash-
board. You can change the name of the NC Sequence from the model tree for
exam-
ple INSIDE_AREA.
Now the first operation is ready and the turned part looks as below:
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3.5
New Operation
After the first operation you need to rotate the part and fix it to the soft jaws.
You
need also to select or define a new coordinate system. The real part looks as
below
Soft jaws are machinable jaws. Basically, the standard jaws are removed and
a set
395
of aluminum or mild steel jaws are bolted onto the chuck where the standard
jaws
used to fit. It is important to make a plug for the new set of machined jaws. A
plug is
turned to a diameter close to the diameter you wish hold in the new soft jaws.
Prior
to machining, the jaws should be tightened around the plug towards the rear
of the
soft jaw set. This will provide rigidity while the jaws are machined and will
insure
that clamping pressure and scroll looseness are removed while turning.
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In this case there is space enough for the collar of the model. The reference
model is
shown in a red color and material which has to be removed in a green color.
To ensure the part fits to the soft jaws, you can make the Global Interference
Analy-
model.
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The Work Center and Clearance are the same, Select a new coordinate
system.
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401
Select Coincident and surfaces from the part and fixture as below:
402
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Status is now Fully Constrained, but you can add one more definition,
Angle Off-
set.
Enable Csys Display and Plane Display. Select the middle Datum Plane from
the jaw
as component item.
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Set Offset to 0 and flip if needed. The result should be that the jaw number 1
is in the
same direction as coordinate axis X. Click Apply Changes for the Component
Placement.
Select the Properties tab and give the name for the operation.
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Select the Options tab from the dashboard and select EN40B in the Stock
Material
text box.
405
or ac-
in the Model Tree and click Activate. All newly created NC sequences are
includ-
ed in this operation.
After Activating:
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Now there is a lot of material to remove from the other end of the part.
Select Area Turning from the Turning group. Select previously used tool
from the
list.
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408
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410
Select the Cut Data tab. Notice EN40B selected from the Stock Material
drop-down
Click the Apply button and Yes to save the changes to the tool. Click OK to
close
Select the Parameters tab and Click Edit Machining Parameters. Select All
parame-
axis. A value of 90 cuts along the x-axis, 90 is normally used for Area Face
cuts.
Click OK.
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Select Turn Profile from the Geometry Group. Define the Turn Profile as
below and
Apply Changes.
Resume back. Select tool Motions tab and Select Area Turning Cut.
Set the Start Extension to Positive X. Set the End Extension to Positive Z. Set
Op-
tions.
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Accept and simulate with material removal. You can see that there is a little
notch at
414
415
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Simulate the toolpath again. Click Apply Changes from the dashboard.
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You can use the same tool for the next sequence.
Select Area Turning from the Turning group. Select Tool Manager from the
dash-
board:
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Select the All Operations check box, and select Area Turning 1. OK. Next,
select
Now you need to create a new Turn Profile. Select the Geometry icon:
421
Select Turn Profile and Use surfaces from the Turn Profile group:
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Select up to two surfaces to define the start and the end for turn profile:
422
Accept.
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Play Path:
Create Material Removal Cut for the Area Turning 4. and save the
manufacturing
model.
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425
426
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Now you can use the Groove Turning Step from the first operation as
reference.
Click Groove Turning from the Turning Group. Select the Tool Manager
icon:
428
The TURN-GROOVING tool should be activated by default. Select the Cut
Data
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From the Parameters tab, select Copy machining parameters and select as
below:
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433
Create Material Removal Cut for the Groove Turning 2. and save the
manufacturing
model.
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Now the part should look as below. You can continue with the same Groove
Tool.
The next NC Sequence is Groove Turning Step for the material between two
collars
Click Groove Turning from the Turning Group. Select the Parameters tab:
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Play Path:
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If you are using MDT-type of grooving tool, it means Multi Directional Tool;
you
can change the parameters from TYPE_1 to SIDE_TURN. See the video.
You can see the Tool Path after changing of parameters below. Entry/Exit
Motion
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445
Click Apply Changes from the dashboard.
Create Material Removal Cut for the Groove Turning 3. and save the
manufacturing
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3.6
The other side hole, diameter 16, can be drilled with indexable drill.
Select the Turn tab and click Standard from the Holemaking Cycles group.
Click New Tool in the Tools Setup dialog box. Select Open Tool Library By
Copy:
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Select the References tab. In the Holes dialog box, activate Holes and select
axis
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Select the Parameters tab, edit as below. Select the Clearance tab and select
the sur-
face from the model as below and give the value 5. outside from the surface.
Play Path:
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Create Material Removal Cut for the Drilling_16 and save the manufacturing
model.
Now there is material left in the 16 dia hole, because of the indexable drill
has flat
end. There is also chamfer in the 16 dia hole. Finally, the right outer end
surface fin-
You can use Inside Area Turning Sequence or Inside Profile for the finishing
of the
16 dia hole.
455
Tip! Use first Operation Inside Area Turning as reference (chapter 3.4.2.2)
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Play Path:
458
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3.7
There is the last NC Sequence left for now. You can use the same kind of NC
Se-
Click Profile Turning from the Turning Group. In the dashboard, select the
drop-
down Tool Manager and select Edit Tools. Select tool and check the Cut
Data:
462
Copy parameters from the first operation:
Create Material Removal Cut for the Final Profile save the manufacturing
model.
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Now you can consider the part is ready. At least the toolpaths looks like
ready. There
The part may need chamfers or rounding’s or better surface quality. These all
464
you
Before the creating of the CNC Code you should know the basics of CNC
language
and structure. As well you should know the CNC machine what is available
for the
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4.1
NC or CNC
basic machine tools which were modified to have motors for movement along
the
465
axes.
with computers. This makes them more versatile in the sense that, suppose a
change
the program in the tape and then feed it to the machine again. But in a CNC
machine,
you just change a variable in the computer and your modification is done.
that the said machine’s advent can be traced back to the invention of the NC
(numer-
was a breakthrough invention that led the way towards modern automated
machines.
The CNC machine first appeared when John Runyon managed to produce
punch
tapes under computer control. This showed dramatic results in terms of time,
reduc-
466
NC.
Today you can see that the both terms are used. For example, there can be job
adver-
In this book the language is based on G-code which is the common name for
the
most widely used programming language. In the world, the standard ISO
6983 is of-
ten used, although in varied states of Europe sometimes used other standards,
exam-
There are also the other languages as Heidenhain, Siemens, Mazak and more.
Many
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4.2
Structure of an NC program
467
ter and line by line.
· Program end
Program start
At the beginning of an NC program the character '%' can represent the start of
the
program. The name of the program is then found following this character.
NC block:
NC word:
468
a special character. The optional following characters specify the meaning
the letters as "words" because each is a "word" telling the controller some-
thing to do
Program end:
this.
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Between the start and end of the program are NC Blocks as mentioned above.
NC
N20
N30
Mostly used G-code words are G and M (for General and Miscellaneous).
O1702
469
N20 G00 T0202 M41
· Many G codes and M codes cause the machine to change from one mode to
another, and the mode stays active until some other command changes it im-
· Non-modal" codes effect only the lines on which they occur. For example,
G4 (dwell) is non-modal.
You can find a lot of G-code lists from the internet for example. The G-codes
can be
machine could have own codes. So you should know the machine functions
and con-
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4.3
Not all codes are available on all controls, and some controls have other
codes. See
470
G00 - Positioning at rapid speed; Mill and Lathe
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G29 - Move to location through reference point; Mill and Lathe (slightly
different
471
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left;
Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right;
Lathe
472
G75 - OD groove pecking; Lathe
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473
G97 - Constant surface speed cancel
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by a single G-code. Canned cycles act as shortcuts that simplify the program.
perform canned cycles. Canned cycles give the programmer the option to do
some
· G70 finishing
475
· G73 pattern repeating
· G74 grooving
· G76 threading
Most CAM systems will take advantage of CNC-based canned cycles. If you
want to
use canned cycles with CAM, you need to set up the postprocessor less or
more. In
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477
4.3.2 Canned Cycle G71 and G70 manual programming
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G76 X_ Z_ I_ K_ D_ F_ A_ P_
478
X
= Amount of taper
= Thread Angle
All other rules of threading applied to this cycle, they are as follows.
479
4. You must start the thread at least one to two threads in front of part
5. You must finish at least ½ to 1 thread after your full thread requirement
Before you can use Canned Cycles in CAM programming, you need to make
some
preliminary work. This work will be useful later as well. The next chapter
shows how
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mensions, any relations between the selected features, and a list of references
for
480
standalone.
The UDF dialog box provides a running status of these UDF elements during
UDF
ufacturing features into other models. MUDF’s can create any number of
features,
UDF file is a file with the . gph extension that you want to insert in the
manufacturing
model.
· area_turning_cycle_G70_G71.gph
· Mapkey + icon
Area_turning_cycle_G70_G71.gph - prompts:
· CSYS
· OPERATION
481
· Home Point
· Reference Model
You can define a Mapkey to load the UDF and create your own Icon to call
the
mapkey:
Working Directory.
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4.3.5 Mapkey
mand sequences to certain keyboard keys or sets of keys. The mapkeys are
saved in
the configuration file mapkey, with each macro beginning on a new line. You
can de-
fine a unique key or combination of keys which, when pressed, executes the
mapkey
macro (for example, F8). You can create a mapkey for virtually any task you
perform
By adding custom mapkeys to your toolbar or menu bar, you can use
mapkeys with a
single mouse click or menu command and thus automate your workflow.
To Define a Mapkey:
box opens.
· Type the key sequence that is to be used to execute the mapkey in the Key
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Click Record and start recording the macro by selecting menu commands in
the ap-
propriate order.
Activate Model from the Ribbon - Select User-defined Feature –Open the
Group.
Stop recording:
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You can add commands to toolbars or to the menus in the menu bar. The new
button
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Accept and return. Now you should see the new Group:
Next you can add icon to the new Canned Cycles Group:
489
Drag and drop:
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491
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Area Turning NC Sequences are utilized when you need to remove of a large
volume
of material (requires multiple cuts). The tool path for area sequences are
automatical-
493
be removed between the part and the workpiece.
You can make this toolpath without using G71 cycle. In this example you
will get
O1303
N10 T0303
N20 M3 S90
N60 Z-40.7
N70 X51.
N870 M5
494
If you are using G71 cycle, the amounts of NC Code lines are significantly
less.
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Select the mapkey if created. If not, select Model from the ribbon and select
User-
directory.
498
499
500
501
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Select Tool from the MOD NC SEQ Menu Manager. Select Open Tool
Library By
503
504
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Entry/Exit Motions:
Machine Settings:
506
507
508
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Machine Settings:
General:
Click OK when parameters ready. Click Done/Return. Click Done. The Area
Turn-
510
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Thread NC sequences are used to cut threads on a lathe. The threads can be
external
and internal, blind and through. This NC sequence does not remove any
material
from the workpiece on the screen. The proper cutter path will, however, be
generat-
ed.
sponds to the major diameter for an external thread and to the minor diameter
512
for an
rameter.
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Thread tool:
515
516
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Create a turn profile from the cosmetic thread surface. Click Use surfaces to
define
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Select the Turn tab. Click Thread Turning from the Turning group. Click
Edit
520
Tools:
Click OK. In the dashboard, edit ISO to AI MACRO from the drop-down
menu. Se-
lect the References tab. Click in the Turn Profile text box and select Turn
Profile 2
Edit THREAD_FEED to 3.
Edit CLEAR_DIST to 5.
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Click Display Toolpath. Click Play in the Play Path dialog box.
In addition there are a lot of parameters that affects in a different way to the
toolpath.
Test different parameters and play the path to see the affects.
When parameter definitions are ready, click Apply Changes from the
dashboard.
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4.4
When facing or straight turning, the tool nose radius has no effect on the part
other
When turning tapers or radii, the tool nose radius leaves excess material as
shown
here:
The tool nose radius is entered into the machine controller, and the program
turns on
compensation for finish cuts only, and then turns it off. The machine
calculates the
· G41 Compensate for tool nose radius to the LEFT of the programmed path.
· G42 Compensate for tool nose radius to the RIGHT of the programmed
path.
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G41 causes the tool to be offset to the left of the programmed toolpath and
G42 di-
Tool Tip Orientation – the chart below identifies the directions of tool radius
center
orientation, measured from the command point to the tool center for CNC
lathes of
the REAR type. (Rear type lathe – slant bed lathe, is the most popular design
for
general work).
Tool tip orientation numbers 0 or 9 define the command point at the center of
the
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531
The chart below shows examples for the right-handed coordinate system
lathe:
532
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Below is an example of the turned part. For the tool nose radius
compensation only
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There are a several settings to change when using tool nose radius
compensation (To
533
Set the CL Data Output on a Contour):
1. On the Output tabbed page of the Work Center dialog box, select Tool
Edge
clude approach and exit moves and enable cutter compensation by provid-
5. Cutter compensation is enabled on the first linear move and the output
6. Postprocessor definitions
To specify a location for the CUTCOM statement on the approach and exit
motion,
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Profile turning allows you to interactively specify the cut motion trajectory.
When
defining cut motions, the Offset Cut check box on the Profile Turning Cut
dialog box
· If you select the Offset Cut check box, the turn profile represents the
finished
geometry, that is, the trajectory of the tip of the tool cutting material. This
535
appropriate direction from the specified trajectory (up for outside turning,
· If you clear the Offset Cut check box, the turn profile represents the
trajecto-
ry of the tool control point. No offset will be applied when creating the cut
motion.
You can also access the Offset Cut shortcut menu in the graphics window.
You must
select the turn profile in the graphics window, right-click, and select or clear
the Off-
The tool path is extended 2mm. (When the chamfer is 45-degree, the square
root of 2
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means that the tool number is 1 and tool compensation data locates in pocket
1. Usu-
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Tool path:
On the line 22 you can see the CUTCOM / RIGHT (G42) directs the tool to
be offset
to the right. NC Code will be: N80 G03 X24. Z-5. F.2 I0. K-5.
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On the line 31 you can see how the CUTCOM is switched off (G40). NC
Code will
be:
N190 M5
The NC Code for the Profile Finishing looks like below so far:
541
O2013
N10 T0101
N70 Z0.
N130 Z-42.
N140 X51.
N190 M5
542
%
The code is not ready yet and there will be more information in the
Postprocessing chapter!
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POST PROCESSING
543
5.1
What is a Postprocessor
system. The toolpath data file contains the machining instructions specified
by the
converts the machining instructions from the toolpath data file into code
understood
figure below shows how you get from a blueprint or a CAD system to a
punch file
The machine control data (MCD) file is the file produced that ultimately is
taken to
has also been referred to as the tape image file (. TAP) and/or the punch file
(. PU1).
You can change the extension (.TAP, .PU1) if needed for example: (.CNC or
.EIA or
544
whatever you want to use.
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An option file is a file created by the user via the Option File Generator. The
file is
read at postprocessor execution time. Upon reading the option file, the
postprocessor
The Option File Generator creates an option file, which is read by the
postprocessor
at execution time in order to obtain its 'personality' (or behavior). The file
naming
· Lathes: uncl01.pnn
· Mills: uncx01.pnn
While using the Option File Generator, the user has the option to create a FIL
file via
545
the built in FIL editor. When the user exits or saves the option file they have
been
creating, the Option File Generator automatically saves any work the user
may have
done in the FIL editor. The file naming convention for the FIL file is:
cessor will ever have the ability to accommodate the many features available
on to-
day's controls, not to mention the new features being added to controls every
day!
lease of the G-POST since it was released many years ago. It is not possible
to ad-
dress the many special features available; thus, this was the primary driving
force in
creation of FIL.
FIL allows the user to go beyond any postprocessor's capabilities through the
ability
546
limited
only by the user's imagination. The FIL macro language allows users to:
In addition, the FIL macro language has many features for logic control:
· Case statements
· Do loops
· Jumpto labels
There are many text string manipulation functions and many other tools
available as
well.
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For example, if you want to use canned cycles with CAM you may need the
FIL-file:
CIMFIL/ON,CYCLE
$$ ****************************************************
547
$$ * Turning Cycle
$$
$$ *
CYCLE/TURN,DEPTH,Depth,XAXIS,xval,ZAXIS,Zval,FEED,feed_rough
$$ * ...
$$ * roughing motions
$$ * ...
$$ * CYCLE/TURN,NOMORE,FEED,feed_finish
$$ * ...
$$ * finish motions
$$ * ...
$$ * CYCLE/TURN,OFF
$$ *
$$ *
$$ * N... Ffeed_rough
$$ * Nstart_seq ...
$$ * ...
$$ * Nend_seq ...
548
$$ ****************************************************
CYCTYP=POSTF(7,4)
IF (CYCTYP.EQ.ICODEF(TURN)) THEN
DVAL=POSTF(7,6)
UVAL=POSTF(7,8)
WVAL=POSTF(7,10)
FVAL=POSTF(7,12)
XX=POSTF(26,5,5,1)
ELSE
XX=POSTF(13)
ENDIF
CIMFIL/OFF
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5.2
CL Data
been completed, you can create ASCII format Cutter Location (CL) data files
for
550
operations or selected NC steps. You can then post-process CL data files into
specif-
eration and post-process this file again to produce an updated MCD file.
· Cutter Location (CL) data files are generated from the toolpaths specified
within NC steps.
· You can create CL data files of one or more selected NC steps, or a whole
operation.
· You can then use the post-processed files to control machine tools such as a
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Task 5.2.1: Create a CL data file and MCD file for camshaft.
and select Play Path. Click the CL data bar to make the CL data visible. In
the
Select the Save CL File also check box. Select the Verbose and Trace check
boxes.
Create an MCD file for the operation. From the menu manager, Move the
cursor on
the UNCL01.P15 to see the name of the NC machine, click to select the
post-
processor.
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Click Close in the information window. Click Close in the PLAY PATH
dialog box.
View the contents of the browser. Click the Web Browser from the Status
bar, and
in the browser window right-click and select Refresh. Notice that the listing
for the
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You can open the NC Code in the text editor such WordPad or Notepad etc.
The de-
NC machine!
PTC makes no guarantee that each postprocessor will create the correct
output
556
for a specific customer's machine. PTC will not provide any support for
these
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Task 5.2.2: Create a CL data file and MCD file for the selected NC
Sequences.
Select Save CL File for a Set from the Save a CL File types drop-down
menu in the
You can see all Operations and NC Sequences. Click the arrow to scroll
down until
you see the Operation 2. and Profile Turning (last on the list). Select the
Profile
Turning check box. (you can pick as many sequences as wanted to create CL
Data).
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562
Click FINISH_OPER_2. Click File. Select the MCD File check box, and
click
formation window. Click Done Output. View the contents of the browser.
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5.3
564
rameters and Postprocessor functions.
For example thread turning. If you are using type AI MACRO, you will get
698 lines
open the NC Post Processor from the Applications tab when the
manufacturing ses-
sion is open.
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Check the Output G76 threading cycle check box. Save the Option File.
Now the thread NC Sequence is generated with the Mazak Quick Turn post
proces-
The code is not ready, but there are only a few lines of code.
The customizing of the post process is a big project and it needs own book
later.
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APPENDIX
567
6.1
File Menu:
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UI Customization
Command Locator
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Keyboard Shortcuts
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Model Appearance
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PTC.com
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INDEX
ANSI .......................................................................87
572
ISO 6983 ............................................................... 214
APT....................................................................... 247
Area Turning
.......................................................... 120
Lathe .......................................................................67
CAM
573
........................................................................ 5
CL Data ................ 7, 68, 69, 71, 83, 250, 251, 254, 255
Machine Tool ... 67, 68, 69, 70, 71, 72, 74, 76, 178, 247,
CNC 6, 7, 46, 51, 74, 112, 213, 214, 216, 219, 239, 247
248
Constraint ................................................................61
Modal.................................................................... 216
Cut Data ... 82, 122, 140, 148, 160, 165, 170, 175, 180,
574
191, 195, 199, 208, 211, 212, 230
Non-Modal............................................................ 216
Nose Radius ................. 49, 50, 217, 238, 239, 241, 242
Operation .................................................................76
575
Postprocessor ................... 219, 242, 247, 248, 253, 256
Groove 97, 112, 113, 130, 132, 138, 139, 140, 141, 142,
Reference Model .. 7, 32, 54, 55, 56, 57, 59, 61, 63, 184,
187
Hardness HB ............................................................52
576
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Workcell
Solid Tools
Workpiece
Standard Tool
..................................................... 80, 81
STEP-format ............................................................. 5
XY Plane .................................................................89
XZ Plane
Tensile Strength
.......................................................52
577
Y
Y-axis ......................................................................19
Yield Stress
Units
..............................................................52
........................................................................23
V,W
Z-axis ......................................................................20
Vericut ................... 86, 89, 92, 127, 128, 136, 145, 206
578
Table of Contents
1
1.3 INTRODUCTION TO TURNING MANUFACTURING
.........................................................
1.4 STARTING ......................................................................................
1.5 OPTIONS AND CONFIGURATIONS
....................................................................
1.5.1
1.6 CREATING A NEW TEMPLATE
.......................................................................
1.7 WORKING DIRECTORY
.............................................................................
1.8 IMPORT REFERENCE MODEL
........................................................................
1.9 MODEL PROPERTIES
..............................................................................
1.10
1.10.1
1.10.2
1.10.3
1.10.4
1.11
2
2.2 REFERENCE
MODEL................................................................................
2.3 WORKPIECE .....................................................................................
2.4 FIXTURE .......................................................................................
2.5 WORKCELL ......................................................................................
2.5.1
2.6 OPERATION .....................................................................................
2.7 CUTTING TOOLS
.................................................................................
2.7.2
2.7.3
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2.7.4
2.7.5
2.7.6
2.7.7
2.8 TOOLS FOR CAMSHAFT
............................................................................
2.8.2
2.8.3
2.8.4
2.8.4.1
2.8.4.2
2.8.4.3
2.8.4.4
2.8.4.5
2.9 COMMON ABOUT NC SEQUENCES
.....................................................................
2.9.1
2.9.2
3
3.1.1
3.1.2
3.1.3
3.1.4
3.1.5
3.2 GROOVE TURNING
................................................................................
3.2.1
3.3 PROFILE TURNING
...............................................................................
580