Creo Parametric Mill-Turn - Jouni Ahola PDF

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Creo Parametric Mil -Turn
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Creo Parametric Mill-Turn
Jouni Ahola
ISBN 978-952-7074-33-6
Copyright Jouni Ahola
February 2015
Publisher: Klaava Media
www.klaava.com
book@klaava.com
All rights reserved. This book may not be reproduced in any form, in whole
or in
part, without written permission from the author.
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Table of contents
CREO PARAMETRIC
INTERFACE.........................................................................................................................
5
1.1 THIS BOOK

.................................................................................................................................................
5
1.2 CHAPTERS AND TASKS

...............................................................................................................................
3
5
1.3 INTRODUCTION TO MILL-TURN MANUFACTURING

........................................................................... 6
1.4 STARTING
.................................................................................................................................................
8
1.5 MILL-TURN PROCESS

.................................................................................................................................
9
1.6 OPTIONS AND CONFIGURATIONS

...........................................................................................................10
1.6.1
MANUFACTURING CONFIGURATIONS
..............................................................................................11
1.7 CREATING A NEW TEMPLATE

.................................................................................................................17
1.8 WORKING DIRECTORY

.............................................................................................................................29
1.9 IMPORT MODEL

..........................................................................................................................................31
1.10
MODEL PROPERTIES
.............................................................................................................................39
1.11
CUTTING PARAMETERS
.......................................................................................................................44
4
1.11.1
CUTTING SPEED FORMULAS

..........................................................................................................46
1.11.2
FEED AND DEPTH OF

CUT................................................................................................................48
1.11.3
SURFACE ROUGHNESS
.....................................................................................................................49
1.11.4
CONSTANT SURFACE SPEED

...........................................................................................................51
1.12
CAMSHAFT CUTTING PARAMETERS

.................................................................................................52
CREO PARAMETRIC MILL/TURN

........................................................................................................................53
2.1 COMMON PROCEDURE FOR CREATING A NEW

MANUFACTURING MODEL ...............................53
2.2 REFERENCE MODEL

..................................................................................................................................54
2.3 WORKPIECE
.................................................................................................................................................
5
2.4 FIXTURE
.................................................................................................................................................
2.5 MILL-TURN WORK CENTER

.....................................................................................................................63
2.5.1
MILL-TURN MACHINE TOOL SIMULATION

.....................................................................................66
2.6 OPERATION
.................................................................................................................................................
2.7 CUTTING TOOLS

.........................................................................................................................................70
2.7.1
MILL-TURN MILLING TOOLS

..............................................................................................................73
2.8 NC SEQUENCES
............................................................................................................................................74
2.8.1
ROUGHING THE CAMS

..........................................................................................................................75
2.8.2
PATTERN NC SEQUENCE
......................................................................................................................83
2.8.3
SURFACE MILLING
................................................................................................................................85
6
2.8.4
SEMI-FINISHING THE CAMS

................................................................................................................86
2.8.5
EDITING THE NC SEQUENCE

...............................................................................................................92
2.8.6
EDITING THE NC SEQUENCE PARAMETERS

...................................................................................95
2.8.7
FINISHING THE CAMS

...........................................................................................................................99
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2.8.8
GROOVE MILLING
...............................................................................................................................
105
POST PROCESSING
..........................................................................................................................................
116
3.1 MILL-TURN POST PROCESSING

............................................................................................................ 116
7
4
APPENDIX
.................................................................................................................................................
122
4.1 CREO PARAMETRIC QUICK REFERENCE CARD

............................................................................... 122
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CREO PARAMETRIC INTERFACE
1.1
This book
This book is a follow-up to the books Creo Parametric Modeling, Creo

Paramet-
ric Basic Milling and Creo Parametric Basic Turning. If you already know
the
basis of the Creo Parametric and modeling you can use this book easily.
If you are using the software first time, and want to go straight to the CAM
module,
you can download the needed 3D models and tools:
· The downloaded models are in the native Creo Parametric 2-format (.prt),
(.asm), (.drw) and (mfg).
· The models are also available in the STEP-format.
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Before you use Creo Parametric to machine components (CAM), it is
important to
understand the complete manufacturing process and the steps involved in this
pro-
cess. It is also important to understand the elements that make up completed

manu-
facturing models.
Download site: http://www.gold-cam.fi/en/download
Or inquire: gold-cam@dlc.fi
1.2
9
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-
bers, for example:
Task 1.2: How to use this book?
When the task is ready, there is a text:
Task 1.2 is ready.
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1.3
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Introduction to Mill-Turn Manufacturing
The Mill-Turn manufacturing process can be divided into different main-
level steps;
1. Manufacturing Template
2. Reference Model
3. Workpiece (premachined)
4. Ref Model and Workpiece
5. Fixture
6. NC Sequences and tools
7. Simulation
8. CL Data and Postprocessing CNC Code
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1. A template manufacturing model can be selected and copied during the

creation
process. Using template manufacturing models enables you to standardize on

the
initial manufacturing model configuration. By default, the template

manufactur-
ing model includes default datum planes and a default coordinate system.
2. The reference model represents the final machined component. Surfaces
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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-
software. You must assemble a reference model before creating NC steps.
3. Workpiece model – This represents the unmachined stock material. It is

an op-
tional element and is not required to create NC steps. However, using a
workpiece enables you to simulate the machining of the stock material.
Workpieces can be standard stock billets or you can configure them to

represent
models such as castings.
4. You can assemble or create a workpiece in a manufacturing model. A

number
of options are available. An automatic workpiece enables you to create a

rectan-
gular or round workpiece depending on your requirements.
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.
6. An NC sequence is a workpiece feature that represents a single tool path.
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The
tool path consists of:
· Cut motions, that is, tool motions while actually cutting the workpiece
material
· Approach, exit, connect moves
· Additional CL commands and post-processor words (for example,
feedrates, PPRINT, OPSTOP).
7. Toolpaths and machine simulations are one of the most important stages
in the
manufacturing process. You can display the toolpath for an operation, a

single
step, or multiple steps. You can also display tool path and machine
simulation to-
gether if the machine assembly is defined.
8. Post-processing is the final stage in the manufacturing process. When

toolpaths
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
have to be postprocessed to generate an MCD file, containing the proper

CNC
codes.
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1.4
Starting
Opening the software:
The main interface:
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1.5
Mill-Turn Process
MiIl-Turn CNC machines combine the technologies of Turning (or Lathe)

and Mill-
ing on one CNC machine. This machine is often referred to as a Lathe with
Live
Tooling.
Typically, any machining that involves removing large amounts of material is

per-
formed with the turning head, while the milling head is used for more
detailed ma-
chining and rotary work. This enables you to machine parts on a single
machine that
would normally require more than one machine and multiple setups, thereby
reduc-
ing the chance of errors.
The live tooling spindle is capable of holding both milling cutters and turning
cutters.
When the secondary spindle (or live tooling) is loaded with milling cutters,
the main
spindle stops and locks into position and can be used as a rotary table.
The following steps are typically used in the mill-turn process:
· Roughing the Part – Rough machine the basic shape of the part using area
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turning sequences.
· Profiling and Turning – Finish the part’s shape using profile and groove
turn-
ing sequences.
· Milling Slots – Mill any slots in the part using either the live tooling head or
the milling head.
· Drilling Holes – Drill any holes in the part using the milling head.
Each operation can be simulated sequentially.
You can create 3-axis, 4-axis, and 5-axis toolpaths using live tooling.
In-Line Twin Spindle CNC Machine with live tooling:
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1.6
Options and configurations
You can access the Creo Parametric Options dialog box by clicking File -
Options.
The options dialog box contains the following categories:
Favorites – You can add favorite config.pro options in this panel.
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Configuration Editor – Location for the config.pro editor. Default settings:
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Save settings:
1.6.1 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:
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Task 1.6.1: NC Options.
Open Configuration Editor. Select Find. Type keyword: pro_mf – Find Now
These all settings are for directories.
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First, select pro_mf_workcell_dir:
Select Browse and give the full path to the folder where are NC Machine
assem-
blies:
OK.
Add/Change.
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You can see the new settings in the options list:
Do the same for pro_mf_tprm_dir.
You can select option and Add to Favorites.
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When options are defined – OK. Save options – Yes.
Give the path to the installation folder where the original config.pro locates
(if you have writing rights).
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Next time you can find and change options easily if needed.
Task 1.6.1 is ready.
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1.7
Creating a new template
New models or assemblies should be created using templates. It means that

every us-
ers of the company has the same way to start the work. The model contains
the same
information, for example:
· Datums – default datum planes and coordinate system, named by user.
· View Orientations – same standard view orientations.
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· Parameters
· Layers
· Units
The system default templates locate in installation folder:
Manufacturing template:
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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.
Task1.7: Own template.
Now the task is create manufacturing template for turning. It should be
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Manufactur-
ing template, because manufacturing session will be assembly.
Start new:
Select Empty.
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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:
Create Coordinate System:
Select up to 3 references, such as plane, edge, coordinate system, or point to

place
coordinate system.
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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).
Give the name:
You can also rename the planes. First you need to think how the lathe
coordinate
system locates.
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Below is the picture of 5 axis mill/turn machine:
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
collinear with turning axis.
You can define the plane as XZ-plane and create view for it. Rotate the
template so
that you can see coordinate system as below:
Select ADTM2 – Rename. Give the new name: FRONT_XZ. You can
rename the
other planes also.
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The other useful way is Creating view orientations:
Select FRONT_XZ as Reference 1- Front. Select Reference 2 – TOP_YZ
Template rotates to the direction. Give the name and Save. OK.
You can open saved views:
Create one Isometric (3D-view) more. Rotate the template just about as
below. Se-
lect Reorient again, give the name and Save the view:
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You can make as many views as you want. Save the template.
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Next step is to define units: File - Prepare - Model Properties:
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Select Units – change:
Select new. Give the units. OK.
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Set new unit_system1 and Convert dimensions – OK. - Close
Close Model Properties window. Save the template.
Using layers in manufacturing assembly. Similar to parts, you can hide
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non-solid
geometry of assembly features including assembly datum features and

surfaces. Un-
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:
Click New Layer:
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Give the name and Layer id. Select planes from the template:
OK.
Activate layer from the tree and hide:
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.
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Make new layer for Coordinate systems.
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Give the name and Id and select coordinate system:
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If you hide or unhide layers, you need to Save Status. (Right lick)
Now, unhide both layers and Save Status. Save the template.
Next parameters. Parameters are metadata information that can be included

in a
model template or created by a user in his own part or assembly. Parameters

enable
you to add important additional information into part and assembly models.
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You can access parameters in many ways:
Or
Parameters window:
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Click plus button and give the parameters. You can select: Integer, Real
Number,
String or Yes No as type.
OK. Save the template. Now the template is ready enough for testing. Make
new
manufacturing assembly and browse your own template:
Task1.7 is ready.
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1.8
Working directory
Creo Parametric is started in the default working directory, which is defined

during
installation of the software. Different working directories can be set by the

user.
There are many ways to define a new working directory:
ü Icon - Select Working Directory:
ü From the Folder Tree or Web browser- Right click the folder and select: Set
Working Directory.
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ü From the File menu:
ü Click (File), Open – Right click the folder:
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1.9
Import model
Note! You can skip this chapter if you want to use ready made reference
model
(CAMSHAFT_INLET.prt).
Sometimes the machinable model is made in different CAD software. In Creo

you
can Open many kind of types:
In this case the original model is in STEP-format. STEP stands as Standard
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Exchange Protocol or international standard for product data exchange and
extension is . STP
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Task 1.9: Import STEP-file.
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
- Select Template (here mmns_part_solid). Ok. - Ok.- Ok.
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Model opens:
You can see the Datum Planes which comes from the template. The datum
planes are
in relation to the coordinate system of the model. From a manufacturing point

of
view, it is important to know how to make planes, axis and coordinate

systems.
You can also see the datum plane and axis names. In the Ribbon – View –
Show or
hide tags:
Creating Datum Axes, Datum Planes and Datum Coordinate Systems.
In the Ribbon - Select Model – Axis. Select surface as below. Ok.
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In the Ribbon - Select Model – Plane. Select Axis and with Ctrl pressed TOP
DATUM PLANE:
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Edit the angle: 42.5 – OK. 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
cam angle plane.
Next task is creating of the coordinate system for turning. Hide unnecessary
planes
and coordinates. In the Ribbon - Select Model – Coordinate System:
Note! It is important to have coordinate systems set up correctly for

subsequent
machine operations to work correctly. The Z-axis must always be along the
axis of
the lathe’s spindle.
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Select plane from the model as below and the new datum planes with Ctrl
pressed.
Coordinate system locates in the intersection of the tree planes. Select

Orientation
page. Change surface from the model to determine Z-axis and DTM2 to
project X.
Flip if needed.
Finally, give the name on Properties page:
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In addition you may need more coordinate systems for the roughing (milling)
of the
cams. The workpiece is round, diameter 45mm. You have to remove material
about
8mm around the cam. You need also Datum Planes for roughing.
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Click Plane from the Datum Group. Select the DTM1 plane and drag the
handle to
an offset of 16. Click Properties tab and give the name:

RIGHT_SIDE_ROUGH.
Click OK in the Datum Plane dialog box.
Do the same for the opposite side and give the name of the plane:
LEFT_SIDE_ROUGH.
Click Plane from the Datum Group. Select the DTM2 plane and drag the
handle to
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an offset of 16. Click Properties tab and give the name:
OPPOSITE_SIDE_ROUGH.
Click OK in the Datum Plane dialog box.
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Click Coordinate System from the Datum group. Press CTRL and select
datum
planes DTM1, DTM2, and end surface of the part as references.
In the Coordinate System dialog box, select the Orientation tab. Use DTM1
to
determine X. Click Flip. Select the Properties tab. Edit the Name to
RIGHT_ROUGH. Click Ok.
These coordinate systems are for milling, so the Z axis should be point up.
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Create the other two coordinate system using the same method. Give the
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corresponding names for the coordinate systems as LEFT_ROUGH and
OPPOSITE_ROUGH.
Datums are ready. Save your work.
Task 1.9 is ready.
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1.10 Model properties
Especially imported modelś has no properties - material information and the

other
useful information. For example if you want to change units or material for
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strength
analyses.
Task 1.10: Model Properties
Click File - Prepare - Model Properties:
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
them from Model Properties.
Material – change:
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Select material from the list and move it to the Materials in Model window.
Select material and make Copy. Select copied material and Properties:
You can give the new name for the material and properties:
Sometimes when changing units, you have to select Convert or Interpret

values.
Convert means for example: One inch is 25.4 millimeter. OK.
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When all wanted values are filled, OK.
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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After material defining, change units:
Select Info.. Now the Mass is tonne. If you want for example grams, you can
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create a
New set of units.
Give the units – OK.
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Set new unit_system1 and Convert dimensions – OK. - Close
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
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calculated
and a lot of more information. OK. Close the Model Properties Window.
Task 1.10 is ready.
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1.11 Cutting parameters
You should know the Basics about Metal Cutting Parameters before creating
toolpaths.
1. Material machinability: The machinability of a material decides how

easy
or difficult it is to cut. The material’s hardness is one factor that has a strong
influence on the machinability.
2. Cutting Tool Material: In metal-cutting, High Speed steel and Carbide

are
two major tool materials widely used.
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
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manufacturers generally give the guidelines for it.
4. Spindle speed: Spindle speed is expressed in RPM (revolutions per

minute).
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
mm) to remove material in the current pass.
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
“feed per tooth,” expressed in millimeters (mm/tooth). At the next stage, it is
“feed per revolution” (mm/rev).
In case of lathe operations, it is feed per revolution that states how much a
tool advances in one revolution of workpiece. In case of milling, feed per
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
105
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
a vast subject in itself.
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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.
9. Machine/ Spindle Power: In the metal-cutting machine, adequate power
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.
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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
and getting the desired accuracy, finish, and speed of production.
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1.11.1 Cutting Speed Formulas
Most machining operations are conducted on machine tools having a rotating

spin-
dle. Cutting speeds are usually given in feet or meters per minute and these
speeds
must be converted to spindle speeds, in revolutions per minute, to operate the

ma-
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chine. Conversion is accomplished by use of the following formulas:
Where N is the spindle speed in revolutions per minute (rpm); V is the

cutting speed
in feet per minute (fpm) for U.S. units and meters per minute (m/min) for
metric
units. In turning, D is the diameter of the workpiece; in milling, drilling,

reaming,
and other operations that use a rotating tool, D is the cutter diameter in inches
for
U.S. units and in millimeters for metric units. π = 3.1417.
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-
late the lathe spindle speed (N).
When the cutting tool or workpiece diameter and the spindle speed in rpm are
known, it is often necessary to calculate the cutting speed (CS) in feet or

meters per minute. In this event, the following formulas are used.
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
standard abbreviations are used for feedrate per revolution:
· Inches per revolution
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in/rev (IPR)
· Millimeters per revolution mm/rev (MMPR)
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More formulas for Turning:
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1.11.2 Feed and Depth of Cut
The axial (or in face turning the radial) tool movement is called feed, fn, and
is
measured in mm/r. When feeding radially towards the centre of the

workpiece, the
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
to the revolving workpiece. This is a key value in determining the quality of
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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 chip forms against the insert geometry.
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
angle usually varies between 45 to 95 degrees but for profiling operations,

even larg-
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-
ing the number of tools needed.
Feed and depth of the cut are chosen together. The ratio (f : ap) is important
112
factor as
well as the cross-sectional area of the chip (A= f x ap)
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
value for roughing feed is 0.2-1.0mm and for finishing 0.1-0.3mm.
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1.11.3 Surface roughness
The surface quality of the machined parts is one of the most important
product quali-
ty characteristics and one of the most frequent customer requirements. The

surface
roughness greatly affects the functional performance of mechanical parts

such as
wear resistance, fatigue strength, ability of distributing and holding a

lubricant, heat
generation and transmission, corrosion resistance, etc.
113
The perfect surface quality in turning would not be achieved even in the
absence of
irregularities and deficiencies of the cutting process, as well as environmental

ef-
fects. There are various parameters used to evaluate the surface roughness. In
the
present research, the average surface roughness ( Ra ) was selected as a

characteristic
of surface finish in turning operations. It is the most used standard parameter

of sur-
face roughness.
The surface roughness factors are previously described:
· 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
chip thickness decreases with increase of nose radius.
In turning operations, the generated surface finish will be directly influenced

by the
combination of nose radius and feed rate.
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Small nose radius:
· Ideal for small cutting depths
· Reduces vibration
· Less insert strength.
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Large nose radius:
· Heavy feed rates
· Large depths of cut
· Stronger edge
· Increased radial forces.
The radial forces that push the insert away from the cutting surface become
more ax-
ial as the depth of cut increases.
The nose radius also affects the chip formation. Generally, chip breaking
improves
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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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1.11.4 Constant Surface Speed
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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
moves towards center. This constantly variable spindle control is called

Constant
Surface Speed (CSS) mode. It is commanded on most machines using G96 to

acti-
vate, and G97 to de-activate.
When the tool moves down the face of the part, the diameter where the
cutting edge
contacts the part gets smaller.
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
keeps the spindle from over-speeding.
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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1.12 Camshaft cutting parameters
When a high quality camshaft is required, engine builders and camshaft

manufactur-
ers choose to make the camshaft from steel billet. In this case the material of
the
camshaft is EN40B. It is a chromium-molybdenum nitriding steel and usually

sup-
plied in the hardened and tempered condition, which offers high wear
resistance to-
gether with good toughness and ductility. It is characterized by its suitability

for ni-
triding, which can give a hard wear resistant core in the range of 61-65Rc.
The rela-
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tively low temperature of the nitriding process produces components with a
scale
free surface, and minimum distortion.
EN40B Related Specifications - 1.8515, 31CrMo12, 30CD12, 722M24
Tensile Strength Rm = 850/1000 N/mm2
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.
Note! Keep in mind previously mentioned the Basics about Metal

Cutting Pa-
rameters.
For example: The diameter of the bar is 50mm and when using carbide
inserts the
cutting speed is 90m/min.
The spindle speed is 573 rev/min.
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CREO PARAMETRIC MILL/TURN
2.1
Common procedure for creating a new manufacturing model
The first step in the manufacturing process is creating manufacturing models.

Manu-
facturing models contain all manufacturing information:
· Operation information
· Workcells
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· Reference models
· Workpiece models
· Fixtures
· NC Machines
· NC Sequence information
When you create a new manufacturing model, the manufacturing model

assembly is
created. The filename format is”filename”.asm
If you check out the Use default template, you can select or browse the
Template
from the list. Template manufacturing models enables you to standardize on

the ini-
tial manufacturing model configuration. You can also make user-defined

template
manufacturing models. Using a template manufacturing model is

recommended.
The new manufacturing model is created by using template. You can see
three de-
fault datum planes and a default coordinate system.
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2.2
Reference model
You must assemble a reference model before creating NC sequences. The

reference
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.
Task 2.2: Select Working directory. Start New – Manufacturing:
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Toggle all display filters on and show datum plane tags.
Select the model:
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Component Placement: Use Automatic and select Coordinate systems from

the tem-
plate and reference model:
NC Assembly is ready – Fully Constrained - Accept.
You can hide the other coordinate systems from model tree so that only in the
screen
is from the reference model.
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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
views named by you.
Save the model.
Task 2.2 is ready.
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2.3
Workpiece
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Workpieces represent the unmachined stock material in a manufacturing
model.
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
workpieces – for example default Automatic. This enables you to create

simple rec-
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
reference model is inside workpiece.
Task 2.3: Create Workpiece.
In this case you can use premachined model. Select Assemble Workpiece:
Select the model:
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Assemble the workpiece model to the reference part. You can use Automatic
and
surfaces as below for the first constrain. Make the surfaces Coincident:
Flip Constraint if needed:
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Select New Constraint and select surfaces as below:
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Status is now Fully Constrained, Accept
Reference model is inside the workpiece.
You can see the working allowance around the reference model. All green
color
means the material what is needed to remove.
Task 2.3 is ready.
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2.4
Fixture
Fixtures are parts or assemblies that can be used to hold the component being
ma-
chined.
Task 2.4: Create Fixture.
Select Components and Add a fixture component. Browse to the folder where
the fix-
ture locates:
Select Distance constraint and surface from the jaw and surface from the
reference
model as below. Give Distance 15mm.
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Next constraint is Coincident – select surfaces as below:
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:
Select Datum Plane from the reference model:
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Give the name for the fixture setup and Accept.
Adjust the jaws. Select jaw number 1.from the fixture. Select Edit
Definition, Give
value 12.5 for Distance as below. Accept.
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Fixture setup is ready.
Task 2.4 is ready.
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2.5
Mill-Turn Work Center
A work center is a feature that specifies a machine tool. A Mill-Turn work

center is
one type of work center that can be created. The following can be configured
for the
Mill-Turn work center feature:
· Name – Enables you to specify the work center name as it appears in the
model tree.
· Type – Automatically specified as Mill-Turn when a Mill-Turn work center
is the type being created.
· Post Processor – Automatically specified as UNCX01 by default. You can

al-
so specify an ID value from 1 to 99.
· Number of axes – Specifies the number of axes that you can use for the
work
center. By default, the number of axes is 3 Axis, although you can specify 3
Axis, 4 Axis, or 5 Axis.
· Number of Heads – Enables you to specify whether the work center uses
one
or two heads.
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· Associated tools – Enables you to configure the associated tools for the
work
center in the Tools tab. You can specify the tool change time in seconds. You
can configure Head 1, which is selected by default. If you specified the num-
ber of heads as 2, then you can also configure Head 2. Most machines use
Head 2 as the milling head. If your machine permits rotation of the turning
tools about the Y-axis, you can activate the Position Turning Tool and speci-
fy the Rotation as Standard. While all machines permit rotation of the
workpiece about the Z-axis, some machines also have the option to rotate the
milling head about the Y-axis.
· Parameters – Enables you to specify additional parameters for the work cen-
ter, including maximum speed, horsepower, and feed rate.
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Task 2.5: Create a Mill-Turn Work Center.
Edit the names as above, select 5 Axis from the Number of Axes drop-down
list. Ed-
it the Number of Heads to 1. In the Mill-Turn Work Center dialog box, select
the
Parameters tab. Click PPRINT:
In the menu manager, click Create. From the Activate PPRINT dialog box,
select
the DATE_TIME, OPERATION_COMMENTS, TOOL_TABLE,
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ONLY_OUTPUT_USED_TOOLS, TOOL_NAME, and
TOOL_COMMENTS
items. Click Yes > OK.
In the menu manager, click Save. Type mz250pp as the PPRINT file name
and press ENTER. Click Done/Return from the menu manager.
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From the Mill-Turn Work Center dialog box, select the Tools tab. Edit the
Tool
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Change Time to 5 seconds. Select the Assembly tab and open the Machine
Assem-
bly if defined. (See more in the next chapter).
Click Apply Changes in the Mill-Turn Work Center dialog box.
Task 2.5 is ready.
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2.5.1 Mill-Turn Machine Tool Simulation
Within Creo Parametric you can simulate the CNC machine running the
various NC
sequences you created. The mill-turn machine assembly is selected within the
As-
sembly tab of the Mill-Turn Work Center dialog box. This machine assembly
can be
edited to represent your CNC machine. You must specify a reference

coordinate sys-
tem for the machine assembly. (MACH_ZERO) This reference coordinate

system
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-
lation, and capturing the simulation to an MPEG file. As the machine

simulation
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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.
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Playing the Machine Simulation
You can play the following types of machine simulations:
· Entire Operation.
· Individual NC Sequences.
To play the machine simulation, select the desired operation or NC sequence

in the
model tree, right-click, and select Machine Play.
Location of Machine Assembly Files
You can select machine assembly files from the following locations:
· Current working directory.
· Can be retained in a directory controlled by the config.pro option
pro_mf_workcell_dir.
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2.6
Operation
Machining operations are a series of NC sequences that are performed by a

particular
workcell (machine tool) and reference a particular coordinate system.

Operations in-
clude the following elements:
· Machine coordinate system
· Retract plane
· Fixtures
Task 2.6: Create an Operation.
Click Operation from the ribbon. Select Coordinate System:
Select the Clearance tab and Cylinder as a type:
Select Coordinate System to specify orientation, give (radius) for the

cylinder:
Parameters and Options:
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Fixture Setup: Select Fixture Setup from the pull down list:
Select Properties tab and give the name for the operation and Comments:
Accept and save your work.
Task 2.6 is ready.
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2.7
Cutting Tools
Tools are an essential step in the manufacturing process. You must configure
a tool
for each NC sequence you create. You can create tools when the workcell is
created
or you can configure them as needed for each NC Sequence.
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 in a different way and is designed for a specific purpose. It is
important to understand the differences between each type of tool and when
165
you should use them.
In this work, only the solid tools are used.
You can configure Head 1, which is selected by default. If you specified the
number
of heads as 2, then you can also configure Head 2. Most machines use Head 2
as the
milling head. If your machine permits rotation of the turning tools about the
Y-axis,
you can activate the Position Turning Tool and specify the Rotation as
Standard.
While all machines permit rotation of the workpiece about the Z-axis, some
ma-
chines also have the option to rotate the milling head about the Y-axis.
In-Line Spindle CNC machines have the ability to machine two ends of the
same
part.
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The live tooling spindle is capable of holding both milling cutters and turning
cut-
ters. When the secondary spindle (or live tooling) is loaded with milling
cutters, the
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main spindle stops and locks into position and can be used as a rotary table.
In addition you can define a tool attachment, such as a right angle head, and
use it in
a NC Manufacturing session. The attachment holds a cutting tool in a fixed,

non-
vertical position, to extend the capabilities of a 3-axis machine. Tool

attachment is an assembly of a tool and an attachment. The tool and the
attachment can be part
models or subassemblies. Below is an example of mill-turn tool attachment:
When you specify a tool attachment at the time of NC sequence setup, you
select a
previously defined Creo model (part or assembly). This model may be as

simple as
two coordinate systems, named SPINDLE_CONTROL_POINT and
TOOL_ATTACH_POINT, or it may be a complete solid model with the

appropriate
coordinate systems defined.
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The model also has to include a parameter ATTACHMENT_NUMBER,

which will
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
display includes both tool and attachment.
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2.7.1 Mill-Turn Milling Tools
In this case you are using premachined (turned) part. So you need to define
and use
live tooling for milling.
Tool 1: 16 diameter bull mill R2 - roughing the cams.
Tool 2: 16 diameter ball mill - finishing the cams.
Tool 3: 12 diameter end mill -milling the groove of the end face of the part.
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2.8
NC Sequences
NC sequence is a workpiece feature that represents a single tool path. When

you
create an NC sequence, a dialog box corresponding to the NC sequence type

is dis-
played. Each of these dialog boxes has the following options:
· Parameter - Open the parameter tree.
· Comment - Type comments regarding NC sequences
· Define - Specify the tool, parameters, and geometric references. You can
also
apply some low-level control depending on the NC sequence type.
· Info - Display parameter and NC sequence information.
· Preview - Display the tool path for the NC sequence prior to completion of
the NC sequence. Available after all elements have been defined.
· Done - Completes creation of the current NC sequence.
· Cancel - Terminates the creation of the current NC sequence after

confirma-
tion.
· Next - Completes the current NC sequence and starts creating another

Nibble Edge NC sequence with the same tool and parameters.
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2.8.1 Roughing the Cams
In this case there is a lot of material to removed, so you need to create

roughing steps
somehow. Because the model is asymmetric, you cannot use the area turning.
Task 2.8.1 Roughing
In the ribbon, select the Mill tab. Click Custom Trajectory from the Milling
group.
In the menu manager, click 3 Axis > Done. Select the Name, Tool,
Parameters, Coord Sys, and Retract Surf check boxes. Click Done.
Give the name as CAMROUGH_RIGHT.
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In the Tools Setup dialog box, click File - Open Tool Library - By Copy and
select
the Bull Mill R5
General tab and Cut tab:
Click OK.
In the Edit Parameters dialog box, edit the CUT_FEED to 150. Edit the
STEP_DEPTH to 2. Edit the CLEAR_DIST to 5. Edit the SPINDLE_SPEED

to
1790.
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Click OK. Select coordinate system RIGHT_ROUGH from the model tree or
from
model.
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Drag the handle or edit value to 25 for the retract. Click OK in the Retract
Setup dialog box. Click Insert in the Customize dialog box.
Click Sketch – Done. Select the Sketch and Height check boxes – Done.
Notice the prompt: Select or create a SKETCHING PLANE. Select the
RIGHT_SIDE_ROUGH as sketching plane.
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Accept Default for the Sketching View. Press CTRL and select DTM2 and
select
front surfaces from the cams as references. Click Close.
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Click Sketch View. Select Line Chain from the Line types drop-down menu
and
sketch the line to the middle of the cam as shown:
Select Setup – Feature Tools – Tool Kerf. Move the cursor to the start point
of the
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line. You can see the 16 diameter tool outline.
Edit the values.
Click OK from the dashboard. Notice the prompt: Select or create surfaces
for tool tip to follow. Select plane as shown. Done/Return
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Click Done Cut. Click OK. Click Done Seq.
In the model tree, select the NC Sequence and Play Path.
Notice the tool movement. In the Play Path dialog box, click Close.
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In the model tree, select the NC Sequence and Machine Play. Click Play.
In the Animate dialog box, click Close.
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Now you can see how the toolpath works and you need to edit the Custom
Trajecto-
ry. In the model tree, select the NC Sequence and Edit Definition –
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Customize. Se-
lect Insert – Automatic Cut. Select the default Sketch – Done.
Select Cut and check the Sketch and Height check boxes – Done. Select Use
Prev for the SETUP SK PLN Menu Manager. Select DTM2 and front surface
from the
lower cam as references. Click Close.
Click Sketch View. Select Line Chain from the Line types drop-down menu
and
sketch the second line to the middle of the cam as shown:
Click OK from the dashboard.
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Notice the prompt: Select or create surfaces for tool tip to follow. Select
plane as shown. Done/Return. Click Play Cut – Done Cut.
In the Customize dialog box, click OK. In the menu manager, click Done
Seq.
Play the Path:
In the Play Path dialog box, click Close.
There are still a few parameters to check.
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In the model tree, select the NC Sequence and Edit Step Parameters. Select
Cut
Depth and Allowances category. Edit the NUMBER_CUTS parameter to 3.
Click OK. Play the Path again. Notice that there are three depth cut for the
both
cams. In the Play Path dialog box, click Close.
In the model tree, select the NC Sequence and Material Removal

Simulation. No-
tice that the Vericut software launches.
Click Play from the bottom of the Vericut software.
Click Reset Model from the bottom of the Vericut software. Click Yes from
the dia-
log box to reset the simulation. At the bottom of the Vericut software, drag
the Ani-
mation Speed to 1% and click Play. Click File > Exit. In the Save Changes
Before Exiting VERICUT dialog box, click Ignore All Changes.
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2.8.2 Pattern NC Sequence
Because the NC sequence is a feature in the model tree, it can be patterned

just like
any other design feature. You can create an Axis pattern in Creo Parametric
to copy
the NC sequence around the part as needed.
Now after roughing one side of the cams you can create the same kind of
procedure
for the other sides or use patterning.
Task 2.8.2: Pattern machine operations
In the model tree, right-click CAMROUGH_RIGHT and select Pattern. In the

Pat-
tern dashboard, edit the pattern type to Axis. Select datum axis A_1. Edit the
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number
of members to 4.
Click the dot to exclude it.
Click Complete Feature.
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In the model tree, select the CAMROUGH_RIGHT NC Sequence and

Material
Removal Simulation. Notice that the Vericut software launches. The yellow
color
is the material to be removed. In the picture below right, you can see the
patterned
roughing NC Sequence.
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2.8.3 Surface milling
When you create a Surface Milling NC sequence, you are given a choice of
several
methods for defining the cut. Depending on the selected method, the tool path
will be
different. You can change the Cut Type (that is, select a different method of
defining
the cut and specify the new parameters and references) at any time when you
rede-
fine a Surface Milling NC sequence.
Surface Milling NC sequences are used to mill horizontal or slanted surfaces.

The se-
lected surfaces must allow for a continuous tool path. There are several
methods of
defining the cut and generating the tool path:
· Straight Cut - Mill the selected surfaces by a series of straight cuts. For 3-
Axis NC sequences, you can also remove material in depth increments.
· From Surface Isolines - Mill the selected surfaces by following the surface
u-v lines.
· Cut Line - Mill the selected surfaces by defining the shape of the first, last,
and some intermediate cuts. When the system generates the tool path, it grad-
ually changes the shape of the cuts according to surface topology.
· Projected Cuts - Mill the selected surfaces by projecting their contours on
202
the retract plane, creating a "flat" tool path in this plane (using the appropri-
ate scan type), and then projecting this tool path back on the original sur-
face(s). This method is available for 3 Axis Surface Milling only.
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2.8.4 Semi-Finishing the Cams
You have to use some kind of finishing sequence to machine components

after
roughing.
Task 2.8.4: Create Surface Milling NC sequence.
In the ribbon, select the Mill tab. Click Surface Milling from the Milling
Group. Se-
lect 4 Axis – Done.
Check as below, Enter NC Sequence name.
NC Sequence Comments:
The comments for an NC sequence can be listed in the Manufacturing info;

they can
also be output in the CL data files using PPRINT.
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In the Tools Setup. Select File – Open Tool Library – By Copy. Select tool
from the library, or define Bull Mill, diameter 16, Radius 5.
Check the values – Edit Cut Data - OK.
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The Edit Parameters dialog box opens, for required parameters, this cell is
highlight-
ed in light yellow color. You can find more parameters under All-tab. Later,
when
you define the Cut Type, there will be new parameters for that. At first you
can fill the Basic parameters as shown below:
After parameters you have to Select SEQ CSYS. Select Coordinate System
and in the Retract Setup dialog box, edit the value to 30. Click OK.
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Next you define how to select surfaces:
Accept SURF PICK from Model as default – Done. Select surfaces as below:
Done/Return.
Notice the command in the bottom of the screen: Please specify plane to
which
the tool axis will be parallel: Select surface as below:
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Cut Definition opens. Select Cut Line, Closed Loops. Add a cut line – press
the green plus-button:
Select the first edge of the cam, use Next if needed, Accept when selected.
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Done –
OK. You should have Cutline 1 on the list as below:
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Press the Plus-button again, Accept the other edge of the cam. Done – OK.
Select Preview, you should see the Cutlines. OK.
Now you need to define Axis Definition. Select Pivot Axis. Notice the
Status Bar
message:
In this case is better to change tool to ball mill. Selec Done Seq under Seq
Setup: Save your work.
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2.8.5 Editing the NC Sequence
The Edit Definition option allows you to modify parameters, references, tool,
coor-
dinate system and other elements of the sequence.
Task 2.8.5: Modify the NC sequence.
Select the CAM_1_FINISHING NC Sequence in the model tree. Right-click

and se-
lect Edit Definition:
Select Seq Setup and check the Tool box- Done. Open Tool Library:
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Select the new tool, Diameter 16 Ball Mill. Edit the Cut Data. OK.
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Select Seq Setup again and check Axis Def box – Done.
Select Pivot Axis – Add – select axis from the model. Done/Return.
Done Seq.
Play the path again. Now you can see the continuous toolpath over the cam.
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Machine Play:
In this case the toolpath consist of three axes movement. The model is fixed
to the
rotating main chuck (C-axis). X-axis is inclined 45-degrees. Z-Axis is

horizontal and
positive direction towards to the main chuck. This is the reason why the
Pivot Axis
needs to define.
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2.8.6 Editing the NC Sequence parameters
When you want modify only NC Sequence parameters, you can select the NC
Se-
quence in the model tree. Right click and Edit Step Parameters:
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Task 2.8.6: Edit Step Parameters.
Select NC Sequence as above. Select All-tab. From the Category, you can
select groups:
Select Cutting Motions and parameters as below. Select Feeds and Speeds:
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Cut Depth and Allowances and Entry/Exit Motions:
Machine Settings and General:
OK.
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Play path. You can see the affect of the NUMBER_CUTS-parameter; there
are now
3 depth cuts. OFFSET_INCREMENT is 2mm. Change

OFFSET_INCREMENT-
parameter to 1mm. The result is below right:
In the model tree, select the operation – Material Removal Simulation.
You can see the result after the rouging and semi-finished front cam. There is
still
working allowance 0.5 mm.
Change the name of the NC Sequence:
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In the model tree, right-click CAM_1_SEMI_FINISH and select Pattern. In

the Pat-
tern dashboard, edit the pattern type to Direction. Select the surface as shown.
Change the direction and edit the value 39. Click Complete Feature.
In the model tree, select the operation and Material Removal Simulation.
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2.8.7 Finishing the Cams
You can use the same NC Sequence to machine components after semi-
finishing.
Only the parameters changes.
Task 2.8.7: Create Surface Milling NC sequence for Finishing
In the ribbon, select the Mill tab. Click Surface Milling from the Milling
Group. Se-
lect 4 Axis – Done.
Check the boxes as below, you do not need check the Tool and Coord Sys.
Enter NC
Sequence name.
Comment:
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Now the tool is the same and the Edit Parameters dialog box opens, for
required
parameters, this cell is highlighted in light yellow color. You can find more
parame-
ters under All-tab.
You can copy parameters from the previous step. Select Edit – Copy from
Step..
Now you have the parameters from the previous step and you need to change
a few
of them. Now the STEP_OVER should be less, edit the value 0.2.
PROF_STOCK_ALLOW is 0. Click OK when parameter definitions are

ready.
From the Menu Manager, select From Prev Seq and select
CAM_1_SEMI_FINISH.
Click Done Sel - Done/Return.
Notice the command in the bottom of the screen: Please specify plane to
which
the tool axis will be parallel: Select surface as below:
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Cut Definition opens. Select Cut Line, Closed Loops. Add a cut line – press
the green plus-button:
Select the first edge of the cam, use Next if needed, Accept when selected.
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Done –
OK. You should have Cutline 1 on the list as below:
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Press the Plus-button again, Accept the other edge of the cam. Done – OK.
Select Preview, you should see the Cutlines. OK.
Now you need to define Axis Definition. Select Pivot Axis.
Done/Return. Done Seq.
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Play the Path:
In the model tree, right-click CAM_1_FINISH and select Pattern. In the

Pattern
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dashboard, edit the pattern type to Direction. Select the surface as shown.
Change the direction and edit the value 39. Click Complete Feature.
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266
267
268
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2.8.8 Groove Milling
The last step is milling the end groove. In this step you need a tool
attachment.
Task 2.8.8: Milling using tool attachment.
In the ribbon, select the Mill tab. Click Custom Trajectory – 3 Axis – Done.
269
In the menu manager, select the Name, Comments, Tool, Attachment,
Parameters, Coord Sys and Retract Surf check boxes. Click Done. Type
END_GROOVE as the NC Sequence name and press ENTER.
Comment:
270
271
272
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In the Tools Setup dialog box, click File – Open Tool Library – By Copy.
Select tool
from the library: end_2_cut.prt . Select the instance: END_2_CUT_12.
Check the General tab. Click the Cut Data tab. Click Apply - OK.
In the menu manager – NCSEQATTACHMENT – Click Add. Select
60_4025sqt10rx100_12.prt – Open – Done/Return.
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274
275
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In the Edit Parameters of Sequence dialog box, click Basic. Edit the
CUT_FEED to
80. Edit the STEP_DEPTH to 2. Edit the CLEAR_DIST to 5. Edit the SPIN-
DLE_SPEED to 800. Click OK.
Enable Csys Display. Select the coordinate system from the model tree or
from the
model. Edit the Retract to 5. OK.
Click Insert in the Customize dialog box. In the menu manager, click Sketch
> Done.
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277
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Select the Sketch and Height check boxes. Click Done. Select the sketching
plane as shown. Click Default for the sketch view.
Select the 4 edges and the round surface as references, Click Close.
You can click Sketch View from the In Graphics toolbar. As well you can
rotate the
model if wanted.
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280
281
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Click Offset from the Sketching Group. Select the edge from the groove.
Enter offset in the direction of the arrow: -6. Select the second edge and enter
offset.
Click close from the Type dialog box. Click Line Chain from the Sketching
Group.
282
Move the cursor along the sketched line until you see the green parallel mark.
283
284
285
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Click on the screen as shown below and draw the line until you see the
perpendicular
constraint and snap to the second line.
Click Corner from the Editing Group. Trim the entities.
Click Line Chain from the Sketching Group. Move the cursor along the
sketched
line until you see the green parallel mark. Click on the screen as shown below
286
and
draw the line until you see the perpendicular constraint and snap to the
second line.
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288
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Click Corner from the Editing Group. Trim the entities.
Click Delete Segment from the Editing Group. Delete entity.
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Edit the values as shown. Place the tool kerf to see the end mill 12 diameter.
290
Save the section.
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292
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Select the depth plane as shown. Done/Return.
294
Play Cut. Done – Done Cut – OK. Done Seq.
In the model tree, select the END_GROOVE NC Sequence and Machine

Play.
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296
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Notice! When the live tooling is used, the main spindle stops and locks into
position
and can be used as a rotary table. In the picture below, the main spindle (C-
Axis) is
locked and you can see the groove is in horizontal position.
Now the X and Y-axis makes the movement.
Review the simulation and click Close.
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Now the machined part is ready. In this case the Automatic Material Removal
298
cannot
be done, so you can manually create it by extruded cut.
This completes the procedure.
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POST PROCESSING
3.1
Mill-Turn Post Processing
Now the part is ready for the creating of the NC Code.
NC (Numerical Control) post processing is commonly used to join two very

unique
technologies. NC is the communication between a CAM (Computer Aided

Manufac-
turing System) and the CNC (Computer Numerated Code) machines. CAM
systems
typically use neutral file formats to communicate these instructions to the

post pro-
cessor(s). The post processor is software responsible for translating

instructions from
the CAM system.
Cutter location data files, often referred to as CL data files, are generated
from the
toolpaths specified within NC sequences. These CL data files can be

processed by
machine-specific or generic post-processors for NC tape generation or DNC

commu-
nications. When you post process a CL data file, you create a specific
300
machine con-
trol data (or, MCD) file. MCD files are used to control machine tools such as
5-axis
mill-turn machines. Creo Parametric comes with “Standard” post processors

within
the software.
Most post processors need to be customized for output to specific CNC

ma-
chines. Any customized post processors should be stored in a specific

directory. The config.pro option “gpostpp_dir” should be used to specify this
directory.
Creating CL Data Files
You can create CL data files using the following methods:
· Create a CL data file for an NC sequence – Select Save a CL File from the
Save a CL File type’s drop-down menu in the Output group. You are prompt-
ed to specify the desired NC sequence to create the CL data for.
· Create a CL data file for a set of toolpaths – Select Save CL File for a Set
from the Save a CL File type’s drop-down menu in the Output group. You
are
prompted to create the name of the set and specify the toolpaths to include in
the set.
· Save a copy of the currently displayed CL data within the Play Path dialog
box – Any toolpath that you are currently displaying can be saved as a CL da-
301
ta file by clicking File > Save As from the Play Path dialog box.
The default filename format for CL files is filename.ncl
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Post Processing CL Data Files
You can post process CL data files using any of the following three methods:
· Post process a CL data file during the creation process – When specifying
that you want to generate the CL file, you can also select the MCD File check
box in the menu manager to create an MCD file at the same time. You are
then prompted to select further post process options in the menu manager, in-
cluding Verbose, Trace, and MACHIN.
· Post process a CL data file that has already been created – Click Post a CL
File from the Output group. You are then prompted to browse for the CL data
file.
· Post process the currently displayed toolpath from the Play Path dialog box
–
Any toolpath that you are currently displaying can be post processed by
click-
ing File > Save As MCD from the Play Path dialog box. This includes
toolpaths for multiple NC sequences.
The default filename format for post processed files is filename.tap.
302
Changes to NC Sequences
CL Data files and MCD files are not associative to NC sequences. If you
make
changes to NC sequences you must regenerate the manufacturing model,

recreate the
associated CL data files, and finally, post process the new CL data files to
create new
MCD files.
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304
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Task 3.1: Create NC (Numerical Control) files for the mill-turn

operation.
From the model tree, right-click work center MAZAK_SQT_250_MSY, and

select
Edit Definition. Ensure that the ID is set to 26. Click Apply Changes.
From the model tree, right-click operation CAMSHAFT_INLET_MILL
[MAZAK_SQT_250_MSY], and select Play Path. The Play Path dialog box
dis-
plays. Click File > Save As MCD. In the Post Processor Options dialog box,
select the MACHIN, Verbose, and Trace check boxes. Click Output. The
Save a Copy dialog box displays. Accept the default name for the New
Name. Click OK.
Review the Information Window dialog box and ensure that no errors are
generated
305
during the file creation process.
In the Information Window dialog box, click Close. In the Play Path dialog
box,
click Close. The necessary machine files will be saved to your local working
directo-
ry.
306
307
308
309
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Note! You can also create CL File from the selected NC Sequence(s).
In the ribbon, select Save CL File for a Set from the Save a CL File type’s
drop-
down menu in the Output group. In the menu manager, click Create. Type
CAM_1
as the output set name, and press ENTER.
In the menu manager, select the NC Sequences check boxes as shown below,
and
click Done Sel. Click CAM_1. Click File - Select the CL File, MCD File,
and Interactive check boxes. Click Done. The Save a Copy dialog box
appears. Accept
CAM_1 for the New Name. Click OK.
From the menu manager, select the Verbose, Trace, and MACHIN check
boxes, and click Done. Review the information window and click Close.
Click File > Done Output.
310
The CAM_1 CL files will be saved to your local working directory.
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312
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You can also use rapid –option to create NC Code from an operation or
single NC
Sequence.
In the ribbon, select Save a CL File from the Save a CL File type’s drop-
down menu
in the Output group. In the menu manager, click NC Sequence > 1:
CAMROUGH_RIGHT.
Click File. Select the CL File and Interactive check boxes, and click Done.
Accept camrough_right in the Save a Copy dialog box. Click OK. Click
Done Output.
The CL file is saved in the local workspace.
Post Process the camrough_right files. In the ribbon, click Post a CL File
from the Output group. Select camrough_right. ncl and click Open.
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Select the Verbose, Trace, and MACHIN check boxes from the menu
manager.
Click Done. Review the information window and click Close. The CL files
will be saved to the local working directory.
This completes the procedure.
Task 3.1 is ready.
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APPENDIX
315
4.1
Creo Parametric Quick Reference Card
File Menu:
316
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UI Customization
Command Locator
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Selection and Mouse Control
317
Keyboard Shortcuts
125/128
Common Dashboard Controls
Orienting the Model
318
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Model Appearance
Advanced Selection: Chain & Surface Set Construction (1/2)
319
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Advanced Selection: Chain & Surface Set Construction (2/2)
PTC.com
128/128
INDEX
Mill/Turn ........................................................... 20, 52
ASCII
....................................................................... 6
320
NC Code ........................................................ 115, 119
NC step ..................................................................... 6
Basic parameters ......................................................87
Operation .................................................................67
CAM ........................................................................ 4
C-axis
......................................................................93
CL Data ................................................ 6, 85, 115, 116
Post-processing ........................................................ 6
Clearance tab ..........................................................67
PPRINT ...................................................................85
CNC .................................... 5, 6, 8, 45, 50, 65, 69, 115
Quick Reference Card ............................................ 121
Datums .............................................................. 16, 37
321
R
Reference Model ................ 6, 30, 53, 54, 56, 58, 59, 60
EN40B .....................................................................51
Retract Plane ............................................................67
Entry/Exit Motions .................................................95
RPM ........................................................................43
Feed rate ........................................................... 43, 48
Solid Tools......................................................... 10, 69
Fixture .....................................................................59
STEP-format ........................................................ 4, 30
Surface Milling ........................................................84
Groove Milling
...................................................... 104
Tensile Strength .......................................................51
322
Hardness
..................................................................51
units .........................................................................38
Import model
V,W
...........................................................30
Isometric ..................................................................21
Vericut ............................................................... 81, 83
Work Center .................................................... 62, 117
Workcell ................................................. 12, 66, 67, 69
Keyboard Shortcuts ............................................. 123
Workpiece ...............................................................56
Lathe ................................................................... 8, 45
X-axis ................................................................ 19, 93
Layers ............................................................... 23, 25
323
XZ-plane..................................................................20
Live Tooling ............................................................. 8
Y-axis ................................................... 19, 62, 69, 113
Machine Assembly ............................................. 64, 66
Machine Simulation
....................................... 6, 65, 66
MCD .......................................... 6, 115, 116, 117, 118
Z-axis ......................................... 19, 20, 33, 34, 62, 69
324

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1

Creo Parametric Mil -Turn

Copyright Jouni Ahola

Publisher: Klaava Media

part, without written permission from the author.

Creo Parametric Mil -Turn

1.1 THIS BOOK

1.2 CHAPTERS AND TASKS

1.3 INTRODUCTION TO MILL-TURN MANUFACTURING

1.5 MILL-TURN PROCESS

1.6 OPTIONS AND CONFIGURATIONS

1.7 CREATING A NEW TEMPLATE

1.8 WORKING DIRECTORY

1.9 IMPORT MODEL

CUTTING SPEED FORMULAS

FEED AND DEPTH OF

CONSTANT SURFACE SPEED

CAMSHAFT CUTTING PARAMETERS