creo milling.pdf

CAM Tutorial CREO PARAMETRIC 1.0 week 1 Part 1

Revised by Tomas Benzon DTU MEK March 2012 on basis of original COACH material Page 1

PART 1: BASIC MACHINING

CREATING A MANUFACTURING MODEL

In this Lesson you will create a Manufacturing Model by assembling the Design Model. TheDesign Model represents the finished part (after all of the machining takes place). You areactually going to start with a forging of this part and remove only a small amount of material insome areas. In this case, you are not going to assemble the forging (as a Workpiece). In laterLessons, you will learn how to utilize both the design part and the forging together.

1. Create a Manufacturing Model. Choose File from the Menu bar Choose New

Before starting this tutorial:

Ensure that you have downloaded all CAM files from the write-protected drive (R:\Kurser\CAM-42817\cam1_mm\) and placed them on your own drive (I:\)Set the Working Directory to the directory on your own drive where you placed the CAM files.

Notice NC Assembly from the Subtype list is the default choice.

Give it a name...

Let this be selected, (it controls whether you work in mm or in inches). If you are uncertain of which units the file is set up to, you can check top menu File / Prepare / Model Properties. In the Model Properties dialoque you can change units by choosing the change button to the right.

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Choose Manufacturing from the Type list Type your initials_basic1 and hit ENTER or choose OK If you are able to choose units in this dialogue choose mmns

2. Assemble the Design Model. (Open the design model when you reside in the manufacturing module) Set the graphic display to Wireframe (not Shaded) Click the Reference Model icon (not the text below with the arrow) In the dialoque box choose Profile1.prt and hit ENTER

Begin the NC Sequence by defining the minimum Operation data of a WorkCell Type.

1. Start the Sequence

Click the Work Center icon on the top ribbon menu. The Milling Work Center dialogue will appear

The Operation Setup dialog displays. You must define an Operation before you can continue with the NC. Notice that the system displays the Operation Name (OP010) and the Fixture Setup (FSETP0) in the Model Tree

To constrain (place) the model press the Automatic button and choose default far down - This will position the model in the same 3D space as when constructed... Accept position by clicking In the Create reference model dialogue box click OK

The Profile1.prt will appear on the screen - probably in a temporary state indicated by the dark purple color . If the model displays in white color (= automatic placement), you should skip the actions in the red frame under-neath. If you dont see anything on the screen, press CTRL+ D

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The Milling Work Center displays...

Define An operation On the top ribbon, choose the operation icon A Machine Coordinate system (MCS) has to be defined. The system wants you to either create one or to point on an existing coordinate system. Here, one comes with the part:

OPERATION SETUP

The Work Center has now been defined. Now it is time to create an operation. You need to do this before you can start defining NC sequences. Think of 1 operation = 1 clamping in the vice. An operation can contain one or several NC sequences.

You are now going to define the Machine Coordinate System (MCS). Whether you Select orCreate the Machine Zero coordi-nate system, you must always make sure that the Z Axis is pointing "up" towards the spindle on the NC Machine, and that the X Axis is pointing along thedefault tool motion. Remember, the tool axis is also going to be parallel to the Z Axis.

2. Define the Cell Type Choose Mill from the Machine Type option menu - Default choice... Choose 3 Axis from the Number of Axes option menu - Default choice... Choose OK - Yes, you didnt change anything in this box, but this entry cant be skipped .

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The Menu Manager will appear on the right side of the sreen. Note that the Sequence Setup menu displays, showing you the required items: - Here you will have to fill out 4 dialogue boxes.

With the Mill pane active, choose the grey Milling zone (Arrow)

Choose Pocketing (meaning Digging holes)

Choose Done - The system will display the first of the four, Tools Setup window as shown next page:

Now the Operation has been partially defined. It appears on the Model tree, and the Menu Manager pops up, requiring you to define the remaining variables:

Select CSO by clicking it in the display window (provided you have turned on Csys Display). Please click on the CSO label and not on the 3D cross itself.(Arrow)

Click on the accept icon. The system has now created a new csys (NC_CS0) to act as the MCS. (Machine Coordinate System) A new pane Mill has now appeared on the top Ribbon. By clicking it, a range of milling options appears.

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When you choose Done, the system will begin to offer you the menus to specify the required information....which in this case will be Tool, Parameters, Retract Surf, and Surfaces. These kinds of menus are known as "Walk Through" menus. You can manually add or remove entries, but stick to these four right now...

The Tools dialoque displays...

- A flat ended 25 mm milling tool has now been defined

2. Define the Tool Choose End Mill ( Arrow)... Type 25 for diameter ( Arrow)...

Choose Apply, followed by OK

Close The Milling Work Center dialogue by clicking the green Yes - You will notice that MILL 01 now appears on the model tree

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SPECIFYING PARAMETERS

The system now displays the Edit Parameters of Sequence window containing the minimum set of the parameters that are appropriate for the type of NC Sequence you are using.(pale yellow)

You should come back and explore more by changing the parameter values after playing the path and then notice the difference each parameter causes.

Alternatively, you can use the DOWN arrow key on the keyboard instead of clicking in the field...

Click with the mouse cursor in the field to the right of the text CUT_FEED Type 75 and hit ENTER

Now to the second point on the four-point list: Specify all of the required parameters, marked yellow:

Click with the mouse cursor in the field to the right of the text STEP_DEPTH Type 6 and hit ENTER Click with the mouse cursor in the field to the right of the text STEP_OVER Type 6 and hit ENTER Click with the mouse cursor in the field to the right of the text CUT_ANGLE Type 90 and hit ENTER Click with the mouse cursor in the field to the right of the text SCAN_TYPE Click on TYPE_2 and hit ENTER

Click with the mouse cursor in the field to the right of the text CLEAR_DIST Type 2.5 Click with the mouse cursor in the field to the right of the text SPINDLE_SPEED and type 500 Choose the All button located at the upper left in the window to display all parameters Find the POCKET_EXTEND option Change TOOL_ON to TOOL_TO Choose OK to exit the parameter setup window - The box closes, and the third dialogue box , Retract Plane is next... Choose Done

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MACHINING SURFACES

The retract Plane defines the height above the Workpiece where the tool safely can hover around when moving from one job to another without crashing into the Workpiece.

The retract Plane distance is now 25 mm

The third point on the list: The system now wants you to define a Retract Plane and select the surfaces to be machined.The Retract Setup dialog has opened by it self and the brown grid shows its current distance from plane to model (=0)

In the (Z Depth) Value text field type 25 and hit ENTER Choose the OK action button: The box closes. Now the tool will idle in a comfortable 25 mm Z distance from the Workpiece...

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First this...

Followed by this...

And then this...

Finally the system prompts you to specify which surfaces to be machined. Choose Model from the SURF PICK menu: This seems not very logical as we are about to pick some surfaces to mill... Choose Done Select the green colored face shown below

In the Select box, Choose OK Choose Done/ReturnPlay the tool path Choose Play Path Choose Screen Play Choose Play Forward Button

In the Play Path dialogue under View there are various display settings for the tool, shaded, wireframe etc.

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You may notice a few things about this tool path. The cutter moved in straight lines, parallel to the Y-Axis because the CUT_ANGLE is 90 degrees. The tool followed along the sides of the pocket to avoid cutting through the part. The tool cut around the protrusion or "island". This type of movement is a result of using the TYPE_2 - SCAN_TYPE. The path also retracts to the Retract Plane each time it must move to a new area. Retracts are automatically created in Pro/NC.

Here is the tool is shown shaded, the tool tip and the tool kerf is visible.

Choose Close4. Save this tool path in memory. Choose Done Sec: - This step is important - it saves the whole operation Choose Done / Return

1. Begin a new sequence. Choose Pocketing - like you did at the upper middle of page 4

Now you will create a second NC Sequence to finish machine the pocket in the other side of the part.

Screen play with Play Path : This is how your first sequence will look.

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The Menu Manager appears, and it only promts you for information on Parameters and Surfaces. Please notice that it in this new sequence the system reuses data from your previous sequense.(same Tool, MCS, and Retract plane)

Choose Done - The Parameter dialogue box appears - Here too you can reuse data: Choose Edit / Copy from Step: A small dialogue box, Select Step, opens

Close the Parameters box with the OK in the bottom of the box

Choose the top line: 1: Pocket Milling, Operation: OP010, and close with an OK Now all the tool parameter data from the previous sequense will be reused.

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Now the Menu Manager will appear and promt you for which surfaces you want milled: In the Menu Manager, under SURF PICK / MODEL, click Done

Select the green colored face below

Choose OK Choose Done/Return4. Play the tool path. Choose Play Path Choose Screen Play Choose Close

5. Save this tool path in memory. Choose Done Seq6. Take one more step. Play the entire Operation to see both pockets machined: Please remember: It takes one or more Sequences to define an Operation. One Clamping in the vice equals one operation

Choose - in the top ribbon - the Manufacturing pane Click on the Rapid Fedrat icon: The Menu Manager opens

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In the Menu Manager choose Operation / OP010 / Compute CL / Done: The Play Path interface appears Choose Play, let it run and notice that both sequences run in one continous movement

ATTENTION

The final step of the above exercise (The play of the whole operation) must be REVIEWED and APPROVED by your INSTRUCTOR to make you eligible for a signature on your approval sheet confirming your successful completion of this tutorial. ww

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PART 2: VOLUME MILLINGDEFINING A VOLUME

Create a mill volume to rough remove material from a block of graphite which is used to form the EDM electrode shown below.

2. Create a workpiece. This simulates a raw piece of material being milled. It is color coded green.

Click on the arrow under the Workpiece icon Choose Create Workpiece Type stock_vol1 as the workpiece part name and hit ENTER In the Menu Manager choose Protrusion / Done Choose Placement Choose Define Select NC_ASM_TOP as the Sketch Plane

1. Create a manufacturing model using the NC Assembly manufacturing type and assemble the Ref Model called volume1.prt into it, similarly to the previous lesson - Remember to check that you work in mm. Accept the (Default) positioning of the Ref Model.

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Since you are going to create all of the curves in the sketch using Use Edge, you can proceed without bothering with References.

Project tool

Use Chain

Sketch Plane

The Workpiece (stock) has been created and, as you can see, contains the entire part.

Click on the edge, approximately here,

and then approximately here,

In the Menu Manager click Accept click yes to the Loop question

click the OK accept-sign

Enter 85 for the Depth value and accept

Choose the Project tool and ignore warnings, if any

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Workpiece has been created

From this surface is where the Mill Volume will start. It will extend upward to the surface which you will specify.

9. Create the mill volume. Choose the Create Mill Volume tool

Choose the Extrude tool

Choose Placement, followed by Define- The Sketch Dialog box appears

Right click this face and left-click it to choose it as the sketch plane

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TRIMMING A VOLUME

Trim the volume to the part.1. Perform the trim operation.

Choose the Trim tool

In the Menu Manager click Accept click yes to the Loop question click the OK accept-sign

click the OK accept-sign.

The system has now created a volume that is a large block....in the next Segment, you will seehow to exclude the area containing the part from this block. You will have to trim the Milling volume with the Ref Model. This his preferably done immediately after the creation of the Milling Volume...

Choose the Extrude to tool, and select the top surface of the Workpiece

Choose Sketch to begin sketching You dont need references for this sketch Choose the Use Project tool, like before Choose Chain type Repeat the edge selection procedure you used before, when you drew the sketch for the Workpiece. The chain may be easyer to create if you select the bottom edges of the part (Arrow)

Select VOLUME1.PRT in the viewportClick OK...

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The Trim feature now appears in the Feature list

The Mill Volume in pink (Defining the material that has to be milled away) displayed in wireframe view

3. Define a Work center Click the Work Center icon on the top ribbon menu. The Milling Work Center dialogue will appear4. Define the cell type. Choose Mill from the Machine Type list - Default setting Choose 3 Axis from the Number of Axes list - Default setting Choose OK from the Machine Tool Setup window - Yes, nothing was actually changed...5. Define an Operation Setup and define Milling type. On the top ribbon, choose the operation icon Select the Coordinate System called CS0 Choose OK Choose the Mill Pane on the top ribbon Click on the Roughing icon, and below that, Click on the Volume Rough icon - The Menu Manager appears with the "Walk Through" menus, containing Tool, Parameters, Retract Surf, and Window In the Menu Manager, change Window to Volume. Close the Menu Manager with Done6. Define a tool Click with the mouse cursor in the field to the right of the tool (Cutter Diameter) and type 25 - Please notice that an End Mill tool is preselected Click with the mouse cursor in the field to the right of the tool (Length) and type 100 Choose the Apply action button and choose OK - Tools Setup closes7. Specify the machining parameters In the Param Tree window, click with the mouse cursor in the field to the right of the text CUT_FEED and type 75 - Please notice that you can choose between viewing Basic or All parameters. Basic parameters view will do here... Click with the mouse cursor in the field to the right of the text STEP_DEPTH and type 25 Click with the mouse cursor in the field to the right of the text STEP_OVER and type 6 Click with the mouse cursor in the field to the right of the text ROUGH_STOCK_ALLOW and type 1 Click with the mouse cursor in the field to the right of the text ROUGH_OPTION and Click on ROUGH_&_CLEAN_UP Click with the mouse cursor in the field to the right of the text CLEAR_DIST and type 2.5 Click with the mouse cursor in the field to the right of the text SPINDLE_SPEED and type 500

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NC/CHECK/Vericut display view. Colors may be different on your screen

Play Path View

You might be able to see that this is not a desirable path. Material was left around the outside of the volume and the outside of the part was not machined because the tool could not fit between the side walls of the part and the volume....To get an acceptable path, the Milling volume needs to be larger.

3. Play the NC/CHECK display. Before proceding, make sure that you can view the NC/CHECK simulation: Choose - in the upper left corner of the screen: File / Options. The Creo Parametric Options dialogue opens. Choose Configuration Editor (bottom left). On the long Config.pro list, being alphabetical, find nccheck_type. in the Value column verify that the Vericut (not nccheck) option is selected. Leave with OK.

Choose Close

10. Play the tool path. Set Display style to Wireframe. Choose Play Path - Either via the Menu Manager or via the Model Tree / 1. Volume Milling [OP010]. You right-click this post and choose Play Path

Choose OK to exit the Parameter Setup menu8. Define the retract plane Type 100 in the value field of the Retract Setup dialog Choose OK button - The Retract dialog box disappears and you are asked to Select previously defined Milling Volume

9. Select the mill volume. Click on the pink Mill Volume on the model to define the NC secuence.

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OFFSETTING SURFACES

Modify the volume to allow the tool to travel beyond the part.1. Return to the PLAY PATH menu. Choose Done / Return from the NC CHECK menu Choose Done Seq2. Modify the volume by offsetting the walls. In the Model tree, right click the Trimmed Mill Volume from the feature list and choose Redefine Mill Volume

Choose the Edit / Offset tool

Choose The four vertical walls, one by one, using the mouse and the CTRL button

You are now editing the trimmed Mill Volume

The system automatically pre - selects all the surfaces. Now you must manually choose which surfaces to offset

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Choose Value Check that Expand Feature is the chosen option Type 25 as the Distance

3. Replay the tool path In the Model Tree, right-click the 1. Volume Milling [OP010] and Choose Play Path Choose Screen Play Choose Play Forward icon

Click the green accept icon below the Mill Volume tab

Click the following green accept icon below the Mill Volume tab

One wall has been chosen Four walls have been chosen

Theapp

The four walls have now been offset 25 mm outwards

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Choose Close4. Play the NC/CHECK display. In the Model Tree, right-click the 1. Volume Milling [OP010] post and choose Edit Definition - The Menu Manager appears In the Menu Manager choose Play Path / Compute CL / NC Check / Run

5. Change the STEP_DEPTH value to allow for a more contoured rough tooling path.

On the Model Tree, Single - click on 1. Volume Milling [OP010] post, to turn it active:

verify that the Manufacturing pane is the active one, and open the Step Parameters dialogue

Both views show that the tool now has access to the Workpiece on all four sides

x

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Click with the mouse cursor in the field to the right of the text STEP_DEPTH Type 3 Exit the Parameter Setup window by choosing OK6. Replay the tool path using the NC/CHECK display. In the Model Tree, right-click the 1. Volume Milling [OP010] post and choose Edit Definition In the Menu Manager choose Play Path / Compute CL / NC Check / Run

ATTENTION

The final step of the above exercise must be REVIEWED and APPROVED by your INSTRUCTOR to make you eligible for a signature on your approval sheet confirming your successful completion of this tutorial.

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