Creo Parametric Mill-Turn - Jouni Ahola.pdf

Creo Parametric Mil -Turn 2/128 Creo Parametric Mill-Turn Jouni Ahola ISBN 978-952-7074-33-6 Copyright Jouni Ahola February 2015 Publisher: Klaava Media www.klaava.com

[email protected] All rights reserved. This book may not be reproduced in any form, in whole or in part, without written permission from the author. Creo Parametric Mil -Turn 3/128 Table of contents 1

CREO PARAMETRIC INTERFACE………………………………………………………………………………………… 5

1.1 THIS BOOK ……………………………………………………………………………………………………… 5

1.2 CHAPTERS AND TASKS ……………………………………………………………………………………………………… 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 ………………………………………………………………………………………………………

1.9 IMPORT MODEL ……………………………………………………………………………………………………… 31 1.10

MODEL PROPERTIES ……………………………………………………………………………………………………… 1.11

CUTTING PARAMETERS ……………………………………………………………………………………………………… 1.11.1 CUTTING SPEED FORMULAS …………………………………………………………………………………………….46 1.11.2

FEED AND DEPTH OF CUT………………………………………………………………………………………………… 1.11.3

SURFACE ROUGHNESS ……………………………………………………………………………………………………… 49 1.11.4 CONSTANT SURFACE SPEED ……………………………………………………………………………………………..51 1.12 CAMSHAFT CUTTING PARAMETERS …………………………………………………………………………………….52 2

CREO PARAMETRIC MILL/TURN ……………………………………………………………………………………………………… 53 2.1 COMMON PROCEDURE FOR CREATING A NEW MANUFACTURING MODEL ………………………….53

2.2 REFERENCE MODEL ………………………………………………………………………………………………………

2.3 WORKPIECE ………………………………………………………………………………………………………

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 ……………………………………………………………………………………………………… 2.7.1 MILL-TURN MILLING TOOLS ………………………………………………………………………………………………..73

2.8 NC SEQUENCES ……………………………………………………………………………………………………… 2.8.1

ROUGHING THE CAMS ……………………………………………………………………………………………………… 2.8.2

PATTERN NC SEQUENCE ……………………………………………………………………………………………………… 2.8.3

SURFACE MILLING ……………………………………………………………………………………………………… 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 Creo Parametric Mil -Turn 4/128 2.8.8

GROOVE MILLING ……………………………………………………………………………………………………… 105 3

POST PROCESSING ……………………………………………………………………………………………………… 116 3.1 MILL-TURN POST PROCESSING ……………………………………………………………………………………………… 116 4

APPENDIX ……………………………………………………………………………………………………… 122 4.1 CREO PARAMETRIC QUICK REFERENCE CARD ……………………………………………………………………. 122 Creo Parametric Mil -Turn 5/128 1 CREO PARAMETRIC INTERFACE 1.1 This book This book is a follow-up to the books Creo Parametric Modeling, Creo Parametric 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. Before you use Creo Parametric to machine components (CAM), it is important to understand the complete manufacturing process and the steps involved in this process. It is also important to understand the elements that make up completed manufacturing models. Download site: http://www.gold-cam.fi/en/download

Or inquire: [email protected] 1.2

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 carefully 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 numbers, 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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6/128 1.3

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 Creo Parametric Mil -Turn 7/128 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 manufacturing model includes default datum planes and a default coordinate system. 2. The reference model represents the final machined component. Surfaces and edges are selected from the reference model and are used as references when creating NC steps. The reference model can be also imported from the other CADsoftware. You must assemble a reference model before creating NC steps. 3. Workpiece model – This represents the unmachined stock material. It is an optional 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 rectangular 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 fixtures.

6. An NC sequence is a workpiece feature that represents a single tool path. 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 together 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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8/128 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 Milling 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 performed with the turning head, while the milling head is used for more detailed machining 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 reducing 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 turning sequences. Profiling and Turning – Finish the part’s shape using profile and groove turning 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:

Creo Parametric Mil -Turn 10/128 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. Configuration Editor – Location for the config.pro editor. Default settings:

Creo Parametric Mil -Turn 11/128 Save settings: 1.6.1 Manufacturing Configurations There are a few useful configurations for manufacturing, for example you can define 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 example:

Creo Parametric Mil -Turn 12/128 Task 1.6.1: NC Options. Open Configuration Editor. Select Find. Type keyword: pro_mf – Find Now These all settings are for directories.

Creo Parametric Mil -Turn 13/128 First, select pro_mf_workcell_dir: Select Browse and give the full path to the folder where are NC Machine assemblies: OK. Add/Change.

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14/128 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).

Creo Parametric Mil -Turn 16/128 Next time you can find and change options easily if needed. Task 1.6.1 is ready.

Creo Parametric Mil -Turn 17/128 1.7 Creating a new template New models or assemblies should be created using templates. It means that every users 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. 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 Manufacturing template, because manufacturing session will be assembly. Start new: Select Empty.

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19/128 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.

Creo Parametric Mil -Turn 20/128 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.

Creo Parametric Mil -Turn 21/128 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.

Creo Parametric Mil -Turn 22/128 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. Select Reorient again, give the name and Save the view: You can make as many views as you want. Save the template.

Creo Parametric Mil -Turn 23/128 Next step is to define units: File - Prepare - Model Properties: Select Units – change: Select new. Give the units. OK.

Creo Parametric Mil -Turn 24/128 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 non-solid geometry of assembly features including assembly datum features and surfaces. Unlike parts, you can add components to layers in an assembly. If you add components to a layer and then hide layer, the component geometry hides. Select Layers: Click New Layer:

Creo Parametric Mil -Turn 25/128 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. Make new layer for Coordinate systems.

Creo Parametric Mil -Turn 26/128 Give the name and Id and select coordinate system: 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.

Creo Parametric Mil -Turn 27/128 You can access parameters in many ways: Or Parameters window:

Creo Parametric Mil -Turn 28/128 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.

Creo Parametric Mil -Turn 29/128 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: Icon - Select Working Directory:

From the Folder Tree or Web browser- Right click the folder and select: Set Working Directory.

Creo Parametric Mil -Turn 30/128 From the File menu: Click (File), Open – Right click the folder:

Creo Parametric Mil -Turn 31/128 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 Exchange Protocol or international standard for product data exchange and extension is . STP

Creo Parametric Mil -Turn 32/128 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.

Creo Parametric Mil -Turn 33/128 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. In the Ribbon - Select Model – Plane. Select Axis and with Ctrl pressed TOP DATUM PLANE:

Creo Parametric Mil -Turn 34/128 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.

Creo Parametric Mil -Turn 35/128 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: 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.

Creo Parametric Mil -Turn 36/128 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 an offset of 16. Click Properties tab and give the name: OPPOSITE_SIDE_ROUGH.

Click OK in the Datum Plane dialog box.

Creo Parametric Mil -Turn 37/128 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.

Creo Parametric Mil -Turn 38/128 Create the other two coordinate system using the same method. Give the corresponding names for the coordinate systems as LEFT_ROUGH and OPPOSITE_ROUGH. Datums are ready. Save your work. Task 1.9 is ready.

Creo Parametric Mil -Turn 39/128 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 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:

Creo Parametric Mil -Turn 40/128 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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41/128 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.

Creo Parametric Mil -Turn 42/128 After material defining, change units: Select Info.. Now the Mass is tonne. If you want for example grams, you can create a

New set of units. Give the units – OK.

Creo Parametric Mil -Turn 43/128 Set new unit_system1 and Convert dimensions – OK. - Close Now you can calculate Mass Properties with new unit_system. Expand Mass Properties and you can see Calculation source and origin and density: Select change for Mass Properties. Press Calculate. Mass Properties are calculated and a lot of more information. OK. Close the Model Properties Window. Task 1.10 is ready. Creo Parametric Mil -Turn 44/128 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 meters 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 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 cutting 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 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 angle, approach angle, etc.). The role played by these angles in tool geometry is a vast subject in itself. Creo Parametric Mil -Turn 45/128 8. Coolant: To take away the heat produced in cutting and also to act as a lubricant in cutting to reduce tool wear, coolants are used in metal-cutting. Coolants 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 depends on work material, tool material, the cutting speed, depth of cut, and feed rate. 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.

Creo Parametric Mil -Turn 46/128 1.11.1 Cutting Speed Formulas

Most machining operations are conducted on machine tools having a rotating spindle. 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 machine. 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, calculate 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 in/rev (IPR) Millimeters per revolution mm/rev (MMPR)

Creo Parametric Mil -Turn 47/128 More formulas for Turning:

Creo Parametric Mil -Turn 48/128 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 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 cutting 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 larger 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 reducing the number of tools needed. Feed and depth of the cut are chosen together. The ratio (f : ap) is important 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.

Creo Parametric Mil -Turn 49/128 1.11.3 Surface roughness The surface quality of the machined parts is one of the most important product quality 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. 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 effects. 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 surface 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. Small nose radius: Ideal for small cutting depths Reduces vibration Less insert strength.

Creo Parametric Mil -Turn 50/128 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 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.

Creo Parametric Mil -Turn 51/128 1.11.4 Constant Surface Speed 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 activate, 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 example, don’t use CSS mode for drilling or tapping on part centerline.

Creo Parametric Mil -Turn 52/128 1.12 Camshaft cutting parameters When a high quality camshaft is required, engine builders and camshaft manufacturers 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 supplied in the hardened and tempered condition, which offers high wear resistance together with good toughness and ductility. It is characterized by its suitability for nitriding, which can give a hard wear resistant core in the range of 61-65Rc. The relatively 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 Parameters. 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.

Creo Parametric Mil -Turn 53/128 2 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. Manufacturing models contain all manufacturing information: Operation information Workcells 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 initial 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 default datum planes and a default coordinate system.

Creo Parametric Mil -Turn 54/128 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 creating NC sequences. Task 2.2: Select Working directory. Start New – Manufacturing: 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 template 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.

Creo Parametric Mil -Turn 56/128 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.

Creo Parametric Mil -Turn 57/128 2.3 Workpiece 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 rectangular 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:

Creo Parametric Mil -Turn 58/128 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: Select New Constraint and select surfaces as below:

Creo Parametric Mil -Turn 59/128 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.

Creo Parametric Mil -Turn 60/128 2.4 Fixture Fixtures are parts or assemblies that can be used to hold the component being machined. Task 2.4: Create Fixture. Select Components and Add a fixture component. Browse to the folder where the fixture locates: Select Distance constraint and surface from the jaw and surface from the reference model as below. Give Distance 15mm.

Creo Parametric Mil -Turn 61/128 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:

Creo Parametric Mil -Turn

62/128 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. Fixture setup is ready. Task 2.4 is ready.

Creo Parametric Mil -Turn 63/128 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 also 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. 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 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 machines also have the option to rotate the milling head about the Y-axis. Parameters – Enables you to specify additional parameters for the work center, including maximum speed, horsepower, and feed rate.

Creo Parametric Mil -Turn 64/128 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. Edit 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, 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.

Creo Parametric Mil -Turn 65/128 From the Mill-Turn Work Center dialog box, select the Tools tab. Edit the Tool Change Time to 5 seconds. Select the Assembly tab and open the Machine Assembly if defined. (See more in the next chapter). Click Apply Changes in the Mill-Turn Work Center dialog box. Task 2.5 is ready.

Creo Parametric Mil -Turn 66/128 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 Assembly 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 system 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 simulation, and capturing the simulation to an MPEG file. As the machine simulation 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.

Creo Parametric Mil -Turn 67/128 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.

Creo Parametric Mil -Turn 68/128 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 include 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:

Creo Parametric Mil -Turn 69/128 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.

Creo Parametric Mil -Turn 70/128 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 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 machines 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.

Creo Parametric Mil -Turn 71/128 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. 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, nonvertical 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.

Creo Parametric Mil -Turn

72/128 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.

Creo Parametric Mil -Turn 73/128 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. Creo Parametric Mil -Turn 74/128 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 displayed. 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 confirmation. Next - Completes the current NC sequence and starts creating another Nibble Edge NC sequence with the same tool and parameters.

Creo Parametric Mil -Turn 75/128 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.

Creo Parametric Mil -Turn 76/128 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. Click OK. Select coordinate system RIGHT_ROUGH from the model tree or from model.

Creo Parametric Mil -Turn 77/128 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. Accept Default for the Sketching View. Press CTRL and select DTM2 and select front surfaces from the cams as references. Click Close.

Creo Parametric Mil -Turn 78/128 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 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

Creo Parametric Mil -Turn 79/128 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.

In the model tree, select the NC Sequence and Machine Play. Click Play. In the Animate dialog box, click Close.

Creo Parametric Mil -Turn 80/128 Now you can see how the toolpath works and you need to edit the Custom Trajectory. In the model tree, select the NC Sequence and Edit Definition – Customize. Select 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.

Creo Parametric Mil -Turn 81/128 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.

Creo Parametric Mil -Turn 82/128 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. Notice 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 dialog box to reset the simulation. At the bottom of the Vericut software, drag the Animation Speed to 1% and click Play. Click File > Exit. In the Save Changes Before Exiting VERICUT dialog box, click Ignore All Changes. Task 2.8.1 is ready.

Creo Parametric Mil -Turn 83/128 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 Pattern dashboard, edit the pattern type to Axis. Select datum axis A_1. Edit the number of members to 4. Click the dot to exclude it. Click Complete Feature.

Creo Parametric Mil -Turn 84/128 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. Task 2.8.2 is ready. Creo Parametric Mil -Turn 85/128

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 redefine a Surface Milling NC sequence. Surface Milling NC sequences are used to mill horizontal or slanted surfaces. The selected 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 3Axis 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 gradually changes the shape of the cuts according to surface topology. Projected Cuts - Mill the selected surfaces by projecting their contours on the retract plane, creating a “flat” tool path in this plane (using the appropriate scan type), and then projecting this tool path back on the original surface(s). This method is available for 3 Axis Surface Milling only.

Creo Parametric Mil -Turn 86/128 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.

Creo Parametric Mil -Turn 87/128 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.

Creo Parametric Mil -Turn 88/128 The Edit Parameters dialog box opens, for required parameters, this cell is highlighted 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.

Creo Parametric Mil -Turn 89/128 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:

Creo Parametric Mil -Turn 90/128 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. Done – OK. You should have Cutline 1 on the list as below:

Creo Parametric Mil -Turn 91/128 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. Task 2.8.4 is ready.

Creo Parametric Mil -Turn 92/128 2.8.5 Editing the NC Sequence The Edit Definition option allows you to modify parameters, references, tool, coordinate 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 select Edit Definition: Select Seq Setup and check the Tool box- Done. Open Tool Library: Select the new tool, Diameter 16 Ball Mill. Edit the Cut Data. OK.

Creo Parametric Mil -Turn 93/128 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.

Creo Parametric Mil -Turn 94/128 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. Task 2.8.5 is ready.

Creo Parametric Mil -Turn 95/128 2.8.6 Editing the NC Sequence parameters When you want modify only NC Sequence parameters, you can select the NC Sequence in the model tree. Right click and Edit Step Parameters: 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:

Creo Parametric Mil -Turn 96/128 Cut Depth and Allowances and Entry/Exit Motions: Machine Settings and General: OK.

Creo Parametric Mil -Turn 97/128 Play path. You can see the affect of the NUMBER_CUTS-parameter; there are now 3 depth cuts. OFFSET_INCREMENT is 2mm. Change OFFSET_INCREMENTparameter 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:

Creo Parametric Mil -Turn 98/128 In the model tree, right-click CAM_1_SEMI_FINISH and select Pattern. In the Pattern 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. Task 2.8.6 is ready.

Creo Parametric Mil -Turn 99/128 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. Select 4 Axis – Done. Check the boxes as below, you do not need check the Tool and Coord Sys. Enter NC Sequence name. Comment:

Creo Parametric Mil -Turn 100/128 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 parameters 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:

Creo Parametric Mil -Turn 101/128 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. Done – OK. You should have Cutline 1 on the list as below:

Creo Parametric Mil -Turn 102/128 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.

Creo Parametric Mil -Turn 103/128 Play the Path: In the model tree, right-click CAM_1_FINISH and select Pattern. In the Pattern dashboard, edit the pattern type to Direction. Select the surface as shown. Change the direction and edit the value 39. Click Complete Feature.

Creo Parametric Mil -Turn 104/128 In the model tree, select the operation and Material Removal Simulation. Task 2.8.7 is ready.

Creo Parametric Mil -Turn

105/128 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. 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:

Creo Parametric Mil -Turn 106/128 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.

Creo Parametric Mil -Turn 107/128 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 SPINDLE_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.

Creo Parametric Mil -Turn 108/128 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.

Creo Parametric Mil -Turn 109/128 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. Move the cursor along the sketched line until you see the green parallel mark.

Creo Parametric Mil -Turn 110/128 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 and draw the line until you see the perpendicular constraint and snap to the second line.

Creo Parametric Mil -Turn 111/128 Click Corner from the Editing Group. Trim the entities. Click Delete Segment from the Editing Group. Delete entity.

Creo Parametric Mil -Turn 112/128 Edit the values as shown. Place the tool kerf to see the end mill 12 diameter. Save the section.

Creo Parametric Mil -Turn 113/128 Select the depth plane as shown. Done/Return. Play Cut. Done – Done Cut – OK. Done Seq. In the model tree, select the END_GROOVE NC Sequence and Machine Play.

Creo Parametric Mil -Turn 114/128 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.

Creo Parametric Mil -Turn 115/128 In the model tree, select the operation and Material Removal Simulation. Now the machined part is ready. In this case the Automatic Material Removal cannot be done, so you can manually create it by extruded cut. This completes the procedure. Task 2.8.8 is ready.

Creo Parametric Mil -Turn 116/128 3 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 Manufacturing System) and the CNC (Computer Numerated Code) machines. CAM systems typically use neutral file formats to communicate these instructions to the post processor(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 communications. When you post process a CL data file, you create a specific machine control 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 machines. 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 prompted 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 data file by clicking File > Save As from the Play Path dialog box. The default filename format for CL files is filename.ncl Creo Parametric Mil -Turn 117/128 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, including 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 clicking 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. 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.

Creo Parametric Mil -Turn 118/128 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 displays. 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 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 directory.

Creo Parametric Mil -Turn 119/128 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 dropdown 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. The CAM_1 CL files will be saved to your local working directory.

Creo Parametric Mil -Turn 120/128 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.

Creo Parametric Mil -Turn 121/128 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.

Creo Parametric Mil -Turn 122/128 4 APPENDIX 4.1 Creo Parametric Quick Reference Card File Menu:

Creo Parametric Mil -Turn 123/128 UI Customization Command Locator

Creo Parametric Mil -Turn 124/128 Selection and Mouse Control Keyboard Shortcuts

Creo Parametric Mil -Turn 125/128 Common Dashboard Controls Orienting the Model

Creo Parametric Mil -Turn 126/128 Model Appearance Advanced Selection: Chain & Surface Set Construction (1/2)

Creo Parametric Mil -Turn 127/128 Advanced Selection: Chain & Surface Set Construction (2/2) PTC.com Creo Parametric Mil -Turn 128/128 INDEX Mill/Turn ………………………………………………….. 20, 52 A ASCII N …………………………………………………………….. 6 NC Code ……………………………………………….. 115, 119 B NC step …………………………………………………………… 6 Basic parameters ………………………………………………87 O C Operation ………………………………………………………..67 CAM ……………………………………………………………… 4 C-axis P

…………………………………………………………….93 CL Data ………………………………………… 6, 85, 115, 116 Post-processing ……………………………………………….. 6 Clearance tab ………………………………………………….67 PPRINT ………………………………………………………….85 CNC ……………………………… 5, 6, 8, 45, 50, 65, 69, 115 Q D Quick Reference Card …………………………………….. 121 Datums …………………………………………………….. 16, 37 R E Reference Model ……………. 6, 30, 53, 54, 56, 58, 59, 60 EN40B ……………………………………………………………51 Retract Plane ……………………………………………………67 Entry/Exit Motions ………………………………………….95 RPM ………………………………………………………………43 F S Feed rate ………………………………………………….. 43, 48 Solid Tools………………………………………………… 10, 69 Fixture ……………………………………………………………59 STEP-format ……………………………………………….. 4, 30 Surface Milling ………………………………………………..84 G Groove Milling T ……………………………………………… 104 Tensile Strength ……………………………………………….51 H Hardness U

…………………………………………………………51 units ……………………………………………………………….38 I Import model V,W …………………………………………………..30 Isometric …………………………………………………………21 Vericut ……………………………………………………… 81, 83 Work Center ……………………………………………. 62, 117 K Workcell …………………………………………. 12, 66, 67, 69 Keyboard Shortcuts ……………………………………… 123 Workpiece ………………………………………………………56 L X Lathe …………………………………………………………. 8, 45 X-axis ………………………………………………………. 19, 93 Layers ……………………………………………………… 23, 25 XZ-plane…………………………………………………………20 Live Tooling ……………………………………………………. 8 Y M Y-axis …………………………………………… 19, 62, 69, 113 Machine Assembly ……………………………………… 64, 66 Machine Simulation Z ………………………………… 6, 65, 66 MCD …………………………………… 6, 115, 116, 117, 118 Z-axis ………………………………….. 19, 20, 33, 34, 62, 69