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Creo Parametric Mil -Turn
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Table of contents
1
CREO PARAMETRIC
INTERFACE
5
5
1.3 INTRODUCTION TO MILL-TURN MANUFACTURING
6
1.4 STARTING
9
1.6 OPTIONS AND CONFIGURATIONS
..10
1.6.1
MANUFACTURING CONFIGURATIONS
.11
1.7 CREATING A NEW TEMPLATE
..17
31
1.10
MODEL PROPERTIES
1.11
CUTTING PARAMETERS
1.11.1
CUTTING SPEED FORMULAS
.46
1.11.2
SURFACE ROUGHNESS
49
1.11.4
CONSTANT SURFACE SPEED
..51
1.12
CAMSHAFT CUTTING PARAMETERS
.52
2
53
2.1 COMMON PROCEDURE FOR CREATING A NEW MANUFACTURING
MODEL .53
2.3 WORKPIECE
2.4 FIXTURE
63
2.5.1
2.6 OPERATION
2.7.1
MILL-TURN MILLING TOOLS
..73
2.8 NC SEQUENCES
2.8.1
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
99
Creo Parametric Mil -Turn
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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
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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: gold-cam@dlc.fi
1.2
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1.3
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1.4
Starting
Opening the software:
The main interface:
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 parts 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:
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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.
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 cant 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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Create planes by selecting Plane tool. Show plane Tags:
If the you cant 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.
Task1.7 is ready.
From the Folder Tree or Web browser- Right click the folder and select: Set
Working Directory.
machine operations to work correctly. The Z-axis must always be along the axis of
the lathes spindle.
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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.
or difficult it is to cut. The materials 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.
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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.
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. = 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)
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
(r). 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.
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.
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, dont use CSS mode for drilling or tapping on part centerline.
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.
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.
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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.
Fixture setup is ready.
Task 2.4 is ready.
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.
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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.
In the model tree, select the NC Sequence and Machine Play. Click Play.
In the Animate dialog box, click Close.
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.
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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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:
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.
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.
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.
In the ribbon, select Save CL File for a Set from the Save a CL File types 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.
.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-plane20
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