Part 1: Basic Machining: Lesson

CAM Tutorial Week 1
PART 1: BASIC MACHINING

CREATING A MANF MODEL
In this Lesson you will create a Manufacturing Model by assembling the Design Model. The
Design Model represents the finished part (after all of the machining takes place). You are
actually going to start with a forging of this part and remove only a small amount of material in
some areas. In this case, you are not going to assemble the forging (as a Workpiece). In later
Lessons, you will learn how to utilize both the design part and the forging together.
Figure 1
Before starting this tutorial
Ensure that you have downloaded all CAM files from the write-protected drive
(R:\WF40\training_wildfire\CAM\proetrainingfiles\cam1\) and placed them on your own drive
(I:\)
Ensure that you have downloaded the configuration file config.pro from the write protected drive
(R:\WF40\training_wildfire\Text\)
Set PRO/E to use your downloaded config.pro by selecting it in the showing box. (choose
Tools / Options).
Set the Shade_mfg_ref_models parameter to YES in the config.pro file. Choose Add/Change
and choose OK
1. Create a Manufacturing Model.
Choose File from the Menu bar
Choose New
Revision 1.1 by Christoffer Andersson s032361 | DTU MAN | April 1, 2009

Original COACH material modified for use with WildFire 4.0
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Figure 2
Choose Manufacturing from the Type list
Notice NC Assembly from the Sub-type list is the default choice.
Type your initials_basic1 and hit
or choose OK
2. Assemble the Design Model.

Choose Mfg Model
Choose Assemble
Choose Ref Model
Type profile1.prt and hit
The part is automatically placed at the default location
Choose OK in the Create Reference Model dialog

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Choose Done/Return

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BEGINNING AN NC SEQUENCE
Begin the NC Sequence by defining the minimum Operation data of a WorkCell Type.
1. Start the sequence.
Choose Machining
The Operation Setup dialog displays. You must define an Operation before you can continue
with the NC Sequence. Notice that the system displays the Operation Name (OP010) and the
Fixture Setup (FSETP0) in the Model Tree.
Figure 1
Choose the Workcell icon (
The Machine Tool Setup dialog displays...

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Figure 2
2. Define the Cell Type.
Choose Mill from the Machine Type option menu
Choose 3 Axis from the Number of Axes option menu
Choose OK

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SETUP AND CLEARANCE

Create an MCS (machining coordinate system).
1. SPIN the model to appear approximately as shown below.
Figure 1
Choose the Selection icon (
Setup dialog
) located next to the Machine Zero option in the Operation
Figure 2
You are now going to define the Machine Coordinate System (MCS). Whether you Select or
Create the Machine Zero coordinate system, you must always make sure that the Z Axis is
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pointing "up" towards the spindle on the NC Machine, and the X Axis is pointing along the
default tool motion. Remember, the tool axis is also going to be parallel to the Z Axis.
Select CSO by clicking it in the display window (provided you have turned on Csys Display) or
by clicking it on the PROFILE1.PRT feature list rollout
Figure 2.5a The Csys Display toggle button
Figure 2.5b The CS0 in the display window

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Figure 2.5c The CS0 in the feature list rollout
The system creates a new csys (NC_CS0) to act as the MCS.

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Figure 3
Choose OK from the Operation Setup dialog
Four new features have been added to the assembly as shown in the Model Tree.
Figure 4
The Fixture Setup (FSETP0), the NC Machine (MACH01), Machine Zero coordinate system
(NC_CS0) and the Operation Name for the NC Machine (OP010).
Depending upon your hardware, you may find it helps to Repaint

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TOOL DEFINITION
Define the tool by specifying a series of tool parameters.
1. Define a tool.
Choose Pocketing
Choose Done
Note that the Sequence Setup menu displays showing you the required items:
Figure 1
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, and Surfaces. These kinds
of menus are known as "Walk Through" menus.
Choose Done
The system displays the Tools Setup window as shown below.
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Figure 2
Double click with the LMB in the Name text field
Type FEM_1_000 for the Name to denote a 1" flat end mill
Click with the mouse cursor in the box (Cutter Diameter) to the right of tool and type 1
Click with the mouse cursor in the rightmost box (Length) and type 4
Choose the Apply action button
When you choose Apply, the system adds the tool to the existing tools list. The tool is not
actually defined until you choose Apply.

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Figure 3
Choose OK

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SPECIFYING PARAMETERS
Specify the minimum required manufacturing parameters to generate a tool path.
1. Specify all of the required 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.
Figure 1
Click with the mouse cursor in the field to the right of the text CUT_FEED
Type 3 and hit
If you want to, 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 STEP_DEPTH
Type .25 and hit
Click with the mouse cursor in the field to the right of the text STEP_OVER
Type .25 and hit
Click with the mouse cursor in the field to the right of the text CUT_ANGLE
Type 90 and hit
Click with the mouse cursor in the field to the right of the text SCAN_TYPE
Click on TYPE_2 and hit
Click with the mouse cursor in the field to the right of the text CLEAR_DIST
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Type .1
Click with the mouse cursor in the field to the right of the text SPINDLE_SPEED
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
Choose Done
You should come back and explore more by changing the parameter values after playing the
path and then notice the difference each parameter causes.

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MACHINING SURFACES
Define a Retract Plane and select the surface to be machined.
1. Define the Retract Plane.
In the Retract Setup dialog
Figure 1
In the (Z Depth) Value text field type 1 and hit
Choose the OK action button
2. Select the bottom of the pocket to be machined.
Choose Model from the SURF PICK menu
Choose Done
Select the face which is outlined in red below
The face is at the bottom of the pocket.
Figure 2
Choose OK
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Choose Done/Return
Repaint the screen
3. Play the tool path.
Choose Play Path
Choose Screen Play
Figure 3
Choose Play Forward button
Figure 4
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The options Tool and Tip are default parameters on the tool display menu. They cause the tool
itself, and the location of the center of the tool at the tip to display.
Figure 5
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. 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.
Choose Close
4. Save this tool path in memory.
Choose Done Seq
Choose Done/Return
Continue on to the Practice and make another NC Sequence to cut the other pocket.
End Of Demonstration
Continue where you left off in the Demonstration and create an NC Sequence to finish
machine the pocket in the other side of the part.

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Figure 1
1. Begin a new sequence.
Choose Machining
Choose NC Sequence
Choose New Sequence
Choose Pocketing
Choose Done
Notice that this time, only the Surfaces options is checked on the SEQ SETUP menu. The
system assumes that you want to use the same Tool, MCS, and Retract plane that you used in
the last sequence.

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Figure 2
Choose Parameters to ensure that they are set up in the following
Choose Done
Select the parameters from the previous sequence by choosing Copy From Sequence
from the Edit drop-down menu and selecting OP010 from the Select Sequence dialog
Choose OK twice to accept the parameters

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2. Repaint the screen.

3. Select the bottom of the pocket to be machined.
Choose Done to accept the default of selecting surfaces on the Model
Select the face which is outlined in red below. The face is at the bottom of the pocket

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Figure 3
Choose OK
Choose Done/Return
Choose Play Path
Choose Screen Play
Figure 4
Notice that the path avoided the hole in the center of the pocket. This is probably wasted
motion....later on, you will learn how to ignore the hole.

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Figure 5
Choose Close
5. Save this tool path in memory.
Choose Done Seq
6. Take one more step. Play the entire Operation to see both pockets machined.
Choose CL Data
Figure 6
Choose Output
Choose Operation
Choose OP010 to display all NC Sequences
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Choose Done
Figure 7
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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PART 2: VOLUME MILLING

DEFINING 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.
Figure 1
1. Create a manufacturing model using the NC Assembly manufacturing type and assemble the
Ref Model called volume1.prt into it.
Figure 2
2. Create a workpiece.

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Figure 3
Choose Mfg Model
Choose Create
Choose Workpiece
Type stock_vol1 as the workpiece part name and hit
Choose Protrusion
Choose Done
Choose Placement
Choose Define
Select DTM2 as the sketch plane
Select the face as shown below as the orientation plane

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Figure 4
Choose Bottom as the Orientation
Choose Sketch
Choose the Use Edge tool (
Since you are going to create all of the curves in the sketch using Use Edge, you can proceed
without bothering with References.
Choose Yes
Select the four edges on the outside of the block as shown below
Figure 5
Choose
Enter 3.25 for the depth value

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Figure 6
Choose
Figure 7
Choose Done/Return
The workpiece (stock) has been created and, as you can see, contains the entire part.
3. Start an Operation.
Choose Machining
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Choose the Workcell icon (
4. Define the cell type.

Choose Mill from the Machine Type list
Choose 3 Axis from the Number of Axes list
Choose OK from the Machine Tool Setup window
5. Select the coordinate system called CS0.
Choose the selection arrow to the right of the Machine Zero text
Select CS0
Choose OK in the Operation Setup window
Accept the default density values of 1 for the working volume and the stock volume by
choosing
twice
Choose Volume
Choose Done
Choose Done to accept the default SEQ SETUP options (Tool, Parameters, Retract
Surf, Volume)
6. Define a tool.
Click with the mouse cursor in the field to the right of the tool (Cutter Diameter) and type
1
Click with the mouse cursor in the field to the right of the tool (Length) and type 4
Choose the Apply action button
Choose OK
7. 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
Type 3
Type 1
Click with the mouse cursor in the field to the right of the text STEP_OVER
Type .25
Click with the mouse cursor in the field to the right of the text ROUGH_STOCK_ALLOW
Type .05
Click with the mouse cursor in the field to the right of the text ROUGH_OPTION
Click on ROUGH_&_CLEAN_UP
Click with the mouse cursor in the field to the right of the text CLEAR_DIST
Type .1
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Click with the mouse cursor in the field to the right of the text SPINDLE_SPEED
Type 500
Choose OK to exit the parameter setup menu
8. Define the retract plane.
Type 4 in the value field of the Retract Setup dialog
Choose the OK action button
9. Create the mill volume.
Choose Create Mill Volume tool
Choose the Extrude tool to begin the protrusion
Choose Placement
Choose Define
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Choose Done
Right click the face outlined below and left click it to choose it as the sketch plane
Figure 8
This is where the Mill Volume will start. It will extend upward to the surface which you will
specify.
Choose Flip
Choose Bottom as the Orientation
Select the face as shown below as the Reference plane
Figure 9
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Choose Sketch to begin sketching

You dont need references for this sketch
Choose the Use Edge tool (
Select the four edges on the outside of the block as shown below
Figure 10
Choose
Choose Up To Surface
Select the top face of the workpiece as shown below

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Figure 11
Accept the Mill Volume by choosing
The system has now created a volume that is a large block....in the next Segment, you will see
how to exclude the area containing the part from this block.

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TRIMMING A VOLUME
Trim the volume to the part.
1. Perform the trim operation.
Choose the Trim tool
Select VOLUME1.PRT in the viewport
The trim feature appears in the feature list

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Accept the trimmed Mill Volume by choosing

Choose Play Path
Choose Screen Play
Choose Play Forward

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Figure 2
Choose Close
3. Play the NC/CHECK display.
Choose NC Check
Choose Run
Figure 3
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
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the side walls of the part and the volume....To get an acceptable path, the volume needs to be
larger.

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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
2. Modify the volume by offsetting the walls.
Choose Seq Setup
Choose Volume
Choose Done
Right click the trimmed Mill Volume from the feature list and choose Redefine Mill
Volume
You are now editing the trimmed Mill Volume

Choose Offset Vertical Walls from the Edit Offset drop-down menu

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Choose Value
Type 1 as the distance

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Figure 1
Choose to
accept the offset walls
Choose to
accept the Mill Volume (with trim and offset walls)

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3. Replay the tool path

Choose Play Path
Choose Screen Play
Choose Play Forward icon
Figure 2
Choose Close
4. Play the NC/CHECK display.
Choose NC Check
Choose Run

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Figure 3
5. Return to the PLAY PATH menu.
Choose Done/Return
6. Change the STEP_DEPTH value to allow for a more contoured rough tooling path.
Choose
Type .125
Exit the Parameter Setup window by choosing OK
7. Replay the tool path
Choose NC Check
Choose Run
Figure 4
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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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Part 1: Basic Machining: Lesson

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