Milling using Creo Parametric 3.

0
Course Objectives

In this course, you will learn how to:

• Understand the manufacturing process
• Create and configure manufacturing models
• Configure the manufacturing environment
• Create and modify milling sequences
• Create and modify holemaking sequences
• Use the process manager to create NC sequences
• Post-process cutter location (CL) data
Training Agenda

• Module 1: Introduction to Manufacturing

• Module 2: Creating Manufacturing Models
• Module 3: Configuring Operations
• Module 4: Using Reference Models
• Module 5: Using Workpiece Models
• Module 6: Creating and Using NC Model Assemblies
• Module 7: Creating and Configuring a Work Center
• Module 8: Creating and Configuring Tools
• Module 9: Using Template Manufacturing Models
• Module 10: Using Manufacturing Parameters
• Module 11: Creating Face Milling Sequences
• Module 12: Creating Volume Milling Sequences
• Module 13: Creating Profile Milling Sequences
• Module 14: Creating Straight Cut Surface Milling Sequences
• Module 15: Creating From Surface Isolines Surface Milling Sequences
• Module 16: Creating Cut Line Surface Milling Sequences
• Module 17: Advanced Surface Milling Options
• Module 18: Creating Roughing and Re-roughing Sequences
Training Agenda

• Module 19: Creating Finishing Sequences

• Module 20: Creating Trajectory Milling Sequences
• Module 21: Creating Holemaking Sequences
• Module 22: Creating Engraving Sequences
• Module 23: Using the Process Manager
• Module 24: Creating and Post-Processing CL Data Files
Module 1: Introduction to Manufacturing
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the Creo Parametric manufacturing process.
• Describe the elements that make up completed manufacturing models.
• Create manufacturing models.
• Create a simple machining sequence.
Manufacturing Process Overview

The manufacturing process can be divided into four high-level steps:

Figure 1 – Creating the Manufacturing Model Figure 2 – Creating the Manufacturing Environment

Figure 3 – Creating NC Sequences and CL Data Figure 4 – Post-Processing CL Data and Machining
Module 2: Creating Manufacturing Models
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the contents of manufacturing models.
• Create manufacturing models.
Creating Manufacturing Models

Creating manufacturing models is the first step in the manufacturing process.

Manufacturing models contain all manufacturing Manufacturing Models

process information, such as:
• Manufacturing model assembly file –
• Operations "filename".asm
• Work Center
• NC sequences
• Reference models
• Workpiece models

Figure 1 – Using Template Manufacturing Models Figure 2 – Template Manufacturing Model Options
Module 3: Configuring Operations
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe elements of manufacturing operations.
• Configure Work Center, fixtures, machine zero positions, and machine retract planes within
operations.
Configuring Operations

Configuring manufacturing operations forms part of the setting up for manufacturing procedure. An operation and
a machine tool must be configured before NC sequences can be created.

Manufacturing operations contain:

• Fixtures (Optional)
• Machine Coordinate System
• Retract Plane
• NC Sequences

Figure 1 – Simple Fixture Assembly

Figure 2 – Machine Coordinate System and Retract

Plane Figure 3 – Machine Tool Configuration
Module 4: Using Reference Models
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the purpose of reference models.
• Assemble reference models using different methods.
Using Reference Models

It is important to understand how reference models are used in manufacturing assemblies.

Reference models represent the finished

machined component. For example, this can be:
• A component machined from solid.
• A machined mold core.
• A machined casting.
Creating reference model options:
• Same Model
• Inherited
• Merged by Reference

Figure 1 – Reference Model Examples

Module 5: Using Workpiece Models
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the purpose of workpiece models.
• Create workpiece models using different methods.
Using Workpiece Models

It is important to understand how workpiece models are used in manufacturing assemblies.

Workpieces represent unmachined stock material,
for example:
• Stock Billets.
• Castings.
Workpiece Features:
• Enable machining simulation of workpiece.
• As-machined versions.
• No machining outside workpiece boundaries.
• Workpiece display.

Figure 1 – Workpiece Examples

Workpiece Options:
• Create an automatic workpiece.
• Assemble using Same Model option.
• Assemble with inherited features.
• Assemble with merged features.
• Create a manual workpiece.
Figure 2 – Automatic Workpiece
Module 6: Creating and Using NC Model Assemblies
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the purpose of NC model assemblies.
• Create NC model assemblies.
• Use NC model assemblies in manufacturing models.
Creating and Using NC Model Assemblies

You can create NC model assemblies that consist of a reference model and a workpiece. You can then use NC
model assemblies by assembling them into manufacturing models.

Creating NC Model Assemblies

• Create Stock Options:
– Workpiece Shape
– Overall Dimensions
– Offset Dimensions
– Rotation Offsets

Figure 1 – Create Stock Options

Using NC Model Assemblies
• Alternative means of creating
manufacturing models.
• Place directly into manufacturing models.
• Components classified automatically.
Figure 2 – Configuring the Workpiece

Figure 3 – Resulting Manufacturing Model

Module 7: Creating and Configuring a Work Center
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the elements that make up Work Center.
• Create Work Center and configure various Work Center options.
Creating and Configuring a Work Center

The Work Center specifies the type of machine used when creating NC sequences, for example, mill, lathe, or
mill/turn. You must specify a Work Center before you can create NC sequences.

Work Center Configuration Machine Tool Elements

• Name • Output Tab Options
• Type – Mill, Lathe, Mill/Turn, or Wire EDM – Multiple Axis Output
• Number of Axes – Parameters
• Post-Processor – Properties
• Probing Option – CL Command Output
– Milling Capability
– Cutter Compensation
• Tools Tab
• Travel Tab
• Cycles Tab
• Assembly Tab
• Parameters Tab
• Properties Tab

Figure 1 – Milling Work Center Dialog Box

Module 8: Creating and Configuring Tools
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the differences between the different tool types: standard, solid, and sketched.
• Create standard and solid tools through the configuration of tool parameters.
• Use cutting data to configure optimum tool feeds and speeds based on stock material.
Understanding Milling Tools

There are three different tool types: standard, solid, and sketched. It is important to understand the differences
between each type of tool and when you should use them.

Tool Types
• Standard
• Solid
• Sketched
Tool Tip Position
• Along centerline of tool.
• Specifies X-, Y-, and Z-positions for CL data.
• Tool position based on machined model
geometry. Figure 1 – Tool Tip Locations

Figure 2 – Machining an Angled Surface

Creating Standard Milling Tools

You configure standard milling tools by specifying tool parameters. It is important to specify the correct tool
parameters to obtain the desired tool configuration.
Standard Tools Configuring Tools
• Tools configured by specifying tool • Tools Setup Dialog Box
parameters. • General Tab
• Available tool type control – Tool Name
parameters:
– Tool Type
– Milling or drilling
– Tool Parameter Values
• Parameter values control resulting – Tool Holder Dimensions
tool shapes in:
• Settings Tab
– Length
– Tool Number
– Cutter_Diam
– Offset Number
• Toolpath display based on
– Gauge Lengths (X and Z)
parameter values.
• Tool Tables
– Display tool information.
– Output tool loading information to CL data files.
• Saving Tools
• Tool Libraries
Figure 1 – Tool Geometry Parameters

Figure 2 – Tool Table Information

Creating Solid Model Milling Tools

You can use solid model milling tools to enhance CL data display and check for interference when verifying
toolpaths.
Solid Model Milling Tools
• Use parts or assemblies.
• Play toolpaths:
– View solid tool.
– Check for interference.
Creating Solid Model Milling Tools Figure 1 – Tool Geometry Parameters
• Create part or assembly.
• Create tool geometry.
• Create coordinate system.
• Associate dimensions with tool parameters.
• Configure parameters to correspond to tool Figure 2 – Tool Relations
parameters.
Using Solid Model Milling Tools
• Information transferred from solid model to tool
parameters.
• Retrieve tool:
– By Reference.
– By Copy.
Figure 3 – Enhanced Tool Display
Creating and Using Tool Cutting Data

You can use cutting data stored within tools to transfer optimum feed, speed, and depth of cut parameter values
into NC sequences.

Cutting Data Creating and Storing Cutting Data

• Optimize parameter values • Two sets of data:
• Data based on: – Workpiece material list
– Workpiece material • Mfg_wp_material_list.xml
– Tool
– Tool cutting data
– Application
• tool_name.xml
• Roughing/finishing
• Alternative methods:
– Material directories
– Use .tpm tool files
Using Cutting Data
• Copy from Tool option
• Parameter relations
• Mfg_param_auto_copy_from_tool
configuration option

Figure 1 – Cut Data Tab

Creating and Using Tool Cutting Data

You can use cutting data stored within tools to transfer optimum feed, speed, and depth of cut parameter values
into NC sequences. (cont'd.)

Figure 2 – Resulting Data In tool_name.xml File

Retrieving Tool Data

You can configure a tool library where all tool data is stored. This enables quick and easy retrieval of tools
by all users.

Tool Parameter Libraries

• Store all tool parameter files.
• Use sub-folders to divide tool types.
• Config.pro option: Retrieving Tools
– pro_mf_tprm_dir. • Use Tools Setup dialog box.
– Creo Parametric searches for tools from this folder. • Display tools with .xml and .tpm file
extensions.
– By default.
• Supported tool file extensions:
– .xml – Pro/ENGINEER Wildfire 3.0 onwards.
– .tpm – .Pro/ENGINEER release 12 to Pro/ENGINEER
Figure 1 – Example Tool Folder Structure Wildfire 2.0.
– .tprm – .pre-Pro/ENGINEER release 12.
• Tools appended in tool table.
• Tool information stored with manufacturing
model.
Figure 2 – Tool Listing – Also store with Work Center.
Module 9: Using Template Manufacturing Models
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the items that you can include in template manufacturing models.
• Create new manufacturing models using template manufacturing models.
Using Template Manufacturing Models

You can use template manufacturing models with pre-configured manufacturing items to speed up the creation of
manufacturing models.

Template Manufacturing Models

• Pre-configure manufacturing items:
– Operation
Figure 1 – Pre-Configure Tools
– Coordinate Systems
– Retract Positions
– Fixtures
– Parameters
– Work Center
– Tooling Figure 2 – Template Model
– NC Sequences
• Default Templates
• User-Defined Templates
• Configuration Options
– mfg_start_model_dir
– template_mfgnc

Figure 3 – Template Features in Model Tree

Module 10: Using Manufacturing Parameters
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe how manufacturing parameters control NC sequences.
• Describe the different methods used to configure and edit parameter values.
• Edit parameter values in NC sequences.
• Edit and activate site parameter files.
Understanding Manufacturing Parameter Concepts

Manufacturing parameters enable you to control how an NC sequence is generated. It is important to understand
the different ways in which you can configure manufacturing parameters.

Manufacturing Parameters Parameter Types

• Control NC sequences • Six logical categories:
• Examples: – Feeds and Speeds
– CUT_FEED = 100 – Cut Depth and Allowances
– SPINDLE_SPEED = 500 – Cutting Motions
– STEP_DEPTH = 2.5 – Entry/Exit Motions
– SCAN_TYPE = TYPE_SPIRAL – Machine Settings
– General
• Required Parameters
– Must be configured
• Optional Parameters
Parameter List Variation
• Based on type of NC sequence

Figure 1 – Feeds and Speeds Category

Configuring Parameter Values

You can configure parameter values using different methods. It is important to understand how these methods
work.

Specifying Parameter Values

• Site Parameter Files
• System Default Values
• Parameter Files
• Edit Parameter dialog box
– Category
– Parameters Basic/All
– Copy from Tool
– Show/Hide Details
• Model Tree
System Default Parameter Values Figure 1 – Specifying Parameter Values
• Required Parameters
• System Default Values
• Optional Parameters
• Numeric Assigned Parameters
• Non-numeric Assigned Parameters
Figure 2 – Parameter Graphic Illustration
Using Site Parameter Files

You can use site parameter files to control default values in NC sequences. They can also control the range
of parameter values and the visibility of parameters.

Site Parameter Files Using Site Parameter Files

• Parameter value control • Activate
– Allowable range of values – Link created
– Parameter visibility • Deactivate
• Links to site parameter files retained – Link broken
• Types
• Work Center
– Mill, turn, holemaking, wire EDM
– Assign different site parameter files
– General
– Each type contains relevant parameters

Figure 1 – Site Parameter File Example

Module 11: Creating Face Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the face milling process.
• Describe the key face milling manufacturing parameters.
• Create face milling sequences.
• Create mill surfaces relevant to face milling.
• Create material removal features specific to face milling.
Basic Face Milling

Face milling enables you to face down the workpiece. This enables you to define the top surface of the job and a
reference surface for other NC sequences.
Face Milling Using Mill Surfaces and Mill Windows for Face
• Face down the workpiece. Milling
• Select or create final machining depth and area. • Alternative machining reference.
– Model surfaces • Mill geometry.
– Mill surfaces • Create before or during creation of NC
sequence.
– Mill volume surfaces
• Mill Surfaces
– Workpiece surfaces
– Mill windows – Fill
– Extrude
• All machining parallel to retract plane.
– Copy
• All inner contours excluded.
• Material removal after completing NC sequence. • Mill Windows
– Closed outline
– Depth considerations

Figure 1 – Basic Face Milling Example Figure 2 – Editing Toolpath Parameters

Lateral Control Face Milling Parameters

Lateral control parameters are a group of parameters that control the lateral movement of the tool in face milling
steps. Lateral movement is also affected by the trim_to_workpiece parameter.
Lateral Control Parameters
• SCAN_TYPE
– TYPE_1, TYPE_3, TYPE_ONE_DIR, or
TYPE_SPIRAL
• CUT_ANGLE
• STEP_OVER Figure 1 – Lateral Control Parameters

– or NUMBER_PASSES
– or TOOL_OVERLAP
• STEP_OVER_ADJUST
• NUMBER_PASSES = 1 Figure 2 – Offset Parameters
– One pass made at center
• ONE_PASS_OFFSET
• INITIAL_EDGE_OFFSET
• FINAL_EDGE_OFFSET
TRIM_TO_WORKPIECE Parameter
• With a workpiece – Can adjust to boundary of Figure 3 – TRIM_TO_WORKPIECE = YES
workpiece.
• No workpiece – Always uses boundary of
machined surface.
Depth Control Face Milling Parameters

There are a number of parameters that control the depth of a cut when creating face milling sequences.

Depth Control Parameters

• STEP_DEPTH
• NUMBER_CUTS
– Smallest resulting depth of cut used.
• If NUMBER_CUTS = 0 or 1 and STEP_DEPTH is greater than depth to be machined.
– One pass taken at full depth.
• BOTTOM_STOCK_ALLOW
– Stock remaining on machined surface.
– Default is zero.

Figure 1 – Depth Control Parameters

Entry and Exit Face Milling Parameters

There are a number of parameters that control entry and exit motions when creating face milling sequences.

Entry and Exit Parameters

• START_OVERTRAVEL and END_OVERTRAVEL
– Offsets for each pass.
• APPROACH_DISTANCE and EXIT_DISTANCE
– Offsets for the first and last passes.
• ENTRY_EDGE and CLEARANCE_EDGE
– Set to LEADING_EDGE, CENTER, or HEEL.

Figure 1 – Entry and Exit Parameters Example

1. APPROACH_DISTANCE and START_OVERTRAVEL

2. END_OVERTRAVEL
3. START_OVERTRAVEL
4. EXIT_DISTANCE and END_OVERTRAVEL
Module 12: Creating Volume Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the volume milling process.
• Describe the key volume milling manufacturing parameters.
• Create volume milling sequences.
• Create mill windows and mill volumes relevant to volume milling.
• Modify volume milling sequences using build cut and customize functionality.
• Create material removal features specific to volume milling.
Basic Volume Milling

Volume milling sequences enable you to machine material inside a configured volume of material. This is useful
for machining mold cavities and machining pockets and slots.

Volume Milling
• Remove material inside volume.
• For example – Mold cavities, mold electrodes,
pockets, and slots.
• Toolpath removes material slice-by-slice.
• Slices parallel to retract plane.
• Roughing and profiling passes.
• Use manufacturing geometry.
– Mill volume or mill window. Figure 1 – Volume Milling Toolpath Example

• Tool does not machine outside specified

volume.
– Specify approach walls.
• Also use top surfaces.
• Modify default cut motions.
– Build cut or customize.
• Material removal after completing NC sequence.
Figure 2 – Extruded Mill Volume
Basic Volume Milling

Volume milling sequences enable you to machine material inside a configured volume of material. This is useful
for machining mold cavities and machining pockets and slots. (cont'd.)

Mill Volume Configuration Tools

• Add solid features – Extrude a sketched outline.
• Trim – Subtract reference model.

Figure 3 – Trimmed Mill Volume

Volume Milling with Mill Windows

You can use mill windows to specify the volume of material to be machined when creating volume milling
sequences.

Mill Windows
• Closed outline projected onto reference model.
• Configuring mill windows:
– Select a closed outline.
– Sketch a closed outline.
– Use reference model silhouette outline. Figure 1 – Selected Outline
• Reference model geometry within window is
machined.
• Options:
– Placement
– Depth
– Offset Window Uniformly Figure 2 – Sketched Outline
– Window Contour Options:
• Inside
• On
• Outside
– Inside loops
Figure 3 – Silhouette Outline
Scanning Volume Milling Parameters

Scanning parameters are a group of parameters that control how the tool machines each slice in volume milling
sequences.

Scanning Parameters • High speed machining options

• ROUGH_OPTION – CONSTANT_LOAD
– ROUGH_ONLY – SPIRAL_MAINTAIN_CUT_TYPE
– ROUGH_AND_PROF – SPIRAL_MAINTAIN_CUT_DIRECTION
– PROF_AND_ROUGH – FOLLOW_HARDWALLS
– PROF_ONLY
– ROUGH_AND_CLEAN_UP
– POCKETING
– FACES_ONLY
• CUT_ANGLE
Figure 1 – ROUGH_OPTION = ROUGH_AND_PROFILE

Figure 2 – CUT_ANGLE = 45 degrees

Scanning Volume Milling Parameters

Scanning parameters are a group of parameters that control how the tool machines each slice in volume milling
sequences. (cont'd.)

• SCAN_TYPE
– TYPE_1
– TYPE_2
– TYPE_3
– TYPE_SPIRAL Figure 3 – SCAN_TYPE = TYPE_ONE_DIR
– TYPE_ONE_DIR
– POCKETING
– FACES_ONLY
Depth and Lateral Control Volume Milling Parameters

There are many parameters that control the depth of cut and lateral movement when you create volume milling
sequences.

Lateral Control Parameters Depth Control Parameters

• Step-over distance: • STEP_DEPTH
– STEP_OVER • WALL_SCALLOP_HGT
– NUMBER_PASSES • MIN_STEP_DEPTH
– TOOL_OVERLAP
– BOTTOM_SCALLOP_HEIGHT
• STEP_OVER_ADJUST

Figure 2 – Depth Control Parameters

Figure 1 – Lateral Control Parameters
Stock Allowance Volume Milling Parameters

There are a number of parameters that control the stock allowance when you create volume milling sequences.

Stock Allowance Parameters

• ROUGH_STOCK_ALLOW – Stock on walls for rough passes.
• PROF_STOCK_ALLOW – Stock on walls for profile passes.
– Used in material removal.
• BOTTOM_STOCK_ALLOW – Stock on bottom faces for rough and profile passes.
– Defaults to PROF_STOCK_ALLOW if set to “-”.

Figure 1 – Stock Allowance Parameters

Gathering Mill Volumes

The gathering technique enables you to create complex mill volume shapes by referencing model geometry
including surfaces and edges.

Gathering Mill Volumes Options

• Select Surfaces – Form extruded quilt.
– Surf and Bound
– Surfaces
Figure 1 – Surf and Bound: Seed Surface
– Features
– Mill Surfaces
• Exclude – Exclude specified items.
– Surfaces
– Loops Figure 2 – Surf and Bound: Bounding Surface
• Fill – Fill inner loops.
– All
– Loops
• Close – Cap mill volume. Figure 3 – Fill Inner Loops
– Specify plane or surface.
– Use retract plane.

Figure 4 – Cap Plane and Resulting Volume

Modifying Volume Milling Toolpaths

You can use the build cut or customize functionality to modify the default cut motions generated for volume
milling sequences.

Modifying Volume Milling Toolpaths

• Modify default cut motions.
• Two tools:
– Build Cut
• By Slice Figure 1 – Build Cut – By Slice
• By Region
– Customize
• Automatic
• Upto Depth
• From-To Depth
Figure 2 – Build Cut – By Region
• Slice/Slice

Figure 3 – Customizing Cut Motions

Module 13: Creating Profile Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the profile milling process.
• Describe the key profile milling manufacturing parameters.
• Create profile milling sequences.
• Create mill surfaces relevant to profile milling.
• Create lead in and lead out motions.
Basic Profile Milling

Profile milling sequences enable you to machine vertical and slanted surfaces. This is useful for machining the
sidewalls of pockets and for machining outside profiles of components.

Profile Milling Using Mill Surfaces for Profile Milling

• Machine vertical or slanted surfaces. • Alternative machining reference.
• Select or create final machining surfaces. • Mill geometry.
• Continuous toolpath required. • Create before or during creation of NC
• Final cut depth determined by machined sequence.
surface depth. • Common mill surface types:
• Approach and exit moves. – Fill
• Material removal after completing NC sequence. – Extrude
Customizing the Toolpath – Copy
• Modify default cut motions.
• Use approach/exit or tool motions.

Figure 2 – Profile Milling Example

Figure 1 – Customize Example
Depth and Lateral Control Profile Milling Parameters

When you create profile milling sequences, you can use a number of parameters to control the depth of cut and
lateral movement.

Depth Control Parameters Lateral Control Parameters

• STEP_DEPTH • PROF_INCREMENT
• AXIS_SHIFT • NUM_PROF_PASSES
• PROF_STOCK_ALLOW

Figure 1 – Depth Control Parameters

Figure 2 – Lateral Control Parameters
Lead In and Lead Out Motions

When you create profile milling sequences, you can use a number of parameters to control lead in and lead
out motions.

Lead In and Lead Out Motion Parameters

• CUTCOM • NORMAL_LEAD_STEP
• CUT_ENTRY_EXT • OVERTRAVEL_DISTANCE
• CUT_EXIT_EXT • APPROACH/EXIT
• LEAD_RADIUS – APPROACH_DISTANCE
• TANGENT_LEAD_STEP – EXIT_DISTANCE

Figure 1 – Lead In and Lead Out Tool Motion

Module 14: Creating Straight Cut Surface
Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the surface milling process.
• Describe the key straight cut surface milling manufacturing parameters.
• Create straight cut surface milling sequences.
• Create mill surfaces relevant to surface milling.
Understanding Surface Milling

You use surface milling to mill horizontal or contoured surfaces. There are four types of surface milling sequences
that you can configure. It is important to understand the benefits of each type of surface milling sequence.

Surface Milling
• Machine horizontal or contoured surfaces.
• Continuous toolpath required.
• Cut types: Figure 1 – Straight Cut
– Straight Cut
– From Surface Isolines
– Cut Line
– Projected Cuts
Figure 2 – From Surface Isolines
Surface Milling Options
• Cut Type
• Geometry Selection
– Model
– Mill Volume
Figure 3 – Cut Line
– Mill Surface
– Mill Window

Figure 4 – Projected Cuts

Straight Cut Surface Milling

Straight cut surface milling enables you to mill the selected surfaces with a series of straight cuts.

Straight Cut Surface Milling

• Machine selected surfaces using straight cuts.
• Machining direction:
– Use CUT_ANGLE parameter.
• Straddle open edges.
• Avoid inner walls.
• Patch slots.

Figure 1 – Straight Cut Example Figure 2 – CUT_ANGLE = 45 Degrees

Straight Cut Surface Milling Parameters

There are a number of parameters that control straight cut surface milling sequences. It is important to understand
how these parameters work.

Straight Cut Parameters

• SCAN_TYPE
– TYPE_1
– TYPE_3
• CUT_ANGLE
Figure 1 – SCAN_TYPE = TYPE_1
• LACE_OPTION
– LINE_CONNECT
– CURVE_CONNECT
– ARC_CONNECT
– LOOP_CONNECT
Figure 2 – SCAN_TYPE = TYPE_3
• Lateral control
– STEP_OVER
– TOOL_OVERLAP
– SCALLOP_HEIGHT
• PROF_STOCK_ALLOW Figure 3 – Lateral Control and Stock Allowance
Creating Surface Milling Reference Geometry

You can use reference geometry such as mill surfaces as alternative machining references in surface milling.
Surface Milling Reference Geometry
Alternative surface machining references.
• Mill Surfaces
– Copy
– Extrude Figure 1 – Copying Surface
– Fill
• Mill surface modification
– Extend
• To Plane
• Along Surface
• Same
• Tangent
• Approximate Figure 2 – Extending a Surface
– Trim
– Merge
• Mill Volumes
• Mill Windows

Figure 3 – Merged Surfaces

Module 15: Creating From Surface Isolines
Surface Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the from surface isolines surface milling process.
• Describe the key from surface isolines surface milling manufacturing parameters.
• Create and edit from surface isolines surface milling sequences.
From Surface Isolines Surface Milling

From surface isolines surface milling creates toolpaths based on the natural UV contours of the machined surfaces.

From Surface Isolines Surface Milling

• Machine using natural UV surface contours.
• Straddle open edges.
• Avoid inner walls.
• No patching of slots. Figure 1 – Surface Contour Directions

From Surface Isolines Parameters

• SCAN_TYPE
– TYPE_1/2/3
• Lateral control:
Figure 2 – Resulting Toolpath
– STEP_OVER
– TOOL_OVERLAP
– SCALLOP_HGT
– NUMBER_PASSES
• PROF_STOCK_ALLOW

Figure 3 – Straight Cut Example

Module 16: Creating Cut Line Surface Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the cut line surface milling process.
• Describe the key cut line surface milling manufacturing parameters.
• Create and edit cut line surface milling sequences.
Cut Line Surface Milling

Cut line surface milling enables you to specify the shape of the first, last, and optionally some intermediate cuts.
The toolpath gradually changes the shape of the cuts according to the surface topology.

Cut Line Surface Milling:

• Mill surfaces using cut lines.
• Toolpath gradually changes shape.
• Open or closed cut lines.
Cut Line Surface Milling Parameters:
Figure 1 – Cut Line Surface Milling
• SCAN_TYPE
– TYPE_1/2/3
– TYPE_SPIRAL
– TYPE_ONE_DIR
– TYPE_HELICAL
Figure 2 – Multiple Cuts
• NUMBER_CUTS
• OFFSET_INCREMENT
• LACE_OPTION
• Lateral control:
– STEP_OVER
– TOOL_OVERLAP
– SCALLOP_HGT
• PROF_STOCK_ALLOW Figure 3 – Stock Allowance and Scallop Height
Module 17: Advanced Surface Milling Options
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the methods that you can use to modify default surface milling cut motions.
• Edit surface milling sequences using different methods.
Advanced Surface Milling Options

You can use various advanced options to modify default surface milling cut motions. You can also change
toolpaths by specifying check surfaces.

Approach and Exit Moves

• Modify default cut motions
• Entry Type
– First cut/each cut
• Exit Type
Figure 1 – Entry/Exit Move Dialog Box
– Last cut/each cut
• Alternative Methods
– Build Cut
– Customize
Check and Scallop Surface Options
• Check Surfs
Figure 2 – Entry and Exit Moves
– Additional surfaces for gouge checking
• ScallopSrf
– Exclude surfaces from scallop height calculation

Figure 3 – Toolpath Adjusted for Check Surfaces

Module 18: Creating Roughing and Re-
roughing Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the roughing and re-roughing process.
• Describe the key roughing manufacturing parameters.
• Create roughing sequences.
• Create re-roughing sequences.
Basic Roughing and Re-roughing

Roughing and re-roughing sequences are intended for high speed mold machining, and for machining imported,
non-solid geometry. You can use these NC sequences to produce more efficient toolpaths when machining
mold cavities or pockets.

Roughing and Re-roughing Sequences

• Roughing – High speed mold machining and machining imported geometry.
– Remove material inside mill windows.
– Scallop height control.
– Automatic degouging.
– Machine by cavity.
– High speed roughing scans.
– Open and closed area scans.
– Open and closed area entry methods.
– No automatic material removal.
• Re-roughing – Machines where previous roughing could not reach.
– Use manufacturing geometry.
– Typically use smaller tool.
– No removal of scallops between slices.
Basic Roughing and Re-roughing

Roughing and re-roughing sequences are intended for high speed mold machining, and for machining imported,
non-solid geometry. You can use these NC sequences to produce more efficient toolpaths when machining
mold cavities or pockets. (cont'd.)

Figure 1 – Basic Roughing Toolpath Figure 2 – Basic Re-Roughing Toolpath

Roughing Scans and Entry and Exit Parameters

For roughing sequences, there are a number of parameters that control the roughing scan type. You can also vary
the entry and exit methods for closed and open areas.

High Speed Roughing Scans

• OPEN_AREA_SCAN and CLOSED_AREA_
SCAN
– CONSTANT_LOAD (default for closed areas)
– MAINTAIN_CUT_TYPE
– MAINTAIN_CUT_DIRECTION Figure 1 – CLOSED_AREA_SCAN =
– FOLLOW_CONTOUR (default for open areas) CONSTANT_LOAD
– TYPE_SPIRAL
– TYPE_3
Entry and Exit Methods
• OPEN_AREA_ENTRY
– Tool enters from open side. Figure 2 – CLOSED_AREA_SCAN =
• CLOSED_AREA_ENTRY MAINTAIN_CUT_TYPE

– TANGENT_HELIX or RAMP

Figure 3 – CLOSED_AREA_SCAN = TYPE_SPIRAL

Step Depth and Tolerance Control Roughing Parameters

For roughing sequences, there are a number of parameters that control the step depth and tolerance control.

Step Depth Calculations Improved Tolerance Control

• Based on the maximum and minimum • Tolerance options
Z-heights in the mill window
– INSIDE_TOLERANCE
• MAX_STEP_DEPTH
– OUTSIDE_TOLERANCE
• MIN_STEP_DEPTH

Figure 1 – Step Depth Calculation Figure 2 – Tolerance Control

Additional Scallop Height Control Roughing Parameters

Scallop height control enables you to generate a semi-finishing toolpath with the same tool and during the same
roughing sequence.

Additional Scallop Height Control

• Optional extra slices
• ROUGH_SCALLOP_CONTROL
– NO
– DURING
– DURING_BOTTOM_UP
– AFTER
• ROUGH_SCALLOP Figure 1 – Scallop Height Control

Figure 2 – No Scallop Height Control Figure 3 – With Scallop Height Control

Roughing Corner Options

When you rough a surface, you can add a filleting move to a sharp corner. You can also create slowdown motions
before a corner and ramp up motions after a corner.

Toolpath Filleting
• Add a filleting move to a sharp corner
• SMOOTH_SHARP_CORNERS
– NO
– CONSTANT_RADIUS
– RADIUS_BY_ANGLE Figure 1 – No Toolpath Filleting
– MAX_RADIUS
• SMOOTH_RADIUS
Progressive Slowdown for Corners
• Slowdown motions and ramp up motions
• CORNER_SLOWDOWN
• SLOWDOWN_LENGTH
• SLOWDOWN_PERCENT
• NUMBER_SLOWDOWN_STEPS
Figure 2 – Toolpath Filleting Applied
Module 19: Creating Finishing Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the finishing sequence process.
• Describe the key finishing sequence manufacturing parameters.
• Create and edit finishing sequences.
Basic Finishing

You can use finishing sequences to machine components after roughing and re-roughing. You can also use them
to directly machine models containing non-solid geometry.

Finishing Sequences
• Reference mill windows.
• Create after roughing and re-roughing.
• Directly machine STL data.

Figure 1 – Basic Finishing Toolpath

Cut Types
• Vertical Slices
• Horizontal Slices
• Combined
Slope Angle Parameter
• Specify areas for machining.
– Steep
– Shallow
Figure 2 – Steep and Shallow Machining Areas
Editing Finishing Parameters

You can use finishing sequence parameters to specify how the vertical and horizontal slicing toolpaths are
created within a finishing sequence.

Finishing Parameters
• SLOPE_ANGLE – Divides steep and shallow areas.
• FINISH_OPTION – Specifies machining method.
– STRAIGHT/PROFILE/SHALLOW/COMBINED
• SHALLOW_AREA_SCAN – Scanning method for shallow areas.
• STEEP_CONNECT_OPTION – Method for connecting profile slices.
• FINISHING_ORDER – Shallow/steep area.
• FLAT_AREA – Method of machining flat areas.

Figure 1 – Finish Option: PROFILE_CUTS Figure 2 – Finish Option: SHALLOW_CUTS

Module 20: Creating Trajectory Milling Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the trajectory milling process.
• Describe different methods of creating trajectory milling sequences.
• Describe how to create sketched tools.
• Create trajectory milling sequences using different methods.
• Create sketched tools.
Understanding Trajectory Milling

Trajectory milling enables you to sweep a tool along any user-defined trajectory. You can use it for milling slots
or chamfers.

Trajectory Milling
• Two Types
– 2-Axis Trajectory Milling
• Select or sketch a curve.
• Curve must be planar.
• Simple to use. Figure 1 – 2-Axis Trajectory Milling
• Automatic material removal.
– 3- to 5-Axis Trajectory Milling
• Interactively configure trajectory.
• Create cut motions.
• More advanced options.
Figure 2 – 3-Axis Trajectory Milling
Sketched or Edited Tools
• Edited Tools
• Sketched Tools – User-defined tool control
point.

Figure 3 – Sketched Tool

Creating Sketched Milling Tools

Trajectory milling sequences enable you to sketch a tool. This enables you to create a user-defined tool
cross-section and specify a non-standard control point for the tool.

Sketched Tools
• Create a sketch during tool configuration.
• Tool Features
– Sketch as revolved solid.
– Half tool cross-section.
– Right side of axis of symmetry.
– Sketch must be closed.
– Tool control point:
• Sketcher coordinate system.
Tool Offset – Tool control point offset from Figure 1 – Sketched Tool
trajectory
• Specify during tool configuration.
• Left, right, or none.
• Offset half cutter diameter.
• Tool center or tool edge cutter compensation.
Figure 2 – Tool Offset
Basic 2-Axis Trajectory Milling

In 2-Axis trajectory milling, you specify the tool trajectory by sketching or selecting a curve that represents
the final trajectory of the tool.

2-Axis Trajectory Milling Configuration

• Specify a curve to represent the final tool
trajectory.
• Configure
– Depth
– Multiple Passes Figure 1 – Datum Curve and Height Same
– Multiple Slices
• Options
– Datum Curve
– Start Height
– Height
– Direction Figure 2 – Alternate Height Specified
– Offset
– Material Side
Parameter Configuration
• Lead In and Lead Out
• Cutter Compensation

Figure 3 – Offset – Left, Right, or None

2-Axis Trajectory Milling Depth Control Parameters

There are many parameters that control the depth of cut when creating 2-axis trajectory milling sequences.

Depth Control Parameters

• NUMBER_LAST_FINPASSES
• NUMBER_FIRST_FINPASSES
• LAST_FINPASS_OFFSET
• FIRST_FINPASS_OFFSET
• WALL_FINISH_CUT
• PERCENT_LENGTH Figure 1 – Depth Control Parameters

Figure 2 – Depth Control Parameters

2-Axis Trajectory Milling - Cutting Slices Parameters

There are many parameters that control the number of cutting slices when creating 2-axis trajectory milling
sequences.

Cutting Slices Parameters – Control cutting slices

and offset values.
• SLICE_PASS_SCAN – Machining order
• NUMBER_LAST_FINCUTS
• NUMBER_FIRST_FINCUTS
• LAST_FINCUT_OFFSET
• FIRST_FINCUT_OFFSET Figure 1 – Cutting Slices Parameters

Figure 2 – Cutting Slices Parameters

Basic 3-Axis Trajectory Milling

In 3-axis trajectory milling, you specify the tool trajectory by creating cut motions using the customize functionality.

3-Axis Trajectory Milling Configuration

• Create cut motions
• Trajectory Options
– Sketch/Edge/Curve/Surface
Figure 1 – Sketch
• Cut motion Options
– Specify Trajectory
– Direction
– Offset
– Start Height Figure 2 – Edge
– Height
– Material Side
• Customize Options – Low-level control

Figure 3 – Curve

Figure 4 – Surface

Figure 5 – Customize Approach and Exit Moves

3-Axis Trajectory Milling Multi-Step and Multi-Pass
Parameters
There are a number of parameters that enable you to create multi-step and multi-pass 3-axis trajectory milling
sequences.

Multi-Step Configuration
• NUMBER_CUTS
• STEP_DEPTH
• Final pass along specified trajectory
• Start Height
• Height
Multi-Pass Configuration Figure 1 – Multi-Step Parameters
• NUM_PROF_PASSES
• PROF_INCREMENT
• Final pass along specified trajectory

Figure 2 – Multi-Pass Parameters

Module 21: Creating Holemaking Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the holemaking process.
• Describe the key holemaking manufacturing parameters.
• Describe different drill cycle types and hole selection methods.
• Create holemaking sequences.
• Create drill groups relevant to holemaking.
Understanding Holemaking

Holemaking enables you to create many different types of drilling cycles including standard, countersink, tapping,
and reaming.

Holemaking Process Cycle Types

• Select the drill cycle type. • Output CYCLE/XXXX in CL data
• Select a tool. • Drill
• Configure holemaking parameters. – Standard/Deep/Break Chip/Web/Back
• Configure the set of holes to be machined.
• Face
• Customize hole connections (optional).
• Bore
• Countersink
• Tap
– Fixed/Floating
• Ream
Figure 1 – Holemaking Example
• Custom

Figure 2 – Drill Cycle Types

Basic Drilling

You can create many different types of drilling sequences by selecting the holes for drilling and configuring
the drill depth options.

Configure Hole Sets

• Selecting Holes
– Axes
– Points
– Diameters
Figure 1 – Selecting Holes
– Surfaces
– Parameters
– Groups
• Depth Options
– Blind
– Auto
– Thru All
Figure 2 – Depth Options
– Shoulder/Tip
• Countersink Drilling
– Start Surface
– Countersink Diameter
– Auto Chamfer Figure 3 – Countersink Drilling
Editing Drilling Toolpaths

You can edit drilling toolpaths by configuring holemaking manufacturing parameters. You can also use customize
functionality to specify the tool movement between drilling holes.

Holemaking Parameters
• SCAN_TYPE
– TYPE_1
– TYPE_SPIRAL
– TYPE_ONE_DIR
– PICK_ORDER
– SHORTEST (default)
• BREAKOUT_DISTANCE
• PECK_DEPTH
Figure 1 – Holemaking Parameters
• CLEAR_DIST
• RAPTO_DIST
• PULLOUT_DIST
Connect Motions
• Insert connect motions between holes.
Creating and Using Drill Groups

You can configure groups of hole axes within drill groups. You can then select drill groups when creating
holemaking sequences. This simplifies the hole selection process.

Drill Groups
• Simplify hole selection.
• Drill group updates.
Configuring Drill Groups
• Selecting holes:
– Axes
– Diameters
– Surfaces
– Parameters

Figure 1 – Drilling Group Dialog Box

Figure 2 – Highlighted Selection

Module 22: Creating Engraving Sequences
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the engrave milling process.
• Describe the key engrave milling parameters.
• Create engrave milling sequences on both flat and complex surfaces.
Engraving on Flat and Complex Surfaces

Engraving NC sequences are generally created by the tool following a curve or a Groove cosmetic feature. The
tool diameter determines the width of cut.

Engraving:
• Flat or Complex Surfaces
• Use Cosmetic Groove or Curve features
• For logos or part numbers

Figure 1 – Engraving
Module 23: Using the Process Manager
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the capabilities of the process manager.
• Create and edit process steps using the process manager.
• Create and use manufacturing templates using the process manager.
Using Process Manager Tools

The process manager enables you to create new manufacturing objects such as Work Center and NC sequences
and modify the properties of existing objects.

Process Manager Process Table Tools:

• Process Table – Table-based view of • Highlighting References
manufacturing model. • Show Step Parameters
• NC Sequences = process steps. • Toolpath Simulation
• Create and edit manufacturing objects. • Compute Step Time
• Process Table Features: • Printable Reports
– View Types • CSV Files
– Custom Views
– Sorting and Filtering Views

Figure 1 – Process Table Figure 2 – Printable Reports

Editing Process Items

The process table enables you to reorder and merge steps. You can also modify the configuration of an existing
step in the process table.

Editing Process Items

• Reordering Steps
– Process view only
– Cut/Copy/Paste
• Merging Steps
– Holemaking Steps

Figure 1 – Editing Steps

Editing Process Items

The process table enables you to reorder and merge steps. You can also modify the configuration of an existing
step in the process table. (cont'd.)

• Edit Existing Steps

– Tool
– Parameters
– Geometry References
– Retract Plane
– Steps supported include:
• Facing Figure 2 – Editing Tools
• Profiling
• Roughing
• Re-roughing
• Finishing
• Corner Finishing
• Holemaking
• Trajectory Milling
Creating New Items in the Process Manager

You can insert and configure many different types of items in the process table, including operations, Work
Center, fixtures, and NC sequences (steps).

Creating New Items

• Inserting Items
– Operations
– Fixtures Figure 1 – Inserting a Work Center
– Work Center
• Inserting NC Steps
– Facing and Profiling
– Roughing and Re-roughing
– Finishing and Corner Finishing
– Holemaking
– Trajectory Milling
• Editing NC Steps Figure 2 – Inserting a Milling Step

– Tool Configuration
– Manufacturing Parameters
– Reference Geometry
– Review Toolpath
– Compute Step Time
Creating New Items in the Process Manager

You can insert and configure many different types of items in the process table, including operations, Work
Center, fixtures, and NC sequences (steps). (cont'd.)

• Other Milling Steps

– Insert
– Configure using menu manager
Figure 3 – Face Milling Configuration Tools
Creating and Using Manufacturing Templates

In the process manager, you can configure manufacturing templates based on existing steps, and then use these
templates to create manufacturing steps in different models.

Manufacturing Templates
• Based on existing NC steps.
– Use in different manufacturing models.
• Work Center templates.
• Stored as XML files.
Using Manufacturing Templates
• Insert new NC steps.
Figure 1 – Creating an NC Step Template
– Step information taken from template.
– Configure missing items.
• Insert Work Center templates.

Figure 2 – Configuring Missing Items

Module 24: Creating and Post-Processing CL Data Files
Milling using Creo Parametric 3.0
Objectives

After completing this module, you will be able to:

• Describe the post-processing method.
• Create CL Data files for operations and selected NC sequence sets.
• Create MCD files using a post-processor.
Creating and Post-Processing CL Data Files

When toolpaths have been completed, you can use them to create ASCII format Cutter Location (CL) data files. You
can then post-process CL data files into specific machine control data (MCD) files using a post-processor.

Post-Processing
• CL data files generated from toolpaths.
• Post-process CL data files into machine-specific
code.
• Machine-specific code used to control machine
tools.
Figure 1 – CL Data File Simulation
Post-Processing Method
• Complete NC Sequences
• Create CL Data Files
– From one or more NC sequences.
– ASCII format. Figure 2 – CL Data File
– Filename.ncl.
• Post-Process CL Data Files
– Create MCD files.
– Filename.tap.
Changes to NC Sequences
• Recreate CL data files and MCD files. Figure 3 – MCD File