FACE MILLING

Face milling NC Sequence is used to face down the workpiece. Usually it is the first
sequence in machining a part. The required reference is a flat surface which is parallel
to the retract plane. This surface may belong to the reference part, mill volume or a mill
surface feature.

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EXERCISE 1

In this exercise we will define a face milling NC Sequence within a manufacturing model
which has no workpiece defined.

The topics covered are as follows.

❖ Defining a new face milling NC Sequence

❖ Optimizing the toolpath for longer tool life
❖ Set the toolpath to cut the material using climb milling strategy
❖ Avoiding direct plunge motion into the material
❖ Changing the start point
❖ How to perform multi step machining

Set the working directory to REGULATOR_CAVITY folder and open the manufacturing
model regulator_cavity1.mfg. Notice that it has no workpiece defined.

To define a new face milling NC Sequence select Machining>NC

Sequence>Face>Done.

Now the SEQ SETUP menu appears and it contains the list of items to define. The
required options are checked by default. You can check any other option at this time or
later whenever you want.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

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Enter FACE as the name of the sequence and click the Accept value icon

4) Enter NC Sequence name []: FACE

The Tools Setup dialog box will pop up. Pick the predefined tool FEM30 in the tools list
and then select [ 0K ~1.

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Now MFG PARAM menu appears. Here different methods are given to set cutting
parameter but at this time we will use the method of entering parameters manually

Select Set and Parameter Tree dialog box will appear as shown below.

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The system initializes the required values as “-1”.

So enter the following values in the Parameter Tree Dialog box

CUT_FEED 1000
STEP_DEPTH 3
STEP_OVER 25
SCAN_TYPE TYPE_1
SPINDLE_SPEED 1400
CLEAR_DIST 1

CUT_FEED is the feed rate used for cutting motion. It is the feed of the tool with respect
to the workpiece in mm/min (in case of metric template). You can also say that rate at
which workpiece is fed into the cutting tool.

STEP_DEPTH is the axial depth of cut. It is the distance between two slices both at
different z levels in case of multi-step machining.

STEP_OVER is the radial depth of cut.

SCAN_TYPE refers to the way a milling tool scans the reference surfaces.

SPINDLE_SPEED is the rate at which the machine spindle rotates (RPM)

CLEAR_DIST is used to set the clearance distance, above the top of the surface to be
machined, at which the rapid motion ends and feed motion begins.

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Select File>Exit or pick s-3 to apply the changes and exit the Parameter Tree Dialog
box.

-PickExit or Pickthis icon ■

P u r am T re e □
File | lait View

Advan..

M U M --------------- .— i 1. FACE
Ouit |Finish editing parameters. |

CUT_FEED 1000
STEP_DEPTH 3
STEP..0VEP 22.5
B0TT0M_ST0CK_ALL0W
CUT_AN0,LE 0
sc an _ type TYPE_1
c5PiNDLE_SPEED 1400
COOLANTJDPTION OFF
CLEAFI_DIST
1
APPROACH_DISTANCE
EXIT_DISTANCE

Distance needed to completely clear the workpiece prior to retraction.

Applying the changes and exiting the dialog box

Pick Done in the MFG PARAMS menu

Now the SURF PICK menu appears.

This menu gives us three options to select the surfaces to be faced. For this exercise
we will use the Model option.

As the Model option is highlighted by default so select Done and pick the top surface of
reference model as shown in the figure below

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Model option is used to select continuous surfaces from reference part to be milled

Select Done/Return or middle-click twice.

To display the toolpath on screen select Play Path>Screen Play.

Seq Setup

Play Path
Customise

Seq Info

Done Seq
Next Seq
Quit Seq

PLAY PATH Dialog box will appear as shown below.

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Click the Play Forward button The resulting tool path is shown in figure
below.

Notice that the center of the tool overlaps with the edge of the part. It creates a very
unfavorable cutting condition. Whenever the center of the cutter overlaps with the edge
of the part or positioned outside of the part to be machined, an unfavorable contact
between the cutting edge and material results. When the center of the cutter is
positioned inside the part to be machined the most favorable cutting action takes place.
It is good practice to engage the minimum of 60% of the tool diameter to avoid the
unfavorable cutting condition. On the upper side it is a good practice to engage
maximum of 75% of the tool diameter.

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 Y_
Select Seq Setup>Parameters>Done>Set or pick ^ icon on the Manufacturing
toolbar and Parameter Tree dialog box will appear.

The parameters we are going to change are listed on advanced page of Parameter Tree
dialog box. So select [ Advanced) ^ access advanced parameters.

Set the following parameters

STEP_OVER CUTTER_DIAM*.75
INITIAL_EDGE_OFFSET CUTTER_DIAM*.25
FINAL_EDGE_OFFSET CUTTER_DIAM*.25

The following figure shows the location of these parameters in the Parameter Tree
dialog box.

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CUTTER_DIAM represents the diameter of the tool used. It automates the definition of
the cutting condition. Suppose later you change the cutter for facing the part so all the
parameters where CUTTER_DIAM is used will be updated with the new values based
on the diameter of new tool.

INITIAL_EDGE_OFFSET parameter allows to offset the first pass with respect to the
edge of the surface being machined. The default is 0, in which case the tool center at
first pass will coincide with the surface edge; the positive value offsets the first pass into
the surface.

FINAL_EDGE_OFFSET allows to offset the last pass with respect to the edge of the
surface being milled. The default is 0, in which case the tool center at last pass will
coincide with the surface edge; the positive value offsets the last pass into the surface

Select File>Exit or pick icon t-J to apply the changes and exit the Parameter Tree
Dialog box.

Now select Play Path>Screen Play to view the modified tool path.

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 Final Edge
▼
/
l
L____________________________________
n ______________
7

ji

Initia Edge

Notice the tool has been pulled into the part both on the initial and final edge. Further
more cutter engagement is 75% of the tool diameter for whole of the sequence.
Also notice that during first cutting pass Up (Conventional) milling takes place but during
second pass Down (Climb) milling. This pattern is repeated to the end of the tool path.

Up Milling Down Milling

Now to change the cutting to climb milling, we have to change the SCAN_TYPE
Parameter to SPIRAL.

Y_
Select Seq Setup>Parameters>Done>Set or pick ^ icon on the Manufacturing
toolbar and set the following parameter.

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 SCAN TYPE TYPE SPIRAL

Select File>Exit or pick ^ icon.

Play the toolpath on screen by picking Play Path>Screen Play. It will appear as shown
below.

Notice that tool makes first pass along initial edge and second pass along final edge.
Both of these passes perform Down (Climb) milling. This pattern is repeated to the
center of the part. (Keep in mind that Yellow color in tool path simulation represents the
rapid feed.)

Now reorient the part to the top view of the part and select View>Repaint or pick the

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The tool path looks ok except that the tool plunges on the edge of the part. To move the

tool away from the edge to plunge down, pick = * and set the following parameter.

APPROACH DISTANCE

Select File>Exit or pick iJJ icon.

Play the toolpath on screen by picking Play Path>Screen Play. You can see in the
following figure that the tool now plunges away from the edge.

In the same way tool should over travel at the start and end of each pass so that tool
Y_
has enough clearance from the part while making non-cutting movement. So pick
and set the following parameters in the Parameter Tree Dialog Box.

START_0V ERT RAV EL 5

END_OVERTRAVEL 5

START_OVERTRAVEL specifies the distance from the tool to the surface outline.
END_OVERTRAVEL specifies the distance that the tool over travels past the surface
outline
Play the toolpath on screen by picking Play Path>Screen Play.

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Pro/NC gives the very low level control over the tool path. We can easily change the
cutting direction of tool and choose to start machining at a specified corner of the
selected face.

To change the cutting direction to parallel to the Y-axis, pick and change the
following parameter.

CUT ANGLE 90

CUT_ANGLE specifies the angle between the cut direction and the X-axis of the NC
Sequence coordinate system.

Play the toolpath by picking Play Path>Screen Play.

The default CUT_ANGLE is 0, which is parallel to the X axis. Notice that now the tool
makes more passes to machine the whole surface. As a result entry/exit movements

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increase which is not good from machining point of view. The more the tool enters and
exits the cut, shorter the tool life. So set the CUT_ANGLE back to “0”.

CUT ANGLE 0

To change the start point select Seq Setup>Start Point>Done. The system is asking
for the datum point or vertex which will be used as the start point. So select the vertex of
upper left corner as shown below.

Select Done.

Play the toolpath on screen by picking Play Path>Screen Play.

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Notice that the tool is now plunging at the upper left corner instead of lower right corner.
Keep in mind that tool will always climb mill the part if the SCAN_TYPE parameter is set
to SPIRAL, whatever the point or vertex you choose as Start Point.

You might have noticed the following warning appearing at the message area

^W AR N IN G : 5TEP_DEPTH will not be used,

It is so that system does not know how to use this parameter. Now we will use another
parameter which in conjunction with STEP_DEPTH gives us more freedom in deciding
the machining strategy.
So set the following parameters in the Parameter Tree Dialog Box.

NUMBER CUTS 2

Now the part will be machined with two cuts both at different z levels. The first cut will
be offset from the reference surface by the STEP_DEPTH parameter and the second
cut at the reference surface level (if the BOTTOM_STOCK_ALLOW parameter is set to
0). The tool path is shown below in the figure.

To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so for.

Keep in mind that tool path will not the same if the manufacturing model has a
workpiece defined.

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EXERCISE 2

In this exercise we will define a face milling NC Sequence for a manufacturing model,
which has both Ref Model and Workpiece defined.

Set the working directory to REGULATOR_CAVITY folder and open the manufacturing
model regulator_cavity2.mfg. It will appear as shown below.

Notice that there are two components

1. regulator_cavity.prt
2. regulator_cavity2_wp.prt

regulator_cavity.prt is the reference model and regulator_cavity2_wp.prt is the

workpiece. Workpiece color is green to distinguish it from the reference model.

For better visualization it is good to display the workpiece in wireframe. So select

View>View Manager or pick icon to launch the View Manager Dialog box and
double click the predefined style state Wireframe.

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 Close
Select to exit the dialog box.

To define a new face milling NC Sequence select Machining>NC

Sequence>Face>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

0
Enter FACE as the name of the sequence and pick CCJ icon or hit Enter key on the
keyboard.

The Tools Setup dialog box will pop up. Pick the predefined tool FEM30 and then select
I 0K I
In MFG PARAM menu select Set>Done and enter the following values in the Parameter
Tree Dialog box.

CUT_FEED 1000
STEP_DEPTH 4
STEP_OVER CUTTER_DIAM*.75
SCAN_TYPE TYPE_SPIRAL
SPINDLE_SPEED 1400
CLEAR_DIST 1
NUMBER_CUTS 2
START_0V ERT RAV EL 5
END_OVERTRAVEL 5
APPROACH_DISTANCE 5
INITIAL_EDGE_OFFSET CUTTER_DIAM*.25

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 FINAL EDGE OFFSET CUTTER DIAMT25

Select File>Exit or pick it-3 to apply the changes and exit the Parameter Tree Dialog
box.

Select Done in the MFG PARAMS menu to proceed.

Now the SURF PICK menu appears. Here we will select the surfaces to be faced.
Select Model>Done and select the top surface of reference part as shown in the figure
below

Select OK>Done/Return.

To display the toolpath on screen select Play Path>Screen Play. Play Path Dialog box
will appear.

Click the Play Forward button The resulting tool path is shown in figure
below.

We can see that the tool is facing the part in three cuts although we have set the
NUMBER_CUTS parameter to 2. In the case when workpiece has been defined or
assembled in the manufacturing model, the parameters NUMBER_CUTS and
STEP_DEPTH behave differently. The software calculates the distance between top
surface of workpiece and reference part and divides this distance by the

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NUMBER_CUTS parameter. The value obtained by dividing is compared with the
STEP_DEPTH parameter and the lower value among these two is used as the step
depth in tool path computation (let us say this lower number STEP_DEPTH_SYS). The
first cut is offset from the top surface of the workpiece by STEP_DEPTH_SYS. More
cuts are added offset from each other by STEP_DEPTH_SYS. The last cut which is on
reference surface may be less than STEP_DEPTH_SYS depending upon distance
between top surface of workpiece and reference part.

In above case the NUMBER_CUTS parameter is 2 and the distance between top
surface of workpiece and reference model is 10mm. so by dividing 10 by 2 we get 5
which is larger than STEP_DEPTH. So the first cut is offset from top surface by 4mm
and the second cut by 4mm from the first cut. The last cut is 2mm offset from previous
because now the tool cannot be offset by the same depth.

Y_
To face the part in only one cut set the following parameters, pick ^ icon on the
Manufacturing toolbar and set the following parameter.

STEP_DEPTH 10
NUMBER_CUTS 1

Select File>Exit or pick iJ i icon.

Play the toolpath by picking Play Path>Screen Play. It should appear as shown below.

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The trick is to set the NUMBER_CUTS parameter to 1 and STEP_DEPTH larger than
the distance between top surface of workpiece and reference part.

If the top surfaces of the workpiece and reference part coincide then the
NUMBER_CUTS and STEP_DEPTH parameters have no effect on the tool path. In this
case only one cut is made along the reference surface of the part.

To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so for.

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VOLUME AND LOCAL MILLING

VOLUME MILLING

Volume milling NC Sequence is a 2.5 axis sequence. It is a very versatile sequence used
not only to rough machine the workpiece but can also perform finishing and facing
operations.

The required references are Mill Window or Mill Volume. They specify the geometry that
you want to mill. Mill Window is usually preferred as it requires less mouse picks and
usually there are no regeneration problems.

Volume Milling NC Sequence automatically degouges the tool path against the references
selected for the cut geometry.

Approaching a Cavity

There are three major options for approaching the workpiece when roughing out a cavity.

1. Linear ramping
2. Helical ramping
3. Plunging at a pre-drilled hole

Linear Ramping

During linear ramping tool moves in X and Z or Y and Z axis to reach a full axial depth of
cut. Ramp Angle is dependent upon the diameter of the cutting tool and dept of cut.

Helical Ramping

During helical ramping tool moves along a helical path to reach a full axial depth of cut
This is the most preferred way of approaching the workpiece.

Plunging

First of all a hole is drilled at the deepest point in the cavity then during rough machining
the tool makes plunge movement at the drilled hole position. Although during plunge
movement there is no load on the tool but due to drilled hole, variation in cutting forces and
temperature leave negative effect on tool. Furthermore recutting of chips also increases
which results in shorter tool life.

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LOCAL MILLING
Local milling NC Sequence is used to remove material left by previous Volume Milling NC
Sequence. Although it can reference Profile, Surface Mill and another Local Mill NC
Sequence we will limit our discussion in this chapter only to Volume Mill.

As far as possible we should use constant z machining both for roughing and finishing as it
results in

❖ Shorter machining time

❖ Less over loading of tool and machine
❖ Improved surface quality resulting in less manual polishing.

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EXERCISE 1

In this exercise we will define a volume milling NC Sequence to rough a cavity using linear
ramping.

The topics covered are as follows.

❖ Creating a Mill Window

❖ Defining a new Volume milling NC Sequence
❖ Specifying the linear ramp motion for approaching the workpiece
❖ Controlling the feed along ramp motion
❖ Controlling the cutting condition at corners to avoid vibration

Set the working directory to CONTAINER_CAVITY folder.

Open the manufacturing model container_cavity.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick icon
to launch the View Manager and double click the predefined style state Wireframe.

Select to exit the dialog box. The model will appear as shown below.

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First of all we will define a mill window to be later referenced in the volume sequence.

So select Mfg Setup>Mfg Geometry>Mill Window>Create Wind

0
Enter MW_A as the name of mill window and pick ££J icon or middle-click.

Now the system will ask you to select a coordinate system. So select the
NC ASM DEF CSYS as shown below.

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The z-axis of this coordinate system determines the direction of projection for the mill
window.

Now the system will ask you to pick the Start Plane. So pick the following surface.

Start Plane must be parallel to the XY plane of the coordinate system.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

Select Silhouette.

Pick i 0K 1to complete the feature.

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The mill window will appear as shown below.

The Silhouette type of Mill Window is created by projecting the silhouette (or you can say
shadow outline) of the reference part on the Start Plane, along the Z-axis. All surfaces
visible within the Mill Window will be milled.

To define a new volume milling NC Sequence select Machining>NC

Sequence>Volume>Done.

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In the SEQ SETUP menu add Name and Window to the list of checked items and select
Done. Notice that Volume is unchecked automatically when you check the Window option

Enter ROUGH as the name of the sequence and pick 0 icon or middle-click.

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The Tools Setup dialog box will pop up. Pick the predefined tool BULL32 and select
i « i
In MFG PARAMS menu select Set and enter the following values in the Parameter Tree
Dialog box

CUT_FEED 1500
STEP_DEPTH 2
STEP_OVER 20
ROUGH_STOCK_ALLOW 1
BOTTOM_STOCK_ALLOW .2
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION ROUGHJDNLY
SPINDLE_SPEED 2000
CLEAR_DIST 1

STEP_DEPTH is the incremental depth of each pass and it depends on the rigidity of the
tool and the material to be cut. Maximum available spindle power should be checked to
ensure that the tool will cut the material without overload.

STEP_OVER is the radial depth of cut. It is the width of the cutter engaged in cutting. It is
good machining practice to engage 60-75% of the tool diameter in cutting.

ROUGH_STOCK_ALLOW represents the amount of material left on the surfaces, which

are not parallel to the retract plane, after the roughing pass.

BOTTOM_STOCK_ALLOW represents the amount of material left on the surfaces parallel

to the retract plane.

SCAN_TYPE refers to the way a tool scans the horizontal cross-section of a milling
volume and avoids islands.

ROUGH_OPTION gives you the options to specify either you want to rough, profile, face or
pocket the reference geometry.

CLEAR_DIST is used to set the clearance distance, above the top of the surface to be
machined, at which the rapid motion ends and feed motion begins.

Select File>Exit or pick *-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu select Select Wind and pick the previously defined window
MW A.

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To display the toolpath on screen select Play Path>Screen Play. Play Path Dialog box will
appear.

Click the Play Forward button Now change the view to FRONT and zoom to
the tool path.

Here you can see that tool plunges directly into next slice and feeds along z-axis only. This
creates a lot of load on tool so the result will be vibration and noise. To avoid such
situations we should ramp the tool to next slice i.e. tool should enter the next slice making
an angular movement.

y
Advanced
So pick icon and select tab to access advance parameters.

To replace the plunge motion with linear ramping, set the following parameters.

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 RAMP_ANGLE 15
RAMP_FEED 750

RAMP_ANGLE is the angle of descent for the ramping movement and it is measured from
the retract plane. Its default value is 90°, and in this case it makes a direct plunge (normal
to the retract plane) in the workpiece.

RAMP_FEED controls the feed along the ramping movement. By default it is set to dash (-
) in which case the CUT_FEED is used as RAMP_FEED.

Ramp Angle and feed along ramping movement depend upon the diameter of the cutting
tool, dept of cut and tool geometry. So tool manufacturer catalogue should be consulted for
proper angle and feed selection.

Play the toolpath and notice that tool enters the next slice by linear ramping. Change the
view to Left and toolpath will appear as shown below.

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Now change the view to Top and notice that tool makes sharp corners as shown below.

At this position the contact area of tool with the work piece material is almost one quadrant
of the tool perimeter. Furthermore there is a very short stop before the servo motors of the
machine tool can change the feed direction. As the spindle is rotating at the same speed
there is no cutting action taking place instead a lot of heat is generated due to friction. The
result of such conditions is vibration and deflection of tool and poor surface finish at radius.
Even the surface may get burning marks. To avoid such situations a radius should be

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32
applied at the sharp corners. To round the tool path at sharp corners we will make use of
the parameter CORNER_ROUND_RADIUS. So set the following in parameter tree.

CORNER ROUND RADIUS 5

CORNER_ROUND_RADIUS specifies the minimum radius allowed for concave corners

Play the tool path. It should appear as shown below.

As the toolpath is satisfactory so select Done Seq from the NC SEQUENCE menu and
select File>Save to save the changes we made so far.

The following figures elaborate the parameters used in this exercise. Keep in mind that
Yellow color in tool path simulation represents the rapid feed.

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EXERCISE 2

In this exercise we will define a volume milling NC Sequence to rough a cavity. We will
specify an axis to plunge the tool to next slice.

Set the working directory to CONTAINER_CAVITY folder.

Open the manufacturing model container_cavity.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick icon
to launch the View Manager and middle-click the predefined style state Wireframe.

f
/
Pick / * icon to display the datum axis on screen. The model will appear as shown
below.

Now we will define a volume milling NC Sequence and specify the shown axis to plunge
the tool to next slice

In practice, first of all a hole is drilled at the axis location then during rough machining the
tool makes plunge movement at the drilled hole position. Although during plunge
movement there is no load on the tool but due to drilled hole, variation in cutting forces and
temperature leave negative effect on tool. Furthermore recutting of chips also increases
which results in shorter tool life. So as far as possible ramping should be preferred for
roughing and plunge along drilled hole should only be considered when ramping is not
possible.

To define the new Volume Milling sequence Select Machining>NC Sequence >New
Sequence>Volume>Done.

In the SEQ SETUP menu add Name, Window and Build Cut to the list of checked items
and select Done.

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Notice that Tool is not checked by default. It is so because system assumes that you will
be using the tool of previous NC Sequence.

Enter ROUGH_A as the name of the sequence and pick 0 icon or middle-click.

In the MFG PARAMS menu, select Use Prev and NC SEQ LIST menu will appear, select
ROUGH in this list.

The system will copy all the parameters of the sequence into this new sequence so we
don’t have to enter all the parameters from scratch.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu select Select Wind and pick the previously defined window
MW_A.

In the Build Cut menu select Approach.

Make sure that Whole Volume option is selected and then pick Done.

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 ►

In the APPR EXIT OPT menu select Axis>Done

Select the axis A 1 on the screen as shown below.

Select Done/Return.

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To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward buttonCZ ^ .

Notice that the tool is plunging right on the axis A_1 as shown below.

By default tool plunges at the feed rate set by CUT_FED parameter but you can specify a
different value by using the PLUNGE_FEED parameter.

Select Done Seq from the NC SEQUENCE menu and select File>Save to save the
changes.

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EXERCISE 3

In this exercise we will define a volume milling NC Sequence to rough a cavity using
helical ramping.

The topics covered are as follows.

❖ Creating a Mill Volume

❖ Defining a new Volume milling NC Sequence
❖ Specifying the helical ramp motion for approaching the workpiece
❖ Controlling the cutting condition at corners to avoid vibration
❖ Simulating toolpath in Vericut for verification

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg.

□
For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Select to exit the dialog box. The model will appear as shown below.

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First of all we will define a mill volume to be later referenced by the volume sequence.
Although we can use the Mill Window for this exercise but we will go for Mill Volume just to
familiarize you with this functionality.

So select Mfg Setup>Mfg Geometry>Mill Volume>Create.

Enter MV_A as the name of mill volume and pick icon or middle-click

We will extrude a protrusion and then trim it to the reference part.

In the CREATE VOL menu select Sketch.

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In the SOLID OPTS menu select Extrude>Solid>Done

In the ATTRIBUTES menu select One Side>Done

Select the top surface of the reference part as Sketch Plane and side surface as Right
Reference Plane as shown in the figure below.

f Sketch 1
Pick L-------- J and system will place you in sketcher.

Pick L tab and Type menu will appear. Select Loop radio button

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Now select the top surface of reference part. As the top surface contains two loops system
will give you the option which one to choose. So select any loop both will work.

Pick to complete the section.

In the SPEC TO menu select Up To Surface>Done

Pick the bottom surface for the depth reference as shown below.

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Pick i 0K 1to complete the extrusion.

Select Trim in the CREATE VOL menu and pick the reference part

Trim option subtracts the reference model from the current volume. During machining only
the remaining volume will be considered.

Select Done/Return and it completes the definition of the mill volume.

For visual check we can shade the volume on screen.

Select Shade on Mill Volume menu.

Pick the volume MV_A. The volume will appear as shown below (in wireframe mode)

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This is the volume to be removed during the NC sequence. The tool will always be within
the Mill Volume.

Select Done>Done>Done to return to main menu.

To define a new volume milling NC Sequence select Machining>NC

Sequence>Volume>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter ROUGH as the name of the sequence and pick 0 icon or middle-click.

The Tools Setup dialog box will pop up. Pick the predefined tool BULL52 and select

In MFG PARAMS menu select Set and enter the following values in the Parameter Tree
Dialog box

CUT_FEED 1500
STEP_DEPTH 5
STEP_OVER CUTTER_DIAM*.65
ROUGH_STOCK_ALLOW 1
BOTTOM_STOCK_ALLOW .2
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION ROUGH_ONLY
SPINDLE_SPEED 1200
CLEAR_DIST 1
CORNER_ROUND_RADIUS 10

STEP_DEPTH is initially set to a larger value and when toolpath looks satisfactory it is
reduced to the required value.

By default BOTTOM_STOCK_ALLOW is set to dash (-) in which case the

PROF_STOCK_ALLOW is used as BOTTOM_STOCK_ALLOW. It implies that if the

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BOTTOM_STOCK_ALLOW is set to dash (-) and PROF_STOCK_ALLOW is set to 0, then
BOTTOM STOCK ALLOW is considered as 0.

Select File>Exit or pick to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu pick Select Vol.

Now pick the previously defined volume MV_A.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward b u tto n ^ * .

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The material remaining in the corner can be easily machined with a LOCAL NC Sequence
using a cutter of smaller diameter. It is a good practice to remove the remaining materials
at corners to ensure that semi finishing or finishing operations are performed at constant
load because even stock will be removed by these tool paths. So it will result in higher
productivity.

Now change the view to FRONT and zoom to the tool path.

Here you can see that tool plunges directly into next slice and feeds along z-axis only. We
will modify the toolpath so that tool enters the next slice by helical ramping. During helical
ramping, tool moves along a helical path to reach a full axial depth of cut. This is the most
preferred way of approaching the workpiece but it requires enough space.

y
To replace the plunge motion between slices with a helical entry motion pick and
Advanced
select tab to access advance parameters. Now set the following parameters.

RAMP ANGLE 1

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 HELICAL_DIAMETER 100
RAMP_FEED CUT_FEED*.75

RAMP_ANGLE is the angle of descent for the helical movement and

HELICAL_DIAMETER is the diameter formed by the center of the tool

If a too large value of HELICAL_DIAMETER is selected relative to the size of Mill Volume
the following error may appear.

Helix violating Mill Volume - discontinue slice processing

In such cases we should first try to reduce the HELICAL_DIAMETER often it solves the
problem. But if the same message reappears then we should use linear ramping. To use
linear ramping instead of helical ramping we should set HELICAL_DIAMETER to which
tells the system not to helically ramp between slices but use linear ramping.

Pick tJ I to apply the changes and exit the Parameter Tree Dialog box.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward buttonCZ ^ .

The tool path looks ok. For further satisfaction we will use Vericut simulation. It allows you
to view a step-by-step simulation of material removal as the tool is cutting the workpiece.
Before running vericut simulation makes sure that config.pro option “nccheck_type” is set

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to vericut otherwise Vericut will not start. Also make sure that workpiece has not been
hidden or blanked.

To unblank the workpiece we should change the style state other than blanked. So select
□
icon to launch the View Manager and double click the predefined style state
Wireframe.

Now select NC Check on the Play Path menu to launch the Vericut.

I I Compute CL

Screen Play
NC Check
Gouge Check

Vericut window will pop up. Click Play to End icon in the Vericut window.

The tool path will be simulated on the screen and material cutting process out of workpiece
will be shown as it will take place on actual machine. The cut model should look like this.

To check for any gouges select Analysis>Auto-DIFF

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AUTO-DIFF dialog box will pop up as shown below.

Now select C°mpare I to compare the Cut model with the Reference part

Pick Reporl- I and a new window titled AUTO-DIFF Report will pop up which gives
information about any errors during tool path simulation.

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At the end of the window you can see “No error records to report”. It means Vericut
detected no error in the simulation.

Select File>Exit to close the Vericut window. If system asks you to save any changes pick

As the toolpath is satisfactory so change the following parameters

STEP DEPTH 2

STEP_DEPTH should be selected based upon the rigidity of the tool and the material to be
cut.

Select Done Seq from the NC SEQUENCE menu

To blank the volume MV_A select Mfg Setup>Mfg Geometry>Mill Volume>Blank

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 Create
Modify Dim
► Modify Vol
Delete
Blank
Unblank
Shade

Done/Return

Pick the MV_A and then select Done.

Select File>Save to save the changes we made so far.

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EXERCISE 4

In this exercise we will use Local Mill NC Sequence to machine the material left by the
previous volume milling NC Sequence. As the tool used in the previous sequence
“ROUGH” was the bull mill of 52mm diameter with corner radius of 6mm. So there will be
enough stock remaining at the corners which should be removed before finishing or semi
finish NC Sequence is created.

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Select t Cl°se) to exit the dialog box.

To define a new local milling NC Sequence Select Machining>NC Sequence >New

Sequence>Local Mill>Done.

Now LOCAL OPT menu will appear. There are four options available to define a local
milling NC Sequence.

But at this time we want to machine the material left by the previous NC Sequence so
select Prev NC Seq>Done.

Now the system is asking for selecting the reference NC Sequence so select
NC Sequence

Pick the previously defined NC Sequence “ROUGH”

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Now the system will ask to select the cut motion of the selected NC Sequence

The reference NC Sequence contains only single cut motion that is listed in the SEL
MENU. So select CUT MTN # 1.

From the SEQ SETUP menu, add Name and Tool to the list of checked items, and select
Done.

Enter LOCAL_ROUGH as the name of the sequence and pick \y j icon or middle-click

From the Tools Setup dialog box select FEM12 and select [ 0K ~l.

In the MFG PARAMS menu, select Set and set the following parameters.

CUT_FEED 1500
STEP_DEPTH .5
STEP_OVER CUTTER_DIAM*.65
PROF_STOCK_ALLOW 1
BOTTOM_STOCK_ALLOW .2
SCAN_TYPE TYPE_SPIRAL
SPINDLE_SPEED 3000
CLEAR_DIST 1
CORNER_ROUND_RADIUS 2
RAMP_FEED 750
RAMP_ANGLE 1

PROF_STOCK_ALLOW represents the amount of material left on the surfaces, which are
not parallel to the retract plane.

Select File>Exit or pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

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To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward b u tto n ^ * .

The tool path generated by the sequence should look like.

Sequence has been completely defined so select Done Seq

Select File>Save to save the changes we made so far.

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EXERCISE 5

In this exercise we will use Volume Milling NC Sequence for semi-finishing the model
top_cover.mfg. It has been roughened in the previous exercises with a volume milling NC
Sequence and local NC Sequence.

The topics covered are as follows.

❖ Using Volume Milling for profiling of the walls of the mill volume
❖ Controlling the entry/exit condition of the tool
❖ Optimizing the Lead in and Lead out motions

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

First we will unblank the mill volume that will be referenced in the NC Sequence.

To unblank the mill volume MV_A, select Mfg Setup>Mfg Geometry>Mill

Volume>Unblank.

Select the volume MV_A and then pick Done.

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To define the new Volume Milling sequence Select Machining>NC Sequence >New
Sequence>Volume>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items, then select
Done.

Enter SEMIFINISH as the name of the sequence and pick icon or middle-click.

In the Tools Setup dialog box select BULL32 and select

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 2000
STEP_DEPTH 2
STEP_OVER CUTTER_DIAM*.65
PROF_STOCK_ALLOW .2
BOTTOM_STOCK_ALLOW -
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION PROF_ONLY
SPINDLE_SPEED 1600
CLEAR_DIST 1
CORNER_ROUND_RADIUS 8
PLUNGE_FEED 100

PROF_STOCK_ALLOW represents the amount of material left on the surfaces, which are
not parallel to the retract plane, after the profiling pass.

PROF_ONLY option is used to perform the profiling of the walls.

Select File>Exit or pick to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Select Vol and pick the already defined volume MV_A.

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Now play the path on screen using Screen Play. It should appear as below.

Zoom to the toolpath and look at it carefully, you will notice that the tool plunges directly to
the next slice.

Direct Plunge is not a good practice. So to introduce smooth entry/exit into the cut, pick

and set the following parameters.

LEAD_RADIUS 50
LEADJN YES
LEAD_OUT YES

Pick U3 to apply the changes and exit the Parameter Tree Dialog box.

Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as
shown below.

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Although now tool enters and exits into the cut very smoothly but it is wasting a lot of time
Y_
in non-cutting motion. To reduce this non-cutting time, again pick ^ and set the
following parameters.

ENTRY_ANGLE 15
EXIT_ANGLE 15

Pick U3 to apply the changes and exit the Parameter Tree Dialog box.

Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as
shown below.

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Notice that the non-cutting motion has been reduced significantly

The entry/exit parameters can be readily understood from the figure below.

LEAD OUT
E X T AN G LE = 90

LEAD RADIUS

E X T ANGLE

ENTRY ANGLE

EN TRY ANG LE = 70
LEAD

It is always advantageous to use a large LEAD_RADIUS because the larger the radius
smoother the entry into cut. But it also increases the idle time while the tool completes its
non cutting movement. To reduce this non-cutting time we have set the ENTRY_ANGLE
and EXIT_ANGLE to a smaller value than default. By doing this we have achieved both i.e.
smoother motion by setting a large LEAD_RADIUS value and reduction in non-cutting time
by smaller entry/exit angles.

As the toolpath is satisfactory so change the following parameters to get smoother surface
quality.

STEP DEPTH 1

Select Done Seq from the NC SEQUENCE menu and select File>Save to save the
changes we made so far.

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EXERCISE 6

In this exercise we will use Volume Milling NC Sequence to finish the model with a ball end
mill.

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

Now make sure that mill volume MV_A is unblank because we will reference it during the
definition of the NC Sequence. If volume is blank then first unblank it.

To define the new sequence Select Machining>NC Sequence >New

Sequence>Volume>Done.

From the SEQ SETUP menu, add Name and Tool to the list of checked items, then select
Done.

Enter FINISH as the name of the sequence and pick c£J icon or middle-click.

In the Tools Setup dialog box pick BEM10 and select [ 0K ~l.

In the MFG PARAMS menu, select Use Prev and NC SEC LIST menu will appear, select
SEMIFINISH in this list. The system will copy all the parameters of the sequence into this
new sequence so we don’t have to enter all the parameters from scratch.

We will only change few parameters to suit this particular sequence. Select Set and enter
the following parameters.

STEP_DEPTH 2
PROF_STOCK_ALLOW 0
SPINDLE_SPEED 4000
CORNER_ROUND_RADIUS 2
WAL L_S CAL LO P_H GT .1

WALL_SCALLOP_HGT controls the step depth and hence the surface quality of the
machined part. It is defined as the maximum height of the cusp left between two passes of
tool as shown below. It adjusts the step depth of the tool according to the shape of the
surface so uniform surface finish will be obtained.

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Pick LJ3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Select Vol and pick the previously defined volume
MV A.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward buttonCZ ^ .

You will notice that step depth is not constant from top to bottom and more slices are
generated for less steep walls.

As this is the finishing tool path one may wish to turn the coolant on. So set the following
parameter in the parameter tree dialog box (use pull down menu to select ON)

COOLANT OPTION ON

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As the toolpath looks satisfactory so change the following parameters for good surface
finish.

STEP_DEPTH .3
SCALLOPJHGT .0009

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the changes we made so far.

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EXERCISE 7

In the previous NC Sequence we used the ball end mill to finish the walls. It did not
machine the surfaces parallel to the retract plane and some portion of the walls due to its
radius. In this exercise we will use Volume Milling NC Sequence to finish these remaining
areas of the model. This time we will make use of pocketing strategy instead of profiling or
roughing. When ROUGH_OPTION is set to Pocketing, the tool not only profiles the walls
but also faces down the flat horizontal surfaces.

The topics covered in this exercise are as follows

❖ Performing profiling and facing within a single NC Sequence by using pocketing

strategy of Volume Milling
❖ Customization of the toolpath

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

Now make sure that mill volume MV_A is unblank because we will reference it during the
definition of the NC Sequence. If volume is blank then first unblank it.

To define the new sequence Select Machining>NC Sequence >New

Sequence>Volume>Done.

In the SEQ SETUP menu, add Name and Tool to the list of checked items, then select
Done.

Enter FINISH_A as the name of the sequence and pick 0 icon or middle-click.

In the Tools Setup dialog box select FEM10 and select l 0K J.

In the MFG PARAMS menu, select Use Prev.

In the NC SEQ LIST menu select FINISH.

We will now change a few parameters to suit this particular sequence. Select Set and
enter the following parameters.

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 STEP_DEPTH 5
ROUGH_OPTION POCKETING
WAL L_S CAL LO P_H GT 0
RAMP_FEED 750
RAMP_ANGLE 1
HELICAL_DIAMETER 25

POCKETING option is used to profile the walls and face down flat horizontal surface in a
single sequence.

We have selected a large value of step depth to create the toolpath fast, later we will
modify the STEP_DEPTH to desired value. It is not recommended to use
WALL_SCALLOP_HGT when flat end mills are used as it will take very long processing
time.

Select File>Exit or pick to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Select Vol and pick the previously defined volume
MV A.

Now it is better if you blank the mill volume as it will unclutter the screen. For this you will
have to exit the NC Sequence by picking Done Seq, blank the mill volume and then again
redefine the NC Sequence.

So select Done Seq to exit the NC Sequence definition menu.

To blank the volume MV_A select Mfg Setup>Mfg Geometry>Mill Volume>Blank and
select the MV_A and then pick Done or middle-click twice.

Select Machining>NC Sequence and pick the above defined FINISH_A sequence.

Select Customize on the NC SEGUENCE menu and customize dialog box will appear.

Delete
In the Current Tool Motion(s) field select “Automatic Cut” and pick

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 Yes
Pick to confirm to delete.

Now we will define a new cut motion according to our requirement

First make sure that Automatic Cut is selected in the drop down menu then pick

In the next menu select From-To Depth>Done.

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In the FROM-TO DEPTH menu select From Depth

Select Make Datum>Offset and select the following surface as reference

From the Offset menu select Enter Value.

Make sure that direction arrow points upward as shown below. Then enter 5.1 and pick
0 icon or middle-click.

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If the arrow points downward then enter -5.1

Select Done in the DATUM PLANE menu.

Although theoretically we should enter the 5mm as the offset value because the ball end
mill of radius 5mm was used in the FINISH NC Sequence but we have entered 5.1 to
make sure that there is no visible step on the surface.

In the FROM -TO DEPTH menu select To Depth.

Menu Manager
▼ FROM-TO DEPTH

Parameters
From Depth
To Depth

Select the following surface as reference

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To complete the definition of tool path select Done Cut.

□K
Pick to exit the Customize dialog box.

Now we will set the value of STEP_DEPTH. So set the following values in the parameter
tree dialog box.

STEP DEPTH .2

If we had entered this value before the customization of the tool path it would have
consumed a lot of time for creating the new tool path.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward button!-------—— . It should appear as below.

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You will notice that for profiling of walls lead in and lead out entry/exit condition is used and
for facing of the flat surface helical ramping motion.

Select Done Seq to complete the definition of the NC Sequence.

Select File>Save to save the changes we made so far.

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EXERCISE 8

In this exercise we will use Volume Milling NC Sequence to finish the bottom surface and
adjacent walls which FINISH NC Sequence could not machine. In this exercise we will
copy the FINISH_A sequence and redefine the references.

Set the working directory to TOP_COVER folder.

Open the manufacturing model top_cover.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

For this exercise blank the mill volume to unclutter the screen.

To blank the volume MV_A select Mfg Setup>Mfg Geometry>Mill Volume>Blank and
select the MV_A and then pick OK>Done.

To copy the previous sequence select Machining>Utilities>Copy and the COPY

FEATURE menu will appear.

T MACHINING T MFG UTILS

Operation Modify 1 New Refs

NC Sequence Delete Same Refs

Matrl Remove Redefine Mirror

Auto Drilling Reorder Move

CL Data CL Data ------------► Mirror NC Seq 1 Select

Modify Pattern
Output Order
Regenerate Del Pattern FromDifModel
Synchronize
Component Suppress FromDifVers
CL Command
5et Up Resume Fromlnheritance
Subroutines
Relations UDF Library 1 Independent
Mfg Setup
Program Group Dependent
Utilities
Integrate Copy D one
D o n e /R e tu rn
Insert Quit
Read Only
Regenerate

Make sure that New Refs and Independent options are selected then select Done>NC
Sequence.

From the NC SEQ LIST menu check the FINISH A and select Done Sel.

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The system is asking whether to copy the mill volume with the NC Sequence. If we select
Yes
the new sequence will be the child of the copied mill volume and will have no
dependency on the original volume. But if we select No the new copied sequence will
reference the original mill volume i.e. MV_A. Usually we copy the volume if we want to
modify it.

No
As we want to reference the same volume so select

Pick Done in the SELECT FEAT menu.

After that GP VAR DIMS menu will appear. Here the system presents the list of
dimensions associated with the sequence. As we don’t want to change any dimension so
don’t select any one and click Done.

In the WHICH REF menu select Same for all the references except the reference surface
which is highlighted in green in the figure below, as we want to change this reference.
(Hint: you need to pick Same for four times)

While the Alternate option is highlighted select the bottom face as shown in the figure
below.

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Now select Done/Return>Done and it completes the copying of the sequence.

Select Machining>NC Sequence and pick the currently copied sequence which is the
sixth in the list and is named by the system Volume Milling.

Select Seq Setup and add Name, Tool and Parameters to the list of checked items, then
Done.

Enter FINISH_B as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select FEM30 and select

We have selected the tool of larger diameter as it will give more smooth surface quality on
flat surfaces as compared to the small one.

In the SEL MENU menu, check NC SEQUENCE and Done Sel.

System has presented this menu because we have defined a new Automatic Cut motion
rather than default Automatic Cut in the FINISH_A sequence. All the parameters we will
modify at the NC Sequence level will be automatically copied to the cut motion level.
Because all the cut motions inherit their parameters from the NC Sequence.

In the MFG PARAMS menu, select Set and modify the following parameters.

STEP_OVER CUTTER_DIAM*.65
CORNER_ROUND_RADIUS 6
HELICAL_DIAMETER 60
LEAD_RADIUS 60

Pick s-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

A new window named INFORMATION WINDOW will pop up that shows the parameters
which have been modified.

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Select to close the window.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward buttonCZ ^ .

The tool path should appear as shown below.

You will notice that for profiling of walls lead in and lead out entry/exit condition is used and
for facing of the flat surface helical ramping motion.

Select Done Seq to complete the definition of the NC Sequence.

Select File>Save to save the changes we made so far.

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EXERCISE 9

In this exercise we will use Volume Milling NC Sequence for creating finishing toolpath.
The topics covered are

❖ How to use excluded surfaces option to exclude the selected surfaces from profiling
❖ How to control the entry/exit into cut for longer tool life and good surface finish.
❖ Introduction to the following entry/exit movements between slices
1. Lea in, Lead out
2. Ramping
3. S-shape Connections

Set the working directory to PILLAR_PUNCH and open pillar_punch.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

First we will unblank the mill volume that will be referenced in the NC Sequence.

To unblank the mill volume MV_A, select Mfg Setup>Mfg Geometry>Mill

Volume>Unblank.

Select the volume MV_A and then pick Done.

To define the new sequence, select Machining>NC Sequence >Volume>Done.

From the SEQ SETUP menu, add Name and Excld Surfs to the list of checked items,
then select Done.

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Enter FINISH as the name of the sequence and pick icon or middle-click.

From the Tools Setup dialog box select BULL25 and select

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1200
STEP_DEPTH 5
STEP_OVER CUTTER_DIAM*.65
PROF_STOCK_ALLOW 0
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION PROF_ONLY
SPINDLE_SPEED 1800
CLEAR_DIST 1
CORNER_ROUND_RADIUS 10
LEAD_RADIUS 50
LEADJN YES
LEAD_OUT YES
ENTRY_ANGLE 15
EXIT_ANGLE 15

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Pick sJ3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Select Vol and select the pre-defined volume MV_A.

In the SELECT SRFS menu select the outer surfaces of the mill volume, while holding
down the Ctrl key, as exclude surfaces as shown in the figure below and select Done.

Now it is better if you blank the mill volume as it will unclutter the screen. For this you will
have to exit the NC Sequence by picking Done Seq, blank the mill volume and then again
redefine the NC Sequence.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward b u tto n ^ * .

Notice that tool enters and leaves each slice by making tangential arc to the cut motion as
shown below.

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Volume milling NC Sequence allows different entry/exit motions. To change the entry/exit
condition to ramping set the following parameters in the parameter tree.

STEP_DEPTH 1
RAMP_FEED 500
RAMP_ANGLE 1
LEADJN NO
LEADJDUT NO

We have set the STEP_DEPTH to a lower value just to see the effect on toolpath clearly
Now play the tool path using PLAY PATH dialog box and zoom to notice that after
completing each slice tool ramps down to next slice as shown in the figure below.

A more efficient and smooth way is to connect the slices with an S-shape motion. So set
the following parameters to change the transition between slices from ramp to “S”.

SCAN TYPE CONSTANT LOAD

Now play the tool path using PLAY PATH dialog box and notice the smooth transitions as
shown below.

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When the tool connects slices with “S” movements there is no sudden change in direction
and the tool is in Continuous Engagement with the material. Both of these factors allow to
run the machine tool with higher feed rates without any bad effect on either the machine
tool or cutter.

You may notice that during first and last slice tool directly plunges and retracts from cut. So
set the following parameters to enter and exit from cut by making tangential arcs.

LEADJN YES
LEADJDUT YES

As the toolpath looks satisfactory so change the following parameters for good surface
finish.

STEP DEPTH .2

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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LOCAL MILLING
Local milling NC Sequence is used to remove material left by previous Volume Milling NC
Sequence. Although it can reference Profile, Surface Mill and another Local Mill NC
Sequence we will limit our discussion in this chapter only to Volume Mill.

As far as possible we should use constant z machining both for roughing and finishing as it
results in

❖ Shorter machining time

❖ Less over loading of tool and machine
❖ Improved surface quality resulting in less manual polishing.

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EXERCISE 10

In this exercise we will use the Corner Edges option of the Local Mill NC Sequence to
machine the material left at corners left by the previous tool. In this type of NC sequence,
we specify one or more corners to clean up by selecting edges.

Set the working directory to PILLAR_PUNCH and open the manufacturing model
pillar_punch.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Select t Cl°se) to exit the dialog box.

We assume that the surfaces highlighted in the figure below were machined using the flat
end mill of diameter 10. So there will be enough material left at the sharp corners for a
smaller tool to machine.

Select Machining>NC Sequence >New Sequence>Local Mill>Done.

Here LOCAL OPT menu will appear. There are four options available to define a local
milling NC Sequence.

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 Menu Manager
^ MANUFACTURE
I Machining T I

I nc Sequence T
LOCAL OPT

By Prev Too!
Pencil Tracing

Done
Quit

Select Corner Edges>Done.

In the SEQ SETUP menu, add Name and Tool to the list of checked items, then select
Done.

Enter LOCAL_CORNERS as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select FEM2 and select [ 0K ~1.

In the MFG PARAMS menu, select Set and set the following parameters.

CUT_FEED 1000
STEP_DEPTH .2
STEP_OVER CUTTER_DIAM*.65
CORNER_OFFSET 7
SPINDLE_SPEED 3000
CLEAR_DIST 1
RAMP_FEED 500
RAMP_ANGLE .5

CORNER_OFFSET parameter determines the amount of material to be removed. Usually

it represents the previous tool radius. Although we assumed that previous tool was of
radius 5 but we entered a larger value just to get smooth surfaces.
Now the SURF PICK menu will appear. Here we will select the surfaces which will be used
to specify corners for local milling.

Select Model>Done to select the surfaces that belong the reference model.

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Select the following three surfaces while holding down the Ctrl key and then pick
Done>Done.

Now the CRNR REGIONS menu will appear. Here we will select corner edges of the
above select surfaces for calculating the material to be removed. The menu offers two
options, one is Suggest and the other is Define.

Suggest option shows possible corners based on the surface selection in the previous
step. Define option is used to define corners by either selecting surfaces that form a
corner, or selecting the corner edges themselves.

Select Suggest and the system will highlight the possible corner edges. System will show
two corners. One of them is as shown below.

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As we want to select both corner edges so select Select AII>Done,

Now play the tool path using PLAY PATH dialog box. It should appear as shown below.

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 11

In this exercise we will use Volume Milling NC Sequence for creating finishing toolpath. In
this exercise we will use Mill Window instead of Mill Volume and see how it reduces the
references selection.

Set the working directory to PHONE_PUNCH folder and open phone_punch.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

To define the new sequence, select Machining>NC Sequence >Volume>Done.

From the SEQ SETUP menu, add Name and Window to the list of checked items, then
select Done.

Enter FINISH as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select BEM10 and select [ 0K ~).

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1200
STEP_DEPTH 5
STEP_OVER 5
PROF_STOCK_ALLOW 0
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION PROF_ONLY
SPINDLE_SPEED 2500
CLEAR_DIST 1
CORNER_ROUND_RADIUS 3
LEADJN YES
LEAD_OUT YES
LEAD_RADIUS 8
ENTRY_ANGLE 25
EXIT_ANGLE 25

Pick to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

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In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick C'J icon or middle-click.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

Select Silhouette

Pick to complete the feature.

The mill window will appear as shown below.

Mill Window is a separate feature that can be created before or at the time of defining an
NC sequence.

When mill window is created within NC Sequence then NC Sequence coordinate system is
considered the Mill Window Coordinate System and Retract Plane is considered
automatically the Start Plane.

Notice that NC Sequence coordinate system is same as the Operation coordinate system
in this exercise and it is mostly the case.

To display the toolpath on screen select Play Path>Screen Play and click the Play
Forward button It will appear as shown below.

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Notice that system automatically identifies exclude surfaces and we do not have to specify
any surface that we want to exclude from profiling.

Apparently toolpath looks satisfactorily but if you look from Top view you will notice that
tool is not machining the walls completely as elaborated below.

It is so because, by default, tool stays within the boundaries of the Mill Window and cannot
travel beyond the boundaries until default options are altered.

So now we will redefine the mill window and change the default settings.

To redefine the mill window, select Seq Setup and check the Window option then pick
Done.

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In the DEFINE WIND menu select Redef Wind.

In the Machine Window dialog box double-click the Tool Side option

Select Past in the TOOL SIDE menu

The Tool Side option controls the limit of the tool travel with respect to mill window. If it is
set to “To” (default) the tool will stay within boundaries of window. If set to “On” the tool can
go outside the window by the half of its diameter value. If set to “Past” the tool can
completely go outside the Mill Window outline.

Now play the path on screen using PLAY PATH dialog box. It will appear as shown below.

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As the toolpath looks satisfactory so change the following parameters for good surface
finish.

STEP DEPTH .2

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 12

In this exercise we will use Volume Milling NC Sequence to face down the workpiece.
Facing the part using volume milling NC Sequence has the benefit of reduced entry/exit
motions into cut which results in longer tool life and reduced machining time.

Set the working directory to REGULATOR_CAVITY and open regulator_cavity2.mfg.

For better visualization it is good to blank the workpiece. So pick icon to launch the
View Manager and double-click the predefined style state Blank.

Close
Select to exit the dialog box.

First we will unblank the mill volume that will be referenced in the NC Sequence.

To unblank the mill volume, select Mfg Setup>Mfg Geometry>Mill Volume>Unblank.

Select the volume MV_A and then pick Done.

To define the new sequence Select Machining>NC Sequence>Volume>Done.

From the SEQ SETUP menu, add Name to the list of checked items, then select Done.

Enter FACE as the name of the sequence and pick 0 icon or middle-click.

In the Tools Setup dialog box select FEM30 and select [ 0K ~1.

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1000
STEP_DEPTH 1
STEP_OVER 22.5
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION FACES_ONLY
SPINDLE_SPEED 1400
CLEAR_DIST 1
RAMP_FEED 500
RAMP_ANGLE 1
HELICAL_DIAMETER 50

Pick to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

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In the DEFINE VOL menu select Select Vol and select the pre-defined volume MV_A.

Now play the tool path using PLAY PATH dialog box. It should look like this.

Notice that tool enters the next cut with 90° movement and there are sharp corners in the
toolpath. Both of these cause the tool to overload momentarily.

So set the following parameters to avoid these problems.

STEP_OVER 14
SCAN_TYPE SPIRAL_MAINTAIN_CUT_DIRECTION

SPIRAL_MAINTAIN_CUT_DIRECTION generates a spiral cutter path with S-shape

connections between cuts. When a cut is finished, the tool S-connects into the next cut.
The tool begins its scan from outside to inward. The outer walls of mill volume are
machined according to the CUT_TYPE parameter (CLIMB or UPCUT) then the tool makes
the next cuts maintaining cutting direction, which results in the cut type reversal with
respect to remaining material. This is a high speed machining option, which minimizes
retracts.

Now play the tool path using PLAY PATH dialog box. It should look like this.

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Notice that system has applied a radius at the corners.
Although with respect to outer walls of the volume first cut is climb milling but as we are
facing the workpiece so the tool is making conventional milling or upcutting the material.
So to climb mill the material set the following parameter.

CUT TYPE UPCUT

Now play the tool path using PLAY PATH dialog box. It should look like this

Select Done Seq to complete the definition of the NC Sequence.

To blank the volume MV_A select Mfg Setup>Mfg Geometry>Mill Volume>Blank and
select the MV_A and then pick OK>Done.

Select File>Save to save the manufacturing model.

In the above tool path, tool stays into contact for the complete machining operation. It has
clear advantage over multiple parallel passes. There are no sudden direction changes and

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single entry/exit motion into cut which results in longer tool life and reduced machining
time.

Sharp direction changes can cause a CNC with look-ahead to slow down. To machine
internal corners more effectively in HSM, tool paths use rounded moves to change
direction. A machining strategy that can generate fluid tool motions during corner
machining can maintain more consistent high feed rates.

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EXERCISE 13

In this exercise we will use Volume Milling NC Sequence to machine a thin wall structure.
To machine the weak structure, lighter depth of cut is employed to avoid the deformation of
wall. To offset the cost due to longer toolpaths, high speed machining strategies are
implemented with higher RPM and feed.

The topics covered are

❖ Defining a Mill Window

❖ Modifying a Mill Window without exiting a NC Sequence
❖ Specifying Tool Side for Mill Window
❖ Machining the part with Slice by Slice strategy

Set the working directory to HONEYCOMB and open the model honeycomb.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick icon
to launch the View Manager and double click the predefined style state Wireframe.

Close
Select to exit the dialog box.

To define new sequence select Machining>NC Sequence >Volume>Done.

From the SEQ SETUP menu, add Name and Window to the list of checked items, then
select Done.

Enter ROUGH as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select FEM10 and select [ 0K ~l.

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 3500
STEP_DEPTH 4
STEP_OVER CUTTER_DIAM*.65
PROF_STOCK_ALLOW 1.5
SCAN_TYPE FOLLOWJHARDWALLS
ROUGH_OPTION ROUGH_ONLY
SPINDLE_SPEED 7000
CLEAR_DIST 1
CORNER_ROUND_RADIUS 3

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For FOLLOW_HARDWALLS scan type, the shape of each cut follows the shape of the
walls of the part or volume, maintaining fixed offset between the respective points of two
successive cuts. If the cuts are closed, there are S-shape connections between the cuts.

Pick L-J to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick 0 icon or middle-click.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

Select Silhouette

Pick to complete the feature.

The mill window will appear as shown below.

Mill Window is a separate feature that can be created before or at the time of defining an
NC sequence.

When mill window is created within NC Sequence then NC Sequence coordinate system is
considered the Mill Window Coordinate System and Retract Plane is considered
automatically the Start Plane.

Notice that NC Sequence coordinate system is same as the Operation coordinate system
in this exercise and it is mostly the case.

The Silhouette type of mill window is created by projecting the silhouette (or you can say
shadow outline) of the reference part on the Mill Window start plane, along the Z-axis.

Pick to complete the feature.

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Run the Vericut by selecting NC Check in PLAY PATH menu.

I I Compute CL

Screen Play
NC Check
Gouge Check

±J
Click Play to End ic o n __ I in the Vericut window.

After the simulation of the toolpath the cut model will appear as shown below.

Notice that tool is leaving material at the outer walls of the workpiece. To remove this
material we should redefine the mill window.
Select File>Exit to close the Vericut window.

To redefine the mill window, select Seq Setup and check the Window option then pick
Done.

In the DEFINE WIND menu select Redef Wind.

In the Machine Window dialog box double-click the Tool Side option

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Select On in the TOOL SIDE menu

The Tool Side option controls the limit of the tool travel with respect to mill window. If it is
set to “To” (default) the tool will stay within boundaries of window. If set to “On” the tool can
go outside the window by the half of its diameter value or you can say the tool center will
coincide with the window boundary.

Select Done.

Pick i 0K 1to exit the dialog box.

Run the Vericut by selecting Play Path>NC Check in PLAY PATH menu

Click Play to End icon ± J in the Vericut window,

During simulation, cut model will appear as shown below.

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You will notice that now tool has machined outer walls. Also notice that tool is machining
one complete pocket before moving to other one. This strategy is not correct for thin walled
components because it causes the walls, which have been machined on the opposite side,
to deflect under the cutting pressure of tool.
So we should modify the toolpath to machine a complete slice for all pockets and then
jump to next slice. In this way the wall is always supported on the opposite side so the wall
does not deflect.

Select File>Exit to close the Vericut window.

Select Seq Setup in the NC SEQUENCE menu and check the Build Cut option then pick
Done.

In the BUILD CUT menu check By Slice option and select Confirm>Done.

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Run the Vericut by selecting NC Check in PLAY PATH menu.

Click Play to End ic o n __ lin the Vericut window.

After machining the first slice the cut model will appear as shown below.

Select File>Exit to close the Vericut window.

As the toolpath looks satisfactory so change the following parameters for good surface
finish and smooth entry into the material.

RAMP_FEED 2000
RAMP_ANGLE 1
HELICAL_DIAMETER 15
STEP_DEPTH .5

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 14

In this exercise we will use Volume Milling NC Sequence to rough out a workpiece with the
tool entering from a side wall of mill volume.

For Volume milling, the tool is supposed to be always inside the milling volume. But
sometimes we may want to perform cutting by the side of the tool only, that is, to make tool
plunge outside the material. The approach wall option allows to select side surfaces of a
mill volume that can be violated during tool approach and exit.
The topics covered in this exercise are as follows

❖ Declaring Approach Walls for a Mill Volume

❖ Offsetting the selected surface of a Mill Volume

Set the working directory to FRONTPANEL and open the model frontpanel.mfg

For better visualization it is good to display the workpiece in wireframe. So pick ^ icon
to launch the View Manager and double click the predefined style state Wireframe.

Close
Select to exit the dialog box.

First we will unblank the mill volume, MV_A, which will be referenced in the NC Sequence.

To unblank the mill volume, select Mfg Setup>Mfg Geometry>Mill Volume>Unblank.

Select the volume MV_A and pick

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Pick Done.

To define the new sequence select Machining>NC Sequence>Volume>Done.

From the SEQ SETUP menu, add Name and Appr Walls to the list of checked items, then
select Done.

Enter ROUGH as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select BULL32 and select [ 0K ~1.

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1000
STEP_DEPTH 8
STEP_OVER CUTTER_DIAM*.6
CORNER_ROUND_RADIUS 8
PROF_STOCK_ALLOW .2
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION ROUGH_ONLY
SPINDLE_SPEED 2500
CLEAR_DIST 1

Pick sJ3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Select Vol and select the pre-defined volume MV_A.

Now the SELECT SRFS menu will appear asking to select surfaces of the mill volume
MV_A as approach walls. So select the following surfaces.

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Select Done and play the tool path using PLAY PATH dialog box. It should look like this

Notice that tool enters the next slice by taking the plunge outside of the volume after
crossing over the approach wall. The distance tool travels after crossing the approach wall
can be controlled by the parameter APPR_EXIT_EXT

Now run the Vericut by selecting NC Check in PLAY PATH menu.

Click Play to End icon ± J in the Vericut window.

After the simulation of the toolpath, the cut model will appear as shown below.
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Notice that tool is leaving the material at the highlighted places. To make sure that tool
machines all the material left at these location we should make the volume somewhat
larger.

Select File>Exit to close the Vericut window.

Select Done Seq to exit the NC Sequence definition menu.

Select Mfg Setup>Mfg Geometry>Mill Volume>Modify Vol and pick the MV_A.

In the CREATE VOL menu select Offset.

In the OPTION menu, select Surfaces>Done

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Enter 25 as the offset value for the wall. This value should be larger than or equal to the
sum of CORNER_ROUND RADIUS and Half of Tool Diameter i.e.

OFFSET > CORNER_ROUND_RADIUS + (TOOL DIAMETER)/2

Select Done>Done>Done.

Select Machining>NC Sequence and pick the above defined ROUGH sequence.

Now we have to again declare the approach wall as the previous surface has been
consumed by offsetting.

Select Seq Setup and check the Appr Walls option then Done.

Select the following surface as the approach wall.

Run the Vericut by selecting NC Check in PLAY PATH menu.

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 Jj
Click Play to End ic o n __ I in the Vericut window.

After the simulation of the toolpath the cut model will appear as shown below.

Select File>Exit to close the Vericut window.

As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

STEP DEPTH 1

Select Done Seq to complete the definition of the NC Sequence.

To blank the volume MV_A select Mfg Setup>Mfg Geometry>Mill Volume>Blank and
select the MV_A and then pick OK>Done.

Select File>Save to save the manufacturing model.

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EXERCISE 15

In this exercise we will use Volume Milling NC Sequence to finish a cavity while minimizing
the time wasted in tool retracts.

The topics covered in this exercise are as follows

❖ Unblanking and Modifying a Mill Volume without exiting NC Sequence

❖ Introduction to Smart retract option
❖ Optimizing the tool entry/exit into cut
❖ Offsetting the selected surface of a Mill Volume

Set the working directory to FRONTPANEL and open the model frontpanel.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick icon
to launch the View Manager and double click the predefined style state Wireframe.

Select t Cl°se) to exit the dialog box.

To define the new sequence select Machining>NC Sequence>New

Sequence>Volume>Done.

From the SEQ SETUP menu, add Name, Tool and Excld Srfs to the list of checked items,
then select Done.

Enter FINISH as the name of the sequence and click the Accept value icon v

From the Tools Setup dialog box select BEM10 and select L 0K 1
In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1200
STEP_DEPTH 5
STEP_OVER CUTTER_DIAM*.6
CORNER_ROUND_RADIUS 3
SCAN_TYPE TYPE_SPIRAL
RETRACT_OPTION SMART
ROUGH_OPTION PROF_ONLY
SPINDLE_SPEED 3500
CLEAR_DIST 1

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When RETRACT_OPTION parameter is set to SMART, the system calculates a minimal
safe level for the tool to traverse to the new position for each intermediate retract within the
NC sequence. This safe level is determined as the level of the lowest slice with no
obstructions on the way of the tool, plus the PULLOUT_DIST value, if specified.

Pick tJ I to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Unblank.

Pick MV B and select

Now pick Select Vol and select the unblanked volume MV_B.

Now the SELECT SRFS menu will appear asking to select surfaces of the mill volume
MV_B to be excluded from profiling. So select the following surfaces.

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Select Done and play the tool path using Screen Play. It should look like this

Notice that after completing the profiling of a slice tool traverses to the start point of next
slice at a Z level which is approximately at the level of slice. This saves the non-cutting
time wasted during retract and plunge motions.

Now look the toolpath from top view. It will appear as shown below

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Notice that tool is not machining the side wall completely furthermore it is directly plunging
into material. If we specify the Lead in and Lead out condition for tool entry/exit then tool
will not make smart retract motions instead it will retract to the retract plane for traverse
motions. So we will modify the mill volume to modify the toolpath.

To redefine the mill volume, select Seq Setup and check the Volume option then pick
Done.

In the DEFINE VOL menu, select Modify Vol

In the CREATE VOL menu select Offset then Surfaces>Done.

Now pick the following surface to be offset then pick

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Enter 12 as the offset value for the wall. This value should be larger than the sum of
CORNER_ROUND RADIUS and Half of Tool Diameter to ensure smooth entry/exit

OFFSET > CORNER_ROUND_RADIUS + (TOOL DIAMETER)/2

Select Done>Done>Done.

Now we have to again declare the exclude surfaces as the previous surface has been
consumed by offsetting.

Select Seq Setup and check the Excld Srfs option then Done.

Select the following surface as the exclude surface.

Select Done

Play the tool path using PLAY PATH dialog box. It should look like this

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As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

STEP DEPTH 5

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 16

In this exercise we will use Volume Milling NC Sequence to machine a mill volume that
does not have a top surface that is parallel to the retract plane to define its top closure

The topics covered in this exercise are as follows

❖ Introduction to Top Surfaces functionality

Set the working directory to BOX_PUNCH and open the model box_punch.mfg.

To define a new Volume Milling NC Sequence select Machining>NC

Sequence>Volume>Done.

From the SEQ SETUP menu, add Name to the list of checked items, then select Done,

Enter ROUGH as the name of the sequence and pick 0 icon or middle-click.

From the Tools Setup dialog box select BULL20 and select [ 0K ~1.

In the MFG PARAMS menu, select Set and set the following parameters

CUT_FEED 1200
STEP_DEPTH 5
STEP_OVER CUTTER_DIAM*.6
PROF_STOCK_ALLOW .5
CORNER_ROUND_RADIUS 5
SCAN_TYPE TYPE_SPIRAL
ROUGH_OPTION ROUGH_ONLY
SPINDLE_SPEED 3500
CLEAR_DIST 1

Pick LJ3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE VOL menu select Unblank.

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Pick MV A

Now pick Select Vol and select the unblanked volume MV_A.

Now play the path on screen using PLAY PATH dialog box. Look at the message window
and read the following message.

It is so because the top surface of the mill volume is not parallel to the retract plane

By default tool penetrates only the top surfaces which are parallel to the retract plane. For
the surface which is not parallel to the retract plane Pro/NC provides the “Top Surface”
option. By declaring a surface to be “Top Surface” we explicitly tell the system to penetrate
the specified surface.

Select Seq Setup and check the Top Surfaces option then pick Done.

Select the following surface.

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Select Done and play the path on screen using PLAY PATH dialog box. The toolpath
should appear as shown below.

As the toolpath is satisfactory so change the following parameters

STEP_DEPTH 1
RAMP_FEED 500
RAMP_ANGLE 1

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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ROUGHING AND REROUGHING
These NC sequence types are used specifically for high-speed mold machining

ROUGHING SEQUENCE
The required geometric reference for roughing NC Sequence is a Mill Window. Tool
machines all the material within this window up to the depth of Mill Window. This
sequence has the added advantage of automatic degouging against all the surfaces of
the reference part. It allows selection of a different high-speed scan types for open and
closed areas. Furthermore it provides different entry methods for open and closed
areas. The tool enters open areas from the side. For closed areas, we can specify either
Tangent Helix or Ramp motion from top. The open and closed areas can be defined as

OPEN AREA
The region or slice that contains at least one open side.
CLOSED AREA
The region or slice that is completely surrounded by hard walls.

In volume milling we had the option to create toolpaths either by “region by region” or
“slice by slice” but roughing sequence only supports “region by region” machining i.e. in
case of multiple cavities the tool will completely machine one cavity before moving to
the next.

Like volume milling it also provides scallop height and minimum corner radius control.

REROUGHING SEQUENCE
Reroughing NC sequences create tool paths to machine only the areas where a
previous Roughing sequence could not reach. Typically they are performed with a
smaller tool and machine the areas that the larger roughing cutter could not enter due to
its size. They do not attempt to remove scallops left between the slices of the
referenced sequence.

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EXERCISE 1

In this exercise we will define a Roughing NC Sequence to machine a slot. We will learn
how to optimize the toolpath for HSM machining.

The topics covered in this exercise are as follows

❖ Defining a new Roughing NC Sequence

❖ Creating a Mill Window
❖ Choosing the most suitable toolpath scanning strategy
❖ Optimizing the toolpath for high speed machining
❖ Eliminating the sudden direction changes with the smooth transition moves

Set the working directory to SLOT and open the manufacturing model slot.mfg

To define a new roughing NC Sequence select Machining>NC

Sequence>Roughing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name SLOT and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool FEM10 and pick [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1000
MAX_STEP_DEPTH 5
STEP_OVER 4
ROUGH_STOCK_ALLOW .3
SPINDLE_SPEED 6500
CLEAR_DIST 1

MAX_STEP_DEPTH specifies the maximum allowed step depth

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick icon or middle-click.

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Now the MILL WIND menu will pop up and present us different options to define a mill
window.

Select Silhouette

Pick i 0K 1to complete the mill window definition.

The mill window will appear as shown below.

The Silhouette type of mill window is created by projecting the silhouette (or you can
say shadow outline) of the reference part on the Mill Window start plane, along the Z-
axis. When mill window is created within NC Sequence then Retract Plane is
considered automatically the Start Plane.

Play the toolpath using PLAY PATH dialog box.

Notice that system has recognized the slot as an Open Area and scanning it with
FOLLOW_CONTOUR (default) scan type.

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The toolpath generated is used in conventional milling of slots where small depths of cut
are employed with low feed rate. The tool’s engagement with the material is 100% when
the tool makes first cut at a slice and depends upon STEP_OVER for subsequent cuts.
This causes the tool to overload at first cut and under-performs during subsequent cuts.

Y_
To change the cutting strategy, pick ^ icon and change the following parameters in
the Parameter Tree dialog box.

CUT_FEED 4000
MAX_STEP_DEPTH 20
0 P EN_A R EA_S CAN CONSTANT_LOAD
SPINDLE_SPEED 6500
CORNER_ROUND_RADIUS 7

Pick L 3 to apply the changes and exit the Parameter Tree Dialog box.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that tool is machining the slot making full depth of cut with constant step over or
radial engagement of tool. This type of machining is called trochoidal milling. In this
special HSM strategy tool makes large axial cuts in combination with a small radial
depths of cut. The result is small and constant chip cross section produced, so the feed
and spindle speed have to be high in order to get a correct cutting action. If the feed and
speed is not high enough, the tool will generate heat by rubbing against the metal
instead of cutting it.

If you look at the toolpath from an isometric view you will notice that tool is entering and
exiting the cut making tangential movement as shown in the figure below.

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You will also notice that at the start and end of traverse motion tool transitions at 90°
and makes a corner which causes the machine tool to experience very high
acceleration/decelerations. To avoid these sudden direction changes we must change
the transition strategy.

So pick icon and set the following parameters.

RETRACTTRANSITIO N ARC_TRANSITION
RETRACT_RADIUS 4

RETRACT_TRANSITION parameter specifies how the tool transitions between a

vertical retract move and a traverse move (a horizontal move), and then between the
traverse move and a vertical plunge move.
ARC_TRANSITION option forces the vertical and horizontal moves to be connected by
a tangent arc.
RETRACT_RADIUS parameter specifies the radius of the transition arc.

Pick L 3 to apply the changes and exit the Parameter Tree Dialog box.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below

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Now the toolpath is highly suitable for high speed machining applications. Now there are
no abrupt changes in direction or sharp corners. By minimizing the changes in the
direction the cycle achieves high and constant feed rates, leading to faster material
removal.

Set the following parameters for final toolpath computation.

STEP OVER 5

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 2

In this exercise we will define a Roughing NC Sequence to machine a cavity. We will

learn how to optimize the toolpath for HSM machining.

The topics covered in this exercise are as follows

❖ Creating a Mill Window

❖ Defining a new Roughing NC Sequence
❖ Optimizing the toolpath for high speed machining

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg

To create a new Mill Window select Mfg Setup>Mfg Geometry>Mill Window>Create

Wind.

0
Enter MW_A as the name of mill window and pick ££J icon or middle-click.

The WIND CSYS menu will appear asking to select the coordinate system for I
Window.

Select NC_ASM_DEF_CSYS with left mouse click.

Select the following surface as the start plane of the window.

In the MILL WIND menu select Silhouette.

Pick t 0K ) to complete the feature.

The mill window will appear as shown below.

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To define a new roughing NC Sequence select Machining>NC
Sequence>Roughing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done,

Enter the sequence name ROUGH and pick CZJ icon or middle-click..

In the Tools Setup dialog box select the predefined tool BULL32 and pick L 0K 1
In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
MAX_STEP_DEPTH 5
STEP_OVER 15
ROUGH_STOCK_ALLOW .3
SPINDLE_SPEED 2200
CLEAR_DIST 1
RETRACTTRANSITIO N ARC_TRANSITION
RETRACT_RADIUS 4
CORNER_ROUND_RADIUS 10
RAMP_ANGLE 10
HELICAL_DIAMETER 80

Remember that tool will not make helix to enter the closed area if the
CORNER ROUND RADIUS is not set to some value other than default

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Select Wind

Select the MW A mill window with left mouse click.

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Select Done>Done and play the toolpath using PLAY PATH dialog box

System has recognized the cavity as Closed Area and scanning it with
CONSTANT_LOAD (default) scan type. Notice that there is no sudden direction change
and tool engagement is constant as specified by the STEP_OVER value. When the tool
enters the next slice it makes helical spline move and for subsequent (within a slice)
entry/exit into material it makes tangential movements. So constant chip thickness and
hence constant material removal rate can be maintained. Furthermore the consistent
feed rate is achieved throughout machining of cavity without any abrupt
acceleration/deceleration.

As the toolpath looks satisfactory so set the following parameters.

MAX STEP DEPTH 1

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 3

In this exercise we will define a Roughing NC Sequence to machine a part which has
both the Open and Closed areas. First we will define a mill window to machine only the
Open area and decide the proper toolpath strategy. Later we will redefine the mill
window to machine both the areas within single NC Sequence.

The topics covered in this exercise are as follows

❖ Creating a Mill Window and specifying its Depth

❖ Defining a new Roughing NC Sequence
❖ Scallop Height control
❖ Implementing different scanning strategies within single sequence

Set the working directory to COVER_PUNCH and open the manufacturing model
cover_punch.mfg.

Open the cover_punch.prt in a separate window and carefully look at the part.

Select Window>Close to close this window.

For better visualization it is good to display the workpiece in wireframe. So pick

icon to launch the View Manager and double click the predefined style state Wireframe

Select I D°se) to exit the dialog box.

To create a new Mill Window select Mfg Setup>Mfg Geometry>Mill Window>Create

Wind.

Enter MW_A as the name of mill window and pick icon or middle-click.

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The WIND CSYS menu will appear asking to select the coordinate system for Mill
Window.

Select NC_ASM_DEF_CSYS with left mouse click.

Select the top surface of the workpiece as the start plane of the window.

In the MILL WIND menu select Silhouette.

Double click the Depth option.

Select the following surface as depth reference

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Then select Done in the WND DEPTH menu.

Pick i 0K 1to complete the mill window definition

The mill window will appear as shown below.

To define a new roughing NC Sequence select Machining>NC

Sequence>Roughing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name ROUGH and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool BULL25 and pick [ 0K

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In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1200
MAX_STEP_DEPTH 5
STEP_OVER 12
ROUGH_STOCK_ALLOW .3
OPEN_AREA_SCAN FOLLOW_CONTOUR
SPINDLE_SPEED 2500
CLEAR_DIST 1
RETRACT_TRANSITION ARC_TRANSITION
RETRACT_RADIUS 4
CORNER_ROUND_RADIUS 5

In FOLLOW_CONTOUR scan type, the shape of each cut follows the shape of the hard
walls, maintaining a fixed offset between the respective points of two successive cuts.

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Select Wind

Select the MW_A mill window with left mouse click.

Select Done>Done and play the toolpath using PLAY PATH dialog box.

You will notice that tool engagement never exceeds the specified STEP_OVER value

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Also notice that toolpath is confined to the workpiece. This is controlled with parameter
TRIM_TO_WORKPIECE. If set to “YES” the system automatically confines the toolpath
according to the size and shape of workpiece. This can be elaborated by the following
figure.

Now will see how to control the scallop. So first set the following parameter.

MAX STEP DEPTH

Now run the Vericut by selecting NC Check in PLAY PATH menu.

Jj
Click Play to End ic o n __ I in the Vericut window.

After the simulation of the toolpath the cut model will appear as shown below.

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Notice that there are very high scallops on the cut model.

Select File>Exit to close the Vericut window.

Set the following parameters in the Parameter Tree dialog box

ROUGH_SCALLOP_CONTROL AFTER
ROUGH_SCALLOP .5

These parameters are located in Advanced page as shown below.

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By setting the ROUGH_SCALLOP_CONTROL to AFTER we are specifying to generate
the extra slices to reduce the scallop height, at the end of regular slices.

ROUGH_SCALLOP is the maximum scallop height for the steps left between the
machining slices. Where the scallops are greater than this value, the system generates
the extra slices that just machine the area required to remove the scallop.
Again run the Vericut and simulate the cutting process. This time cut model will appear
smoother as shown below.

Select File>Exit to close the Vericut window.

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As the toolpath looks satisfactory, so now will redefine the window to change the depth
to machine the part completely.

To redefine the mill window, select Seq Setup and check the Window option then pick
Done.

In the DEFINE WIND menu select Redef Wind.

In the Machine Window dialog box double-click the Depth option and select the
following surface as Depth Reference.

Select Done

Pick i 0K 1to complete the mill window definition.

Set the following parameters to control the entry of tool into closed area

RAMP_ANGLE 1
HELICAL_DIAMETER 35

Remember that tool will not make helix to enter the closed area if the
CORNER ROUND RADIUS is not set to some value other than default

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Play the toolpath using PLAY PATH dialog box and notice that system has recognized
the bottom pocket of reference part as Closed Area and scanning it with
CONSTANT LOAD scan.

Now run the Vericut by selecting NC Check in PLAY PATH menu

Click Play to End icon Jj in the Vericut window,

After the simulation of the toolpath the cut model will appear as shown below.

Select File>Exit to close the Vericut window.

As the toolpath looks satisfactory so set the following parameters for final toolpath
computation.

MAX STEP DEPTH 1

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 4

In this exercise we will define a Reroughing NC Sequence to machine the material left
by the tool in the previous exercise.

The topics covered in this exercise are as follows

❖ Defining a new Reroughing NC Sequence

❖ Simulation of two sequences in the Vericut simultaneously

Set the working directory to COVER_PUNCH and open the manufacturing model
cover_punch.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick

icon to launch the View Manager and double click the predefined style state Wireframe

Close
Select to exit the dialog box.

To define a new reroughing NC Sequence select Machining>NC Sequence>New

Sequence>Re-Roughing>Done.

The system will ask to select the reference roughing NC Sequence. So select ROUGH
in the NC SEQ LIST menu.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name REROUGH and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool FEM10 and pick [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 2000
MAX_STEP_DEPTH 2
STEP_OVER 4
ROUGH_STOCK_ALLOW .3
SPINDLE_SPEED 4000
CLEAR_DIST 1
RETRACTTRANSITIO N ARC_TRANSITION
RETRACT_RADIUS 4
CORNER_ROUND_RADIUS 4

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Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Play the toolpath using PLAY PATH dialog box, it should appear as shown below.

You will notice that tool is not entering slices making a cutter friendly move. To
introduce tangent entry and exit set the following parameters.

OPEN AREA SCAN MAINTAIN CUT TYPE

Now play the toolpath it will appear as shown below.

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As the toolpath looks satisfactory so set the following parameters for final toolpath
computation.

MAX STEP DEPTH 1

Select Done Seq to complete the definition of the NC Sequence

To simulate the toolpaths of the two sequences i.e. ROUGH and REROUGH in Vericut,
first generate CL Data files of both.

To create the CL data file for ROUGH NC Sequence, select CL Data>NC Sequence

Mfg Model
Mfg Setup
Process Mgr
Machining
CL Data [
Modify
Regenerate
Component
Set Up
Relations
Program
Integrate

Now select the ROUGH sequence in the NC Sequence SEQ LIST menu

In the PATH menu pick File and then Done

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 OK
Pick in the Save a Copy dialog box. The file rough.ncl will be created. You
should take notice that in which directory this file is being saved.

In the same way create the CL Data file for REROUGH sequence. So you will get the
rerough.ncl at the end.

To start the Vericut select CL Data>NC Check>CL File,

Select the rough.ncl then pick Done.

In the Vericut window select Setup>Toolpath

Toolpath dialog box will appear as shown below,

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Select __ __I and browse to the file rerough.ncl in the folder to which configuration
file option pro_mf_cl_dir refers or any other folder where this file was saved. Make sure
that Filter is set to “ncl” file.

After selecting the rerough.ncl.1 p ic k ----------- = ------------- 1

The NCL file rerough.ncl will appear in the Toolpath dialog box as shown below.

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Select Jj
and Click Play to End ic o n ___I in the Vericut window.

After the simulation of the toolpath the cut model will appear as shown below.

Select File>Exit to close the Vericut window.

Select File>Save to save the manufacturing model.

In W.F 2 and later releases you can perform a Reroughing of previous Reroughing
sequence without setting any Configuration file option.

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EXERCISE 5

In this exercise we will define a Roughing NC Sequence and look at the different
scanning options available for Open Area.

Set the working directory to PHONE_PUNCH and open the manufacturing model
phone_punch.mfg.

For better visualization it is good to display the workpiece in wireframe. So pick

icon to launch the View Manager and double click the predefined style state Wireframe.

Close
Select to exit the dialog box.

To define a new roughing NC Sequence select Machining>NC

Sequence>Roughing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name ROUGH and pick c£J icon or middle-click.

In the Tools Setup dialog box select the predefined tool BULL20 and pick [ 0K ~).

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
MAX_STEP_DEPTH 5
STEP_OVER 9.5
ROUGH_STOCK_ALLOW 0.2
OPEN_AREA_SCAN FOLLOW_CONTOUR
SPINDLE_SPEED 2500
CLEAR_DIST 1
RETRACT_TRANSITION ARC_TRANSITION
RETRACT_RADIUS 4
CORNER_ROUND_RADIUS 5

In FOLLOW_CONTOUR scan type, the shape of each cut follows the shape of the hard
walls, maintaining a fixed offset between the respective points of two successive cuts.

In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick b iJ icon or middle-click.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

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Select Silhouette

Pick i 0K 1to complete the mill window definition.

Play the toolpath using PLAY PATH dialog box. During simulation toolpath will appear
as shown below.

You should notice that cutter engagement never exceeds the STEP_OVER value
except at the highlighted location. There material is being machined by using the full
width of cutter. It causes the sudden increase in load. So we can’t say that load on the
tool is constant.

To change the cutting strategy, change the following parameter.

OPEN AREA SCAN MAINTAIN CUT TYPE

SPIRAL_MAINTAIN_CUT_TYPE scan type generates a spiral cutter path. When a cut

is finished, the tool arcs into the next cut. This option minimizes retracts.

Play the toolpath using PLAY PATH dialog box. During simulation toolpath will appear
as shown below.

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Although tool makes smooth movement to enter and exit a cut and there are just few
retracts but the problem of full tool engagement is still there.

So to change the cutting strategy, change the following parameter.

OPEN AREA SCAN CONSTANT LOAD

Play the toolpath using PLAY PATH dialog box. During simulation toolpath will appear
as shown below.

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You will notice that tool engagement never exceeds the specified STEP_OVER value

As the toolpath looks satisfactory, so set the following parameters for final toolpath
computation.

MAX STEP DEPTH 2

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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FINISHING

Finishing sequence first analyses and then applies suitable machining strategy
according to the geometry of reference model.

While machining a part it is always preferable to

1. Machine the steep surfaces (near vertical) with a constant Z type toolpath like
volume milling or profile milling offers,

2. Machine shallow areas (near horizontal)toolpath with a little step over

3. Machine Flat surfaces with large face milling cutters

To accomplish all these requirements finishing NC Sequence gives the option to apply
different machining strategies for steep, shallow and horizontal faces of the reference
model.

In the Finishing NC Sequence surface slope rather than boundaries determine the
machining strategies. Steep surfaces (near vertical) are machined using high-speed
machining, Z-profile cuts using an “S connection”. Shallow (near horizontal) and flat
surfaces are machined either with straight (conventional) cuts or high-speed spiral cuts.
User has the complete control on which area needs to be machined and in which order.

Use Finishing NC sequences to machine the detail of the reference part after Roughing
and Reroughing. Finishing NC sequences can also directly machine models containing
facet data in STL format.

An important parameter that controls the tool path for a Finishing NC sequence is
SLOPE_ANGLE, which is a threshold angle value dividing all the surfaces being
machined into two areas, steep (near vertical) and shallow (near horizontal). You can
then use other manufacturing parameters, specific to Finishing NC sequences, to select
whether you want to machine just the steep or the shallow area or both, whether to
include the flat (horizontal) surfaces into the shallow area, which slicing algorithm to use
on either area, and how to perform the connections and entry moves.

At any given point, slope angle is defined as the angle between Surface Normal and the
Direction Vector as elaborated in the following figure.

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Direction vector is always parallel to the Z-axis and Surface Normal depends upon the
topology of the surface.

So a Flat surface has Slope angle of 0° and a Vertical surface has Slope Angle of 90°.

System calculates the slope angle along complete surface. If a surface patch has slope
angle greater than the SLOPE_ANGLE parameter, it is considered a Steep area and if
its value is lesser then it is considered as Shallow area.

This new tool path requires minimum input to cut cost by reducing manufacturing lead­
time. The optimized tool path produces a quality surface finish.

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EXERCISE 1

In this exercise we will define a Finishing NC Sequence to machine the steep areas of a
cavity.

The topics covered in this exercise are as follows

❖ Defining a new Finishing NC Sequence

❖ Creating a Mill Window
❖ Profiling of steep surfaces
❖ Optimizing the entry/exit into slice

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg

To define a new Finishing NC Sequence select Machining>NC

Sequence>Finishing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name PROFILE and pick UU icon or middle-click.

In the Tools Setup dialog box select the predefined tool BEM10 and pick [ 0K ~).

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1500
STEP_OVER 2
SLOPE_ANGLE 60
FINISH_OPTION PROFILE_CUTS
SPINDLE_SPEED 3500
CLEAR_DIST 1

FINISH_OPTION is used to specify what area of the part we want to machine. By

setting it to PROFILE_CUTS we are telling the system to machine only the steep area
(surfaces) of the reference part.
The depth of cut is equal to the STEP_OVER value for steep area machining.

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Create Wind

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Enter MW_A as the name of mill window and pick 0 icon or middle-click.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

In the MILL WIND menu select S ilhouette.

Pick i 0K 1to complete the feature.

Play the toolpath using PLAY PATH dialog box. Zoom to the toolpath and look at it
carefully.

You will notice that toolpath is connected with “S” connection between slices. This is
controlled with STEEP_CONNECT_OPTION parameter and by default it is set to
“S_CONNECT”. You will also notice that for entry/exit into slices tool is directly plunging
into the material. To add lead in and lead out motions set the following parameter.

LEAD RADIUS 5

Now play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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 Y_
Now the toolpath looks satisfactory so pick ^ icon and set the following parameters,
according to the finish required, for final toolpath computation.

STEP_OVER .4
SCALLOPJHGT .05

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 2

In this exercise we will define a Finishing NC Sequence to machine the shallow areas of
a cavity.

The topics covered in this exercise are as follows

❖ Machining the shallow surfaces of reference model

❖ Specifying smooth entry/exit into the cut.

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg

To define a new Finishing NC Sequence select Machining>NC Sequence>New

Sequence>Finishing>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name SHALLOW and pick icon or middle-click.

In the Tools Setup dialog box select the predefined tool BEM10 and pick L_
In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1500
STEP_OVER 2
SLOPE_ANGLE 60
FINISH_OPTION SHALLOW_CUTS
FLAT_AREA FLAT_EXCLUDED
SHALLOW_AREA_SCAN SPIRAL_SCAN
SPINDLE_SPEED 4500
CLEAR_DIST 1

By setting the FINISH_OPTION to SHALLOW_CUTS we are telling the system to

machine only the shallow areas of the cavity.
FLAT _EXCLUDED option is used to exclude the flat area (parallel to the XY plane of
the NC Sequence coordinate system) from toolpath computation.
SPIRAL_SCAN option uses connected concentric loops.

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

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In the DEFINE WIND menu pick Select Wind

Select the MW_A mill window with left mouse click.

Play the toolpath using PLAY PATH dialog box. Zoom to the toolpath and look at it
carefully.

You will notice that toolpath is connected with “S” connection between slices. This is so
because the SHALLOW_AREA_SCAN parameter is set to SPIRAL_SCAN by default.
SPIRAL_SCAN uses connected concentric loops that start along the perimeter of the
area and move towards the center, with S-shaped connections between the loops.
You will also notice that for entry/exit into cut tool is directly plunging into the material.
To add lead in for the tool to enter into cut, set the following parameter.

ENTRY_TO_SHALLOW_AREA LEAD
LEAD_RADIUS 20
ENTRY_ANGLE 15

Now play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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Now the toolpath looks satisfactory so set the following parameter for final toolpath
computation.

STEP_OVER .4
SCALLOPJHGT .001
INSIDE_TOLERANCE .0009
OUTSIDE_TOLERANCE .0009

We have set the tolerances lower than the SCALLOP_HGT because this is the
requirement of system.

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 3

In this exercise we will define a Finishing NC Sequence to machine the bottom

horizontal faces of a cavity.

The topics covered in this exercise are as follows

❖ Machining only the flat surfaces of reference model

❖ Excluding surfaces from toolpath computation
❖ Specifying smooth entry/exit into the cut.

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg

We will use the Finishing NC Sequence to face the highlighted surface shown in the
following figure.

To define a new Finishing NC Sequence select Machining>NC Sequence> New

Sequence>Finishing>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name FACE and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool FEM20 and pick [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1000
STEP_OVER 15

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 FLAT_AREA FLATO N LY
SPINDLE_SPEED 2500
CLEAR_DIST 1

FLAT_ONLY option is used to machine only the flat area of the part and same toolpath
scanning is used as for shallow area.

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Select Wind

Select the MW_A mill window with left mouse click.

Play the toolpath using PLAY PATH dialog box

Notice that tool is machining all the horizontal surfaces of the reference model but our
desired surface is only the bottom surface of the part. To exclude the unwanted
surfaces from toolpath computation set the configuration file option excl_surfs_visible
to YES and a new option Excld Surfs will appear in SEQ SETUP menu.

Select Seq Setup and check the Excld Surfs option then pick Done.

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Now select the following two surfaces with left mouse pick

The selected surfaces will be excluded from being considered for machining

Select Done and play the toolpath using PLAY PATH dialog box.

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You will notice that toolpath is connected with “S” connection between slices. This is so
because the SHALLOW_AREA_SCAN parameter is set to SPIRAL_SCAN by default.
SPIRAL_SCAN option uses connected concentric loops that start along the perimeter of
the area and move towards the center, with S-shaped connections between the loops
To add lead in for tool entry into the cut, set the following parameter.

ENTRY_TO_SHALLOW_AREA LEAD
LEAD_RADIUS 20
ENTRY_ANGLE 15

Now play the toolpath using Screen Play it should appear as shown below.

Now the toolpath looks satisfactory so select Done Seq to complete the definition of the
NC Sequence

Select File>Save to save the manufacturing model

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EXERCISE 4

In this exercise we will define a Finishing NC Sequence to face a part

The topics covered in this exercise are as follows

❖ Defining Close Loops for the part

❖ Specifying Tool Side for Mill Window
❖ Specifying Offset for Mill Window

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg

To define a new Finishing NC Sequence select Machining>NC Sequence> New

Sequence >Finishing>Done.

In the SEQ SETUP menu add Name, Tool and Closed Loop to the list of checked
items and select Done.

Enter the sequence name FACE_TOP and pick icon or middle-click.

In the Tools Setup dialog box select the predefined tool FEM40 and pick

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1000
STEP_OVER 30
SPINDLE_SPEED 2000
CLEAR_DIST 1

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Select Wind

Select the MW A mill window with left mouse click.

In the CLOSE LOOPS menu pick Define Loops and make sure Surf Loops is
highlighted in the CHAIN menu.

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Select the top surface of the reference part as shown below.

System will highlight the following loop of surface

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 Desired Loop

As it is the desired loop so select Done>Done.

Now the system will not consider any surface within cavity and will machine only the top
surface with the loop closed. You may consider it equivalent to copying the top surface
and filling the hole with Fill Hole option then facing this surface.

Play the toolpath using PLAY PATH dialog box

Notice that system is only machining the top surface due to loop closure.

Also notice that tool is machining from outside to inward and its first pass is offset
inward from the outer loop of top surface by tool’s radius value. So the full diameter is
performing the cutting operation. To change this behavior we will redefine the Mill
Window.
To redefine the mill window, select Seq Setup and check the Window option then pick
Done.

In the DEFINE WIND menu select Redef Wind.

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Select Suspend All to suspend the children.

In the Machine Window dialog box double-click the Tool Side option

Select On in the TOOL SIDE menu

The Tool Side option controls the limit of the tool travel with respect to mill window. If it
is set to “To” (default) the tool will stay within boundaries of window. If set to “On” the
tool can go outside the window by the half of its diameter value or you can say the tool
center will coincide with the window boundary.

Select Done.

Pick t 0K ) to exit the dialog box.

Play the toolpath using PLAY PATH dialog box. It will appear as shown below.

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Notice that the center of the tool overlaps with the edge of the part and only half of tool
diameter is engaged in cutting. It creates a very unfavorable cutting condition.
Whenever the center of the cutter overlaps with the edge of the part or positioned
outside of the part to be machined, an unfavorable contact between the cutting edge
and material results. When the center of the cutter is positioned inside the part to be
machined the most favorable cutting action takes place. It is good practice to engage
the minimum of 60% of the tool diameter to avoid the unfavorable cutting condition. On
the upper side it is a good practice to engage maximum of 75% of the tool diameter.

Now we will modify the Mill Window so that only75% of tool is engaged.

To redefine the mill window, select Seq Setup and check the Window option then pick
Done.

In the DEFINE WIND menu select Redef Wind.

Select Suspend All to suspend the children.

In the Machine Window dialog box double-click the Offset option

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Enter 10 in the message area then press Enter key on the keyboard.

Make sure that arrow points inward and select Okay in the DIRECTION menu

Pick i 0K l to exit the dialog box.

Play the toolpath using PLAY PATH dialog box. It will appear as shown below.

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Notice that tool has been pulled inward by 10mm. So the cutter engagement is 30mm
equal to the STEP_OVER now. We can say that tool engagement is constant over the
complete facing of the part.

To add lead in motion set the following parameter.

ENTRY_TO_SHALLOW_AREA LEAD
LEAD_RADIUS 20
ENTRY_ANGLE 15

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 5

In this exercise we will define a Finishing NC Sequence to machine all the areas of a
cavity except the flat surfaces.

Set the working directory to PULSATOR_CAVITY and open the manufacturing model
pulsator_cavity.mfg

To define a new Finishing NC Sequence select Machining>NC

Sequence>Finishing>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FINISH and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool BEM10 and pick [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1500
STEP_OVER 5
SLOPE_ANGLE 60
FINISH_OPTION COMBINED_CUTS
FLAT_AREA FLAT_EXCLUDED
OVERLAP_ANGLE 3
SPINDLE_SPEED 4000
CLEAR_DIST 1

By setting the FINISH_OPTION to COMBINED_CUTS we are telling the system to

machine both the shallow and steep areas of the cavity in a single sequence.
OVERLAP_ANGLE defines the extent of the overlap between the steep and shallow
areas. By overlapping machining of two areas we assure that continuous surface finish
is obtained.

Pick L-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick 0 icon or middle-click.

Now the MILL WIND menu will pop up and present us different options to define a mill
window.

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In the MILL WIND menu select Silhouette.

Pick i 0K 1to complete the feature.

Play the toolpath using PLAY PATH dialog box. The toolpath will appear as shown
below.

To add lead in for the tool to enter into cut, set the following parameter.

ENTRY_TO_SHALLOW_AREA LEAD
LEAD_RADIUS 5
ENTRY_ANGLE 45

After playing the toolpath you will notice that it is satisfactory so set the following
parameter for final toolpath computation.

STEP_OVER .4
SCALLOPJHGT .001
INSIDE_TOLERANCE .0009
OUTSIDE_TOLERANCE .0009

We have set the tolerances lower than the SCALLOP_HGT because this is the
requirement of system.

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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EXERCISE 6

In this exercise we will learn to machine the complete part using the Spiral scan.

Set the working directory to BELL_PUNCH and open the manufacturing model
bell_punch.mfg

To define a new Finishing NC Sequence select Machining>NC

Sequence>Finishing>Done.

In the SEQ SETUP menu add Name and Excld Surfs to the list of checked items and
select Done.

Excld Surfs option will be visible only if excl_surfs_visible option in the Configuration file
is set to YES.

Enter the sequence name FINISH and pick 0 icon or middle-click.

In the Tools Setup dialog box select the predefined tool BEM8 and pick [ 0K ~1.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 2
SCALLOPJHGT 0.3
SLOPE_ANGLE 60
FINISH_OPTION COMBINED_CUTS
SPINDLE_SPEED 4000
CLEAR_DIST 1
ENTRY_TO_SHALLOW_AREA LEAD
LEAD_RADIUS 10
ENTRY_ANGLE 30

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

In the DEFINE WIND menu pick Create Wind

Enter MW_A as the name of mill window and pick 0 icon or middle-click.

In the MILL WIND menu select Silhouette.

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Pick t 0K ) to complete the feature.

Now system will ask you to select the surfaces that you want to exclude from
machining. So select the following surface.

Select Done or middle-click twice to complete the selection of surfaces.

Play the toolpath using PLAY PATH dialog box. The toolpath will appear as shown
below.

Notice that tools enters and exits the cut several times. It causes accelerated wear of
tool.

Now we will set the parameters so that tool machines the complete part with Spiral
Scan.

SLOPE ANGLE 90

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When SLOPE_ANGLE parameter is set to 90, all the surfaces within the mill window
are considered shallow areas.

Play the toolpath using PLAY PATH dialog box. The toolpath will appear as shown
below.

Notice that tool enters and leaves the machining just once

Set the following parameter for final toolpath computation.

STEP_OVER .4
SCALLOPJHGT .01
INSIDE_TOLERANCE .009
OUTSIDE_TOLERANCE .009

We have set the tolerances lower than the SCALLOP_HGT because this is the
requirement of system.

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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PROFILE MILLING
Profile milling NC Sequence is a 2.5 axis sequence. It is usually used to semi-finish or finish the
vertical or slanted surfaces. The surface finish can be controlled with Step Depth adjustment or
Scallop Height parameter.

The required references are surfaces which may be the selected surfaces of either of the
Reference model, Mill Surface or Mill Volume. It automatically degouges the tool path against the
references selected for the cut geometry.

Locating Cutting Parameters

There are a lot of cutting parameters associated with the sequence. You can see all the
parameters by picking tab on the Edit Parameters dialog box.

If you don’t know the exact location of a parameter then it is better to arrange the parameters
alphabetically by picking Tools > Sort Parameters > By Parameter Name and then you can
easily locate the desired parameters.

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EXERCISE 1

In this exercise we will define a profile milling NC Sequence to machine the vertical walls of a
block.

The topics covered in this exercise are as follows

� Defining a new Profile Milling NC Sequence

� Selecting the surfaces using Loop option
� Creating smooth entry/exit motions
� Optimizing the entry/exit conditions

Set the working directory to INSERT and open the model insert.asm.

For better visualization it is good to display the workpiece in wireframe. So select View

Manager icon to launch the View Manager Dialog box and double click the predefined style
state Wireframe
Wireframe.

Select to exit the dialog box.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

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Pick the icon and Tools Setup dialog box will pop up.

In the Tools Setup dialog box pick FEM20 from the list and select .

Pick tab and click inside the Machining References collector to activate it.

Here we will use the Loop selection technique to select the desired surface quickly.

Now select the top face of the reference model as shown below.

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Now hold down Shift key and place mouse pointer over any edge forming the boundary of the
selected surface.

Pick on the edge with left mouse to select the Loop Surfaces while Shift key is held down. The
selected surfaces will appear as shown below.

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Loop option is used to select a closed loop of surfaces by choosing a face they surround.

Now pick tab and enter the following values/relations and parameters.

CUT_FEED 1200
STEP_DEPTH 5
CLEAR_DIST 1
SPINDLE_SPEED 3000

Now pick tab and enter PROFILE as the name of the sequence.

To display the toolpath on screen pick icon. . Play Path Dialog box will appear.

Click the Play Forward button and toolpath will appear as shown below.

Zoom to the toolpath and look at it carefully, you will notice that the tool plunges directly to the
next slice.

Direct plunge is not a good practice. To introduce smooth entry/exit into the cut, parameters
need to be changed.
So pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

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 Chapter 6 PROFILE MILLING

CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 30

You can see all these parameters by picking tab and changing to “Entry/Exit Motions”
category as shown below.

Pick to apply the changes and exit the Edit Parameters Dialog box.

Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as shown
below.

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Although now tool enters and exits into the cut very smoothly but it is wasting a lot of time in non-

cutting motion. To reduce this non-cutting time, again pick in Parameters panel and set the
following parameters. You will find these by picking tab and changing to “Entry/Exit
Motions” category.

ENTRY_ANGLE 50
EXIT_ANGLE 50

Pick to apply the changes and exit the Edit Parameters Dialog box.

Now play the tool path using PLAY PATH dialog box. From TOP view it will appear as shown
below.

Notice that the non-cutting motion has been reduced significantly. The Entry and Exit angles
must be sufficient large so that tool makes the plunge motion when it is out of the workpiece.

The entry/exit parameters can be readily understood from the figure below.

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It is always advantageous to use a large LEAD_RADIUS because the larger the radius,
smoother the entry/exit into cut. But it also increases the idle time while the tool completes its
non-cutting movement. To reduce this non-cutting time we have set the ENTRY_ANGLE and
EXIT_ANGLE to a smaller value than default. By doing this we have achieved both i.e. smoother
motion by setting a large LEAD_RADIUS value and reduction in non-cutting time by smaller
entry/exit angles.

As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

STEP_DEPTH 2

To complete the NC Sequence select .

Select File > Save to save the manufacturing model.

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EXERCISE 2

In this exercise first we will define a Mill Surface to find the area which previous Ball End Mill
cutter could not machine. Then we will machine this surface with a Profile Milling NC Sequence.
The topics covered in this exercise are as follows

� Defining a Mill Surface as “Machinable Area”

� Creating smooth entry/exit motions

The Machinable Area Mill Surface is an advanced technique that calculates whether the
selected surfaces can be entirely machined with the selected cutting tool, and creates explicit
surface representations of the millable area (the portion of the selected surfaces that can be
milled), as well as of the remainder area (the portion that can not be milled with the selected tool).

This technique allows to automate surface selection for subsequent machining with a smaller
tool or with a different machining strategy.

You have to specify surfaces to be milled, additional surfaces for gouge checking (if any), the
cutting radius of a ball end mill tool and the tool axis orientation. The system then calculates the
machinable area based on tool contact and gouge avoidance.

The manufacturing model, referred in this exercise, has been finish machined in the previous
chapter “Volume and Local Milling” with a ball end mill of diameter 10mm. So for this exercise we
assume that the reference model was previously finished with the ball end mill.

Set the working directory to TOP_COVER and open the manufacturing model top_cover.asm

For better visualization it is good to display the workpiece in wireframe. So pick icon to
launch the View Manager Dialog box and double click the predefined style state Wireframe
Wireframe.

First of all we will define a Mill Surface to be later referenced in the Profile sequence.

So pick on the Mill tab to invoke the Mill Surface Tool.

Pick icon to give a name to this volume.

Enter MS_A as the name of the mill surface and pick .

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Pick icon to define a "Machinable Area Reference" surface.

System will ask to select the surfaces for finding the machinable area. So pick the highlighted
surface of reference model shown in the figure below.

Select or middle-click to proceed.

In the SRF PRT SEL menu, check the Add Ref Prts option then select Done/Return
Done/Return.

When Add Ref Prts (Add Reference Parts) option is checked, system uses all the surfaces of the
reference model to check gouging against.

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Now the system will ask to enter radius of ball end mill for calculating Machinable Area.
So enter 5.2 and pick icon or middle-click.

Although we should enter 5 as we used Ball end mill of diameter 10 to machine the cavity in a
previous NC Sequence but we have entered a larger value just to make sure that we get smooth
surface quality.

Now select the top surface of the reference model as the direction reference.

You may also pick the retract plane or any other surface or plane that is parallel to the retract
plane.

Make sure that arrow points upward then select Okay.

This direction of the arrow specifies the tool axis orientation.

Double-click the Srf Option in the dialog box.

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In the MILLABLE OR REMAINING menu select Find Remaining Area > Done.

Find Remaining Area option finds the portion of the surface that can not be milled with the
specified tool.

Select to exit the dialog box. The surface will appear as shown below.

Now we will trim the unwanted part of the surface. We will use the extrude tool to trim the
unwanted part of the surface.

So pick icon to invoke the Extrude Tool.

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Pick tab in the Placement panel.

Pick ASM_RIGHT as the Sketch Plane ASM_TOP datum as Right Orientation Reference.

Now sketch a rectangle after choosing the suitable reference as shown below.

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Exact dimensioning is not important; purpose is to cover the surface.

Pick to complete the section

Pick so that the extruded surface trims the existing quilt.

Select Through All for both the Side1 and Side 2 in the Options slide-up panel as shown below.

Pick on the Material Side arrow to flip the direction as shown below.

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Now the system will keep the inner side of the sketch.

Pick the icon to exit the Extrude tool.

The mill surface will appear as shown below.

Pick and it completes the definition of the mill surface. if you don’t get the shown result then
you need to redefine the features and fix the problem otherwise you will not be able to do the
remaining exercise.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

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Pick the icon and Tools Setup dialog box will pop up.

In the Tools Setup dialog box pick FEM10 from the list, then select .

Pick tab and click inside the Machining References collector to activate it then select
the above defined mill surface MS_A.

The arrow in the above figure should point away from the surface. This direction indicates side of
surface to be machined.

Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

CUT_FEED 1200
STEP_DEPTH 0.5
CLEAR_DIST 1
SPINDLE_SPEED 4000
COOLANT_OPTION ON
CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 20
ENTRY_ANGLE 15
EXIT_ANGLE 15

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter CORNER as the name of the sequence.

Play the toolpath using PLAY PATH dialog box.. It should appear as shown below.

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As the toolpath looks satisfactory so change the following parameters for good surface finish.

STEP_DEPTH 0.2

Remember never to use WALL_SCALLOP_HGT parameter for controlling the surface finish,
while machining with a flat end mill.

To complete the NC Sequence select .

Select File > Save to save the manufacturing model.

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EXERCISE 3
In this exercise we will define a profile milling NC Sequence to machine a sharp corner with a
single pass of cutter.

Set the working directory to COVER_INSERT and open the manufacturing model
cover_insert.asm

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

From the drop-down list in front of icon, pick FEM25

Alternatively you can also pick the icon to access the Tools Setup dialog box and then select
or define a tool.

Pick tab and click inside the Machining References collector to activate it.

Select the model surfaces (while holding down the Ctrl key) as shown in the figure below.

Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

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CUT_FEED 1200
STEP_DEPTH 50
CLEAR_DIST 1
SPINDLE_SPEED 3000
COOLANT_OPTION ON
CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 20

The large value of STEP_DEPTH will force the tool to machine only the last slice.

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter CORNER as the name of the sequence.

Play the toolpath using PLAY PATH dialog box and notice that the tool is machining the
complete surface with a single pass only as shown below.

To complete the NC Sequence select .

Select File > Save to save the manufacturing model.

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 Chapter 6 PROFILE MILLING

EXERCISE 4

In this exercise we will use the profile milling NC Sequence to finish a hole. We will also learn the
following

� How to control the plunge location of the tool

� How to perform multi-pass machining
� How to mirror a NC Sequence
� Playing the tool path for multiple Sequences

We assume that the hole has been previously drilled with the drill of diameter 12mm.

Set the working directory to LID_CAVITY and open the manufacturing model lid_cavity.asm.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

From the drop-down list in front of icon, pick FEM 10

FEM10

Pick tab and click inside the Machining References collector to activate it.

Select the model surfaces (while holding down the Ctrl key) as shown in the figure below.

Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

CUT_FEED 1200
STEP_DEPTH 2
CLEAR_DIST 1
SPINDLE_SPEED 5000
COOLANT_OPTION ON

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CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 8

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter FINISH as the name of the sequence.

Play the toolpath using PLAY PATH dialog box.. It should appear as shown below.

Notice that there is no lead in or lead out motion. System also warns about this by showing this
message.

It is so because lead radius value we have specified is larger than the radius value toolpath
consists of. This fact can be elaborated by the following figure.

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Please notice that “10” is the radius of the hole and 5 is the radius of the tool path arc. In this
case tool will gouge the part while making lead in or lead out motion therefore system has
ignored them.

So we should set the lead radius less than 5 (radius of toolpath arc) to make sure that tool
makes lead in and lead out motions.

So set the following parameter in Edit Parameters Dialog box.

LEAD_RADIUS 4

Play the toolpath using Screen Play. It should appear as shown below.

As we assumed at the start of the exercise that the hole was pre-drilled with the drill of diameter
12mm. So the tool will be cutting material during plunge motion because there is enough
material at the walls of the hole. The tool must plunge to the next slice at the center of the hole to
avoid cutting of material during plunge motion.

So pick tab and click inside the Approach Axis collector to activate it.

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Select the axis AA_1 as Approach axis as elaborated below.

Now pick in the Exit Axis collector to activate it and select the axis AA_1 as exit axis.

Pick tab and set the following parameters

PLUNGE_FEED 100

PLUNGE_FEED parameter controls the feed rate along the plunge motion. By default it is set to
dash (-) in which case the CUT_FEED is used as PLUNGE_FEED.

Play the toolpath on screen using PLAY PATH dialog box and notice that the tool is plunging
right on the axis AA_1 as shown below (tool not shown).

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You should notice that tool is climb milling the hole surfaces.

We can machine the hole in multiple passes so that we don’t have to define separate sequences
for semi-finishing and finishing toolpaths.

Pick in the Parameters panel and set the following parameters to machine the hole in two
steps.

NUM_PROF_PASSES 2
PROF_INCREMENT 0.3

These parameters can be found in “Cut Depth and Allowances” Category as shown below.

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NUM_PROF_PASSES together with PROF_INCREMENT allows to create multiple profiling

passes horizontally offset from each other.
NUM_PROF_PASSES specifies the number of passes that will be generated.
PROF_INCREMENT specifies the horizontal distance between the passes generated according
to NUM_PROF_PASSES.

Play the toolpath on screen using PLAY PATH dialog box. It will appear as shown below.

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Notice that tool first machines the walls from top to bottom of hole at the offset of
PROF_INCREMENT then retracts and again machines the walls from top to bottom without
PROF_INCREMENT. This type of machining is called PASS_BY_PASS scanning. We can
machine the hole by fist making the profile passes specified by the NUM_PROF_PASSES at the
given z level and then plunging down to the next slice. This type of machining is called
SLICE_BY_SLICE scanning. The scanning strategy is specified by the SLICE_PATH_SCAN
parameter.

As the toolpath looks satisfactory so change the following parameters.

STEP_DEPTH 0.5

To complete the NC Sequence select .

Now we will mirror this sequence to machine the second hole.

So select the FINISH sequence in the model tree and pick Edit > Mirror Step on the Mill tab.

In the NC Sequences Mirroring dialog box, pick

Select the datum ASM_RIGHT as mirroring plane.

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Notice that the option “Keep” is selected for Cutting Conditions in the dialog box

Pick to complete the mirroring operation.

Right click the MIRROR_FINISH in the model tree and pick Play Path.

Play the toolpath on screen using PLAY PATH dialog box. It will appear as shown below.

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Notice that tool is Climb milling the hole surfaces. It is so because the option “Keep” is selected
for Cutting Conditions in the NC Sequences Mirroring dialog box

Now we will play the tool path for both of the sequences together.

Select the both sequences in the model tree while holding down the Ctrl key.

Right-click and select Play Path.

Click the Play Forward button in the Play Path Dialog box. Toolpath will appear as
shown below.

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Select File > Save to save the manufacturing model.

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EXERCISE 5

In this exercise we will define a profile milling NC Sequence to machine an undercut, with a
special round insert milling cutter.

The topics covered in this exercise are as follows

� Defining a side milling cutter

� Selection of surfaces by loop option
� Checking gouges visually, by placing the tool at desired location on the tool path

The cutter to be used in this exercise is shown below.

Set the working directory to BACK_PLATE and open the manufacturing model back_plate.asm.

Change the view to Front and zoom in to the reference part and see that lower surfaces of the
plate form an undercut.

Conventionally, to machine this undercut we will need to machine first from top side and then
invert the plate and machine the bottom side i.e. two separate operations in Creo NC. By using
the special round insert cutter we will machine the complete plate with only one operation.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

Pick the icon and Tools Setup dialog box will pop up.

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In the Tools Setup dialog box, define a new “Side Milling” cutter of diameter 25. Other parameter
of the tool should be as shown below.

Pick tab and tool will appear in the Tools List.

To see the tool in separate window click in the diloag box and the detailed sketch of the tool
will appear as shown below.

Pick to close this window.

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Select to complete the definition of the tool.

Pick tab and click inside the Machining References collector to activate it.

Here we will use the Loop selection technique to select the desired surfaces quickly.

Now select the bottom surface of the reference model as shown below.

Now hold down Shift key and select any edge forming the inner loop of selected surface as
shown below.

The selected loop of surfaces will be highlighted as shown below.

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Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

CUT_FEED 1200
STEP_DEPTH 3
CLEAR_DIST 1
SPINDLE_SPEED 2000
COOLANT_OPTION ON
CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 20
ENTRY_ANGLE 20
EXIT_ANGLE 20

We have set the large value of STEP_DEPTH to make the computation of the toolpath faster.
Later when the toolpath has been defined satisfactorily, we will change it to suit the surface finish
required.

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter UNDERCUT as the name of the sequence.

Play the toolpath using PLAY PATH dialog box and it will appear as shown below.

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Change the view to Front and zoom-in to see that toolpath has followed the surface forming
undercut as shown below (in Wireframe mode).

To check visually if the tool is gouging anywhere on the part, pick icon on the PLAY PATH
dialog box.

Now pick on the toolpath as shown below.

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The tool will move to the picked point as shown below.

Notice that tool shank is clear of the reference part surfaces and does not gouges the part
anywhere.

To be sure, that the tool does not violate the reference part, we should perform the gouge
checking.

So select icon on the dashboard as shown below.

Now the system will ask to select the surfaces for checking gouges. As we want to check the
gouges for the surfaces of complete part so check the Add Ref Prts option..

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When Add Ref Prts option is checked, system adds all surfaces of the reference part for gouge
checking.

Select Done > Run.

System will report that no gouges are detected.

It is always good practice while machining undercut to use larger values for ENTRY_ANGLE and
EXIT_ANGLE parameter. So that on the retract path tool does not gouges the part.

As the toolpath looks satisfactory so change the following parameters for good surface finish.

STEP_DEPTH 0.2

To complete the NC Sequence select .

Select File > Save to save the manufacturing model.

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EXERCISE 6
In this exercise we will define a profile milling NC Sequence to machine an undercut with a T-slot
cutter.

The topics covered in this exercise are as follows

� Defining a new profile milling NC Sequence to machine and undercut

� Defining a new Key cutter
� Introduction to NORMAL_LEAD_STEP parameter
� Inserting a CL Command at the end of CL Data
� Patterning a NC Sequence
� Generating CL Data for a patterned NC Sequence
� Gouge checking patterned NC Sequence

Set the working directory to FLOAT_PLATE and open the manufacturing model float_plate.asm.

Change the view to FRONT and zoom-in to the reference part and see that each bore has an
undercut.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

Pick the icon and Tools Setup dialog box will pop up.

In the Tools Setup dialog box, define a new Key Cutter of diameter 16. Other parameter of the
tool should be as shown below.

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Pick tab and tool will appear in the Tools List.

To see the tool in separate window click and the detailed sketch of the tool will appear as
shown below.

Pick to close this window.

Select to complete the definition of the tool.

Pick tab and click inside the Machining References collector to activate it.

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Select the surfaces forming undercut of first hole as shown in the figure below (view is set to
ISO2). It is important to select the surfaces belonging to the first instance in the pattern as it will
allow to reference pattern the NC Sequence.

Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

CUT_FEED 800
STEP_DEPTH 2
CLEAR_DIST 1
SPINDLE_SPEED 2000
COOLANT_OPTION ON
CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 15
ENTRY_ANGLE 25
EXIT_ANGLE 25

It is always good practice while machining undercut to use larger values for ENTRY_ANGLE and
EXIT_ANGLE parameter. So that on the retract path, tool does not gouges the part.

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter UNDERCUT as the name of the sequence.

Play the toolpath using PLAY PATH dialog box.. It should appear as shown below.

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To be sure, that the tool does not violate the reference part, we should perform the gouge
checking.

So select icon on the dashboard as shown below.

Now the system will ask to select the surfaces for checking gouges. As we want to check the
gouges for the surfaces of complete part so check the Add Ref Prts option..

When Add Ref Prts option is checked, system adds all surfaces of the reference part for gouge
checking.

Select Done > Run.

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System will report gouges by the following message at message area.

Tool is gouging the part during plunge and retract motion. So we should modify the toolpath so
that tool clears the reference part during motions along z-axis.

So set the following parameter.

NORMAL_LEAD_STEP 5

You can find this parameters by picking tab and changing to “Entry/Exit Motions” category

NORMAL_LEAD_STEP is the length of the linear movement that is normal to the lead-in or lead-
out motion.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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To perform gouge checking pick icon and check the Add Ref Prts option..

Select Done > Run. System will report that no gouges are detected.

Now we will insert an an Optional Stop at the end of the CL Data.

So select tab and pick on icon.

In the CL Command dialog box pick icon.

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In the “cmd edit” menu select LOADTL-OPTSTOP > OPTSTOP.

OPTSTOP command will appear in the dialog box as shown below.

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Select to exit the CL Command dialog box.

To complete the NC Sequence select .

Now we will pattern the sequence to machine all the undercuts. We will use the Reference
Pattern technique.

So right-click the NC Sequence in the model tree and pick Pattern

Notice that Reference is selected by default as shown below.

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Pick icon or middle-click to complete the pattern.

Now we will create the CL Data file for the patterned toolpath. To do this first we will create a set
of patterned sequences.

So select on the Manufacturing tab as shown below.

Pick Create in the OUTPUT SET menu and enter Set_UNDERCUT as the name of the set and
hit Enter key.

In the CREATE SET menu, select the first instance of the pattern and system will ask to include
all instance in the set. Pick to confirm as shown below.

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Select Done Sel in the CREATE SET menu.

Now select the Set_UNERCUT in the SELECT SET menu.

In the PATH menu pick File and then Done

Pick in the Save a Copy dialog box. The file set_undercut.ncl.1 will be created.

To display the toolpath on screen select Display > Done on the PATH menu.

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Play the toolpath using PLAY PATH dialog box.. It should appear as shown below.

To perform gouge checking pick Validate and then icon on the Manufacturing tab as shown
below.

Select the newly created file set_undercut.ncl and pick

Check the box Add Ref Prts and select Done > Run.

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System will report that no gouges are detected.

Although we could insert an optional stop in Edit Parameters Dialog box, but it will only appear at
the end of patterned MCD data i.e. once in the tape file. By inserting CL Command at the end of
CL Data, the Optional Stop will appear at the end of each patterned instance i.e. 6 times in tape
file for above case as shown in the figure below.

So the machine operator may have the option to stop the machine at the end of machining each
bore and check the cutter condition or may perform some other task.

Select File > Save to save the manufacturing model.

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EXERCISE 7
In this exercise first we will define a “Sloped” mill surface and then use the profile milling NC
Sequence to machine it.

The topics covered in this exercise are as follows.

� Defining a Sloped Mill Surface

� Introduction to Check Surfaces functionality
� Setting the “Configuration file” option related to check surfaces.

While finish machining a part it is preferable to machine the steep walls with a constant Z type
toolpath (as Profile and Volume Milling NC Sequence offer) and shallow surfaces with a little
step over (as Surface Milling NC Sequence offers). Sloped Mill Surface is used to classify
surfaces into Steep (near vertical) and Shallow (near horizontal) areas.

The criterion to classify surfaces into Steep and Shallow areas is the Slope Angle. At any given
point, Slope angle is defined as the angle between Surface Normal and the Direction Vector as
elaborated in the following figure.

Direction vector is always parallel to the Z-axis and Surface Normal depends upon the topology
of the surface.

So a Flat surface has Slope angle of 00 and a Vertical surface has Slope Angle of 900.

During the definition of Sloped Surface, we specify a Draft Angle. If a surface patch has Slope
angle greater than this Draft Angle it is considered a Steep area and if its value is lesser then it is
considered as Shallow area.

During the definition of Sloped Surface, we have the option either to keep the steep or shallow
side of the selected surfaces. When we select Keep Steep Side
Side, the system keeps only those
portions of the selected surfaces where the Slope Angle is greater than the specified Draft Angle
value. And when we select to Keep Shallow Side
Side, the system keeps only those portions of the
selected surfaces where the Slope Angle is less than the specified Draft Angle value.

Set the working directory to BASE_PUNCH and open the manufacturing model base_punch.asm.

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First of all we will define a Mill Surface to be later referenced in the Profile sequence.

So pick on the Mfg Geometry toolbar or pick Mill Surface icon on the Mill tab to invoke the
Mill Surface Tool.

Pick icon to give a name to this surface.

Enter MS_A as the name of the mill surface and pick .

Pick icon to create a Sloped mill surface.

We will use the Seed and Boundary surface selection method to speed up the surface selection
process.

Select the model surface as shown in the figure below as the seed surface.

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Now hold down the Shift key and select the following two highlighted surfaces as Boundary
surfaces.

After relieving the Shift key the system will highlight the selected surfaces as shown below.

Select or middle-click.

Now select the top surface of the reference model as the direction reference. Make sure that
arrow points upward. This direction is used for measuring the slope angle.

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Then select Okay.

690

In the message area system will ask to enter the Draft angle value. This value is used to classify
surfaces as steep or shallow.

Enter 60 and hit Enter key or middle-click.

Now select Keep Steep Side > Done

Select to exit the dialog box.

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Pick and it completes the definition of the mill surface.

To define a new profile milling NC Sequence, select Profile Milling icon ( ) on Milll tab.

From the drop-down list in front of icon, pick BEM10

You can also pick the icon to access the Tools Setup dialog box and then select or define a
tool.

Pick tab and click inside the Machining References collector to activate it.

Pick the currently defined mill surface MS_A.

Now make sure that arrow points outward as shown in figure below and select .

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Now pick tab and then icon on the Parameters panel to open the Edit
Parameters Dialog box . Enter the following values/relations and parameters.

CUT_FEED 1000
STEP_DEPTH 3
CLEAR_DIST 1
SPINDLE_SPEED 2000
COOLANT_OPTION ON
CUT_ENTRY_EXT LEAD_IN
CUT_EXIT_EXT LEAD_OUT
LEAD_RADIUS 20
ENTRY_ANGLE 15
EXIT_ANGLE 15

Pick to apply the changes and exit the Edit Parameter Dialog box.

Now pick tab and enter STEEP as the name of the sequence.

Play the toolpath using PLAY PATH dialog box and notice that tool is gouging the part as shown

below. (You can also use the Gouge Check functionality i.e. by picking to confirm gouging)

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To avoid the gouging Creo NC provides the function of Check Surfaces. Although system checks
gouging against the surfaces selected as cut geometry (Mill Surface in this case) automatically
but it does not perform gouge checking against the reference part surfaces while computing the
toolpath. So by declaring a surface to be Check Surface we are explicitly telling the system to
avoid gouging them while computing the toolpath.

Pick on the dashboard and check the Add Reference Parts option as shown
below.

When Add Ref Prts (Add Reference Parts) option is checked, system uses all the surfaces of the
reference model to check gouging against.

Play the toolpath using PLAY PATH dialog box.. It should appear as shown below.

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To perfrom gouge checking, pick icon on the dashboard as shown below.

Now the system will ask to select the surfaces for checking gouges. As Add Ref Prts is already
checked so select Done > Run.

System will report that no gouges are detected.

As the toolpath looks satisfactory so change the following parameters for good surface finish.

STEP_DEPTH 0.2

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To complete the NC Sequence select .

We can set the Configuration file option chk_part_surfs_profpock to Yes to force the system to
add all the surfaces of the reference part as Check surfaces.

To blank the Mill Surface MS_A, select icon on the View tab.

Pick the MS_A quilt on the screen and then middle-click.

Select File > Save to save the manufacturing model.

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Trajectory milling is a 2 to 5 axis milling sequence. It allows to sweep a tool along any
user-defined trajectory. It gives the user very low level control over the tool path.

In a 3-Axis workcell we can create either a 2-Axis or 3-Axis trajectory milling NC

Sequence.

You can adjust the depth of the final pass, specify multiple cutting passes with a vertical
offset, as well as create multiple trajectory milling slices with horizontal offset with
respect to the final tool trajectory.

2- Axis Trajectory Milling

To define the tool path for 2-axis Trajectory milling, you sketch or select a curve as
trajectory. The curve must lie in the plane normal to the z-axis of the NC sequence
coordinate system.

3- Axis Trajectory Milling

To define the tool path for 3-axis Trajectory milling, you must interactively specify the
trajectory using the Customize functionality.

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EXERCISE 1

In this exercise we will learn to create a 2-axis Trajectory Milling NC Sequence

Topics covered are

❖ Defining a Composite datum curve

❖ Defining a 2-axis trajectory milling NC Sequence.
❖ How to perform multi-step trajectory milling
❖ How to perform multi-pass trajectory milling

Set the working directory to the COVERJNSERT folder and open the model
coverjnsert.mfg

First we will define a Composite datum curve that will be used as trajectory in the NC
Sequence.

Change the filter setting to Geometry as shown below.

Smart
Features
Geometry
Datums
Quilts
Annotation
Smart

Select the following edge by picking on it

Hold down the Shift key and place the mouse pointer over any of the tangent edges and
Right-Click to query.

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225
You should query until Tangent tool-tip displays on the screen as shown below.

Pick with left mouse button to select the highlighted chain. The selected chain will
appear as shown below.

Select Edit>Copy or press Ctrl+C on the keyboard

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226
 I ^ j Copy Ctrl+C
(J) Paste Ctrl+V
1 ^ ]Paste Special...

Select Edit>Paste or press Ctrl+V on the keyboard

Copy Ctrl+C
( J i Paste Ctrl+V
1 ^ ]Paste Special...

Now the dashboard will appear as shown below.

Pick l_ J icon to complete the feature.

To define a new trajectory milling NC Sequence, select Machining>NC Sequence.

In the MACH AUX menu select Trajectory>2 Axis>Done.

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In the SEQ SETUP menu add Name to the list of checked items and select Done,

Enter the sequence name FINISH and hit Enter key or middle-click.

In the Tools Setup dialog box select FEM25 from the list and select [ 0K ~1.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
SPINDLE_SPEED 2000
CLEAR_DIST 1
LEADJN YES
LEAD_OUT YES
LEAD_IN_RADIUS 60
LEAD_OUT_RADIUS 60
ENTRY_ANGLE 20
EXIT_ANGLE 20

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

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228
Now system will ask you to select the Reference Curve, so pick the datum curve as
shown below.

Select Done in the CHAIN menu

System will show the Tool Movement Direction arrows as shown below.

The arrow represents the tool movement direction along the trajectory. So now the tool
will perform Down-Milling action (assuming that tool is rotating clockwise).

So pick Okay in the DIRECTION menu.

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229
Now system will ask you to select the tool offset direction

Select Left>Done

If we select None the tool center will follow the trajectory and gouge the part and if we
select Left or Right then the tool center will be offset from the trajectory by the half of
tool diameter to the either direction.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that tool plunges with rapid move and retracts with cutting feed rate. During
retract there is no need to move the tool with cutting feed rate as it wastes a lot of time

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230
So pick icon and set the following parameter.

RETRACT FEED 0

The RETRACT_FEED is defined as rate at which the tool moves away from the
workpiece. The default is a dash (-), in which case the CUT_FEED will be used. When it
is set to 0, system issues the RAPID command.

Pick iJ i to exit the Parameter Tree Dialog box and play the toolpath using PLAY PATH
dialog box. It should appear as shown below.

To perform machining in multiple steps, set the following parameters

NUMBER_LAST_FIN PASSES 5
LAST_F 1N PASS_0 FFS ET 6

NUMBER_LAST_FINPASSES specifies the number of cutting passes offset in the

vertical direction from the final tool trajectory

LAST_FINPASS_OFFSET specifies the vertical offset between the cutting passes.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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231
To perform machining in multiple passes in the horizontal direction, set the following
parameters.

NUMBER_LAST_FIN PASSES 1
LAST_F 1N PASS_0 FFS ET 0
NUMBER_LAST_FINCUTS 4
LAST_FINCUT_OFFSET 2

NUMBER_LAST_FINCUTS specifies the number of cutting passes offset in the

horizontal direction from the final tool trajectory.

LAST_FINCUT_OFFSET specifies the horizontal offset between the cutting passes

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so for.

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232
The following figures elaborate the parameters associated with 2-AxisTrajectory NC

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EXERCISE 2

In this exercise we will define a 3-Axis trajectory milling NC Sequence to machine the
material left at a corner. Topics covered are

❖ Defining a 3-Axis trajectory milling NC Sequence.

❖ Adding smooth entry/exit motions.
❖ Checking the gouges against reference part.
❖ How to shift the toolpath upward to avoid gouging.
❖ How to perform multi-step trajectory milling.

Set the working directory to COVERJNSERT and open the manufacturing model
coverjnsert.mfg.

To define a new trajectory milling NC Sequence select Machining>NC Sequence>New

Sequence>T rajectory>Done.

Notice that 3 Axis is selected by default.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name SHARP and hit Enter key or middle-click.

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234
In the Tools Setup dialog box select FEM6 from the list and select

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1200
SPINDLE_SPEED 6000
COOLANTOPTION ON
CLEAR_DIST 1

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box

Select Done in the MFG PARAMS menu to proceed.

Now the Customize dialog box will open. First make sure that Automatic Cut is selected
Insert
in the drop down menu then select

Now select Edge>Done>Done.

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Select the following chain of edges One By One as shown in the figure below.

Remember to hold-down Ctrl key while selecting multiple edges

Select Done to complete the selection of edges.

Make sure the arrow’s direction is as shown below then Okay.

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236
The arrow represents the tool movement direction along the trajectory. So now the tool
will perform climb milling action (assuming that tool is rotating clockwise).

Now the SLOT OFFSET menu will appear asking to select tool offset direction. If we
select None the tool center will follow the trajectory and gouge the part and if we select
Left or Right then the tool center will be offset from the trajectory by the half of tool
diameter to the either direction.

So select Left>Done.

In the INT CUT menu select Play Cut to view the toolpath.

Cut
Ends
Comers
Parameters
Check 5urFs
Build Cut
Play Cut
InFo
Done Cut
Next Cut
Quit Cut

Toolpath will appear as shown below.

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Look over the toolpath carefully and notice that we need to add smooth entry/exit
motions.

To avoid direct plunging into the material select Ends>Start>Specify>Done.

Pick on the screen somewhere away from the reference part as shown below.

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In the END DIM TYPE menu select Ext Length and enter 5 then hit Enter key

Select Done.

So the system has extended the trajectory of toolpath 5mm away from the previous start
point.

We can also extend the other end of the trajectory by the same technique but we will
use a different option just to familiarize with it.

So select Build Cut>Exit>Lead Out.

•w INT CUT ■v BLD CUT - r BP EXIT

Cut Approach Sketch

Ends Exit Retract
Comers Parameters AlngToolAxis
Parameters -------► Play Cut Normal
-------►
Check SurFs Info Tangent
Build Cut Lead Out
□one
Play Cut GoTo Point
Quit
InFo GoTo End

Done Cut Helical

Next Cut None

Make sure that arrow points away from the reference part and select Okay.

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239
As we have not set the LEAD_RADIUS parameter so the system is asking to enter the
radius value. So enter 5 and hit Enter key.

Select Done.

As the toolpath has been completely defined so select Done Cut to finish creating the
toolpath.
r —
M enu M anager

T IMT CUT

Cut
Ends
Corners
1 Parameter;
1 Check 5urfs
Build Cut
Play Cut
Jnfo
Done Cut
Next Cut
Quit Cut

The Automatic Cut motion will appear in the Customize dialog box as shown below.

Pick I 0K ) to exit the Customize dialog box.

Play the toolpath using PLAY PATH dialog box, it should appear as shown below.

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To be sure, that the tool does not violate the reference part, we should perform the
gouge checking.

So select Gouge Check in the PLAY PATH menu

Now the system will ask to select the surfaces for checking gouges. So check the Add
Ref Prts option.

When Add Ref Prts option is checked, system adds all surfaces of the reference part for
gouge checking.

Select Done>Run. System will report gouges by displaying message in the message
area.

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 Gouges were detected.
/■YTool gouges into part by -0.1073 .

We can not avoid these gouges because the trajectory of the tool is a 3D curve and
while following this trajectory tool will gouge the curved surface. It can only be
machined correctly on five axis milling machine. It can be elaborated by the following
figure.

The best solution is to lift the tool upward so that the tool does not violate the surface
So select the following parameter.

AXIS SHIFT 25

AXIS_SHIFT allows to shift the CL data along the tool axis. If set to a positive value, will
shift all CL data down along the tool axis; a negative value will shift the CL data up.

Now again perform Gouge Checking and notice that no gouges are detected.

To perform machining in multiple steps set the following parameters.

STEP_DEPTH .2
NUMBER_CUTS 3

NUMBER_CUTS parameter is used to perform milling in STEP_DEPTH increments. So

in the above case system will make three pass offset from each other by 0.2 in the Z
direction.

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To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so far.

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EXERCISE 3

In this exercise we will define a 3-Axis trajectory milling NC Sequence to machine a slot
in multiple steps.

Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg.

To define a new trajectory milling NC Sequence select Machining>NC Sequence>New

Sequence>T rajectory>Done.

Notice that 3 Axis is selected by default in the MACHIN AUX menu.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name SLOT and hit Enter key or middle-click.

In the Tools Setup dialog box select FEM2 from the list and select [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1200
STEP_DEPTH .5
SPINDLE_SPEED 6000
COOLANTOPTION ON
CLEAR_DIST 1

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the Customize dialog box will open. First make sure that Automatic Cut is selected
Insert
in the drop down menu then select

In the INTERACT PATH menu select Edge>Done and add the Start Height and
Height to the list of checked items then select Done.

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 Cn/Offset
Fit
0Edge
□ Direction
0 Offset
0 Start Height
0 Height
H Matrl Side
Done
Quit

The Start Height and Height options are used to specify the height of the first pass and
last pass respectively. The Start Height option is grayed out if neither STEP_DEPTH
nor NUMBER_CUTS has been specified for the NC sequence.

In the CHAIN menu select Tangent Chain.

Now pick the edge as shown in the figure below.

The system has selected the chain of edges which are tangent to the picked edge

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Select Done to proceed

Now select Flip>Okay to change the direction of trajectory

As we have selected outer edges of the slot hence the tool should be offset inside. So
select Left>Done. The tool movement direction and offset direction should appear as
shown below.

Now system will ask you to specify the plane where machining will begin (Start Height)
So select the lower flat face of the part and select Done.

Now system will ask you to specify the plane where last pass will occur (Height
reference). So select the lower surface of the slot as shown below and select Done

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From side view Start Height and Height references are elaborated in the figure below.

As the toolpath has been completely defined so select Done Cut to finish creating the
toolpath.

OK
Pick to exit the Customize dialog box.

Play the toolpath on screen using PLAY PATH dialog box. Notice that tool directly
plunges to the next slice as shown in the figure below.

In the following steps we will modify the toolpath so that tool enters the next slice with a
ramp motion.

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First change the following parameter in the Parameter tree dialog box

CONNECTION_TYPE SIMULTANEOUS
APPROACH_DISTANCE 20

When CONNECTION_TYPE option is set to SIMULTANEOUS, the tool moves directly

from the end of the previous cut to the start of the next cut.

APPROACH_DISTANCE specifies the length of approach motions.

Select Customize and the customize dialog box will appear. Pick the previously defined
Redefine
Automatic Cut motion then select

Now select Build Cut>Approach>Tangent,

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Tangent Approach allows the tool to approach an Automatic Cut motion in the direction
tangent to the toolpath at its start point. The length of the approach motion is
determined by the APPROACH_DISTANCE parameter value.

In the CR/SEL POINT menu select Create and pick on the toolpath as shown in the
figure below.

Select Done>Done Cut to finish modifying the toolpath

OK
Pick to exit the Customize dialog box.

Play the toolpath on screen using PLAY PATH dialog box. Notice that now tool is
entering the next slice by a ramp movement as shown below.

Ramp Motion

We can control the ramp angle by changing the values of STEP_DEPTH and
APPROACH_DISTANCE parameters. The relationship can be explained by the
following figure.

RAMP ANGLE

STEP DEPTH

APPROACH DISTANCE

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You have noticed that during ramping, tool moves at the rapid feed. To change this
behavior set the following parameter.

FREE FEED 100

FREE_FEED is the feed rate used for rapid traverse. The default FREE_FEED is a
dash (-), in which case the RAPID command will be output.

Again Play the toolpath using PLAY PATH dialog box and notice that now tool does not
ramp at rapid feed as shown in the figure below.

You may notice that during first slice the tool directly plunges into the material. To avoid
this set the following parameter.

NUMBER CUTS 2

Play the toolpath by selecting PLAY PATH dialog box. The toolpath appears as shown
below.

You can see that during first cut the tool still plunges but there is no material being cut.
And during second slice and afterwards the tool enters into next slice by ramp motion.

NUMBER_CUTS parameter is used to specify the desired number of cuts and it forces
the tool to take first cut at Start Height reference.

The main use of NUMBER_CUTS parameter is for multi-step machining. But we have
just used it to force the tool to take first cut at start height.

As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

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 STEP DEPTH .2

To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so far.

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251
EXERCISE 4

In this exercise we will define a 3-Axis trajectory milling NC Sequence to machine a slot
(groove) which lies on a curved surface.

Set the working directory to PANEL_PUNCH and open the manufacturing model
panel_punch.mfg.

To define a new trajectory milling NC Sequence select Machining>NC Sequence>New

Sequence>T rajectory>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name SLOT and hit Enter key or middle-click.

In the Tools Setup dialog box select BEM12 from the list and select [ 0K ~).

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_DEPTH 1
SPINDLE_SPEED 4000
COOLANTOPTION ON
CLEAR_DIST 1
CONNECTION_TYPE SIMULTANEOUS
NUMBER_CUTS 5
FREE_FEED 100
APPROACH_DISTANCE 20

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the Customize dialog box will open. First make sure that Automatic Cut is selected
Insert
in the drop down menu then select

In the INTERACT PATH menu select Edge>Done and EDGE FIT menu will open
Here select Fit>Done.

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Fit option forces the tool to fit between the surfaces adjacent to the edges specified to
form the trajectory. And only ball end mill can be used for this operation

In the CHAIN menu select Tangent Chain and pick the edge as shown in the figure
below.

The system will select the chain of edges which are tangent to the picked edge

Select Done to proceed to next step.

Now select Flip>Okay to change the direction of trajectory.

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As we have selected outer edges of the slot hence the tool should be offset inside. So
select Left>Done. The cutting direction and offset direction should appear as shown
below.

Now select Build Cut>Approach>Tangent,

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In the CR/SEL POINT menu select Create and pick on the toolpath as shown in the
figure below.

Pick Here

Select Done>Done Cut to finish modifying the toolpath.

OK
Pick to exit the Customize dialog box.

Play the toolpath on screen using PLAY PATH dialog box. It should appear as shown
below.

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255
Notice that now tool is entering the next slice by a ramp movement as shown below.

As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

STEP_DEPTH .3
NUMBER_CUTS 20

To complete the NC Sequence select Done Seq.

Select File>Save to save the changes we made so far.

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256
EXERCISE 5

In this exercise we will define a 3-Axis trajectory milling NC Sequence to face a part by
a succession of trajectory passes with horizontal offset.

Multi-pass Trajectory milling can be performed by using the NUM_PROF_PASSES and

PROFJNCREMENT parameters. The last pass will coincide with the specified
trajectory. We will also make use of CONNECTION_TYPE parameter to control the
intermediate tool retracts.

Set the working directory to PILLAR_STRIPPER and open the manufacturing model
pillar_stripper.mfg.

To define a new trajectory milling NC Sequence select Machining>NC Sequence>New

Sequence>T rajectory>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name FACE and c hit Enter key or middle-click.

In the Tools Setup dialog box select FEM25 from the list and select [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1200
SPINDLE_SPEED 2000
CLEAR_DIST 1
NUM_PROF_P ASSES 3
PROFJNCREMENT CUTTER_DIAM*.75
LEAD_RADIUS 50
ENTRY_ANGLE 60
EXIT_ANGLE 60

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the Customize dialog box will open. First make sure that Automatic Cut is selected
in the drop down menu then select Insert
In the INTERACT PATH menu select Sketch>Done and add the Offset to the list of
checked items then select Done.

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 ▼ I nteract p a th :

1 Sketch 1 0 Sketch

Edge 0 Offset
----------- ►
Curve 1 1Start Height

Surface 1 1Height

Done
1 1Matrl Side

Quit Done
Quit

Select the following reference for sketching the trajectory

In the Missing Reference pop up window select

In the Type menu, select Loop option.

Now pick the top surface of the reference part

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In the SEL CHAIN menu, select Next to highlight the outside loop as shown in the figure
below.

Select Accept when the outer loop is highlighted and enter 2 as the offset value. Notice
that sketch entity is created offset from the loop to the outer boundary of the part as
shown in the figure below.

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The yellow arrow represents the start point and direction of the trajectory. If the arrow is
not directed as shown in figure then right click the point, to which this arrow is attached,
and in the pop up menu select Start Point. System will reverse the direction of the
arrow.

Pick ^ to complete the section.

In the SLOT OFFSET menu select Left >Done.

To add the lead in motion select Build Cut>Approach>Lead In

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Select a suitable point on the trajectory as shown in the figure below.

Now make sure that direction arrow points inward and select Okay.

To add a lead out motion select Exit>Lead out and make sure arrow points inward and
select Okay.

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Select Done>Done Cut to finish modifying the toolpath

OK
Pick to exit the Customize dialog box.

Play the toolpath on screen using PLAY PATH dialog box. Notice that tool retracts after
each pass as shown in the figure below.

Set the following parameter to connect the end of the previous cut to the start of the
next cut directly.

CONNECTION TYPE SIMULTANEOUS

Again play the toolpath it should appear as shown below.

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You may notice that tool moves at rapid feed during connection movement. To change
this behavior set the following parameter.

FREE FEED 1000

FREE_FEED is the feed rate used for rapid traverse. The default FREE_FEED is a
dash (-), in which case the RAPID command will be output.

Select Done Seq to complete the NC Sequence.

Select File>Save to save the changes we made so far.

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263
SURFACE MILLING
Surface milling NC Sequence is usually used to semi-finish or finish the shallow
surfaces. It is a versatile sequence which can generate a lot of toolpath strategies. The
surface finish can be controlled with Step Over adjustment or Scallop Height parameter.
It gives a lot of entry/exit control options. It can be also used to rough and finish
imported surface models.

The required references are surfaces which may be the selected surfaces of either of
the Reference model, Mill Surface or Mill Volume. It automatically degouges the tool
path against the reference part.

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EXERCISE 1

In this exercise we will define a surface milling NC Sequence to machine the top
surfaces of the reference model.

We will learn the following techniques in this exercise

❖ Defining a surface milling NC Sequence

❖ Introduction to Straight Cut toolpath strategy
❖ Effect of CUT_ANGLE parameter on the toolpath
❖ Introduction to Cutline toolpath technique
❖ Effect of SCAN_TYPE parameter on toolpath
❖ Adding smooth Entry/Exit motions
❖ Adding smooth connection movements between tool passes
❖ Multi-step surface milling

Set the working directory to C O VERJN SER T and open the manufacturing model
coverjnsert.m fg.

To define a new surface milling NC Sequence select Machining>NC Sequence

>Surface Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FINISH and hit Enter key or middle-click.

In the Tools Setup dialog box pick BEM10 from the list and select [ 0K ~l.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 2
SPINDLE_SPEED 8000
C O O LAN TO P TIO N ON
CLEAR_DIST 1

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the SURF PICK menu appears. This menu gives us three options to select the
surfaces. Model option is selected by default as shown below.

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Model option is used to select surfaces from reference part.

As we want to select the surfaces from the reference part, so select Done and select
the model surfaces as shown in the figure below.

Select Done>Done to complete the selection of surfaces.

Now the Cut Definition dialog box will appear. It presents different options for defining
the toolpath.

This time we will use the simplest option of Straight Cut, which is selected by default as
shown below.

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 OK
So select

Play the toolpath using PLAY PATH dialog box and notice that tool scans the surface
with straight movement parallel to the x-axis of NC Sequence coordinate system as
shown below.

We can control the angle of cutter movement relative to X-axis with CUT_ANGLE

parameter. To see the effect of CUT_ANGLE parameter pick icon and set the
parameter as follows.

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 CUT ANGLE 90

The Cut Angle can also be set in the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and notice that now tool scans the
surface with straight movement at 90° to the x-axis of NC Sequence coordinate system

Although the above toolpath will give good surface finish, provided the suitable value of
step over is selected, but it is not good from tool and machine point of view. As there
are a lot of entry/exit movements into the cut and direction changes at the start and end
of each cut so the tool life will be shorter and machine tool will suffer from continuous
acceleration and deceleration. So we should strive for least entry/exit movement and
direction changes.

We will use the Cut Line Surface Milling to produce cuts shaped according to the
surface topology. This option gives more control over the actual shape of the cuts

Select Seq Setup and check the Define Cut box then pick Done.

In the Cut Definition dialog box select Cut Line and the related options will appear. Note
that Open Ends option is selected by default.

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 - C u t D e fin itio n
Cut Type
w\mm C u t D e fin itio n
Cut Type
□ DH
® j Straight Cut: O Straight Cut
O From Surface Isolines O From Surface Isolines
Cut Line Cut Line'
O Projected Cuts O Projected Cuts
Straight Cut Along Cut Line

Cut Angle Reference Cut Lines Options

® Relative to X-Axis
► Cut Line References
O By Surface
O By Edge ® Machine Surfaces
Refract Plane

Cut Angle GOO Setup Cut Lines

Cut Line Style
Cut Direction Sd1 m
® Open Ends O'Closed Loops

0 & >■!

Cutting Direction -■ ■ y

OK Cancel Preview OK 1 [ Cancel ]

Cut Line Surface Milling produces tool path according to the surface topology.

Now select “Add a cut line” icon 0 .

In the CHOOSE menu select Next until outer loop of selected surface is highlighted as
shown in the figure below.

When the desired loop is highlighted then select Accept.

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Now the system will highlight all the vertices located on this loop to select “from ” and
“to” vertex for the cutline as shown below.

Pick the “from ” and “to” vertices as shown below.

System will give us the following two options for selection

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Our desired selection is “Option 1” . So in the CHOOSE menu select Accept when the
desired selection is highlighted. You may need to pick Next to toggle between shown
options.

Select Done to complete the selection of chain.

Select to complete the definition of Outline.

Notice that “Cutline 1" appears in the Cut Definition dialog box

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Now we will add the second Cutline.

So select Add a cut line icon 0 .

In the CHOOSE menu select Next until outer loop of selected surface is highlighted as
shown in the figure below.

When the desired loop is highlighted then select Accept.

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Now the system will highlight all the vertices located on this loop to select “from ” and
“to” vertex for the cutline as shown below.

Pick the “from ” and “to” vertices as shown below.

System will give us the following two options for selection

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Our desired selection is “Option 2” . So in the CHOOSE menu select Accept when the
desired selection is highlighted. You may need to pick Next to toggle between shown
options.

Select Done to complete the selection of chain.

OK
Select to complete the definition of Outline.

Notice that “Cutline 2" appears in the Cut Definition dialog box.

OK
Select to exit the Cut Definition dialog box.

To display the toolpath on screen select Play Path>Screen Play. Play Path Dialog box
will appear.

Click the Play Forward button . Toolpath should appear as shown below.

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Note that tool enters and exits out of cut several times. It is so because the SCAN_TYPE
option is set to TYPE_3. When the SCAN_TYPE is set to TYPE_3 the tool machines the
selected surfaces zone by zone. The tool completely machines one zone before moving
to the next.

To change the cutting strategy, p ic k and set the following parameter.

SCAN TYPE TYPE 1

When TYPE_1 scanning strategy is used, the tool continuously machines the selected
surfaces, retracts upon encountering islands.
Play the toolpath using PLAY PATH dialog box. Toolpath will appear as shown below.

The "cut lines" that we select, determine the shape of the first and last passes in the tool
path. The passes between the first and last slice will first mimic the shape of the edge
or entity specified as the cut line, then gradually change shape as necessary to
accommodate different surface topology.
Zoom to the toolpath and notice that see that the tool enters the next pass making a line
move from the previous pass as shown below.

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275
The line connection movement between passes causes the machine tool to experience
sudden direction changes and very sharp acceleration and deceleration. To change the
Y_
connection movement from line to smooth transition, pick ^ and set the following
parameter.

LACE OPTION LOOP CONNECT

LOOP_CONNECT is used to connect the adjacent passes by vertical loops, with the
tool leaving and entering material tangent to the surface being machined

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

You will notice that at entry and exit of the tool into cut, it is directly plunging onto the
surface. To introduce smooth entry/exit motions set the following parameters.

LEAD_RADIUS 20
INITIAL_ENTRY_EXT LE AD JN
FINAL_EXIT_EXT LEAD_OUT
ENTRY_ANGLE 10
EXIT_ANGLE 10

INITIAL_ENTRY_EXT specifies the entry move type for the first cut

FINAL_EXIT_EXT specifies the exit move type for the last cut.

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276
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

We can perform Cut Line Surface Milling in step depth increments. So to set the
toolpath to machine the surface in two steps offset by 0.5mm set the following
parameters.

NUMBER_CUTS 2
O FFSETJNCREM ENT 0.5

NUMBER_CUTS specifies the number of cuts to machine a surface in depth

increments.

OFFSETJNCREM ENT specifies the offset between cuts.

Now play the tool path using PLAY PATH dialog box and notice that tool makes two
cuts to machine the surface.

As the toolpath looks satisfactory so change the following parameters for good surface
finish.

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 STEP_OVER .2
SCALLOPJHGT .0001

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the changes we made so for.

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278
EXERCISE 2

In this exercise first we will define a “sloped” mill surface and then use the surface
milling NC Sequence to machine it.

We will learn the following techniques in this exercise

❖ Defining a Sloped Mill Surface

❖ Introduction to Closed Loop Cutline toolpath strategy
❖ Selecting suitable SCAN_TYPE for selected surfaces
❖ Adding smooth Entry/Exit motions

While finish machining a part it is preferable to machine the steep walls with a constant
Z type toolpath (as Profile and Volume Milling NC Sequence offer) and shallow surfaces
with a little step over (as Surface Milling NC Sequence offers). Sloped Mill Surface is
used to classify surfaces into Steep (near vertical) and Shallow (near horizontal) areas.

The criterion to classify surfaces into Steep and Shallow areas is the Slope Angle. At
any given point, Slope angle is defined as the angle between Surface Normal and the

Direction vector is always parallel to the Z-axis and Surface Normal depends upon the
topology of the surface.

So a Flat surface has Slope angle of 0° and a Vertical surface has Slope Angle of 90°.

During the definition of Sloped Surface, we specify a Draft Angle. If a surface patch has
Slope angle greater than this Draft Angle it is considered a Steep area and if its value is
lesser then it is considered as Shallow area.

During the definition of Sloped Surface, we have the option either to keep the steep or
shallow side of the selected surfaces. When we select Keep Steep Side, the system
keeps only those portions of the selected surfaces where the Slope Angle is greater
than the specified Draft Angle value. And when we select to Keep Shallow Side, the
system keeps only those portions of the selected surfaces where the Slope Angle is
less than the specified Draft Angle value.

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Set the working directory to BASE_CAVITY and open the manufacturing model
base_cavity.mfg.

To create a new Mill Surface select Mfg Setup>Mfg Geometry>Mill Surface>Create

Enter MS_A as the name of mill surface and hit Enter key or middle-click.

In the SURF DEFINE menu select Add>Advance>Done>Sloped>Done.

'W SR F O PTS T ADV FEAT OPT

E x tr u d e V ar Sec S w p 1

R e v o lv e S w e p t B le n d

S w eep H e lic a l S w p

B le n d --------------► B o u n d a rie s

F la t S e c t t o S rfs

O ffs e t S rfs t o S rfs

C opy F ro m File

1 C o p y b y T rim T a n g e n tT o S r f

F ille t F re e F o rm

A dvanced S lo p e d

Done M a c h in a b le A re a

Q u it Done
Q u it

We will use the Seed and Boundary surface selection method to speed up the surface
selection process.

Select the model surface as shown in the figure below as the seed surface.

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280
Now hold down the Shift key and select the following two highlighted surfaces as
Boundary surfaces.

After relieving the Shift key the system will highlight the selected surfaces as shown
below.

Select t 0K or middle-click

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281
Now select the top face of the reference model as the direction reference. Make sure
that arrow points upward. This direction is used for measuring the slope angle.

Then select Okay.

In the message area system will ask to enter the slope angle value. This value is used
to classify surfaces as steep or shallow.

Enter 30 and hit Enter key or middle-click.

Now select Keep Shallow Side>Done

Select t 0K ) to complete the definition of mill surface.

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282
Select Done>Done>Done.

To define a new surface milling NC Sequence select Machining>NC

Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FINISH and hit Enter key or middle-click.

In the Tools Setup dialog box select BEM10 from the list and pick L 0K 1

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 2
SPINDLE_SPEED 8000
C O O LAN TO P TIO N ON
CLEAR_DIST 1

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In SURF PICK menu select Mill Surface>Done>Select Srf and pick the currently
defined mill surface MS A.

Now the system is asking to decide the side of surface to be machined. Make sure that
arrow points upward and select Okay.

As we want to machine all the surfaces included in the mill surface so select Select
AII>Done.

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In the Cut Definition dialog box select Cut Line and Closed Loops options

Now select “Add a cut line” icon

In the CHOOSE menu select Next until outer loop of mill surface is highlighted as
shown in the figure below.

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284
Select Accept>Done

Select l———>to complete the definition of Cutline. And notice that Cutline 1 appears in
the Cut Definition dialog box.

Again select “Add a cut line” icon L U and in the CHOOSE menu select Next until inner
loop of mill surface is highlighted as shown in the figure below.

Select Accept>Done

OK
Select to complete the definition of Cutline. And notice that Cutline 2 appears in
the Cut Definition dialog box.

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285
 OK
Select to exit the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and zoom to see that the tool enters the
next pass making a line move as shown below.

The line connection movement between passes causes the tool to sudden direction
change so the result is early tool failure and vibration mark on surface. Now we will
modify the parameters to get the smooth toolpath.

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286
Pick icon and set the following parameters.

SCAN_TYPE TYPEJHELICAL
LACE_OPTION NO
LEAD_RADIUS 30
ENTRY_ANGLE 10
EXIT_ANGLE 10
INITIAL_ENTRY_EXT ARC_TANGENT
FINAL_EXIT_EXT ARC_TANGENT

TYPE_HELICAL parameter is used to move the tool along a helix. As the tool moves
along the helix so we don’t need any connection movement therefore LACE_OPTION
has been set to NO.

Now instead of making line connection between cuts tool will machine the surface
moving along a helix so there will be no connection movement required.

Play the toolpath using PLAY PATH dialog box and notice that there is no connection
movement as shown in the figure below.

Also notice that tool enters the cut making a smooth tangential movement to the
surface.

As the toolpath looks satisfactory so change the following parameters for good surface
finish.

STEP_OVER .2
SCALLOPJHGT .0001

Select Done Seq to complete the definition of the NC Sequence.

Select File>Save to save the changes we made so for.

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287
EXERCISE 3

In this exercise we will define a surface milling NC Sequence to face the reference
model.

We will learn the following techniques in this exercise

❖ Defining a surface milling NC Sequence

❖ Adding smooth Entry/Exit motions
❖ Adding smooth connection movements between tool passes
❖ Using OVERTRAVEL_DISTANCE parameter to control the contact of tool with
reference model

Set the working directory to REGULATOR_CAVITY and open the manufacturing model
regulator_cavity.mfg.

To define a new surface milling NC Sequence select Machining>NC

Sequence>Surface Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FACE and hit Enter key or middle-click.

In the Tools Setup dialog box pick FEM30 from the list and select [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1000
STEP_OVER CUTTER_DIAM*.65
SCAN_TYPE TYPE_1
LACE_OPTION ARC_CONNECT
SPINDLE_SPEED 2500
C O O LAN TO P TIO N ON
CLEAR_DIST 1

ARC_CONNECT option connects the neighboring cutting passes with smooth arc-like
connections. It only works when Straight Cut option is used in Cut Definition dialog box

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

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288
Now the system will ask you to select the reference surfaces. We will select the
surfaces from reference model.

As the Model option is highlighted in SURF PICK menu, so select Done and select the
model surfaces as shown in the figure below.

Select Done or middle-click twice to complete the selection of surfaces.

Now the Cut Definition dialog box will appear. We will machine the selected surface with
the Straight Cut option that is selected by default, as show below.

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289
So select OK to exit the dialog box.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

We can force the tool to completely clear the surface before starting the next pass. To
achieve this set the following parameter

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290
 OVERTRAVEL DISTANCE CUTTER DIAM*.5

OVERTRAVEL_DISTANCE specifies the distance that the tool travels past the surface
outline, both at the beginning and end of each cutting pass.

Play the toolpath using PLAY PATH dialog box. It will appear as shown below.

Notice that now tool comes out of the cut and then starts the new pass as desired

To introduce smooth entry/exit set the following parameters.

LEAD_RADIUS 30
ENTRY_ANGLE 15
EXIT_ANGLE 15
IN ITI AL_ENTY_EXT ARC_TANGENT
FINAL_EXIT_EXT ARC_TANGENT

Play the toolpath using PLAY PATH dialog box. It will appear as shown below.

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291
Notice that the center of the tool overlaps with the edge of the part. It creates a very
unfavorable cutting condition. Whenever the center of the cutter overlaps with the edge
of the part or positioned outside of the part to be machined, an unfavorable contact
between the cutting edge and material results. When the center of the cutter is
positioned inside the part to be machined the most favorable cutting action takes place.

System does not provide any parameter to pull the tool into the part. Therefore we will
define a Mill Surface that smaller than the face of the reference part.

So select Seq Setup and check the Surfaces box then pick Done.

In the SURF PICK menu select Mill Surface>Done.

In the DEFINE SRF menu select Create Srf.

Enter MS_A as the name of mill surface and hit Enter key or middle-click.

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292
In the SURF DEFINE menu select Add>Flat>Done,

'V S U R F D E F IN E T SRFOPTS

Add 1 E x tr u d e

M e rg e R e v o lv e

T rim Sw eep

E x te n d ------------------------- ► B le n d

T r a n s fo r m F la t ]

D ra ft O ffs e t

A re a O ffs e t C opy

D ra ft O ffs e t C o p y b y T rim

D one/Return F ille t

A dvanced

Done
Q u it

Now select the Sketching and Right orientation plane as shown below.

Now sketch the section as shown below.

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293
Pick v to complete the section.

Pick t 0K ) to exit the dialog box.

Select Done>Okay>Select AII>Done

OK
So select to exit Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box. It will appear as shown below.

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294
Notice the tool has been pulled into the part both on the initial and final edge. Further
more cutter engagement is 65% of the tool diameter for whole of the sequence.

Select Done Seq to complete the definition of the NC Sequence.

Select File>Save to save the changes we made so for.

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295
EXERCISE 4

In this exercise we will use the surface milling NC Sequence to finish a hole. Later the
CL data created by the NC Sequence will be mirrored to finish another hole.

We will also learn the following

❖ Selecting suitable SCAN_TYPE for selected surfaces

❖ Introduction to ARC_TANGENT entry/exit condition
❖ How to create CL data for a given NC Sequence
❖ How to mirror the CL Data

Set the working directory to LID_CAVITY and open the manufacturing model
lid_cavity.mfg.

To define a new surface milling NC Sequence select Machining>NC

Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FINISH and hit Enter key or middle-click.

In the Tools Setup dialog box select FEM10 from the list and select [ 0K ~l.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 2
SPINDLE_SPEED 5000
C O O LAN TO P TIO N ON
CLEAR_DIST 1

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In SURF PICK menu select Done and select the right hole surfaces while holding down
the Ctrl key. The selected surfaces are shown below.

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296
Select Done>Done to complete the selection of surfaces.

In the Cut Definition dialog box select Cut Line and Closed Loops options

t=r Cut Definition 0 (1 1 1

Cut Type
O Straight Cut
O From Surface Isolines
© Cut Line
O Projected Cuts
Along Cut Line

Cut Lines Gptions

► Cut Line Refeiences

® Machine Surfaces
O FI street Plane
Setup Cut Lines
Cut Line Style
( ) Open Ends © jClosed Loops

Now select “Add a cut line” icon 0 .

In the CHOOSE menu select Next until upper loop of selected surfaces is highlighted as
shown in the figure below.

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297
Select Accept>Done

OK
Select to complete the definition of Cutline. And notice that Cutline 1 appears in
the Cut Definition dialog box.

Again select “Add a cut line” icon L f J and in the CHOOSE menu select Next until lower
loop of mill surface is highlighted as shown in the figure below.

Select Accept>Done

OK
Select to complete the definition of Cutline. And notice that Cutline 2 appears in
the Cut Definition dialog box.

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298
 OK
Select to exit the Cut Definition dialog box.

y
Pick = * and set the following parameters.

SCAN_TYPE TYPEJHELICAL
LACE_OPTION NO

We can not set the SCAN_TYPE to TYPE_HELICAL at the initial setting of parameters
because it becomes available only after we have set the Cut Type to Cut Line in the Cut
Definition dialog box.

Pick ^ to apply the changes and exit the Parameter Tree Dialog box.

Play the toolpath using PLAY PATH dialog box and look that the toolpath is satisfactory
except the entry/exit into cut.

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299
To introduce the smooth entry/exit motions set the following parameters

LEAD_RADIUS 4
IN ITI AL_ENTY_EXT ARC_TANGENT
FINAL_EXIT_EXT LEAD_OUT

Again play the toolpath using PLAY PATH dialog box and notice the smooth entry and
exit motions into the cut as shown in the figure below.

ARC TANGENT

■LEAD OUT

ARC TANGENT

SIDE VIEW TOP VIEW

As the toolpath looks satisfactory so change the following parameters for good surface
finish.

STEP OVER .2

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300
Select Done Seq to complete the definition of the NC Sequence.

To create the CL data file for FINISH NC Sequence, select CL Data>NC Sequence

M fg M o d e l

M fg S e tu p

P ro c e s s M g r

M a c h in in g

CL D a ta [

M o d ify

R e g e n e r a te

C om ponent

Set Up

R e la tio n s

P ro g ra m

In te g ra te

Now select the FINISH sequence in the NC Sequence SEQ LIST menu

In the PATH menu pick File and then Done

Pick in the Save a Copy dialog box. The file finish.ncl. 1 will be created.

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301
To mirror the toolpath to machine the second hole, select Mirror in the PATH menu

Pick the datum ASM_RIGHT as mirroring plane.

Now select File>Done to create the CL Data file for mirrored toolpath

Enter the mirrored CL data file name as FINISH_M in the Save a Copy dialog box.

Pick [ 0K 1to create the file.

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302
Select Display>Done to view the simulation of CL Data file on screen

It should appear as shown below.

Select File>Save to save the manufacturing model

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303
EXERCISE 5

In this exercise we will use the Closed Loop Cutline toolpath strategy to machine model
surfaces and learn how to control the cutting direction.

Set the working directory to PHONE_PUNCH and open the manufacturing model
phone_punch.mfg.

To define a new surface milling NC Sequence select Machining>NC

Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name FINISH and hit Enter key or middle-click.

In the Tools Setup dialog box select FEM10 from the list and select [ 0K

In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 1200
STEP_OVER 2
SPINDLE_SPEED 5000
CLEAR_DIST 1

Pick to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In SURF PICK menu select Done and select the following surfaces while holding down
the Ctrl key.

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304
Select Done or middle-click twice to complete the selection of surfaces.

In the Cut Definition dialog box select Cut Line and Closed Loops options

t=r Cut Definition mmm

Cut Type
O Straight Cut
O From Surface Isolines
© Cut Line
O Projected Cuts
Along Cut Line

Cut Lines Gptions

► Cut Line Refeiences

® Machine Surfaces
O FI street Plane
Setup Cut Lines
Cut Line Style
O Open Ends Closed Loop?

Now select “Add a cut line” icon 0 .

In the CHOOSE menu select Next until upper loop of selected surfaces is highlighted as
shown in the figure below.

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305
Select Accept>Done

OK
Select to complete the definition of Cutline. And notice that Cutline 1 appears in
the Cut Definition dialog box.

Again select “Add a cut line” icon L U and in the CHOOSE menu select Next until lower
loop of mill surface is highlighted as shown in the figure below.

Select Accept>Done.

OK
Select to complete the definition of Cutline. And notice that Cutline 2 appears in
on dialog box.
the Cut Definition

OK
Select to exit the Cut Definition dialog box.

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306
Pick ^ and set the following parameters

SCAN_TYPE TYPEJHELICAL
LACE_OPTION NO

We can not set the SCAN_TYPE to TYPE_HELICAL at the initial setting of parameters
because it becomes available only after we have set the Cut Type to Cut Line in the Cut
Definition dialog box.

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Play the toolpath using PLAY PATH dialog box and tool path will appear as shown
below.

You should notice that tool is Up Milling (Conventional) the surfaces. To change the
cutting condition to Climb milling we should reverse the cutting direction.

So select Seq Setup and check the Define Cut box then pick Done.

In the Cut Definition dialog box pick to specify the cutting direction

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307
Pick Filp>Okay to reverse the cutting direction

OK
Select to exit the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and tool path will appear as shown
below.

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308
Now you should notice that tool is Climb Milling the selected surfaces.

To introduce the smooth entry/exit motions set the following parameters

LEAD_RADIUS 10
ENTRY_ANGLE 45
EXIT_ANGLE 45
IN ITI AL_ENTY_EXT LE AD JN
FINAL_EXIT_EXT LEADJDUT

Again play the toolpath using PLAY PATH dialog box and notice the smooth entry and
exit motions into the cut as shown in the figure below.

In the above tool path, tool stays into contact for the complete machining operation
There are no sudden direction changes and single entry/exit motion into cut which
results in longer tool life and reduced machining time.

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309
As the toolpath looks satisfactory so change the following parameters for final tool path
computation.

STEP OVER .2

Remember never to use SCALLOP_HGT parameter for controlling the surface finish,
while machining with a flat end mill.

Select Done Seq to complete the definition of the NC Sequence.

Select File>Save to save the manufacturing model.

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310
EXERCISE 6

In this exercise we will define a surface milling NC Sequence to machine a part

consisting of surfaces of different topologies.

We will learn the following techniques in this exercise

❖ Adding Auto Inner Cutlines

❖ Adding smooth Entry/Exit motions
❖ Adding smooth connection movements between tool passes
❖ Inserting a CL Command at the end of CL Data
❖ Patterning a NC Sequence
❖ Generating CL Data for a patterned NC Sequence
❖ Gouge checking patterned NC Sequence

Set the working directory to FAN_CAVITY and open the manufacturing model
fan_cavity.mfg.

To define a new surface milling NC Sequence select Machining>NC Sequence

>Surface Mill>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name SEMIFINISH and hit Enter key or middle-click.

In the Tools Setup dialog box pick BEM8 from the list and select [ 0K ~).

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 3
PROF_STOCK_ALLOW .2
SCAN_TYPE TYPE_1
SPINDLE_SPEED 6000
C O O LAN TO P TIO N ON
CLEAR_DIST 1

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In SURF PICK menu select Done and select the model surfaces as shown in the figure
below.

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311
The order of selecting the surfaces is not important. To select more than one surface,
hold down the Ctrl key on the keyboard.

Select Done or middle-click twice to complete the selection of surfaces.

Now the Cut Definition dialog box will appear.

We will use the Cut Line Surface Milling to produce cuts shaped according to the
surface topology.

In the Cut Definition dialog box select Cut Line option

Note that Open Ends option is selected by default

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312
Now select “Add a cut line” icon

In the CHAIN menu select Tangnt Chain

Menu Manager

O ne By O ne

T a n g n t C h a in

S u r f C h a in

I n t e n t C h a in

System will select the adjacent tangent chain of edges

Select Done in the CHAIN menu.

OK
Select to complete the definition of Cutline. And notice that Cutline 1 appears in
the Cut Definition dialog box.

Again select “Add a cut line” icon

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313
In the CHAIN menu select Tangnt Chain and pick the highlighted edge shown in the
figure below.

System will select the adjacent tangent chain of edges.

Select Done in the CHAIN menu.

Select t 0K ) to complete the definition of Cutline. And notice that Cutline 2 appears in
the Cut Definition dialog box.

You can confirm the cutlines by picking anyone in the Cut Definition dialog box and
system will highlight it on the screen.

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314
 OK
Select to exit the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and view it from different sides.

You will notice that only at the start and end, toolpath follows the surface topology but
when it gets away from the cutlines it does not. To have more control over the toolpath
we should add more cutlines between the Cutline 1 and Cutline 2.

The edges highlighted in the following figure are a good choice for intermediate cutlines
between Cutline 1 and Cutline 2.

But it is very tedious to add all of these edges as cutlines. To cope this, Pro/NC
provides the option to add all the inner edges of selected surfaces as cutlines
automatically.

To add more cutlines select Seq Setup and check the Define Cut box then pick Done

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315
In the Cut Definition dialog box pick the Optlons tab

Here check the Auto Inner Cutlines option.

When Auto Inner Cutlines option is checked, system will consider the inner edges of
selected surfaces as the cutlines.

OK
Select to exit the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and notice that now the toolpath follows
the surface topology.

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316
Although now the machining time will be slightly longer but tool will machine the part
more comfortably and will result in improved finish and less tool wear.

To introduce smooth entry/exit motions and connection movements between passes,

set the following parameters.

LACE_OPTION LOOP_CONNECT
LEAD_RADIUS 20
IN ITI AL_ENTY_EXT LE AD JN
FINAL_EXIT_EXT LEAD_OUT
ENTRY_ANGLE 10
EXIT_ANGLE 10

Play the toolpath using PLAY PATH dialog box; it should appear as shown below.

To insert an Optional Stop at the end of the CL Data select Customize

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317
 T NC SEQUENCE

S e q S e tu p

P la y P a th

C u s to m iz e

S eq In fo

D o n e S eq

N e x t Seq

Q u it S e q

Now make sure that in the Customize dialog box <end of tool path> is highlighted and
select CL Command in the Insert drop down field as shown below.

In the CL Command dialog box pick icon.

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318
In the “cmd edit” menu select LOADTL-OPTSTOP>OPTSTOP

A 1 R -C L R 5 R F L O A D T i.

C O O L N T -F R O M M A C M IN

G O H O M E -L IN T O L MODE

LO A D T L -O P 5 T O P M U LT A X

O R IG IN -P O S T N M U L F A X _ o n _ o rf

P P F U N -R O T A E L OFSTNO

5 E L C T L -T M A R K O P S K IP

T O O L N O -U N IT 5 OPSTOP

CVCLES

PROBE_ CYCLES

PPO BE_5ETU P

SYN C PT

OPTSTOP command will appear in the dialog box as shown below.

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319
 OK
Select to exit the CL Command dialog box.

OK
Select to exit the Customize dialog box.

As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

SCALLOP HGT 05

Select Done Seq to complete the definition of the NC Sequence.

To pattern this sequence select Machining>Utilities>Pattern>NC Sequence and

select the SEMIFINISH NC Sequence.

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320
Now make sure that Csys Pattern is selected in the next menu and pick
Done>Rotate>Enter.

Enter 72 as the angle of rotation for the CL Data and hit Enter key.

ROT TYPE menu will appear. All the required options are selected by default so select
Done Rot.

In the ENTER VAL menu select Enter and enter 5 then hit Enter key.

As we don’t want to pattern in the second direction so select None in the PAT TYPE
menu.

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321
To create the CL data file for SEMIFINISH sequence, select CL Data>NC Sequence

M fg M o d e l

M fg S e tu p

P ro c e s s M g r

M a c h in in g

CL D a ta [

M o d ify

R e g e n e r a te

C om ponent

Set Up

R e la tio n s

P ro g ra m

In te g ra te

Now select the SEMIFINISH sequence in the NC Sequence SEQ LIST menu

In the PATH menu pick File and then Done

Pick in the Save a Copy dialog box. The file semifinish.ncl. 1 will be created.

To display the toolpath on screen select Display>Done on the PATH menu

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322
The toolpath will appear as shown below.

To perform gouge checking select CL

M fg M o d e !

M fg S etLip

P ro c e s s M g r

M a c h in in g

jC L D a ta

M o d ify '

R e g e n e r a te

C om ponent

5 e t Up

R e la tio n s

P ro g ra m

in t e g r a t e

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323
Select the newly created file semifinish.ncl and pick L

Check the box Add Ref Prts and select Done>Run.

System will report that no gouges are detected.

Although we could insert an optional stop in manufacturing parameter tree dialog box,
but it will only appear at the end of patterned MCD data i.e. once in the tape file. By
inserting CL Command at the end of CL Data, the optional stop will appear at the end of
each patterned instance i.e. 6 times in tape file for above case as shown in the figure
below.

So the machine operator may have the option to stop the machine at the end of
machining each bore and check the cutter condition or may perform some other task

Select File>Save to save the manufacturing model

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324
EXERCISE 7

In this exercise we will define a mill surface to find the area which previous ball end mill
cutter could not machine. Then we will machine this surface with a Surface Milling NC
Sequence.

The topics covered in this exercise are as follows

❖ Defining a Mill Surface as “Machinable Area”

❖ Defining a surface milling NC Sequence
❖ Adding smooth connection movements between tool passes

The Machinable Area Mill Surface is an advanced technique that calculates whether
the selected surfaces can be entirely machined with the selected cutting tool, and
creates explicit surface representations of the millable area (the portion of the selected
surfaces that can be milled), as well as of the remainder area (the portion that can not
be milled with the selected tool).
This technique allows to automate surface selection for subsequent machining with a
smaller tool or with a different machining strategy.
You have to specify surfaces to be milled, additional surfaces for gouge checking (if
any), the cutting radius of a ball end mill tool and the tool axis orientation. The system
then calculates the machinable area based on tool contact and gouge avoidance.

Set the working directory to FAN_CAVITY and open the manufacturing model
fan_cavity.mfg.

For this exercise we assume that the reference model was previously finished with the
ball end mill of diameter 8mm.

To create a new Mill Surface, select Mfg Setup>Mfg Geometry>Mill Surface>Create.

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325
Enter MS_A as the name of mill surface and hit Enter key or middle-click.

In the SURF DEFINE menu select Add>Advance>Done>Machinable Area>Done,

T SRFOPTS

Add E x tr u d e V ar Sec S w p

M e rg e R e v o lv e S w e p t B le n d

T rim S w eep H e lic a l S w p

E x te n d ------------ B le n d B o u n d a rie s

T r a n s fo r m F la t S e c t t o S rfs

D ra ft O ffs e t S rfs to S rfs

A re a O ffs e t C opy F ro m File

D ra ft O ffs e t C o p y b y T rim T a n g e n tT o S r f

Done/Return F ille t F re e F o rm

A dvanced S lo p e d

Done M a c h in a b le A r e a

Q u it Done
Q u it

System will ask to select the surfaces for finding the machinable area. So pick the
highlighted surface of reference model shown in the figure below.

System will use this surface to calculate the machinable area

Select or middle-click to proceed

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326
In the SRF PRT SEL check the Add Ref Prts box then select Done

Menu Manager
SR F PRT SEL

P I A d d R e f P rts

D one/Return

When Add Ref Prts (Add Reference Parts) option is checked, system uses all the
surfaces of the reference model to check gouging against.

Now the system will ask to enter radius of ball end mill for calculating Machinable Area

So enter 4.2 and hit Enter key or middle-click.

Although we should enter 4 but we have entered a larger value just to make sure that
we get smooth surface quality.

Now select the ASM_FRONT datum as the direction reference. Make sure that arrow
points upward then select Okay.

This direction of the arrow specifies the tool axis orientation

Double click the Srf Option in the dialog box.

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327
In the MILLABLE OR REMAINING menu select Find Remaining Area>Done

Find Remaining Area option finds the portion of the surface that can not be milled with
the specified tool.

Select i 0K ) to exit the dialog box. The surface will appear as shown below.

To define a new surface milling NC Sequence select Machining>NC Sequence >New

Sequence>Surface Mill>Done.

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328
In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name LOCALFINISH and hit Enter key or middle-click.

In the Tools Setup dialog box pick BEM3 from the list and select [ 0K ~1.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 1200
STEP_OVER 3
SCAN_TYPE TYPE_1
LACE_OPTION LOOP_CONNECT
SPINDLE_SPEED 6000
C O O LAN TO P TIO N ON
CLEAR_DIST 1

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

In SURF PICK menu select Mill Surface>Done>Select Srf and select the above
defined mill surface MS A.

T D E F IN E SR F

M odel S e le c t S rf

Mill V o lu m e C r e a te S rf

Mill S u r fa c e M o d ify S rf

Done B la n k

Q u it U n b la n k

Shade

Q u it

In the DIRECTION menu select Okay after making sure that arrow points away from the
surface. This direction indicates side of surface to be machined.

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In the SEL/SEL ALL menu select Select All to select all the surfaces included in the mill
surface.

This menu gives the option to select only desired surface patches included in the mill
surface quilt.

Select Done>Done to complete the selection of surfaces

Now the Cut Definition dialog box will appear.

We will use the Cut Line Surface Milling to produce cuts shaped according to the
surface topology.

In the Cut Definition dialog box select Cut Line option

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 —

- Cut Definition BE®

Cut Type
O Straight Cut
O From Surface Isolines
j(*)|Cut Line
O Projected Cuts
Along Cut Line

Cut Lines Options

► Cut Line References

® Machine Surfaces
O Retract Plane
Setup Cut Lines
| Cut Line Style
(♦) Open Ends O Closed Loops

________ III.

Note that Open Ends option is selected by default

Now select “Add a cut line” icon

In the CHAIN menu select Tangnt Chain

Pick the highlighted edge shown in the figure below.

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System will select the adjacent tangent chain of edges

Select Done in the CHAIN menu.

OK
Select to complete the definition of Cutline. And notice that Cutline 1 appears in
the Cut Definition dialog box.

Again select “Add a cut line” icon

In the CHAIN menu select Tangnt Chain and pick the highlighted edge shown in the
figure below.

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System will select the adjacent tangent chain of edges

Select Done in the CHAIN menu.

OK
Select to complete the definition of Cutline. And notice that Cutline 2 appears in
the Cut Definition dialog box.

OK
Select to exit the Cut Definition dialog box.

Play the toolpath using PLAY PATH dialog box and view it from different sides.

To introduce smooth entry/exit motions and connection movements between passes,

set the following parameters.

LEAD_RADIUS 20
IN ITI AL_ENTY_EXT LE AD JN
FINAL_EXIT_EXT LEAD_OUT
ENTRY_ANGLE 10
EXIT_ANGLE 10

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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As the toolpath looks satisfactory so change the following parameters for final toolpath
computation.

STEP_OVER .3
SCALLOPJHGT .001

Select Done Seq to complete the definition of the NC Sequence

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ENGRAVING
Engraving NC sequence is used to machine a Groove cosmetic feature. The tool
diameter determines the width of cut.

This sequence is used to machine text, logos or any other mark on reference part. We
don’t have to select individual entities like lines, arcs of the feature like in trajectory
milling.

The Groove feature can be machined in multiple steps. We can add more cuts with
STEP_DEPTH parameter.

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335
EXERCISE 1

In this exercise we will engrave text, projected on a surface as cosmetic Groove feature

The topics covered in this tutorial are as follows

❖ Creating a new Engraving NC Sequence

❖ Defining a new Grooving Tool
❖ Machining the Groove feature with multiple cuts

Set the working directory to INSERT and open the manufacturing model insert.mfg

Open the reference part insert.prt in a separate window and notice that it has a
cosmetic Groove feature as shown below.

□ INSERT.PRT
a RIGHT
\■a TOP
a FRONT
PRT_CSYS_DEF
i=»jb Protrusion id 39
H I Cosmetic id 32 H
4 Insert Here

To define a new engraving NC Sequence select Machining>NC

Sequence>Engraving>Done.

In the SEQ SETUP menu add Name to the list of checked items and select Done.

Enter the sequence name ENGRAVE and hit Enter key or middle-click.

In the Tools Setup dialog box define a new grooving tool of following parameters.

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To see the tool in separate window click Tool Window icon and the detailed
sketch of the tool will appear as shown below.

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 Close
Select to close the tool window.

Select [ 0K ~) to complete the definition of the tool.

In the MFG PARAMS menu select Set and enter the parameters as follows

C U TFE E D 800
GROOVEDEPTH .5
SPINDLESPEED 2500
COOLANTOPTION ON
C LE AR D IST 1
PLUNG EFEED 200

GROOVE_DEPTH parameter specifies the depth of cut

Pick ifc-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the system will ask to select the groove feature. So select the following cosmetic
groove feature with mouse pick.

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338
We can also perform engraving in STEP_DEPTH increments by setting the

STEP_DEPTH increment. So pick and set the following parameter in Parameter

Tree dialog box

STEP DEPTH .25

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

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Select Done in the MFG PARAMS menu to proceed

Now play the tool path using PLAY PATH dialog box. It should appear as shown below.

Select Done Seq to complete the definition of the NC Sequence

Select File>Save to save the manufacturing model.

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HOLEMAKING
A large number of operations like drilling, boring, countersinking, tapping and reaming
can be performed by using proper Holemaking NC Sequence.

The holes to be machined should be specified by defining the Hole Set. A Hole Set
includes one or more holes to be drilled. Each Hole Set has a drilling depth specification
associated with it. More than one Hole Set can be included in a single Holemaking NC
sequence. This allows drilling of holes with different depth specifications within a single
NC Sequence. There are various methods of selecting the holes some of those are

❖ By including all holes with a certain value of a feature parameter

❖ By selecting individual hole axes
❖ By including all holes on a specified surface
❖ By including all holes of a specified diameter
❖ By selecting individual datum points to mark the drill locations

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EXERCISE 1

In this exercise we will learn to define a Standard Holemaking NC Sequence.

Set the working directory to BLOCK and open the manufacturing model block.mfg. The
model will appear as shown below.

You should notice that the reference model contains four holes. These holes were
created with the Hole Tool of Pro/ENGINEER. System automatically creates the notes
and parameters for a hole feature. Notice that hole is of M8*1.25 specification and we
need to drill it with the drill of diameter 6.8

To define a new holemaking NC Sequence select Machining>NC Sequence

>Holemaking>Done.

In the HOLE MAKING menu, make sure that Drill and Standard are highlighted and
select Done.

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In the SEQ SETUP menu add Name to the list of checked items then pick Done.

Enter the sequence name DRILL and pick 0 icon or middle-click.

In the Tools Setup dialog box select the drill DRILL_M8 and pick ' 0K ). Notice
that it has the diameter of 6.8

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 100
SPINDLE_SPEED 1000
CLEAR_DIST 1

CLEAR_DIST parameter is used to set the clearance distance above the top of the hole
at which the FREE_FEED ends and the CUT_FEED begins.

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now HoleSet dialog box will open. Here different methods of selecting holes are present
but at this time we will use the Parameters option.

Parameters
So pick tab.

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343
Parameters Page enables you to include holes that have certain parameter values.
Feature Parameter list box contains a list of all feature parameters associated with Hole
features in the reference model.

We will use the DRILL_DIAMETER parameter to select the holes of a specific diameter.

So select DRILL_DIAMETER parameter in the Feature Parameter list box and notice
that by default Operator is set to “=” and Value for the parameter is given as “6.8”.

Pick to add this condition.

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 - HoleSet
HoleSet

Hole Selection H o e Seection

Awes Groups Points Axes G roups Points

D lameters Surfaces Parameters Parameters
Diameters o urfaces

Feaiure Parameter Feature Parameter

DRILL POINT A NGLE DR LL PO NT ANGLE
DRILL DIAMETER DRILL DIAMETER
CLASS CLASS
METR C METRIC
Operator value ■'aerator . iiue
v S. 800000 v 6.800000

Delete Delete

DR LL D AM ETER=b.800000

Options IJ ptions

ArSO Chamfei Use Prev... ] [ Depth...

Start hole (cr scan Select. Start ho e for scan Select.

Direction for 5-axis drilling Direction for 5-axis drilling

Show ru es used in seection Show ru es used in se ection

Preview Cancel Freview Cancel

Value field contains a drop-down list of all the currently present values for this
parameter.

Operator field contains a drop-down list of available operators for specifying a condition

Now the system will include all the holes that meet the criterion i.e. all holes with
DRILL_DIAMETER equal to 6.8

Now we will set the depth of tool travel into the holes. The desired depth is to drill the
hole to its full depth.

Select icon to specify the depth of drilling

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Hole Set Depth dialog box will pop up. Notice that Auto option is selected by default

Auto option determines the depth of drilling automatically, by referencing hole geometry

Select to exit Depth dialog box

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346
Again select to exit the Hole Set dialog box.

Select Done in the HOLES menu.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that system has automatically determined the depth of each hole by analyzing its
geometry.

You should also notice that tool is gouging the part while traversing from right to left
side. To avoid gouging, tool must retract to a certain level and then traverse.

To lift the tool upward so that it has sufficient clearance from the reference part, pick
Y_
^ and set the following parameters.

PULLOUT DIST 10

PULLOUT_DIST parameter allows the tool to lift by a certain distance before traversing
The default is a dash (-), in which case this parameter is not used.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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347
Although tool is now sufficient above than the previous traverse level but it is still very
close to the reference part. It is better if we force the tool to traverse at the retract plane
level.

So pick and set the following parameters.

PULLOUT DIST 0

The default is a dash (-), in which case this parameter is not used. If the value of
PULLOUT_DIST is set to 0, then the tool will return to the retract plane when moving to
the next hole.
Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Now the tool is at a very significant distance from the part during traverse motion.

You should notice that tool comes down towards the hole with rapid feed rate and when
it is just 1mm (equal to CLEAR_DIST parameter value) above the hole, starts moving
down at the cutting feed rate as elaborated in the figure above.

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To stop the rapid movement well above the hole, set the following parameter.

CLEAR DIST 3

Play the tool path using PLAY PATH dialog box. It should appear as shown below.

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349
Now the tool stops its rapid movement 3mm above the start point of the hole and then
come down with cutting feed.

As the toolpath looks satisfactory so select Done Seq to complete this sequence.

Select File>Save to save the changes we made so for.

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350
EXERCISE 2

In this exercise we will learn to define a Countersink Holemaking NC Sequence.

Set the working directory to BLOCK_CS folder and open the manufacturing model
block_cs.mfg. The model will appear as shown below.

You should notice that the reference model contains six holes. Four holes are
countersunk and two are not. Now we will define a Countersink Holemaking NC
Sequence to countersink the holes.

To define a new holemaking NC Sequence select Machining>NC Sequence

>Holemaking>Done.

In the HOLE MAKING menu, select Countersink>Done.

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In the SEQ SETUP menu add Name to the list of checked items then pick Done.

Enter the sequence name COUNTERSINK and pick icon or middle-click.

In the Tools Setup dialog box select the drill CSINK12 and pick [ 0K ~1.

In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 100
SPINDLE_SPEED 1000
CLEAR_DIST 1
PULLOUT_DIST 0

Pick t-3 to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now HoleSet dialog box will open. Check the Auto Chamfer option and notice that
system automatically selects the axis of those holes which are countersunk.

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If Auto Chamfer is checked, the system will automatically include all holes with
chamfers that can be machined with the current tool, and automatically determine depth
for Countersink drilling.

Select to exit the HoleSet dialog box.

Select Done in the HOLES menu

Play the toolpath using PLAY PATH dialog box. Notice that system is only machining
the holes which are countersunk as shown below.

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353
Notice that system has automatically determined the depth of Countersink drilling for
each hole by analyzing its geometry as elaborated below.

As the toolpath looks satisfactory so select Done Seq to complete this sequence

Select File>Save to save the changes we made so for.

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EXERCISE 3

In this exercise we will learn to center-drill the holes to the required depth with Standard
Holemaking NC Sequence.

Center-drilling is usually first step in drilling operations. It helps to avoid deflection of drill
while entering the material.

Set the working directory to BLOCK_CD folder and open the manufacturing model
block_cd.mfg. The model will appear as shown below.

To define a new holemaking NC Sequence select Machining>NC Sequence

>Holemaking>Done.

In the HOLE MAKING menu, make sure that Drill and Standard are highlighted and
select Done.

In the SEQ SETUP menu add Name to the list of checked items then pick Done.

0
Enter the sequence name CENTER-DRILL and pick ULJ icon or middle-click.

In the Tools Setup dialog box select the center-drill CD8 and pick L 0K 1
In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 100
SPINDLE_SPEED 1000
CLEAR_DIST 1
PULLOUT_DIST 0

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Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Parameters
Now HoleSet dialog box will open. Here pick tab.

Select DRILL_DIAMETER parameter in the Feature Parameter list box and pick
I Add 1tab.

Now the system will include all the holes with DRILL_DIAMETER parameter equal to
6.8

Now we will set the depth of tool travel into the holes. The desired depth is to take the
tool tip 3mm below from the top surface of reference part.

Select icon to specify the depth of drilling.

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Hole Set Depth dialog box will pop up. Select Blind option and the interface of the
dialog box will change.

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r-----------------------------------------------------
H o le Set D e p th B t*i H o le Set D e p th
B ’
Hole Depth Criteria Hole Depth Criteria

Hole Depth Tool Depth T ool Control point Hole Depth Tool Depth T ool Control point 1
O Blind ® Shoulder (T ip 1 ) ® lB iin d ® Shoulder (Tip 1) V

® Auto O Tip 0 Auto Tip

O Thru All O Thru All
Start Surface
Select parts to be used for depth calculation -----rV
© Surface 1__________
Select... r
k
I Select All 1 I Select... 1 Unselect...
0 1 Depth )

m i 1 Cancel -
End Surface
\_____ ___________ _____ I
(+ Surface Select... |

Ot Depth

□ Use breakout distance

| OK Cancel
3 L

Blind option specifies to drill from the start surface (or Z level) to specified depth.

S elect...
To specify the Start Surface, pick.

Select the top surface of the part as shown below.

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The start surface is used to determine the starting point for each hole. The starting point
is created at the intersection of the start surface and hole axis

To specify the depth of drilling, select Z Depth and enter 3.

So the tool will move by 3mm from the start point down in the negative Z direction

Now change the Tool Depth option from Shoulder to Tip.

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The Tool Depth option determines if the drilling depth will be with reference to the
Shoulder or the Tip of the tool.

Select to exit Depth dialog box.

Again select to exit the HoleSet dialog box.

Select Done in the HOLES menu.

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Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

As the toolpath looks satisfactory so select Done Seq to complete this sequence

Select File>Save to save the changes we made so for.

The following figure elaborates the difference between Shoulder and Tip options.

Tool Depth Option

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361
EXERCISE 4

In this exercise we will center-drill the holes to the required depth.

We will select the holes by selecting the surface and system will include all the holes
located on this surface in a hole set.

Set the working directory to COVERJNSERT and open the manufacturing model
coverjnsert.mfg.

To define a new holemaking NC Sequence select Machining>NC Sequence

>Holemaking>Done.

In the HOLE MAKING menu, make sure that Drill and Standard are highlighted and
select Done.

In the SEQ SETUP menu add Name to the list of checked items then pick Done.

Enter the sequence name CENTERDRILL and pick 0 icon or middle-click.

In the Tools Setup dialog box select center-drill CD6 from the list and then pick
I 0K I
In the MFG PARAMS menu select Set and enter the parameters as follows.

CUT_FEED 100
SPINDLE_SPEED 1000
COOLANTOPTION ON
CLEAR_DIST 3
PULLOUT_DIST 0

CLEAR_DIST parameter is used to set the clearance distance above the top of the hole
at which the FREE_FEED ends and the CUT_FEED begins.

Pick iJ i to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now the Hole Set dialog box will open. Here different methods of selecting holes are
present but at this time we will use the Surfaces option.

Surfaces
Select tab to access the Surfaces page.

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Pick tab to select the surfaces for gathering holes.

Now pick the top surfaces of the reference model as shown in the figure below and then
middle-click to confirm the selection

The system automatically includes all Holes or round Cut features located on selected
surfaces. So the system will select the two round cuts located on these surfaces. You
can confirm it by looking in the selection bins in Surfaces and Axes pages.

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Now we will set the depth of tool travel into the holes. The desired depth is to take the
tool 5mm below from the top surface of reference part.

Select icon and Hole Set Depth dialog box will pop up.

Select Blind option and the interface of the dialog box will change.

Blind option specifies to drill from the start surface (or Z level) to specified depth.

Select... |
To specify the Start Surface, pick

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364
Select the top surface of the part as shown below.

The start surface is used to determine the starting point for each hole. The starting point
is created at the intersection of the start surface and hole axis

To specify the depth of drilling, select Z Depth and enter 5.

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So the tool will move by 5mm from the start point down in the negative Z direction

Now change the Tool Depth option from Shoulder to Tip.

The Tool Depth option determines if the drilling depth will be with reference to the
shoulder or the tip of the tool.

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Select to exit Depth dialog box.

Again select to exit the Hole Set dialog box.

Select Done in the HOLES menu.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that only one hole is being machined although we have selected both. It is so
because both holes are located on different surfaces and we selected only one surface
as Start Surface. The system cannot determine depth for the second hole so it has
ignored it.
We should specify depth references for both holes separately. As we can specify only
one depth option for a hole set so we will remove the second hole from the selection
and then define a new hole set.

Select Seq Setup>Holes>Done

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Pick the above defined hole set Hole Set # 1

Delete
In the Hole Set dialog box pick axis A_8 and select and A 8 will be removed
from selection bin.

Select to exit the Hole Set dialog box.

In the HOLES menu select Hole Set>New Set to define a new hole set

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368
 Surfaces
tab to access the Surfaces page,

tab to select the surfaces for gathering holes.

Now pick the top surface of the reference model as shown in the figure below and then
middle-click to confirm the selection

Select icon and Hole Set Depth dialog box will pop up

Select... |
Select Blind option and to specify the Start Surface, pick

Select the following surface of the part.

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To specify the depth of drilling, select Z Depth and enter 5.

Now change the Tool Depth option from Shoulder to Tip.

Select to exit Depth dialog box.

Again select to exit the Hole Set dialog box.

Select Done in the HOLES menu.

Now play the tool path using PLAY PATH dialog box. It should appear as shown below.

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Now the drilling depth is 5mm from the selected top surface for each hole.

As the toolpath looks satisfactory so select Done Seq to complete this sequence

Select File>Save to save the work done so for.

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371
EXERCISE 5

In this exercise we will drill the holes which have been center-drilled in the previous
exercise. This time instead of using standard drill NC Sequence we will use the Deep
type sequence. This sequence performs peck drilling. The tool feeds in the specified
distance then rapids back out of the hole. The next peck takes the tool deeper and it
rapids out of the hole. This process is repeated until the final depth is reached.

Set the working directory to COVERJNSERT and open the manufacturing model
coverjnsert.mfg.

To define a new holemaking NC Sequence select Machining>NC Sequence>New

Sequence>Holemaking>Done

In the HOLE MAKING menu, select Deep and make sure that Constant Peck is
highlighted and select Done.

•w H O LE M A K IN G

1 D rill 1 D rill

Face Face

B o re B o re

C o u n te r s in k C o u n te r s in k

Tap Tap

R eam R eam

C u s to m C u s to m

| S ta n d a r d | S ta n d a r d

D eep D eep
------------- ►
B r e a k C h ip B r e a k C h ip

W eb W eb

Back Back

F ix e d F ix e d

F lo a tin g F lo a tin g

C o n s ta n t P e c k C o n s ta n t P e c k 1

V a ria b le P e c k V a ria b le P e c k

Done Done

Q u it Q u it

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name PECK_DRILL and pick ULJ icon or middle-click. 0
In the Tools Setup dialog box select DRILL6 from the list then select [ 0K

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In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 100
PECK_DEPTH 5
SPINDLE_SPEED 800
COOLANTOPTION ON
CLEAR_DIST 2
PULLOUT_DIST 0

PECK_DEPTH sets the incremental depth for each drilling pass.

Pick sJi to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed.

Now HoleSet dialog box will open. Here different methods of selecting holes are present
but at this time we will use the Axes option.

Axes
So pick tab if not active by default.

Pick and pick the axis A_8 and A_9 while holding down the Ctrl key.

Now middle-click to confirm the selection. The axis will appear in the selection bin as
shown below.

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Select icon to specify the depth of drilling

Notice that Auto and Shoulder options are selected by default

Auto option determines the depth of drilling automatically, by referencing hole geometry.

Select to exit Depth dialog box

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374
Again select to exit the Hole Set dialog box.

Select Done in the HOLES menu.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that tool has traveled below the bottom surface of reference part. It is just to
clear the material left by the angled shoulder of the drill.

H i icon on the PLAY PATH dialog box.

Pick L5J

Pick on the toolpath as shown below and tool will move to the picked point as shown
below.

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Notice that shoulder of the drill travels up to the bottom surface of the reference part. It
is due to the Shoulder option selected in the Depth dialog box. It will be better if we take
the drill further down to make sure that drill completely clears the material at the bottom
of the hole.

Y_

So pick ^ and set the following in Parameter!"ree dialog box.

BREAKOUT DISTANCE 3

BREAKOUT_DISTANCE specifies the distance added to the depth of drilling.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

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Select Done Seq to complete this sequence.

Select File>Save to save the changes we made so for.

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377
EXERCISE 6

In this exercise we will drill the holes with the Break Chip type NC Sequence. This
sequence performs high-speed peck drilling. This cycle differs from the peck drilling
cycle by the fact that the tool feeds in the specified distance then rapids back by a
distance specified by a parameter instead of retracting out of the hole. This process is
repeated until the final depth is reached.

This time we will select the holes by their diameters.

Set the working directory to COVERJNSERT and open the manufacturing model
coverjnsert.mfg.

To define a new holemaking NC Sequence select Machining>NC Sequence>New

Sequence>Holemaking>Done

In the HOLE MAKING menu, select Bread Chip>Done.

In the SEQ SETUP menu add Name and Tool to the list of checked items and select
Done.

Enter the sequence name HS_PECK_DRILL and hit Enter key or middle-click.

In the Tools Setup dialog box select DRILL6 from the list and select [ 0K ~)

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In the MFG PARAMS menu select Set and enter the parameters as follows

CUT_FEED 100
PECK_DEPTH 5
BREAKOUT_DISTANCE 3
SPINDLE_SPEED 800
COOLANTOPTION ON
CLEAR_DIST 2
PULLOUT_DIST 0
INTER_RET_HEIGHT 1

INTER_RET_HEIGHT specifies the distance the tool retracts between pecks

Pick ^ to apply the changes and exit the Parameter Tree Dialog box.

Select Done in the MFG PARAMS menu to proceed

Now HoleSet dialog box will open. Here different methods of selecting holes are present
but at this time we will use the Diameters option.

In the Hole Set dialog box select

Pick I Add 1

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The “Select hole diameter” dialog box opens. It lists all the hole diameters present in the
model.

Select the given diameter 6.0 in the list then pick 1 0K 1.

Select tab and see that both hole axis A 8 and A 9 are listed

Select icon to specify the depth of drilling

Notice that Auto and Shoulder options are selected by default. So you do not need to
change any option.

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380
Select to exit Depth dialog box.

Again select to exit the Hole Set dialog box.

Play the toolpath using PLAY PATH dialog box. It should appear as shown below.

Notice that toolpath is same as of Deep hole drilling cycle except that retraction height
has been reduced.

Select Done Seq to complete this sequence.

Select File>Save to save the changes we made so for.

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