Creo Parametric Milling PDF

Creo
Parametric Mil ing

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Creo Parametric Milling
Jouni Ahola
ISBN 978-952-7074-31-2
Copyright Jouni Ahola
February 2015
Publisher: Klaava Media
www.klaava.com
book@klaava.com
All rights reserved. This book may not be reproduced in any form, in whole or in
part, without written permission from the author.
Creo Parametric Mil ing
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Table of contents
1
CREO PARAMETRIC INTERFACE
………………………………………………………………………………………………..
6
1.1 THIS BOOK
………………………………………………………………………………………………………
6
1.2 CHAPTERS AND TASKS
………………………………………………………………………………………………………
6
1.3 INTRODUCTION TO MILLING MANUFACTURING
…………………………………………………………………………………… 7
1.4 STARTING
………………………………………………………………………………………………………
9
1.5 OPTIONS AND CONFIGURATIONS
………………………………………………………………………………………………………
10
1.5.1
MANUFACTURING CONFIGURATIONS
…………………………………………………………………………………………….12
1.6 CREATING A NEW TEMPLATE
………………………………………………………………………………………………………
1.7 WORKING DIRECTORY
………………………………………………………………………………………………………
1.8 IMPORT REFERENCE MODEL
………………………………………………………………………………………………………
1.8.1
CREATING DATUM FEATURES
………………………………………………………………………………………………………
1.8.2
MODEL PROPERTIES
………………………………………………………………………………………………………
1.9 CUTTING PARAMETERS
………………………………………………………………………………………………………
41
1.9.1
CUTTING SPEED FORMULAS
………………………………………………………………………………………………………
1.9.2
MILLING FEED CALCULATING
………………………………………………………………………………………………………
1.9.3
SURFACE ROUGHNESS
………………………………………………………………………………………………………
46
1.10
CAMSHAFT PLATE CUTTING PARAMETERS
………………………………………………………………………………………47
2
CREO PARAMETRIC BASIC MILLING
…………………………………………………………………………………………48
2.1 COMMON PROCEDURE FOR CREATING A NEW MANUFACTURING
MODEL ………………………………………………48
2.2 REFERENCE
MODEL………………………………………………………………………………………………
2.3 WORKPIECE
MODEL………………………………………………………………………………………………
51
2.4 CONFIGURING WORKCELL
………………………………………………………………………………………………………
2.4.1
3-AXIS MILL MACHINE TOOL SIMULATION
………………………………………………………………………………………60
2.4.2
CREATING WORKCELL
………………………………………………………………………………………………………
2.5 MANUFACTURING
OPERATIONS………………………………………………………………………………………
2.5.1
CREATING MACHINE COORDINATE SYSTEM
…………………………………………………………………………………….65
2.5.2
CREATING OPERATIONS
………………………………………………………………………………………………………
2.6 FIXTURES
………………………………………………………………………………………………………
2.7 CUTTING TOOLS
………………………………………………………………………………………………………
75
2.7.1
STANDARD MILLING TOOLS
………………………………………………………………………………………………………
2.7.2
CREATING STANDARD MILLING TOOLS
…………………………………………………………………………………………..80
2.7.3
CREATING TOOL CUTTING DATA
……………………………………………………………………………………………………
82
2.7.4
SOLID MILLING
TOOLS………………………………………………………………………………………………
2.7.5
SOLID TOOLS COORDINATE SYSTEMS
……………………………………………………………………………………………..87
2.7.6
SOLID TOOL PARAMETERS
………………………………………………………………………………………………………
88
2.8 TOOLS FOR CAMSHAFT PLATE
………………………………………………………………………………………………………
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2.8.1
FACE MILLING TOOL
………………………………………………………………………………………………………
2.8.2
END MILL
………………………………………………………………………………………………………
2.8.3
SPOT DRILL
………………………………………………………………………………………………………
92
2.8.4
DRILLING TOOL
………………………………………………………………………………………………………
2.8.5
TAPPING TOOL
………………………………………………………………………………………………………
93
2.8.6
CHAMFER TOOL
………………………………………………………………………………………………………
2.9 TOOL LIBRARY
………………………………………………………………………………………………………
2.10
COMMON ABOUT NC SEQUENCES
…………………………………………………………………………………………………
98
2.10.1
MILLING MANUFACTURING PARAMETERS
………………………………………………………………………………….99
2.10.2
MILLING NC
SEQUENCES………………………………………………………………………………………
101
3
CAMSHAFT PLATE MILLING SEQUENCES
………………………………………………………………………………. 102
3.1 FACE MILLING
………………………………………………………………………………………………………
102
3.1.1
EDITING NC SEQUENCE PARAMETERS
………………………………………………………………………………………….. 107
3.1.2
LATERAL CONTROL FACE MILLING PARAMETERS
…………………………………………………………………………… 112
3.1.3
MATERIAL REMOVAL FEATURE
……………………………………………………………………………………………………
115
3.2 PROFILE MILLING
………………………………………………………………………………………………………
116
3.2.1
LEAD IN AND LEAD OUT
………………………………………………………………………………………………………
119
3.2.2
DEPTH AND LATERAL CONTROL PARAMETERS
………………………………………………………………………………. 122
3.2.3
CUTTER COMPENSATION
………………………………………………………………………………………………………
124
3.2.3.1
CUTTER COMPENSATION IN CREO
……………………………………………………………………………………………
125
3.3 VOLUME MILLING
………………………………………………………………………………………………………
129
3.3.1
SCANNING VOLUME MILLING PARAMETERS
…………………………………………………………………………………. 139
3.4 POCKET MILLING
………………………………………………………………………………………………………
144
3.5 HOLEMAKING
………………………………………………………………………………………………………
148
3.5.1
BASIC DRILLING
………………………………………………………………………………………………………
150
3.5.2
COUNTERSINK DRILLING CYCLE
……………………………………………………………………………………………………
151
3.5.3
STANDARD DRILLING CYCLE
………………………………………………………………………………………………………
153
3.5.4
TAPPING CYCLE
………………………………………………………………………………………………………
157
3.6 TRAJECTORY MILLING
………………………………………………………………………………………………………
160
3.6.1
2-AXIS TRAJECTORY MILLING
………………………………………………………………………………………………………
161
3.7 OPERATION 2.
………………………………………………………………………………………………………
169
3.8 MILL SURFACES AND MILL WINDOWS FOR FACE MILLING
…………………………………………………………………… 171
3.9 MILL WINDOW FACE MILLING
………………………………………………………………………………………………………
173
3.10
2-AXIS TRAJECTORY MILLING
………………………………………………………………………………………………………
176
3.11
CHAMFER AND ROUND MILLING STEPS
……………………………………………………………………………………….. 180
3.12
TOOLPATH SIMULATION
………………………………………………………………………………………………………
184
3.12.1
PLAY PATH
………………………………………………………………………………………………………
185
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3.12.2
MATERIAL REMOVAL SIMULATION
…………………………………………………………………………………………. 186
3.12.3
MACHINE PLAY
………………………………………………………………………………………………………
187
3.13
CAMSHAFT PLATE TOOLPATH SIMULATION
………………………………………………………………………………….. 188
3.13.1
VERICUT SIMULATION
………………………………………………………………………………………………………
190
3.13.2
MACHINE PLAY CONFIGURATION
…………………………………………………………………………………………….
194
3.13.3
MACHINE PLAY
SIMULATION………………………………………………………………………………………
198
4
POSTPROCESSING
………………………………………………………………………………………………………
202
4.1 WHAT IS A POSTPROCESSOR
………………………………………………………………………………………………………
202
4.2 CL DATA
………………………………………………………………………………………………………
205
4.3 CL DATA FOR THE CAMSHAFT PLATE BOTTOM SIDE
…………………………………………………………………………… 207
4.3.1
CL DATA FOR THE CAMSHAFT PLATE TOP SIDE
………………………………………………………………………………. 210
4.3.2
MANIPULATING CL DATA FOR THE CAMSHAFT PLATE
…………………………………………………………………….. 213
5
CNC LANGUAGE AND STRUCTURE
………………………………………………………………………………………… 214
5.1 NC OR CNC
………………………………………………………………………………………………………
214
5.2 STRUCTURE OF AN NC
PROGRAM…………………………………………………………………………………………
215
5.3 COMMON G- AND M-CODES
………………………………………………………………………………………………………
217
5.3.1
G-CODE CANNED CYCLES
………………………………………………………………………………………………………
219
5.4 CAMSHAFT PLATE NC CODE
………………………………………………………………………………………………………
220
5.5 CUSTOMIZING NC CODE OUTPUT
…………………………………………………………………………………………………….
221
6
3 AXIS MACHINING
………………………………………………………………………………………………………
223
6.1 2.5 VERSUS 3 AXIS
………………………………………………………………………………………………………
223
6.2 3 AXIS SURFACE MACHINING
………………………………………………………………………………………………………
224
6.2.1
STRAIGHT CUT SURFACE MILLING
………………………………………………………………………………………………..
225
6.2.2
MILL WINDOW SURFACE MILLING
……………………………………………………………………………………………….
232
7
APPENDIX
………………………………………………………………………………………………………
238
7.1 CREO PARAMETRIC QUICK REFERENCE CARD
……………………………………………………………………. 238
INDEX
………………………………………………………………………………………………………
244
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1
CREO PARAMETRIC INTERFACE
1.1
This book
This book is a follow-up to the book Creo Parametric Modeling. If you already
know the basis of the Creo Parametric and modeling you can use this book easily.
If you are using the software first time, and want to go straight to the CAM module,
you can download the needed 3D models and tools:
The downloaded models are in the native Creo Parametric 2-format (.prt),
(.asm), (.drw) and (mfg).
Also the models are available in the STEP-format. In the chapter 1.7 are in-
structions how to import models from the other systems.
Before you use Creo Parametric to machine components (CAM), it is important to
understand the complete manufacturing process and the steps involved in this pro-
cess. It is also important to understand the elements that make up completed manu-
facturing models.
Download site: http://www.gold-cam.fi/en/download
Or inquire: gold-cam@dlc.fi
1.2
Chapters and Tasks
This book consists of several chapters each dealing with a primary theme of Creo
Parametric and are meant to be used alongside the running Creo Parametric.
You will learn the material best if you take time along the way to read the text care-
fully and think about what you are doing and observing what happens.
Usually, first is the theory and then is the Task. Tasks are marked as chapter num-
bers, for example:
Task 1.2: How to use this book?
When the task is ready, there is a text:
Task 1.2 is ready.
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1.3
Introduction to Milling Manufacturing
The milling manufacturing process can be divided into different main-level steps;
1. Manufacturing Template
2. Reference Model
3. Workpiece
4. Ref Model and Workpiece
5. Fixture
6. NC Sequences and tools
7. Simulation
8. CL Data and Postprocessing CNC Code
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1. A template manufacturing model can be selected and copied during the creation
process. Using template manufacturing models enables you to standardize on the
initial manufacturing model configuration. By default, the template manufactur-
ing model includes default datum planes and a default coordinate system.
2. The reference model represents the final machined component. Surfaces and
edges are selected from the reference model and are used as references when cre-
ating NC steps. The reference model can be also imported from the other CAD-
software. You must assemble a reference model before creating NC steps.
3. Workpiece model – This represents the unmachined stock material. It is an op-
tional element and is not required to create NC steps. However, using a
workpiece enables you to simulate the machining of the stock material.
Workpieces can be standard stock billets or you can configure them to represent
models such as castings.
4. You can assemble or create a workpiece in a manufacturing model. A number
of options are available. An automatic workpiece enables you to create a rectan-
gular or round workpiece depending on your requirements.
5. Fixtures are parts or assemblies that can be used to hold the component being
machined. For example, you can create chuck assemblies and use them as fix-
tures.
6. An NC sequence is a workpiece feature that represents a single tool path. The
tool path consists of:
Cut motions, that is, tool motions while actually cutting the workpiece
material
Approach, exit, connect moves
Additional CL commands and post-processor words (for example,
feedrates, PPRINT, OPSTOP).
7. Toolpaths and machine simulations are one of the most important stages in the
manufacturing process. You can display the toolpath for an operation, a single
step, or multiple steps. You can also display tool path and machine simulation to-
gether if the machine assembly is defined.
8. Post-processing is the final stage in the manufacturing process. When toolpaths
and simulation have been completed, you can create ASCII format cutter location
(CL) data files for operations or selected NC steps. This CL data file will then
have to be postprocessed to generate an MCD file, containing the proper CNC
codes.
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1.4
Starting
Opening the software:
The main interface:
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1.5
Options and configurations
You can access the Creo Parametric Options dialog box by clicking File - Options.
The options dialog box contains the following categories:
Favorites – You can add favorite config.pro options in this panel.
Configuration Editor – Location for the config.pro editor.
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Default settings:
Save settings:
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1.5.1 Manufacturing Configurations
There are a few useful configurations for manufacturing, for example you can de-
fine where cutting tools and NC machines locates. Before that you need to create
folders and put your solid tools and machine assemblies and so on to them. For ex-
ample:
Task 1.5.1: NC Options.
Open Configuration Editor. Select Find
Type keyword: pro_mf – Find Now
These all settings are for directories.
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First, select pro_mf_workcell_dir:
Select Browse and give the full path to the folder where are NC Machine assem-
blies:
OK.
Add/Change.
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You can see the new settings in the options list:
Do the same for pro_mf_tprm_dir.
You can select option and Add to Favorites.
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When options are defined – OK. Save options – Yes.
Give the path to the installation folder where the original config.pro locates (if you
have writing rights).
Next time you can find and change options easily if needed.
Task 1.5.1 is ready.
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1.6
Creating a new template
New models or assemblies should be created using templates. It means that every us-
ers of the company has the same way to start the work. The model contains the same
information, for example:
Datums – default datum planes and coordinate system, named by user.
View Orientations – same standard view orientations.
Parameters
Layers
Units
The system default templates locate in installation folder:
Manufacturing template:
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When you start the new model and give the name and clear Use default template
box, you get the New File Options window. Here you can select or browse template.
Note! Sometimes may happen, that you can´t open templates or there is no template
what you need. You can create customized templates that can be used to create new
parts and assemblies.
Task 1.6: Own template
Now the task is create manufacturing template for milling. It should be Manufactur-
ing template, because manufacturing session will be assembly.
Start new:
Select Empty.
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Create planes by selecting Plane tool. Show the plane Tags:
If the you can´t see the plane names in the model tree, select settings and Tree
Filters:
Create the Coordinate System:
Select up to 3 references, such as plane, edge, coordinate system, or point to place
coordinate system.
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Select planes in order. Select Orientation page. You can change the orientation if
needed.
Your coordinate system is shown in to the same direction as the spin center. Red
means X-axis, Green means Y-axis and blue is the Z-axis. (RGB).
Give the name and click OK.
You can also rename the planes as above.
Below is the picture of the 3-axis milling machine. Now the coordinate system of the
template matches to the milling machine axis. Usually in Vertical Machining Centre
(VMC), Z-axis is the tool axis pointing up and X-axis is to the right and Y-axis
pointing forward.
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The other useful way is Creating view orientations. Click Reorient from the bot-
tom of the Named Views drop-down list in the In Graphics toolbar. Select the
NC_FRONT plane as Reference 1 (Front). Select the NC_TOP plane as Reference 2
(Top). Expand the Saved Views menu and give the name: NC_FRONT > Save. OK.
You can open saved views:
You can make as many views as you want. Save the template.
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Next step is to define units: File - Prepare - Model Properties:
Select Units – change:
Select new:

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Give the units. OK.
Set new unit_system1 and Convert dimensions – OK. - Close
Close Model Properties window. Save the template.
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Using layers in the manufacturing assembly. Similar to parts, you can hide non-
solid geometry of assembly features including assembly datum features and surfaces.
Unlike parts, you can add components to layers in an assembly. If you add com-
ponents to a layer and then hide layer, the component geometry hides.
Select Layers:
Click New Layer:
Give the name and Layer id. Select planes from the template:
OK. Activate layer from the tree and hide:
Planes are hided from the template and you can see the name of the layer dimmed.
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Click Layers again and you can see the model tree. Planes are hided. Make new lay-
er for Coordinate systems. Give the name and Id and select coordinate system:
If you hide or unhide layers, you need to Save Status. (Right lick)
Now, unhide both layers and Save Status. Save the template.
Next parameters. Parameters are metadata information that can be included in a
model template or created by a user in his own part or assembly. Parameters enable
you to add important additional information into part and assembly models.
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You can access parameters in many ways:
Or From the Ribbon and Tools tab:
Select one previously mentioned way to create parameters: Parameters window:
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Click plus button and give the parameters. You can select: Integer, Real Number,
String or Yes No as type.
OK. Save the template. Now the template is ready enough for testing. When you are
going to make a new manufacturing assembly, you can browse your own template:
Task 1.6 is ready.

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1.7
Working directory
Creo Parametric is started in the default working directory, which is defined during
installation of the software. Different working directories can be set by the user.
There are many ways to define a new working directory:
Icon - Select Working Directory:
From the Folder Tree or Web browser- Right click the folder and select: Set
Working Directory.
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From the File menu:
Click (File), Open – Right click the folder:
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1.8
Import reference model
Sometimes the machinable model is made in different CAD software. In Creo you
can Open many kind of types:
In this case the original model is in STEP-format. STEP stands as Standard
Exchange Protocol or international standard for product data exchange and
extension is . STP
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Note! Skip this task if you already have the model!
Task 1.8: Import STEP-file.
Crerate Working Directory first! Download and save STEP-type model to your
working directory. In the Ribbon, click Open. Select Type: STEP and select
camshaft_plate.stp
From Import New Model window: Use Part as Type, Check Use Templates – Select
Details – Select Options - Select Template (here: mmns_part_solid). Ok. - Ok.- Ok.

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Model opens:
The Datum Planes comes from the template. The datum planes are in relation to the
coordinate system of the model. From a manufacturing point of view, it is important
to know how to make planes, axis and coordinate systems. You can also see the
datum plane and axis names. In the Ribbon – View – Show or hide tags.
Task 1.8 is ready.

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1.8.1 Creating Datum Features
Datum features are commonly required as references when creating other features.
Datum features can be used as dimensioning references, feature placement refer-
ences, and assembly references. The default color of datum features in the graphics
window is brown (datum planes are both brown and gray, depending upon which
side is currently being viewed). The following four types of datum features can be
created:
Datum Planes
Datum Axes
Datum Points
Datum Coordinate Systems
Datum Axis Definition
Datum axes are individual features that can be redefined, suppressed, hidden, or
deleted. A datum axis is a linear reference that has no mass. It is infinite in length,
but its display length can be edited by selecting a reference, specifying a value, or
dragging the drag handle.
A datum axis can be used as construction geometry in a feature. It can also be used
as a reference for:
Other datum features, such as datum planes.
Other features, such as a hole location.
Assembling components
Task 1.8.1: Create datum axes on a part model
Enable only the Datum Axis Display type. In the Ribbon - Select Model – Axis:
Select the hole surface as above. OK.

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Create axis for all holes. You can preselect the hole surface and then select the Axis
Tool.
Creating Coordinate System.
In the Ribbon - Select Model – Coordinate System:
Click Create a datum coordinate system from the Datum Group.

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Select the RIGHT Datum Plane and press CTRL and select the TOP Plane and the
surface as shown below:
Select the Orientation tab. Click Flip to project Y. Select the Properties tab and edit
the name of the coordinate system: PLATE_BOTTOM_NC. OK.
The coordinate system should be located as shown below:

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Do the same procedure to the top side of the model and name the coordinate system
as PLATE_TOP_NC.
Save the model and close the window. Return to the manufacturing assembly.
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1.8.2 Model properties
You can establish a system of units and a density value for the specific material type
used in your models. You can then create various types of analyses, such as measur-
ing distances, angles, and surface areas. You can also calculate mass properties and
perform interference checks on assemblies. These analyses can be useful for extract-
ing data from a model or determining whether the model meets the required design
intent.
When you start your work using templates, for example: mmns_part_solid.prt,
there are some information already. You can change the properties whenever you
want.
Task 1.8.2: Edit Model Properties
Click File > Prepare > Model Properties to open the Model Properties dialog box.
In the Materials section, click change in the Material row:
Select material from the list and move it to the Materials in Model window.
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Select the material and make Copy. Select the copied material and click Properties:
You can give the new name for the material and Description and change the units to
kg/m3:
When changing units, you have to select Convert or Interpret values. Convert means
for example: One inch is 25.4 millimeter. OK.
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Edit values as below. OK.
The new material is in the Materials in Model window and the original remain on
the list. Select the new material, then Right click and Assign. OK.
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In the Materials section, click info in the Mass Properties row. Now the Mass unit is
tonne. If you want for example grams, you can create a new set of units.
In the Materials section, click change in the Units row. In the Units Manager dialog
box, select New and edit drop-down menus as below and OK.
Select the new units system and SET. Select Convert dimensions > OK > Close the
Unit Manager.
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Now the model has new material and unit system. Click Close.
Analyzing Mass Properties
You can view a model’s mass properties within the Materials section of the Model
Properties dialog box.
You can also calculate the mass properties by selecting the Analysis tab from the
ribbon and clicking Mass Properties from the Model Report group.
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1.9
Cutting parameters
You should know the Basics about Metal Cutting Parameters before creating
toolpaths.
1. Material machinability: The machinability of a material decides how easy
or difficult it is to cut. The material’s hardness is one factor that has a strong
influence on the machinability.
2. Cutting Tool Material: In metal-cutting, High Speed steel and Carbide are
two major tool materials widely used.
3. Cutting speed: Cutting speed is the relative speed at which the tool passes
through the work material and removes metal. It is normally expressed in me-
ters per minute (or feet per inch in British units). It has to do with the speed
of rotation of the workpiece or the tool, as the case may be. The higher the
cutting speed, the better the productivity. For every work material and tool
material combo, there is always an ideal cutting speed available, and the tool
manufacturers generally give the guidelines for it.
4. Spindle speed: Spindle speed is expressed in RPM (revolutions per minute).
It is derived based on the cutting speed and the work diameter cut (in case of
turning/ boring) or tool diameter (in case of drilling/ milling etc). If V is the
cutting speed and D is the diameter of cutting, then Spindle speed N = V /(Pi
x D)
5. Depth of cut: It indicates how much the tool digs into the component (in
mm) to remove material in the current pass.
6. Feed rate: The relative speed at which the tool is linearly traversed over the
workpiece to remove the material. In case of rotating tools with multiple cut-
ting teeth (like a milling cutter), the feed rate is first reckoned in terms of
“feed per tooth,” expressed in millimeters (mm/tooth). At the next stage, it is
“feed per revolution” (mm/rev).
In case of lathe operations, it is feed per revolution that states how much a
tool advances in one revolution of workpiece. In case of milling, feed per
revolution is nothing but feed per tooth multiplied by the number of teeth in
the cutter.
To actually calculate the time taken for cutting a job, it is “feed per minute”
(in mm/min) that is useful. Feed per minute is nothing but feed per revolution
multiplied by RPM of the spindle.
7. Tool geometry: For the tool to effectively dig into the component to remove
material most efficiently without rubbing, the cutting tool tip is normally
ground to different angles (known as rake angle, clearance angles, relief an-
gle, approach angle, etc). The role played by these angles in a tool geometry
is a vast subject in itself.
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8. Coolant: To take away the heat produced in cutting and also to act as a lubri-
cant in cutting to reduce tool wear, coolants are used in metal-cutting. Cool-
ants can range from cutting oils, water-soluble oils, oil-water spray, and so
on.
9. Machine/ Spindle Power: In the metal-cutting machine, adequate power
should be available to provide the drives to the spindles and also to provide
feed movement to the tool to remove the material. The power required for
cutting is based on the metal removal rate – the rate of metal removed in a
given time, generally expressed in cubic centimeters per minute, which de-
pends on work material, tool material, the cutting speed, depth of cut, and
feed rate.
10. Rigidity of machine: The rigidity of the machine is based on the design and
construction of the machine, the age and extent of usage of the machine, the
types of bearings used, the type of construction of slide ways, and the type of
drive provided to the slides. All play a role in the machining of components
and getting the desired accuracy, finish, and speed of production.

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1.9.1 Cutting Speed Formulas
Most machining operations are conducted on machine tools having a rotating spin-
dle. Cutting speeds are usually given in feet or meters per minute and these speeds
must be converted to spindle speeds, in revolutions per minute, to operate the ma-
chine. Conversion is accomplished by use of the following formulas:
Where N is the spindle speed in revolutions per minute (rpm); V is the cutting speed
in feet per minute (fpm) for U.S. units and meters per minute (m/min) for metric
units. In turning, D is the diameter of the workpiece; in milling, drilling, reaming,
and other operations that use a rotating tool, D is the cutter diameter in inches for
U.S. units and in millimeters for metric units. π = 3.1417.
Example: The cutting speed for turning a 4-inch (102-mm) diameter bar has been
found to be 575 fpm (175.3 m/min). Using both the inch and metric formulas, calcu-
late the lathe spindle speed (N).
When the cutting tool or workpiece diameter and the spindle speed in rpm are
known, it is often necessary to calculate the cutting speed (CS) in feet or meters per
minute. In this event, the following formulas are used.
Feed (F): In the CNC Lathe work the feedrate is not measured in terms of time but,
as the actual distance the tool travels in one spindle revolution (rotation). Two
standard abbreviations are used for feedrate per revolution:
Inches per revolution
in/rev (IPR)
Millimeters per revolution mm/rev (MMPR)
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More formulas for Milling:
Axial depth, ap:

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1.9.2 Milling Feed Calculating
Calculation Formula of the Feed speed of worktable (vf)
Vf = fz * z * n (mm/min)
fz = feed / tooth
z = number of teeth
n = rotation speed of spindle
For example:
Vf = 0.1 * 5 * 572
= 286 mm/min
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1.9.3 Surface roughness
The surface quality of the machined parts is one of the most important product quali-
ty characteristics and one of the most frequent customer requirements. The surface
roughness greatly affects the functional performance of mechanical parts such as
wear resistance, fatigue strength, ability of distributing and holding a lubricant, heat
generation and transmission, corrosion resistance, etc.
The perfect surface quality in turning would not be achieved even in the absence of
irregularities and deficiencies of the cutting process, as well as environmental ef-
fects. There are various parameters used to evaluate the surface roughness. In the
present research, the average surface roughness ( Ra ) was selected as a characteristic
of surface finish in turning operations. It is the most used standard parameter of sur-
face roughness.
The surface roughness factors are previously described:
Cutting speed
Feed rate
Depth of cut
Nose Radius
Surface roughness is decreasing with decreasing of the feed rate. High nose radius
produce better surface finish than small nose radius because of the maximum uncut
chip thickness decreases with increase of nose radius.

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1.10 Camshaft Plate Cutting Parameters
When a high quality camshaft is required, engine builders and camshaft manufactur-
ers choose to make the camshaft from steel billet. In this case the material of the
camshaft is EN40B. It is a chromium-molybdenum nitriding steel and usually sup-
plied in the hardened and tempered condition, which offers high wear resistance to-
gether with good toughness and ductility. It is characterized by its suitability for ni-
triding, which can give a hard wear resistant core in the range of 61-65Rc. The rela-
tively low temperature of the nitriding process produces components with a scale
free surface, and minimum distortion.
EN40B Related Specifications - 1.8515, 31CrMo12, 30CD12, 722M24
Tensile Strength Rm = 850/1000 N/mm2
Yield Stress Re
= 650 N/mm²
Hardness HB
= 248/302
Cutting speed (V) for High Speed Steel (HSS) tools is 60 foot per minute (ft/min) =
18m/min.
Cutting speed (V) for Carbide tools is 300 foot per minute (ft/min) = 90m/min.
Note! Keep in mind previously mentioned the Basics about Metal Cutting Pa-
rameters.
For example: The diameter of the face milling tool is 50mm and when using carbide
inserts the cutting speed is 90m/min.
The spindle speed is 573 rev/min.
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2
CREO PARAMETRIC BASIC MILLING
2.1
Common procedure for creating a new manufacturing model
The first step in the manufacturing process is creating manufacturing models. Manu-
facturing models contain all manufacturing information:
Operation information
Workcells
Reference models
Workpiece models
Fixtures
NC Machines
NC Sequence information
When you create a new manufacturing model, the manufacturing model assembly is
created. The filename format is”filename”.asm
If you check out the Use default template, you can select or browse the Template
from the list. Template manufacturing models enables you to standardize on the ini-
tial manufacturing model configuration. You can also make user-defined template
manufacturing models. Using a template manufacturing model is recommended.
The new manufacturing model is created by using template. You can see three de-
fault datum planes and a default coordinate system.
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2.2
Reference model
You must assemble a reference model before creating NC sequences. The reference
model represents the final machined component. Surfaces and edges and the other
features are selected from the reference model and are used as references when creat-
ing NC sequences.
Task 2.2: Create a manufacturing model using a template manufacturing model.
Click New in the main toolbar. Select the Manufacturing and NC Assembly op-
tions. Type CAMSHAFT_PLATE_NC in the Name text box. Clear the Use default
template check box, and click OK.
Create a manufacturing model with metric units. Select mmns_mfg_nc and click
OK.
Note! You can use your own template if available.
Observe the new manufacturing model is created with three datum planes and a co-
ordinate system. Toggle all display filters on and show datum plane tags:
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Click Assemble Reference Model from the Components group. Select cam-
shaft_plate.prt, and click Open.
Enable only the following Datum Display type: Csys Display. Select coordinate sys-
tem from the CAM_PLATE.prt > select assembly coordinate system.
Status is Fully Constrained. Click Complete Component in the dashboard.
You can also assemble component at default location:
Task 2.2 is ready. Save your work.

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2.3
Workpiece Model
Workpieces represent the unmachined stock material in a manufacturing model.
They are optional components, but if used, you can simulate the material removing
when creating and running NC Sequences. There are different methods how to create
workpieces – for example default Automatic. This enables you to create simple rec-
tangular or round workpiece. You can also create workpieces using the Inherited
Features option. As well you can select the model as workpiece. Workpieces can be
standard stock billets or they can represent castings. Using workpieces provides you
with a number of capabilities:
You can simulate the cutting tool machining the workpiece.
After creating each toolpath, you can update the workpiece to display an as-
machined version of the workpiece.
Unless you specify otherwise, there is no machining outside the workpiece
boundaries.
The workpiece is displayed in green to help you visually distinguish between
the workpiece and the reference model geometry. In addition, when the dis-
play style is set to shaded, the workpiece is displayed as semi-transparent.
This enables you to view the reference model geometry which would normal-
ly be obscured by the workpiece.
In the pictures below the reference model is inside the workpiece.
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You can assemble or create a workpiece in a manufacturing model. A number of op-
tions are available:
Create an automatic workpiece – This enables you to create a rectangular or
round workpiece depending on your requirements. A dashboard interface en-
ables you to easily control the size and position of the workpiece relative to
the reference model.
Assemble a workpiece using the Same Model option – This enables you to
assemble an existing part into the manufacturing model as the workpiece.
Assemble a workpiece with features inherited from a selected part. The new
workpiece inherits geometry and feature information from the selected part.
At any time, you can specify the geometry and the feature data that you want
to modify on the workpiece without changing the original part. Inheritance
provides greater freedom to modify the workpiece without changing the orig-
inal part.
Assemble a workpiece with features merged from a selected part. In this
case, a new workpiece part is created. The new workpiece contains an exter-
nal merge feature, and this feature contains all geometry and datum features
which have been copied from the originally selected part. All layer infor-
mation is also copied into the new workpiece.
Create a manual workpiece – This enables you to create a new workpiece in
the manufacturing model by manually creating features and geometry as re-
quired.
The first picture below is a reference model. The second picture is the workpiece. In
the third picture is an assembly of the reference model and part model.
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Task 2.3: Create the Workpiece.
Click Automatic Workpiece from the Workpiece drop-down menu from the Compo-
nents group.
In the dashboard, select the Placement tab. You change the default coordinate system
if needed. > In the dashboard, select the Options tab. At first you can see the Overall
Dimension of the model.
Type 2 in the +X text box, type 2 in the –X text box, type 2 in the +Y text box, type 2 in
the –Y text box. Type 4 in the +Z text box, and press ENTER.
Observe the workpiece preview geometry update, as shown. Click Complete Fea-
ture in the dashboard.

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Observe the new workpiece displayed in green in the manufacturing model.
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2.4
Configuring Workcell
The workcell specifies the type of machine used when creating NC sequences, for
example, mill, lathe, or mill/turn. You must specify a workcell before you can create
NC sequences.
Workcells consist of a number of different elements that describe the capabilities of
the machine tool, including post-processor options, multiple axis output options, site
parameter file options, and the ability to configure a PPRINT table.
Workcell Configuration:
Name
Type – Mill, Lathe, Mill/Turn,
or Wire EDM
Number of Axes
Post-Processor
Probing Option
Machine Tool Elements:
Output Tab Options
 Multiple Axis Output
 Parameters
 Properties
 CL Command Output
 Milling Capability
 Cutter Compensation
Tools Tab
Travel Tab
Cycles Tab
Assembly Tab
Workcell Configuration
You configure a workcell within the Machine Tool Setup dialog box. You can speci-
fy many different options that describe the type of machine tool configuration. You
must specify the workcell name and the workcell type. This can be Mill, Lathe,
Mill/Turn, or Wire EDM. The number of axes you can specify is dependent on the
workcell type.
For Mill – 3 axis (default), 4 axis, or 5 axis.
For Lathe – 1 turret (default) or 2 turrets.
For Mill/Turn – 2 axis, 3 axis, 4 axis, or 5 axis (default).
For Wire EDM – 2 axis (default) or 4 axis.
You can also specify a number of other items including the controller name.
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Machine Tool Elements
The Setup: Work Center dialog box has a number of tabs that enable you to config-
ure different optional elements of a machine tool.
The Output tab has a number of options including:
 Cutter location (CL) Command Output Options – You can specify how
the FROM, LOADTL, COOLNT/OFF, and SPINDL/OFF statements are
output in CL data files.
 Multiple Axis Output Options – These options are only accessible for a
mill type machine tool when you set the number of axes to 4 axis.
Use Rotation – When you select this option, the system outputs
the applicable TRANS and ROTABL commands to specify linear
and rotational transformations. If this option is not selected (de-
fault), all CL data is transformed and output in the coordinates of
the program zero coordinate system.
Rotation Output Mode – Only available when you select Use Ro-
tation. Controls output of ROTABL statements. The values are:
Incremental (default) and Absolute.
Rotation Direction – Only available when you select Use Rota-
tion. Enables you to specify the direction of rotation. You can al-
so specify the rotation to be about the A axis or B axis.
 Cutter Compensation – When you expand this field, the following output
cutter position options become available:
Tool Center – Cutter location (CL) data is output with respect to
the tool center.
Tool Edge – Cutter location (CL) data is output with respect to the
cutting edge of the tool.
Parameters Tab – Specifies the maximum spindle speed, and the spindle
horsepower. As well as the rapid feed rate units and the rapid feed rate.
Tools Tab – Specifies the time needed to change a tool, in seconds. You can
also access the Tool Setup dialog box to configure tools associated with the
machine tool.

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Travel Tab – Specifies the travel limits and the stroke for the machine tool
along the X-, Y-, and Z-axes. Note, values for the travel limits along the axes
should be the actual dimensions that indicate the extent of the machine tool
workspace relative to the Program Zero coordinate system. If you output CL
data that exceeds the defined limits, an information window appears, listing
the values of the limits that have been exceeded and their corresponding val-
ues.
Properties Tab – Enables you to specify the location of the machine, and type
comments associated with the machine tool in a text box.
Cycles Tab – Enables you to configure custom cycles for holemaking.
Machine Assembly Tab – Specifies the machine assembly to be used when
displaying tool motion on the machine tool.
The Output tab:
Cutter Location (CL) Command Output Options – You can specify how the FROM,
LOADTL, COOLNT/OFF, and SPINDL/OFF statements are output in CL data files.
– Cutter Compensation – When you expand this field, the following output cutter
position options become available:
Tool Center – CL data is output with respect to the tool center.
Tool Edge – CL data is output with respect to the cutting edge of the tool.
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Tools tab:
Tool Change Time > Specifies the time needed to change a tool, in seconds.
Parameters tab specifies the maximum spindle speed, and the spindle horsepower
and the rapid feed rate units and the rapid feed rate.
To output some model information to the CL files, you have to set up a PPRINT ta-
ble for this model. This table contains all the items that can be output through
PPRINT. Whether an item will be output or not is determined by the flag value. The
default flag value for all items is No. Change it to Yes if you want the item to be
output. You can add an optional comment to be output along with the item. (More in
the Postprocessor chapter).
Assembly tab specifies the machine assembly to be used when displaying tool mo-
tion on the machine tool. You need to give full path to the location in config.pro.
Also you have to select Mach_Zero-Coordinate System from the fixture. (See more
in the next chapter).
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Travel tab specifies the travel limits and the stroke for the machine tool along the X-
, Y-, and Z-axes. Note, values for the travel limits along the axes should be the actual
dimensions that indicate the extent of the machine tool workspace relative to the
Program Zero coordinate system. If you output CL data that exceeds the defined lim-
its, an information window appears, listing the values of the limits that have been ex-
ceeded and their corresponding values.
Cycles tab enables you to configure custom cycles for holemaking.
Properties tab enables you to specify the location of the machine, and type com-
ments associated with the machine tool in a text box:
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2.4.1 3-Axis Mill Machine Tool Simulation
Within Creo Parametric you can simulate the CNC machine running the various NC
sequences you created. The mill machine assembly is selected within the Assembly
tab of the Mill Work Center dialog box. This machine assembly can be edited to rep-
resent your CNC machine. You must specify a reference coordinate system for the
machine assembly. (MACH_ZERO) This reference coordinate system should be the
same location as the machine zero coordinate system for the operation.
Once the machine has been properly defined, the simulation of the operation with the
machine can be reviewed. The system displays the machine tool simulation in a new
window. You can then use typical play commands from the Animate dialog box.
Some commands include controlling the speed of the simulation, stopping the simu-
lation, and capturing the simulation to an MPEG file. As the machine simulation
plays you can zoom and rotate the machine to any desired view. When you close the
machine tool simulation display, the system returns you to the manufacturing model.
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Playing the Machine Simulation
You can play the following types of machine simulations:
Entire Operation.
Individual NC Sequences.
To play the machine simulation, select the desired operation or NC sequence in the
model tree, right-click, and select Machine Play.
Location of Machine Assembly Files
You can select machine assembly files from the following locations:
Current working directory.
Can be retained in a directory controlled by the config.pro option
pro_mf_workcell_dir.
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2.4.2 Creating Workcell
Task 2.4.2: Configure and save a mill workcell.
In the ribbon, select the Manufacturing tab. In the Machine Tool Setup group, click
the Work Center drop-down menu, and select Mill.
Configure the required options. Below is an example of the vertical machining cen-
tre: Fadal 3016 HT.
Click Accept in the Milling Work Center dialog box. Select the Work Center drop-
down menu from the Machine Tool Setup group > Click Save Work Center.
You can configure the other tabs later.
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2.5
Manufacturing Operations
Machining operations are a series of NC sequences that are performed by a particular
workcell (machine tool) and reference a particular coordinate system. They include
the following elements:
Machine coordinate system – Also referred to as the machine zero position.
This specifies the program zero position in X, Y, and Z on the machine tool.
Retract plane – Also referred to as the retract surface. This specifies the
clearance level to which the tool retracts after completing an NC sequence.
Fixtures – Are parts or assemblies that can be used to hold the component
being machined. For example, you can create vise assemblies and use them
as fixtures.
When these items have been specified, you can create NC sequences to machine
components assembled into the manufacturing model. These NC sequences reference
the machine tool and the machine zero position. You cannot create NC sequences un-
til you configure the manufacturing operation and configure a machine tool.
Machine Coordinate System and Retract Plane
One of the most important configuring is the Machine Coordinate System and Re-
tract Plane. The machine coordinate system, often referred to as the machine zero
position, acts as the origin position for CL data output.
The machine coordinate system specifies the direction of the X-, Y-, and Z-
axes on the machine tool.
You can configure the machine coordinate system by selecting or creating a
coordinate system in the manufacturing model.
 When configuring the machine coordinate system, you can reference ex-
isting datum features in the manufacturing model, or you can reference
fixture geometry, or use reference model or workpiece geometry.
The retract plane (or surface) specifies the level to which the tool retracts to between
cutting motions.
You can specify the retract plane at the operation level, and then modify its
position for specific NC sequences as required.
Note, depending on your requirements, you can specify the retract position to
be a plane, cylinder, sphere, or a custom-made surface.
By default, the retract plane is configured along the Z-axis of the machine
coordinate system. You can select an alternative reference if required.
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The idea of the Retract Plane:
Coordinate Systems:
In the VMC, Vertical Machining Centre, the tool axis is Z.
The way of orienting the axes is following the left hand rule, placing the left hand on
the plane with the thumb pointing up. When pointing the thumb away from the origin
along an axis towards positive, the curvature of the fingers indicates a positive rota-
tion along that axis.
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2.5.1 Creating Machine Coordinate System
Before creating Operations and NC Sequences, you need to specify the locations of
the machine coordinate system. You need two coordinate systems, for the top and
bottom of the model.
Task 2.5.1: Create Coordinate Systems.
Open the CAMSHAFT_PLATE.PRT from the model tree. Hide
PRT_CSYS_DEF-coordinate system. Enable the Plane Display.
Click Create a datum coordinate system from the Datum Group.
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Select the RIGHT Datum Plane and press CTRL and select the TOP Plane and the
surface as shown below:
Select the Orientation tab. Click Flip to project Y. Select the Properties tab and edit
the name of the coordinate system: PLATE_BOTTOM_NC. OK.
The coordinate system should be located as shown below:

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Do the same procedure to the top side of the model and name the coordinate system
as PLATE_TOP_NC.
Save the model and close the window. Return to the manufacturing assembly.
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2.5.2 Creating Operations
Task 2.5.2: Create an operation.
OPERATION 1:
Click Operation from the Process group. Select datum coordinate system
PLATE_BOTTOM_NC on the manufacturing model.
Select the Clearance tab. Change Type to Plane from the drop-down menu. Select
PLATE_BOTTOM_NC for the Reference. Type 5 in the Value text box.
Select the Options tab. Select EN40B from the drop down menu or Create new if it
there is no material: EN40B > Enter > Accept.
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Select the Fixture Setup tab and select Add a fixture component.
Browse to the folder where the fixture locates and select: nc-vice-300.asm > Open.
Now you should think the order of the machining, in this case, the flat surface side of
the part will be machined first. Create the first assembly constraint. Select surfaces
as shown above.
Flip constraint if needed, select Coincident constraint, right click > Flip Constraint.
Rotate the assembly. Create the second assembly constraint. In the dashboard, select
the Placement tab > Click New Constraint.
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Keep Automatic as the Constraint Type. Constrain the NC_VICE_BASE front sur-
face coincident to the model front surface as shown below:
Create the third assembly constraint. In the dashboard, select the Placement tab >
Click New Constraint.
Status is fully constrained. Click Complete Component in the dashboard.
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Select the Properties tab and edit the name of the operation: PLATE_BOTTOM and
press ENTER.
Click Complete Operation. Now the first Operation is defined. You need to define
the same procedure for the top side of the manufacturing model.
OPERATION 2:
Click Operation from the Process group. Rotate the model. Select datum coordinate
system PLATE_TOP_NC on the manufacturing model.
Select the Clearance tab. Change Type to Plane from the drop-down menu. Select
PLATE_TOP_NC for the Reference. Type 10 in the Value text box.
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Select the Options tab. Select EN40B from the drop down menu.
Select the Fixture Setup tab and select Add a fixture component.
Browse to the folder where the fixture locates and select: nc-vice-300.asm > Open.
Now you need to remember, that the working allowance (2mm) is machined in the
first Operation and fixing. Create the first assembly constraint. Select surfaces as
shown below left. Create the second assembly constraint as shown below right.
Create the second assembly constraint. In the dashboard, select the Placement tab >
Click New Constraint. Select surfaces as shown below:
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Status is fully constrained. Click Complete Component in the dashboard.
Select the Properties tab and edit the name of the operation: PLATE_TOP and press
ENTER.
Click Complete Operation. Now the second Operation is defined.
You can activate the operations from the model tree.
Task 2.5.2 is ready. Save your work. Now it is recommended that you use Save a
Backup-function. It saves all objects to the current working directory. Do not give a
new name, just click OK!
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2.6
Fixtures
Fixtures are parts or assemblies that can be used to hold the component being ma-
chined. For example, you can create vice assemblies and use them as fixtures. Fix-
tures are assembled into manufacturing models, and they can be easily activated and
deactivated as required. Fixtures can be used as references, for example:
To specify the location of the machine coordinate system.
To locate the position of reference models in the manufacturing model.
To locate the position of workpiece models in the manufacturing model.
In this case you need two fixing to the vice, because the model has top and bottom
side to machine.
You can adjust the vice by selecting the component from the vice and Edit defini-
tion. The length of the workpiece is 54mm.
Select the moving component from the vice, right click and edit definition. Select
Distance and edit to 54.
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2.7
Cutting Tools
Tools are an essential step in the manufacturing process. You must configure a tool
for each NC sequence you create. You can create tools when the workcell is created
or you can configure them as needed for each NC Sequence. Once you configure a
tool, you can store the information and use it again.
There are three different tool types: standard, solid, and sketched. Each type of tool
is created in a different way and is designed for a specific purpose. It is important to
understand the differences between each type of tool and when you should use them.
Tool Types
Standard
Solid
Sketched
Tool Tip Position
Along centerline of tool.
Specifies X-, Y-, and Z-positions for CL data.
Tool position based on machined model geometry.
Tool Types
You can configure tools when creating workcells or you can configure them as need-
ed when creating NC sequences. Once you configure a tool, you can store the infor-
mation and use it again. There are three different milling tool types: standard, solid,
and sketched. Each type of tool is created in a different way and is designed for a
specific purpose.
Standard tools – You can use standard tools when no special tool representa-
tion is required. These tools are configured within the Tool Setup dialog box.
Solid tools – You can use solid tools when you need to enhance the tool dis-
play and check for interference between the tool and workpiece when review-
ing toolpaths.
Sketched tools – You typically use sketched tools when a non-standard tool
shape or an alternative tool control point is required, for example, during tra-
jectory milling. You can, for example, create a sketched tool for machining
slots.

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The difference between standard and solid tool:
Tool Tip Position
For standard milling tools, the tool tip position is defined along the centerline of the
tool, and at the lowest point of the tool geometry (see examples).
You can use this tool tip position for calculating the tool position in X-, Y-, and Z-
coordinates when creating CL (cutter location) data.
Creo Parametric calculates the resulting tool position based on the model geometry
being machined, the tool geometry, and any manufacturing parameters that may af-
fect the resulting tool tip position (for example, stock allowances).

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2.7.1 Standard Milling Tools
You configure standard milling tools by specifying tool parameters. It is important to
specify the correct tool parameters to obtain the desired tool configuration.
Standard Tools
Tools configured by specifying tool parameters.
Available tool type control parameters:
 Milling or drilling
Parameter values control resulting tool shapes in:
 Length
 Cutter_Diam
Toolpath display based on parameter values.
When you start configure a tool, the default is standard tool:
Standard Tools
You create standard tools by configuring tool parameters within the Tool
Setup dialog box.
The type of tool, for example milling or drilling, determines the tool cross-
section and therefore which parameters are available for configuration.
The tool parameter values control the tool shape, for example:
 Length
 Cutter_Diam
Note, when playing a toolpath, the tool is displayed based on the parameter
values.
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Configuring Tools
Tool Setup Dialog Box
General Tab
 Tool Name
 Tool Type
 Tool Parameter Values
 Tool Holder Dimensions
Settings Tab
 Tool Number
 Offset Number
 Gauge Lengths (X and Z)
Tool Tables
 Display tool information.
 Output tool loading information to CL data files.
Saving Tools
Tool Libraries
You can create, delete, or edit tools using the Tool Setup dialog box. A number of
tabs are available within the dialog box that enables you to configure different types
of tool information.
General – In the general tab, a graphic image of the tool appears during con-
figuration. You can configure the tool name and tool type. Many different
standard tool types are available for selection. The selected tool type deter-
mines the displayed tool shape.
 When the tool type has been specified, you can then configure the tool
geometry parameter values that specify the tool dimensions.
 When configuring the tool geometry, you can also configure tool holder
dimensions. This provides you with a visual representation of the tool
holder when you review a toolpath. Tool holder dimensions are also used
for automatic gouge avoidance in trajectory, straight cut surface milling,
isolines surface milling, roughing, re-roughing, finishing, and corner-
machining NC sequences.
Settings – You can specify a number of items relating to the tool table, in-
cluding:
 Tool Number – This corresponds to the number field in a tool table,
which specifies the tool’s pocket number.
 Offset Number – This corresponds to the offset field in a tool table, which
supplies a value for the gauge length register.
 Gauge X Length and Gauge Z Length – Optional parameters used to cre-
ate length qualifiers in the LOADTL or TURRET statements.
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Tool Tables – Provide you with tool information which appears in the Tool
Setup dialog box.
 You can use tool tables to pass tool loading information into CL data
files. For example, you can output LOADTL and OSETNO commands
from a tool table.
 When you create or retrieve tools in a workcell, the tool_id (tool name) is
checked and if the tool does not already exist in the tool table then it is
appended at the end of the table.
 As tools are added to the tool table, the tool position (tool number) auto-
matically increments by one with respect to the last tool in the table. You
can manually edit the tool number to change its position in the tool table,
if required.
Saving Tools
You can save tool parameter information as files and reuse the tools in differ-
ent NC sequences and in different manufacturing models.
Saving a tool creates an XML format file. For example, tool_name.xml.
Note old format tool parameter files are also recognized. These are:
 .tpm for Pro/ENGINEER release 12 to Pro/ENGINEER Wildfire 2.0.
 .tprm for pre-Pro/ENGINEER release 12.
Tool Parameter Libraries
You can create your own tool library, where all the tool parameter files are
stored.
 This enables you to access a standard set of tools for retrieval into manu-
facturing processes, for modifying, or for setting up new tools.
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2.7.2 Creating Standard Milling Tools
You can use standard tools when no special tool representation is required or Solid
Tools are not available. These tools are configured within the Tool Setup dialog box.
Task 2.7.2 Create standard tool, Face mill 50mm.
Click Cutting Tools from the Machine Tool Setup group, to open the Tool Setup di-
alog box.
Create the Face Mill tool (you have to define End Mill type of tool for the face mill-
ing). Click File > New in the Tool Setup dialog box. Select END MILL from the
Type drop-down list.
Type TURBO_50_STD in the Name text box. Type CARBIDE in the Material text
box. Type 5 in the Number of Flutes text box. Edit the geometry parameters, as
shown above. Click the Apply button. Notice the tool is added to the tool table.
Select the Settings tab. Notice that the tool number is already configured automati-
cally as 1. Type 1 in the Offset Number text box. Click the Apply button to update
the tool information. Click Yes to change the tool description.

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Save the tool:
In the Tool Setup dialog box, click Save Tool to save the tool. A file named tur-
bo_50_std.xml is saved in the working directory.
In the Tool Setup dialog box, click Display Tool.
Click Close to close the tool display window. Click OK. To close Tools Setup.
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2.7.3 Creating Tool Cutting Data
You can create cutting data for tools, enabling you to configure optimum feed rates,
spindle speeds, and depth-of-cut. This data can then be passed into NC sequences.
The cutting data is based on the material that you are machining, the specific tool
you are using, and the application, which can be either roughing or finishing.
Creating and Storing Cutting Data
You can create cutting data by specifying different stock materials for machining,
and by specifying feed, speed, and depth of cut data for each tool. Within each tool
file, you need to specify different cutting data for each different stock material.
You need to create two sets of data: an .xml file listing the workpiece materials and a
series of .xml files – one for each different tool you want to use.
Mfg_wp_material_list .xml – You store the list of workpiece (stock) materi-
als within this file. You can create this file from the Operation Setup dialog
box. You can then manually add more materials to the file, as required.
Tool_name.xml – You configure feed, speed, and depth of cut data within
these files. You can specify cut data for more than one workpiece material.
You can configure the cut data information using the Tool Setup dialog box,
and save the cut data when you save the tool.
Using Cutting Data
You can pass the feed, speed, and depth of cut data into manufacturing pa-
rameters of an NC sequence. You can achieve this using a number of meth-
ods:
 You can manually transfer parameter values using the Copy from Tool
option when configuring parameters in the parameter tree.
 You can automatically transfer parameter values through relations, either
in a parameter site file or as a parameter value in the parameter tree.
For example, you can specify the relation STEP_DEPTH =
TOOL_ROUGH_AXIAL_DEPTH. This controls the value of the
STEP_DEPTH parameter in an NC sequence.
 You can use the mfg_param_auto_copy_from_tool configuration option
to copy parameters from a tool into the parameter tree of an NC

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Task 2.7.3: Create cutting data for the tool. Edit the previously created tool.
Click Cutting Tools to open the Tools Setup dialog box. Select the Cut Data tab.
Notice EN40B selected from the Stock Material drop-down list.
You can change the Speed value m/min ( Surface Speed) or rev/min ( Spindle rpm) These
values are corresponding with:
Type 90 in the Speed text box (m/min). Type 0.1 in the Feed text box (mm/tooth).

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Round and edit the other values as show below:
Click the Apply button. Click Yes to save the changes to the tool.
In the Tool Setup dialog box, click Save Tool to save the tool.
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2.7.4 Solid Milling Tools
You can create solid model tools as assemblies or parts. When playing toolpaths, you
can view these solid tools. You can also use the solid tools to interactively check for
interference between the tool and the component being machined. When you use sol-
id model tools, you have the option to display the default section or the solid model
tool.
You need to complete the following steps to use solid models as tools when creating
NC sequences.
Create a part or assembly with the tool’s name.
Create the desired tool geometry in the solid model.
Create a coordinate system in the model, and name it TIP. For milling and
holemaking tools, the Z-axis of the coordinate system must point to the tool. This
coordinate system represents the tool tip (often referred to as the control point).
This point specifies the X-, Y-, and Z-positions for the tool in NC sequences.
Associate solid model dimensions with tool parameters. You can do this by
changing dimension symbols to correspond to tool parameter names. For exam-
ple, length, cutter_diam, and corner_radius.
Configure solid model parameters to correspond to tool parameters. For example,
tool_material and num_of_teeth. You can use the tool_material and
num_of_teeth parameters with a machinability database to determine cut feed
and spindle speed.
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Using Solid Model Milling Tools
You can use solid model tools in NC sequences by retrieving them in the Tool Setup
dialog box. Model dimensions and parameter values are automatically transferred in-
to the tool configuration parameters.
During the tool configuration process, you have two options when retrieving
solid model tools:
 By Reference – You can directly associate the solid model with the tool
configuration. You cannot directly modify the tool parameters using this
option. However, if you modify the stored solid model, then all the manu-
facturing data is updated when you regenerate the manufacturing model.
 By Copy – You can copy the tool information into the manufacturing
model. You can directly modify the tool parameters in the Tool Setup dia-
log box. Any changes to the stored solid model do not affect the manufac-
turing model.
You can find existing models from:
Ptc.com
Your supplier - Kennametal, Iscar, Seco, Sandvik..
STEP, SAT, etc.
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2.7.5 Solid Tools coordinate systems
You have to create a coordinate system in the model, and name it TIP. For
milling and holemaking tools, the Z-axis of the coordinate system must point
to the tool. This coordinate system represents the tool tip (often referred to as
the control point). This point specifies the X-, Y-, and Z-positions for the tool
in NC sequences.
The other Coordinate Systems are TOOL_POINT and HOLDER.
The HOLDER – coordinate system is for the assembly of the holder
and the tool.
The TOOL_POINT – coordinate system is for the machine simula-
tion to assemble the solid tool model on the machine assembly.

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2.7.6 Solid Tool Parameters
You need to define a number of parameters for the tools. If an assembly is used as a
tool model, the system will search the assembly first, and then all the component
parts in the same order as they were assembled (that is, the first component will be
searched first), for the tool parameters and origin data. Once a parameter is set, all
values for the same parameter found later will be ignored. In other words, the top-
level assembly parameters take precedence over component parameters, and after
that the precedence is determined by the order of assembly.
If, after all components are searched, some of the tool parameters are missing, an er-
ror message will appear and you will be asked to select another tool.
If you are using your own made tool or PTC standard solid tools, you can find pa-
rameters from part level as below:
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2.8
Tools for Camshaft Plate
The camshaft Plate part needs different type of tools for bottom- and topside .There
are numerous types of tools available for both. It is not so easy to find out which are
the best ones. There are also numerous suppliers as well as different type of ma-
chines and holders for them. You can ask from suppliers to help you and ask if there
are 3D-models of the tools.
The 3D-model Tools what are used in this book can be found from the author’s
website.
You can also use the Standard Tools.
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2.8.1 Face Milling Tool
The face milling tool is 20mm diameter end mill or 50mm diameter Face mill with 5
inserts.
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2.8.2 End Mill
The End Mills are 20mm diameter end mill and 8mm diameter end mill.
Standard Tools:
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2.8.3 Spot Drill
The Spot Drill:
Solid tool
Standard Tool General settings
Standard tool Play Path
2.8.4 Drilling Tool
The Basic Drill:
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2.8.5 Tapping Tool
The Tapping Tool:
2.8.6 Chamfer Tool
The Chamfer Tool:
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2.9
Tool library
You can configure a tool library where all tool data is stored. This enables quick and
easy retrieval of tools by all users.
You can create a tool library where all tool parameter files are stored. You can divide
the library into folders for different types of tools, for example, milling tools, drills,
and center drills.
You can specify the location of a tool library using the configuration option
pro_mf_tprm_dir pathname.
 For example, pro_mf_tprm_dir d:\ptc\tool_lib.
 Creo Parametric then automatically starts searching in the specified
location whenever you retrieve a tool.
Task 2.9: Configuration Editor
Click File > Options. Select Configuration Editor.
Click Find…
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Type: pro_mf and click Find Now:
You can see all the options starting pro_mf. Select pro_mf_tprm_dir.
Click Browse.
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Select the folder where the tools are. OK.
Click Add/Change > Close
You should now see the new option on the list.
Click OK. Select Yes to Save the configuration file. The default folder is active
working directory.
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If possible (writing rights), try save the config.pro to the installation directory and to
the text folder:
If this is not possible, save the config.pro to your working directory.
Task 2.9 is ready.
Note! By default, Creo Parametric starts searching for tools in the pro_mf_tprm_dir
folder, or the current working directory if no configuration option is specified.
So you can copy all the tool files to your working directory, but this is not
recommended, because the libraries are better places for the tools and fixtures and
the other components.
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2.10 Common about NC Sequences
NC sequence is a workpiece feature that represents a single tool path. When you
create an NC sequence, a dialog box corresponding to the NC sequence type is dis-
played. Each of these dialog boxes has the following options:
Parameter - Open the parameter tree.
Comment - Type comments regarding NC sequences
Define - Specify the tool, parameters, and geometric references. You can also
apply some low-level control depending on the NC sequence type.
Info - Display parameter and NC sequence information.
Preview - Display the tool path for the NC sequence prior to completion of
the NC sequence. Available after all elements have been defined.
Done - Completes creation of the current NC sequence.
Cancel - Terminates the creation of the current NC sequence after confirma-
tion.
Next - Completes the current NC sequence and starts creating another Nibble
Edge NC sequence with the same tool and parameters.

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2.10.1 Milling Manufacturing Parameters
Manufacturing parameters enable you to control how an NC sequence is generated.
You can specify and edit parameter values as needed. You can configure and store
manufacturing parameters in global site files or in NC specific parameter files. You
can retrieve these files, enabling you to quickly and easily set suitable parameter val-
ues when creating NC sequences.
It is important to understand the different ways in which you can configure
manufacturing parameters!
Parameter types are divided by six logical categories:
Required parameters must be configured (marked yellow color).
You create NC sequences by selecting or creating geometry to machine. You then
determine how to generate the toolpath by modifying manufacturing parameters. The
parameters available for configuration can vary depending on the type of NC se-
quence that you are creating.
Some parameters such as feed rate and spindle speed are present in all NC
sequence types.
Some parameters are specific to certain types of sequences. When you create
NC sequences, only the relevant parameters are available for configuration.
Required parameters – If a parameter is highlighted in a light yellow color in the
Edit Parameters dialog box, then it is a required parameter. You must specify a value
for this type of parameter to calculate a toolpath.
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Optional parameters – If a parameter has a default value of “-,” it is an optional pa-
rameter. –You can leave this type of parameter unchanged if required. For example,
APPROACH_FEED = -.
– This type of parameter is not used unless you specify a value.
Numeric assigned parameters – This type of parameter is assigned a specific nu-
meric value by default. – For example, CUT_ANGLE = 0. – You can change these
parameters to other specific values if desired.
Non-numeric assigned parameters – This type of parameter is assigned a specific
non-numeric value by default. – For example, COOLANT_OPTION = OFF.
– You can change these parameters to other specific values if desired. You can select
the available values from a drop-down list.
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2.10.2 Milling NC Sequences
To access Mill type NC sequences, you must be in a Mill or Mill/Turn workcell. The
following NC Sequence types are available:
Face - Facing down the workpiece.
Volume Rough - 2.5-Axis slice-by-slice milling used to remove material
from a specified volume.
Roughing - High-speed milling sequences used to remove all material inside
a Mill Window boundary.
Plunge Rough - 2.5-Axis rough milling of deep cavities by a series of over-
lapping plunges into the material, using a flat-bottom tool.
Re-rough - Used to machine only the areas where a previous Roughing or
Reroughing sequence could not reach.
Local Milling - Used to remove material left after a Volume, Profile, Con-
ventional or Contour Surface, or another Local milling NC sequence (usually
with a smaller tool). Can also be used to clean up material in specified cor-
ners.
Surface Milling - 3- to 5-Axis milling of horizontal or slanted surfaces. You
are given a choice of several methods for defining the cut.
Profile Milling - 3- to 5-Axis milling of vertical or slanted surfaces.
Finishing - Used to machine the detail of the reference part after Roughing
and Reroughing.
Corner Finishing - 3-axis milling, to automatically machine corners and
valleys that cannot be reached by a previous ball end mill.
Pocketing - 2.5-Axis milling of horizontal, vertical, or slanted surfaces. The
walls of the pocket will be milled as with Profiling, the bottom—as the bot-
tom surfaces in Volume milling.
Swarf Milling - 5-Axis milling of a series horizontal or slanted surfaces by
cutting with the side of the tool.
Trajectory - 3- to 5-Axis milling, with the tool moving along a specified tra-
jectory.
Custom Trajectory - Define the tool path for 3- to 5-axis Trajectory milling
by interactively specifying the trajectory of the control point of the tool.
Engraving - 3- to 5-Axis milling, with the tool moving along a Groove cos-
metic feature or a curve.
Thread Milling - 3-Axis helical milling.
Drilling - Drilling, boring, tapping.
Auto Drilling - Auto drill selected holes using the selected coordinate system
or retract plane.

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3
CAMSHAFT PLATE MILLING SEQUENCES
3.1
Face Milling
A Face Milling sequence enables you to face down the workpiece with a flat or radi-
us end mill tool. This enables you to configure the top surface of the job and a refer-
ence surface for other NC sequences. When creating face milling sequences, it is im-
portant that you use the correct manufacturing parameters to ensure that the toolpath
is efficiently generated. You can also create mill surfaces and use them as alternate
references when model surfaces are inappropriate, for instance, when you need to
machine multiple model surfaces as one surface.
All machining movements are parallel to the retract plane.
All inner contours in the configured reference geometry (holes, slots) are au-
tomatically excluded from machining.
If you have a workpiece in the manufacturing model, then you can remove
the machined volume from the workpiece by creating a material removal fea-
ture. You can do this after you complete the NC sequence.
Task 3.1: Create a Face Milling NC sequence and edit parameter values.
Disable all Datum Display types. Select the Mill tab.
Click Face from the Milling group. Select the drop-down arrow next to the box
containing “No tool” and select Edit Tools…
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Now you can create the standard tool or select the Solid Tool from the specified
folder. Return to the Chapter 1.4 if needed.
The following instructions are for the solid tools.
Select: end_long_sk40.asm and from the Instance window:
END_LONG_SK40_D20 > Open.
Select the Cut Data tab. Notice EN40B is selected from the Stock Material
drop-down list.
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Now, if you are using High Speed Steel (HSS), the Cutting speed (V) for
High Speed Steel (HSS) tools is 60 foot per minute (ft/min) = 18m/min.
Type 18 (m/min) in the Speed text box and type 0.2 (mm/tooth) in the Feed text
box.
These values are equivalent for the Speed 286 (rev/min) and for the Feed 114.59
(mm/min). You can round the feed as 120 mm/min.
Click the Apply button. Click Yes to save the changes to the tool. In the Tool
Setup dialog box, click Save to save the updated tool information. OK.
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Note, the saved end_long_sk40_d20.xml file now contains feed and speed in-
formation, as shown. The xml-file locates in the tool-folder.
Select the Reference tab. Click in the Machining References box. Select the top
surface of the model, as shown
Select the Parameters tab. Required Parameters are highlighted in a light yellow
color in the Edit Parameters dialog box until they have been configured.
Edit CUT_FEED to 120.
Edit STEP_DEPTH to 2.
Edit STEP_OVER to 10.
Edit CLEAR_DIST to 5.
Edit SPINDLE_SPEED to 286.
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Review the resulting toolpath. Click Display Toolpath > Click Play
Notice that the toolpath follows the outline of the selected model surface. You
can change this by changing parameters. Click Close in the Play Path dialog box
when finished.
Click Complete Feature.
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3.1.1 Editing NC Sequence Parameters
Manufacturing parameters enable you to control how an NC sequence is generat-
ed. It is important to understand the different ways in which you can con-
figure manufacturing parameters.
For example the previous Face Milling NC Sequence is not good enough with
the default parameters.
The tool approach straight over the workpiece and the toolpath is not good either.
Task 3.1.1: Editing NC Sequence parameters.
Select the Face Milling 1 NC Sequence from the model tree and Edit Defini-
tion. Select the Parameters tab in the dashboard. Click Edit Machining Pa-
rameters.
Click the All button, and select All categories from the Categories drop-down
list. Edit TRIM_TO_WORKPIECE to YES. Click OK in the Edit Parameters
dialog box.
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Click Display Toolpath > Click Play. Notice that the toolpath now follows the
outline of the workpiece.
Click Close in the Play Path dialog box when finished.
TRIM_TO_WORKPIECE Parameter:
If TRIM_TO_WORKPIECE is set to NO, then Creo Parametric machines
the selected surface without regard to the workpiece outline.
If TRIM_TO_WORKPIECE is set to YES, then the toolpath extends or
trims to the workpiece cross-section at the depth of the surface you are
machining.
Edit entry and exit parameter values in an existing NC step.
Select the Parameters tab in the dashboard. Click Edit Machining Parameters. Click
the All button, and select Entry/Exit Motions from the Categories drop-down list.
Edit APPROACH_DISTANCE to 1 and EXIT_DISTANCE to 1. OK.

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Click Display Toolpath > Click Play. Notice the tool now extends an extra distance
on the first and last pass, as shown.
Entry and Exit Face Milling Parameters:
There are a number of parameters that control entry and exit motions when creating
face milling sequences.
Entry and Exit Parameters:
START_OVERTRAVEL and END_OVERTRAVEL
 The START_OVERTRAVEL parameter adds an offset to the beginning
of each pass in a slice. The END_OVERTRAVEL adds an offset to the
end of each pass in a slice.
APPROACH_DISTANCE and EXIT_DISTANCE
 The APPROACH_DISTANCE parameter adds an extra approach dis-
tance to the first pass of each slice. The EXIT_DISTANCE parameter
adds an extra distance to the last pass of each slice.
ENTRY_EDGE and CLEARANCE_EDGE
 You can edit the ENTRY_EDGE parameter to LEADING_EDGE (the
default), CENTER, or HEEL. This parameter controls which point of the
tool is used for measuring the approach and over travel motions when the
tool approaches the component being machined during each pass in a
slice.
 You can edit the CLEARANCE_EDGE parameter to HEEL (the default),
CENTER, or LEADING_EDGE. This parameter controls which point of
the tool is used for measuring the exit and over travel motions when the
tool leaves the material during each pass in a slice.
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Editing depth control parameter values in an existing NC step.
There are a number of parameters that control the depth of a cut when creating face
milling sequences. Depth Control Parameters:
STEP_DEPTH
NUMBER_CUTS
 Smallest resulting depth of cut used.
If NUMBER_CUTS = 0 or 1 and STEP_DEPTH is greater than depth to
be machined.
 One pass taken at full depth.
BOTTOM_STOCK_ALLOW
 Stock remaining on machined surface.
 Default is zero.
Select the Parameters tab in the dashboard. Click Edit Machining Parameters. Click
the All button, and select Cut Depth and Allowances from the Categories drop-
down list.
Edit STEP_DEPTH to 1. Edit START_OVERTRAVEL and
END_OVERTRAVEL to 1. Edit NUMBER_CUTS to 2. OK.

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Click Display Toolpath > Click Play. Notice that the tool now makes two passes,
one at a depth of 1 and one at full depth, as shown.
Task 3.1.1 is ready. Save your work.
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3.1.2 Lateral Control Face Milling Parameters
Lateral control parameters are a group of parameters that control the lateral
movement of the tool in face milling steps. Lateral movement is also affected by
the trim_to_workpiece parameter.
The following is a summary of the key parameters that control the lateral move-
ment of the tool in face milling steps.
SCAN_TYPE
 TYPE_1 – Moves the tool back and forth across the surface.
 TYPE_3 – If there are separate zones, then each zone is machined
separately. Otherwise the same as TYPE_1.
 TYPE_ONE_DIR – Machines in one direction and retracts between
passes.
 TYPE_SPIRAL – Creates a spiral toolpath.
CUT_ANGLE – Is the angle between the cut direction and the X-axis of
the NC Step coordinate system.
STEP_OVER – Three parameters control the step-over distance. The fi-
nal toolpath uses the parameter that produces the smallest calculated step-
over:
 STEP_OVER – Controls the step-over within a slice.
 Or NUMBER_PASSES – Explicitly sets the number of passes to take
in each slice.
 Or TOOL_OVERLAP – An alternative method to control the step-
over based on the tool overlap.
If NUMBER_PASSES is equal to 1, however, step-over is ignored and
one pass is created at the center of the machined surface for each slice.
STEP_OVER_ADJUST – Adjusts the passes in the slice to start and fin-
ish near the edges of the surface that you are machining. It only reduces
the step-over distance, and adds an extra pass if needed.
ONE_PASS_OFFSET – Controls the distance away from the centerline
when NUMBER_PASSES is equal to 1, and a single pass is made.
INITIAL_EDGE_OFFSET – Enables you to offset the first pass in rela-
tion to the edge of the surface being milled.
FINAL_EDGE_OFFSET – Enables you to offset the last pass in relation
to the edge of the surface being milled.
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Below are a few examples of the lateral control parameters:

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If the tool diameter is greater than the face to mill, you can use the parameter
NUMBER_PASSES = 1, One pass made at center.
As you can notice, the manufacturing parameters affects to toolpath substantial-
ly!
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3.1.3 Material Removal Feature
When you have a workpiece in the manufacturing model, then you can remove
the machined volume from the workpiece by creating a material removal fea-
ture. You can do this after you complete the NC sequence.
Task 3.1.3: Create a material removal feature to cut away the machined volume
from the workpiece for the face milling sequence
Select Material Removal Cut from the Manufacturing Geometry Group drop-
down menu.
Click Face Milling 1 from the menu manager. Click Automatic > Done. Click
the Auto Add button to select the workpiece to intersect. Click OK to complete
the feature.

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3.2
Profile Milling
Profile milling sequences enable you to rough and finish mill both vertical and slant-
ed surfaces. This is useful for machining the sidewalls of pockets and for machining
outside profiles of components. When creating profile milling sequences, you can
create mill surfaces and use them as alternate references when model surfaces are in-
appropriate, for instance, when the model surface being machined has a variable
depth. Another important skill with profile milling is the ability to refine the entry
and exit motions of the toolpath to enable proper application of cutter compensation
and to eliminate witness lines from the machined surfaces.
Surfaces selected for machining must enable a continuous toolpath.
The depth of the surfaces selected for machining determines the final cut
depth.
You can configure tool approach and exit motions (customizing).
If you have a workpiece in the manufacturing model, you can remove the
machined volume from the workpiece by creating a material removal feature.
You can do this after you complete the NC sequence.
Customizing the Toolpath
By default, toolpaths are generated based on the selected reference geometry
and the manufacturing parameters.
It is possible to modify these default cut motions by adding alternative ap-
proach and exit moves.
You can use two tools to do this:
 Approach/Exit – This option enables you to add or remove slices or cut-
ting passes, and specify approach and exit paths.
 Tool Motions – This option enables you to modify default cut motions.
This includes removing default cut motions and adding your own cut mo-
tions including approach and exit tool motions.
 Both tools provide essentially the same functionality, but use different in-
terfaces.
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Task 3.2: Create a profile milling sequence and edit parameter values.
Disable all Datum Display types. In the ribbon, select the Mill tab. Click Profile
Milling from the Milling group.
Click Tool Manager in the Profile Milling dashboard. Ensure that the
END_LONG_SK40_D20 tool is selected, and then right-click and select Select tool
and return.
Select the Reference tab in the dashboard, and click Details below the Machining
References collector. In the Surface Sets dialog box, click Add. Notice the default
rule selection is Loop surfaces. Cursor over the model, right-click, and select the
bottom surface of the reference model, as shown.
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Select outer edge of the reference model for the loop edge, as shown. Notice that the
selected loop of surfaces highlight.
Click OK.
Select the Parameters tab in the dashboard. Edit CUT_FEED to 120. Edit
STEP_DEPTH to 5. Edit CLEAR_DIST to 5. Edit SPINDLE_SPEED to 286.
Review the resulting toolpath. Click Display Toolpath in the dashboard. Click
Play. Notice that the toolpath make a straight pass to the profile, because there is no
lead in or lead out motions configured for the toolpath. Click Close in the Play Path
dialog box when finished.
Click Complete Feature. Save your work.
Task 3.2 is ready.
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3.2.1 Lead In and Lead Out
When you create profile milling sequences, you can use a number of parameters to
control lead in and lead out motions.
Lead In and Lead Out Motion Parameters:
CUTCOM - Turns cutter compensation on or off in the CL data file. When
configuring a workcell, you can specify whether the cutter compensation is
toward the tool center (default) or tool edge.
CUT_ENTRY_EXT / CUT_EXIT_EXT - Set to LEAD_IN/LEAD_OUT,
tool enters and exits the workpiece along a tangent arc.
LEAD_RADIUS - Radius value of the tangent circle move for lead in or
lead out.
TANGENT_LEAD_STEP - Linear distance of the tangent section of a lead
in or lead out motion.
NORMAL_LEAD_STEP - Linear distance of the normal section of a lead
in or lead out motion.
OVERTRAVEL_DISTANCE - For profile milling. The distance the tool
travels past the start of a profile pass.
APPROACH/EXIT - For profile milling, this is an optional element. It ena-
bles creation of approach and exit moves. You can use these as an alternative
to lead in and lead out motions.
 APPROACH_DISTANCE - You can use this parameter when creating cut
motions or using the approach/exit option. The distance of an approach
move for a tangent or normal approach.
 EXIT_DISTANCE - You can use this parameter when creating cut mo-
tions or using build cut. The distance of an exit move for a tangent or
normal exit.
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Task 3.2.1: Edit the lead in and lead out parameters in a profile milling sequence.
Select the Profile Milling 1 NC sequence in the model tree. Right-click and select
Edit Definition.
Select the Parameters tab. Click Edit Machining Parameters. Click the All button,
and select Entry/Exit Motions from the Categories drop-down list. Select
LEAD_IN from the CUT_ENTRY_EXT drop-down menu. Select LEAD_OUT
from the CUT_EXIT_EXT drop-down menu. Edit LEAD_RADIUS to 10. Click
OK.
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Review the resulting toolpath. Click Display Toolpath. Click Play. Notice that lead
in and lead out motions are now created, as shown left.
Adjust the entry and exit moves. Select the Parameters tab. Click Edit Machining
Parameters. Edit TANGENT_LEAD_STEP to 10. Edit
OVERTRAVEL_DISTANCE to 5. Click OK. Review the resulting toolpath. Click
Display Toolpath in the Profile Milling dashboard. Click Play. Notice the over
travel distance removes any witness lines from the machined surfaces.
Click Complete Feature. Save your work.

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3.2.2 Depth and Lateral Control Parameters
When you create profile milling sequences, you can use a number of parameters to
control the depth of cut and lateral movement.
Depth Control Parameters:
STEP_DEPTH - The incremental depth of each cut for each profile pass.
AXIS_SHIFT – Moves the CL data up or down along the tool axis. If set to a
positive value, all CL data is shifted down along the tool axis. If set to a neg-
ative value, all CL data is shifted up along the tool axis. The default is 0.
Lateral Control Parameters:
PROF_INCREMENT - The horizontal distance between passes.
NUM_PROF_PASSES - The number of profile passes at each depth.
PROF_STOCK_ALLOW - The remaining stock material left on profile
milled surfaces.
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Task 3.2.2: Edit depth control parameter values in a profile milling sequence.
Select the Profile Milling 1 NC sequence in the model tree. Right-click and select
Edit Definition.
Click Step Parameters. Click the All button and select Cut Depth and Allowances
Category from the Categories drop-down list. Edit the following parameters:
Edit NUM_PROF_PASSES to 2.
Edit PROF_INCREMENT to 1.
Edit AXIS_SHIFT to 0.2
Click OK.
Review the resulting toolpath. Click Display Toolpath > Click Play. Notice that the
toolpath now makes two passes at each step as shown above right.
Click Complete Feature. Select Material Removal Cut from the Manufacturing
Geometry Group drop-down menu.
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3.2.3 Cutter Compensation
Generally the CAM software used to generate a tool path also generates the tool off-
set to account for the diameter of the tooling. CAM systems allow the user to pro-
gram as if with a zero-diameter cutter.
Why Cutter Diameter Compensation?
When machining finished surfaces with the side of a milling cutter (generally
called profiling), the accuracy of the finished surface depends on the cutter
accuracy and how closely the cutter diameter matches the programmed size.
Cutters wear causing size changes in profiled surfaces.
Reground endmills are always smaller than nominal size.
Cutter radius compensation can be one of the more difficult programming fea-
tures to fully master. There are many rules, and when something goes wrong, it
can be difficult to diagnose and correct the problem.
Cutter Compensation is mostly used in manual CNC programming but can be used
with different CAM systems also.
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3.2.3.1
Cutter Compensation in Creo
When configuring a workcell, you can specify whether the cutter compensation is
toward the tool center (default) or tool edge. (This is not a Task!)
Parameters used for Cutter Compensation:
For example. T1, H1 and D1, where D is Register number.
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The Register number is automatically the number of the tool if this is chosen in the
postprocessor: Output tool number as the diameter offset number when not
specified:
In addition you have to define the TANGENT_LEAD_STEP parameter – Linear
distance of the tangent section of a lead in or lead out motion.
Cutter compensation is enabled on the first linear move and the output switches from
the center to the edge of the tool.
Cutter compensation must be turned on or off with a line move, never an arc. Com-
manding G40/G41/G42 with an arc move will cause a diameter compensation error
that will stop the program.
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Below is an example how the cutter compensation works. Positioning:
CUTCOM LEFT:
The tool edge is on the left side of the profile edge:
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CUTCOM OFF:
NC code:
%
N1 T1 M6
N2 S286 M3
N3 G0 X15. Y-45.
N4 G43 Z5. H1 M7
N5 Z4.3
N6 G1 Z-3.7 F120.
N7 G41 X25. Y-35. D1
(G41= Compensation Left)
N8 G3 X5. Y-15. I-20. J0.
N9 G1 X-20.
N50 G2 X20. Y-15. I-5. J0.
N51 G1 X-5.
N52 G3 X-25. Y-35. I0. J-20.
N53 G1 G40 X-15. Y-45.
(Compensation Off)
N54 Z5.
N55 M5
N56 M30
%
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3.3
Volume Milling
When machining, it is important that you be able to remove large amounts of
workpiece material. You typically use volume milling sequences for this purpose.
Examples include machining mold cavities, machining pockets and slots, and facing
down a workpiece. The volume milling process involves specifying the volume of
material to be removed. You achieve this by creating either mill windows or mill
volumes. You can modify volume milling sequences using build cut and customized
functionality. This enables you to edit and remove the default cut motions and add
new cut motions as required.
You can use the following features to describe volume milling NC sequences:
Volume milling sequences remove the material inside a specified volume
slice-by-slice.
All slices are parallel to the retract plane.
You can create both roughing and profiling passes within a volume milling
sequence.
You use manufacturing geometry to configure the volume of material to ma-
chine.
 You can use a mill volume or mill window to represent the volume of
material to be removed.
By default, the tool does not machine outside the specified volume.
 However, the tool can break through surfaces of a volume if they are spe-
cifically selected as approach walls.
Top surfaces are surfaces of a mill volume that the tool can also penetrate
when creating the toolpath.
 You only have to use this option if some of the top surfaces of the volume
are not parallel to the retract plane. If you use a mill window, this option
is not available. You can use the window start plane as the top surface.
You can modify the default cut motions by using the build cut or customize
functionality.
If you have a workpiece in the manufacturing model, you can remove the
machined volume from the workpiece by creating a material removal feature.
You can do this after you complete the NC sequence.
Mill Volume Configuration Tools
The following tools enable simple mill volume configuration:
Add solid features – You can sketch an outline and create an extruded mill
volume. If required, you can also create more complex shapes using tools
such as revolve, sweep, and blend.
Trim – You can automatically subtract the reference model material from an
existing mill volume. You usually apply this to sketched volumes.

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Gathering Mill Volumes
The gathering technique enables you to create complex mill volume shapes by refer-
encing model geometry including surfaces and edges.
The gathering process involves several steps and the selection of various options:
Select Surfaces – You select the surfaces to machine. There are several
methods available. With each method, the selected surfaces are sewn together
to form a single quilt which is by default extruded up to the retract plane to
form a volume. Alternatively, you can extrude the quilt to a user-defined
plane if required. There are four options for selecting surfaces.
 Surf and Bound – You select one of the surfaces for machining (the seed
surface) and then select bounding surfaces. The seed surface and all
neighboring surfaces up to the boundary surfaces are sewn together into a
single quilt. You can also configure boundary loops to add outer loops of
edges to the boundary.
 Surfaces – You select continuous surfaces to machine.
 Features – You select features to be machined. All the surfaces of selected
features are included.
 Mill Surfaces – You select pre-configured mill surfaces.
Exclude – This option is available only if you gather using an option other
than Surf and Bound (for example, Surfaces). There are two exclude options.
 Surfaces – Exclude some of the selected surfaces by selecting each of
them individually. This is especially convenient when gathering using the
Features or Mill Surf options.
 Loops – Exclude outer loops. Use this option to delete unwanted portions
of surfaces selected for gathering.
Fill – When you fill an inner loop of edges on a surface selected for gather-
ing, it is equivalent to “patching” the base quilt of the mill volume. The vol-
ume is built as if there was a smooth surface with no perforations. Two fill
options are available.
 All – Fill all loops on a selected surface. Select a surface. All inner loops
on this surface are filled, whether they belong to bounding surfaces or
not.
 Loops – Select loops to be filled. For each loop to be filled, you must se-
lect only one edge. If you gather using Surf and Bound, the edges must lie
on the bounding surfaces. Select additional bounding surfaces if neces-
sary.
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Close – This enables you to specify the mill volume capping plane.
 The mill volume is generated by extruding the boundaries of the selected
surface quilt vertically up to the specified plane or surface.
 If you create a mill volume during the creation of a volume milling se-
quence, then by default Creo Parametric closes the mill volume automati-
cally. This is done by extruding the boundaries of the surface quilt verti-
cally up to the retract plane. Note in this case, you can still specify an al-
ternative capping plane if required.
Trimming Mill Volumes
You can also create a volume milling sequence using the trimmed mill volume.
You can subtract the reference model from the mill volume geometry using the trim
functionality.
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Task 3.3: Create a volume milling sequence using an extrude feature and trim func-
tionality.
In the ribbon, select the Mill tab. Select Volume Rough from the Roughing drop-
down menu in the Milling group.
Notice that in the SEQ SETUP menu, the Tool, Parameters, and Window check box-
es are automatically selected. Select the Volume check box. You must configure
these items to generate a toolpath. In addition, select the Name box and Click Done.
Edit the name for the NC Sequence. Click New in the Tool Setup dialog box.
Retrieve tool By Copy (or create standard tool).
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Select Instance: END_LONG_SK40_D8.
Cut Data:
Click the Apply button. Click Yes to save the changes to the tool. In the Tool Setup
dialog box, click Save to save the updated tool information. OK.
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Edit the required parameters for the NC sequence:
Click OK.
Click Mill Volume from the Manufacturing Geometry group. Click Extrude from
the Shapes group. Right-click and select Define Internal Sketch.
Select the top surface of the reference model, as shown. Click Sketch.
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Orient the sketching plane parallel to the screen. Click References from the Setup
group.
Select the left and top edges of the reference model as references, as shown.
Click Close in the References dialog box. Click Project. Select the Loop option.
Right click to query on the model and select the top surface of the reference model,
as shown.
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Click next until the loop is highlighted as shown below. Accept to select the loop of
edges.
Click Close.
Click OK in the Sketch dashboard. Click Change Depth Direction in the Extrude
dashboard. Edit the depth to selected and select the surface as shown below:
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Click Complete Feature in the Extrude dashboard. Click Trim from the Volume
Features group.
Select the reference model, as shown below. Click OK from the Controls group.
Click Done Seq. Select the NC sequence from the model tree and Play Path.
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Notice the tool path, the scanning parameter is now TYPE_3.
Click close.
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3.3.1 Scanning Volume Milling Parameters
Scanning parameters are a group of parameters that control how the tool machines
each slice in volume milling sequences. The following is a summary of the key pa-
rameters that control how the tool scans each slice in volume milling sequences.
Scanning Parameters:
ROUGH_OPTION - Controls whether a profiling and/or roughing pass is
created during volume milling.
 ROUGH_ONLY - No profiling.
 ROUGH_&_PROF - Rough then profile.
 PROF_&_ROUGH - Profile then rough.
 PROF_ONLY - Only profiling.
 ROUGH_&_CLEAN_UP - Cleans up the walls of the volume without
creating a profiling pass.
 POCKETING - Profiles the walls of the volume and finish mills all the
planar surfaces inside the volume that are parallel to the retract plane (is-
land tops and bottom of the volume).
 FACES_ONLY - Finish mills only the planar surfaces inside the volume
that are parallel to the retract plane (island tops and bottom of the vol-
ume).
CUT_ANGLE - The angle between the cut direction and the X-axis of the
NC Sequence coordinate system.
SCAN_TYPE - For volume milling. Refers to the way a milling tool scans
the horizontal cross-section of a milling volume and avoids islands.
 TYPE_1 - Continuously machines the volume. Retracts upon encounter-
ing islands.
 TYPE_2 - Continuously machines the volume without retracting, while
moving around the islands.
 TYPE_3 - Removes material from continuous zones defined by the island
geometry, machining them in turn and moving around the islands.
 TYPE_SPIRAL - Generates a spiral cutter path.
 TYPE_ONE_DIR - The tool only cuts in one direction.
 POCKETING - Profiles the walls of the volume and finish mills all the
planar surfaces, inside the volume, that are parallel to the retract plane (is-
land tops and bottom of the volume).
 FACES_ONLY - Finish mills only the planar surfaces, inside the volume,
that are parallel to the retract plane (island tops and bottom of the vol-
ume).
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SCAN_TYPE examples: TYPE_3
TYPE_SPIRAL:
TYP_ONE_DIR:
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High speed machining options:
CONSTANT_LOAD - Performs high speed roughing (with
ROUGH_OPTION set to ROUGH_ONLY) or profiling (with
ROUGH_OPTION set to PROF_ONLY).
SPIRAL_MAINTAIN_CUT_TYPE - Generates a spiral cutter path with re-
verse arc connections between cuts. This is a high speed machining option,
which minimizes retracts.
SPIRAL_MAINTAIN_CUT_DIRECTION - Generates a spiral cutter path with
S-shape connections between cuts. This is a high speed machining option,
which minimizes retracts.
FOLLOW_HARDWALLS - The shape of each cut follows the shape of the
walls of the volume, maintaining fixed offset between the respective points of
two successive cuts. If the cuts are closed, there are S-shape connections be-
tween the cuts.
CONSTANT_LOAD:
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Task 3.3.1: Edit parameters relating to scanning and depth in the previously VOL-
UME MILLING NC sequence.
Select the BOT_POCKET NC sequence in the model tree. Right-click and select
Edit Step Parameters. Click the All button, and select Cutting Motions from the
Categories drop-down list. Select SCAN_TYPE parameter and change to SPIRAL
and click OK.
Play the Path:
Entry and Exit Motions for the volume milling:
Edit Step Parameters. Click the All button, and select Entry/Exit Motions from the
Categories drop-down list. Select RAMP_ANGLE parameter and edit to 15. Click
OK.
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Play the Path. Notice the angle that tool enter to the workpiece.
Edit Step Parameters. Click the All button, and select Entry/Exit Motions from the
Categories drop-down list. Select RAMP_ANGLE parameter and edit to 3. Select
HELICAL_DIAMETER parameter and edit to 10. Click OK.
Play the Path. You can hide the volume before the Play Path.
Create the Material Removal Cut for the volume from the Manufacturing Geometry
Group drop-down menu.
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3.4
Pocket Milling
Pocketing can be used to finish mill after a rough Volume operation, or for direct fin-
ishing. The surfaces selected must allow for a continuous tool path. The pocket may
include horizontal, vertical, or slanted surfaces. The walls of the pocket will be
milled as with Profiling, the bottom - as the bottom surfaces in Volume milling.
Now the machined part looks as below:
Task 3.4: Pocket Milling.
Select Pocketing from the Milling drop-down menu. Select the Name check box. Pa-
rameters and Surfaces check boxes are automatically selected. The tool is the same
as in the previous NC Sequence.
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Type the name for the NC Sequence:
Edit the following parameters for the NC sequence.
Edit SCAN_TYPE to TYPE_SPIRAL
Edit RAMP_ANGLE to 5.
Edit SPINDLE_SPEED to 716
Click OK.
From the menu manager > SURF PICK > accept the default Model – Done.
Press CTRL and Select the two surfaces within the pocket as shown. >
Done/Return.
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From the menu manager, click Play Path > Screen Play.
Click Close in the Play Path dialog box when finished. Click Done Seq.
Create the Material Removal Cut for the Circular Pocket from the Manufacturing
Geometry Group drop-down menu. Select Automatic. If you get the message FEAT
FAILED > Quit and create it again.
Select Construct. > Done. Select Solid > Cut > Extrude > Solid > Done.
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Right-click and select Define Internal Sketch.
Select the placement surfaces as shown above. In the Sketcher, select Project and se-
lect the two edges as shown below. Click Save the section and exit.
Select the depth as shown below. Click complete feature. Click Done/Return.

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3.5
Holemaking
Holemaking sequences enable you to create many different types of drilling cycles
for machining. During the holemaking process, you need to select the appropriate
cycle type. These include standard drilling, boring, tapping, reaming, and countersink
drill cycles. It is important to understand when you should use each type of drill cy-
cle. Another important stage in the holemaking process is creating hole sets that de-
fine the holes to be drilled. If you need to perform a series of holemaking sequences
on the same set of holes, you can configure a drill group that simplifies the selection
process.
Holemaking Process:
Select the drill cycle type, for example, deep drilling or reaming.
Select an appropriate holemaking tool
Configure holemaking parameters.
Configure the set of holes to be machined by selecting the holes and specify-
ing depth options.
Customize hole connections (optional)

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Cycle Types:
Depending on the cycle type you select, a different CYCLE/XXXX statement is out-
put in the CL data file. You can configure a number of different cycle types.
Drill - Drill a hole. Depending on the additional option you select, the follow-
ing statement is output to the CL file.
 Standard (default) – CYCLE/DRILL.
 Deep – CYCLE/DEEP.
 BreakChip – CYCLE/BRKCHP.
 Web – CYCLE/THRU (for multiple plates).
 Back – GOTO and SPINDLE statements for back spotting.
Face - Drill a hole with an optional dwell at final depth to help ensure a clean
surface at the bottom of the hole. The CYCLE/FACE statement is output to
the CL file.
Bore - Bore a hole to create a finish hole diameter with high precision. The
CYCLE/BORE statement is output to the CL file
Countersink - Drill a chamfer for a countersunk screw. The CYCLE/CSINK
statement is output to the CL file. If you select the Back option together with
Countersink option, the system performs back countersinking.
Tap - Drill a threaded hole. Pro/NC supports ISO standard thread output. The
CYCLE/TAP statement is output to the CL file. Two additional options are
available.
 Fixed - The feed rate is determined by the combination of thread pitch
and spindle speed.
 Floating - Enables you to modify the feed rate using the parameter
FLOAT_TAP_FACTOR.
Ream - Create a precision finish hole. The CYCLE/REAM statement is out-
put to the CL file.
Custom - Create and use your own customized cycles for the current machine
tool.
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3.5.1 Basic Drilling
When creating drilling sequences, you need to configure the hole sets for drilling.
This involves specifying a number of options.
Selecting holes – You can select the holes to drill using any combination of
the following methods:
 Axes – Specify holes by selecting individual hole axes.
 Points – Specify drill locations by selecting datum points or reading in a
file with datum point coordinates.
 Diameters – Specify holes by selecting diameter value(s).
 Surfaces – Specify holes by selecting surfaces of the reference part or
workpiece.
 Parameters – Select holes with a certain parameter value.
 Groups – Select predefined drill groups. You can define groups of holes
at setup time for later use in Holemaking NC sequences. This simplifies
later hole selection.
Depth options – You need to configure depth options as part of the hole set
configuration process. You can configure many different depth options:
 Blind – Drill from the start surface (or Z-height) to specified depth. Spec-
ify the start and end surfaces (by either selecting a surface or typing a Z-
depth).
 Auto – Depth of drilling is determined automatically, by referencing hole
geometry.
 Thru All – Drill a through hole from the retract surface all the way
through the workpiece(s) or reference part(s) that the hole intersects.
 The Tool Depth option buttons, Shoulder and Tip, available for blind and
auto drilling, determine whether the drilling depth references the shoulder
or the tip of the tool.
Countersink Drilling – A number of specific options enable you to configure
countersink drilling cycles:
 The depth for countersink drilling is defined by the start surface and the
countersink diameter value, specified at the time of configuring the hole
set.
 The countersink diameter is the final diameter of the hole after drilling.
This diameter is measured on the start surface.
 Auto Chamfer – Instead of typing a countersink diameter, you can specify
that Creo Parametric automatically finds all the applicable chamfers and
makes the necessary calculations.
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3.5.2 Countersink Drilling Cycle
Drill a chamfer for a countersunk screw. This cycle is also useful if you want to cre-
ate a tapped hole or need only chamfers for the holes. The CYCLE/CSINK statement
is output to the CL file.
Task 3.5.2: Create a countersink drilling sequence.
In the ribbon, select the Mill tab. Select Countersink from the Countersink drop-
down menu in the Holemaking Cycles group. Click Tool Manager in the Counter-
sinking dashboard.
Click File > Open Tool Library > By Copy. Select nc_spot_drill_weldon.asm.
Select the Cut Data tab. Edit the values as shown.
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Select the References tab. Select the Auto Chamfer check box. Notice four axes
and the holes highlight on the model, as shown. (Countersink Diameter: 7).
Select the Parameters tab.
Edit SPINDLE_SPEED to 500
Click Display Toolpath in the Countersinking dashboard. Click the CL data bar to
make the CL data visible. Click Play. Notice that the four holes are drilled and a
CYCLE/CSINK statement is output in the CL data. Click Close in the Play Path dia-
log box when finished.
Click Complete Feature in the Countersinking dashboard.
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3.5.3 Standard Drilling Cycle
The Standard drilling cycle can be used for the short holes.
Task 3.5.3: Create a standard drilling sequence.
Click Standard in the Holemaking Cycles group. Click Tool Manager in the Drill-
ing dashboard. Click New.
Click File > Open Tool Library > By Copy. Select drill_chuck_sk40.asm. Select the
Instance:
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Select the References tab.
Select the Details button. Select the 5 diameter in the available list and click Add.
Select the Depth tab in the Holes dialog box. Notice in the Depth tab that the Auto
and By Shoulder depth options are configured by default, as shown.
Click Done in the Holes dialog box. Select the Parameters tab.
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Click Display Toolpath in the Drilling dashboard. Click Play. Notice that the four
holes are drilled and a CYCLE/DRILL statement is output in the CL data.
Select Position Cutting Tool button and click the end point of the red coloured
toolpath:
You can see that there is a collison to the support plate. Click Close in the Play Path
dialog box when finished.
Select the References tab again. You can change the Depth End to Machine to se-
lected reference. Select surface as shown below:
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Click Display Toolpath in the Drilling dashboard. Click Play. Now there is no colli-
sion. The other and better option is to move the support plates.
Click Complete Feature in the Drilling dashboard.
Create the Material Removal Cut for the Countersinking and Drilling NC Sequenc-
es from the Manufacturing Geometry Group drop-down menu. Select Automatic.
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3.5.4 Tapping Cycle
The Tapping Cycle can be used for the thread holes.
Task 3.5.4: Create a Tapping sequence.
Click Tapping in the Holemaking Cycles group. Click Tool Manager in the Tap-
ping dashboard. Click File > Open Tool Library > By Copy. Select
tap_m3_m24_sk40.asm. Select the Instance:
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Select the References tab.
Select the Details button. Select the 6 diameter in the available list and click Add.
Select the Depth tab in the Holes dialog box. Notice in the Depth tab that the Auto
and By Shoulder depth options are configured by default, as shown. Select Machine
to selected reference and select the surface as shown below:
Click Done in the Holes dialog box. Select the Parameters tab.
Edit THREAD_FEED to 1.
Edit THREAD_FEED_UNITS to MMPR.
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Click Display Toolpath in the Tapping dashboard. Click Play. Notice that the four
holes are drilled and a CYCLE/TAP statement is output in the CL data.
Click Complete Feature in the Tapping dashboard.
Create the Material Removal Cut for the Tapping NC Sequence from the Manufac-
turing Geometry Group drop-down menu. Select Automatic.
Note! There is a collision with M6 tap, because the drilled 5 diameter hole is too
shallow. You will make the corrections later.
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3.6
Trajectory Milling
Trajectory milling enables you to sweep a tool along any user-defined trajectory.
During the trajectory milling process, you must configure the trajectory for the tool
to follow. You can use trajectory milling sequences for milling slots where the shape
of the tool corresponds to that of the slot. You can also use them to chamfer edges.
You can either use an edited tool or you can sketch your own tool for the sequence.
This enables you to specify the tool control point anywhere on the tool.
There are two types of trajectory milling sequences:
2-Axis Trajectory Milling:
 To configure the toolpath for 2-axis trajectory milling, you sketch or se-
lect a curve that represents the final trajectory of the control point of the
tool.
 The curve must lie in the plane normal to the Z-axis of the NC sequence
coordinate system.
 In the simplest case, the tool makes just the one cutting pass along this
trajectory, with or without tool offset.
 This type of trajectory milling sequence also benefits from automatic ma-
terial removal.
3- to 5-Axis Trajectory Milling
 To configure the toolpath for 3- to 5-axis trajectory milling, you must in-
teractively specify the trajectory of the control point of the tool by creat-
ing cut motions using the customize functionality.
Sketched or Edited Tools
You can use either edited tools or sketch your own tool for the NC sequence.
If you sketch a tool, you can create a user-defined control point for the tool.
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3.6.1 2-Axis Trajectory Milling
2-Axis Trajectory Milling Configuration:
In 2-Axis trajectory milling, you specify the tool trajectory by sketching or
selecting a curve that represents the final trajectory of the tool.
You can adjust the depth of the final pass and specify multiple cutting passes
with a vertical offset. You can also create multiple trajectory milling slices
that are horizontally offset from the final tool trajectory.
You can specify a number of options when you configure a 2-axis trajectory
milling sequence.
 Datum Curve – You need to select or create a datum curve that lies in a
plane normal to the Z-axis of the NC sequence coordinate system. You
can create the datum curve before or during the creation of the trajectory
milling sequence.
 Start Height – Select the height from which you want the tool tip to start.
 Height – Adjust the depth of the final pass of the tool by selecting a
plane. By default, Creo Parametric uses the datum curve plane.
 Direction – You can specify the direction of trajectory.
 Offset – Specify the direction in which the cut motion is offset (none, left,
or right). The offset distance is half of the cutter diameter.
The direction of the offset corresponds to the direction of trajectory.
When you select an offset option, the arrow shows the offset direc-
tion.
 Material Side – If the offset direction is none, then you can specify the
material side to be left or right.
Parameter Configuration:
You can configure many parameters to control the toolpath; however, a number of
important parameters control lead in and lead out motions and the application of cut-
ter compensation.
Lead In and Lead Out
 LEAD_IN/LEAD_OUT – If configured to YES, then the tool makes lead
in and lead out motions.
 TANGENT_LEAD_STEP – Linear distance of the tangent section of a
lead in or lead out motion.
 NORMAL_LEAD_STEP – Linear distance of the normal section of a
lead in or lead out motion.
 LEAD_RADIUS – Radius value of the tangent circle move for lead-in or
lead-out.
Cutter Compensation
 CUTCOM – Turns cutter compensation on or off in the CL data file.
You can configure the workcell to specify whether the cutter compen-
sation is toward the tool center (default) or the tool edge.
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Task 3.6.1: Create a 2-axis trajectory milling sequence for the chamfer and config-
ure sequence options. In this case the chamfer tool is 10 diameter V-CUT end mill.
The tool tip is 2mm below the edge of the chamfer as shown below
At first, you specify the tool trajectory by sketching a curve on that represents the fi-
nal trajectory of the tool. You need to define a new Datum Plane for the sketch.
The model tree insertion indicator, shown in the model tree as Insert Indicator, in-
dicates where features are inserted upon creation. By default, its position always suc-
ceeds all items listed in the model tree. You may drag it higher or lower in the model
tree to insert features between other features in the tree.
In addition to dragging the Insert Indicator up into the model tree, you can specify an
insert location in the tree. To do this, select a feature, right-click, and select Insert
Here. The insert indicator is then placed directly below the selected item.
The plane for the trajectory has to locate after the last Material Removal Feature in
the model tree > you can select the feature and right click > Insert Here.
Click Plane from the Datum group. Select the top surface for the reference as shown.
Create the new plane 2mm below the selected surface.
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When the plane is activated from the model, select the Sketch Tool from the ribbon.
Select Offset from the Sketching Group. Select Single and select the edge as shown:
Notice the direction of the arrow and edit the negative or positive value to 1.5.
Continue selecting edges and values until the loop is ready:
Click Save the Section and Exit.
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In the ribbon, select the Mill tab. Select 2 Axis Trajectory from the Trajectory Mill-
ing drop-down menu in the Milling group. Click Tool Manager in the Curve Trajec-
tory dashboard. Click New.
Click File > Open Tool Library > By Copy. Select v_cut_10_weldon_sk40.asm:
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Select the References tab. Click in the Machining Reference collector to select the
datum curve.
Select the sketched line as shown below. Click Material to Remove to change the
direction. Click the red arrow on the sketch to change the direction as shown below.
Click the Details tab. Press CTRL and select all sketched lines and arcs. Change the
direction of the arrow by clicking it. OK.
You can move the start point by dragging the handle or click the value and edit to
0.5.
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Select the Parameters tab.
Review the resulting toolpath. Click Display Toolpath in the Curve Trajectory dash-
board. Click Play.
Click Resume Feature. Select the Parameters tab and Edit Machining Parameters.
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Click the All button and select Entry/Exit Motions from the categories drop-down
list.
Edit the values as shown. Click OK. Review the resulting toolpath. Click Display
Toolpath in the Curve Trajectory dashboard. Click Play.
Click Close. Click Complete Feature.
You cannot create the automatic material removal for the trajectory milling.
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Now there are 8 NC Sequences for the first operation. The machined stock looks like
below. (plus chamfer)
Drag the Insert Indicator to the bottom of the model tree.
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3.7
Operation 2.
When the first side and Operation (here PLATE_BOTTOM_NC) is ready enough
you can rotate the part and create more NC Sequences to make the part finished.
Task 3.7: Activate Operation 2. top side of the part.
Select the operation from the model tree (here: PLATE_TOP) and right click > Acti-
vate:
Rotate the assembly and save the work view.
You can use the saved views later.

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Now you can see the rest of the unmachined material. You can also adjust the fixture.
Select the NC_VICE_SLIDER. prt and Edit definition. Edit distance to 50.
Task 3.7 is ready.
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3.8
Mill Surfaces and Mill Windows for Face Milling
When creating face milling sequences, you can use mill geometry such as mill sur-
faces and mill windows as alternative machining references when model surfaces are
not appropriate, for example, when you face mill multiple model surfaces. You can
create mill surfaces and mill windows before creating an NC sequence or during the
creation of an NC sequence.
Mill Surfaces:
 Mill surfaces are surface features and are often referred to as mill geome-
try.
 When referencing surfaces for face milling:
By default, the toolpath completely machines the selected surfaces.
The selected surfaces can be model surfaces, mill surfaces, surfaces
from mill volumes, or workpiece surfaces.
 The most common mill surface types are:
Fill – Use the fill tool to create a flat surface by sketching an outline
on a sketching plane.
Extrude – Create an extruded surface by sketching an outline on a
sketching plane.
Copy – Copy existing model surfaces to form a new mill surface.
Mill Windows:
 Mill windows are manufacturing geometry features that you can use when
creating face milling sequences. They consist of a closed outline that de-
fines the area to be machined. You can create them before or during the
creation of an NC sequence.
 When referencing mill windows for face milling, the depth of the mill
window and the depth of the machined reference geometry are considered
in the following way:
If the highest Z-depth of the reference geometry is lower than the mill
window depth, then the final machined depth is defined by the mill
window plane.
If the highest Z-depth of the reference geometry is higher than the
mill window depth, then the final machined depth is defined by the
highest Z-depth of the reference geometry.

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Task 3.8: Use a mill window as a machining reference for the NC sequence.
Click Mill Window from the Manufacturing Geometry drop-down list. In the
Placement tab, Select the top surface from the workpiece as Window Plane. Clear
the Keep Inside Loops checking box.
Select the Depth tab. Check the Specify the depth and select To Selected from the
Depth Options drop down menu. Select the surface as shown.
Select the Options tab. Check the Offset window uniformly check box and edit the
value to 6.

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You can see the Mill Window in the model and the model tree:
Task 3.8 is ready.
3.9
Mill Window Face Milling
You can use the Mill Window for the Face Milling.
Task 3.9: Create a face milling sequence using Mill Window.
Select the Mill tab. Click Face from the Milling group. Select the drop-down arrow
next to the box containing “No tool” and select the END_LONG_SK40_D20. Select
the Reference tab. Select the drop-down arrow under Type and select Mill Window.
Select the MILL WINDOW_1 from the model.

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Select the Parameters tab. Edit CUT_FEED to 60. Edit STEP_DEPTH to 5. Edit
STEP_OVER to 10. Edit SCAN_TYPE to TYPE_SPIRAL. Edit CLEAR_DIST to 5.
Click Display Toolpath in the Face Milling dashboard. Click Play.

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Create the Material Removal Cut for the Face Milling 2. NC Sequence from the
Manufacturing Geometry Group drop-down menu. Select Automatic.
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3.10 2-Axis Trajectory Milling
In 2-Axis trajectory milling, you specify the tool trajectory by sketching or selecting
a curve that represents the final trajectory of the tool.
In the next case you can select the curves from the model.
Task 3.10: Create a 2-axis trajectory milling sequence using model edges.
Select 2 Axis Trajectory from the Trajectory Milling drop-down menu in the Mill-
ing group. Click Tool Manager in the Curve Trajectory dashboard. Ensure that the
END_LONG_SK40_D20 tool is selected, and then right-click and select Select tool
and return.
Select the References tab. Click in the Machining Reference collector to select the
datum curve. Select the surface loop with shift as shown.
Select the Offset Cut check box. Change Material to Remove as shown.
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Select the Start Point button and select the edge as shown. Edit the ratio to 0.5 >
Accept.
Edit the required parameters for the NC sequence. Select the Parameters tab. Edit
CUT_FEED to 100. Edit CLEAR_DIST to 5. Edit SPINDLE_SPEED to 477.
Click Edit Machining Parameters.
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Click the All button and select Entry/Exit Motions from the categories drop-down
list. Edit the parameters as shown.
Click OK. Review the resulting toolpath. Click Display Toolpath in the Curve Tra-
jectory dashboard. Click Play.
Create the Material Removal Cut for the Curve Trajectory 2. NC Sequence from
the Manufacturing Geometry Group drop-down menu. Select Automatic.
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3.11 Chamfer and Round Milling Steps
Chamfer Milling
Chamfer milling consists of milling chamfer-like surfaces. You can chamfer-mill a
single chamfered edge, a single chain of chamfered edges (open on both ends), or a
single closed loop of chamfered edges. For example, on top of a Pocket feature. You
must use a tool of the type Chamfering, Drilling, or Countersink, with the Point
Angle parameter of the tool corresponding to the chamfer angle. For example, if you
have a 45 degree chamfer, use the tool with the Point Angle of 90 degree.
The parameters used for machining are CUTTING_DIAMETER, NUM-
BER_FIRST_FINCUTS, NUMBER_LAST_FINCUTS, FIRST_FINCUT_OFFSET,
LAST_FINCUT_OFFSET,CORNER_FINISH_TYPE, INTER_RET_HEIGHT,
PERCENT_LENGTH, SIDE_CLEARANCE, and TOOL_OVERLAP. Here the
CUTTING_DIAMETER defines the point on the tapered tool which follows the
basic contact point on the chamfer.
Round Milling
Round Milling consists of milling round surfaces such as surfaces of cylinders, fil-
lets, and so on. You can machine a single rounded edge, a single chain of rounded
edges (open on both ends), or a single closed loop of rounded edges. For example, on
top of a Pocket feature. You must use either a tool of the type Corner Rounding with
the Radius parameter of the tool equal to the radius of the Top Round, or a sketched
tool.
The parameters used for machining are NUMBER_FIRST_FINCUTS, NUM-
BER_LAST_CUTS, FIRST_FINCUT_OFFSET,
LAST_FINCUT_OFFSET,CORNER_FINISH_TYPE, INTER_RET_HEIGHT,
SIDE_CLEARANCE, and TOOL_OVERLAP.
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Task 3.11: Create a Chamfer step.
Click the Mill tab and select Chamfer. Select the previously defined NC_SPOT
DRILL.
Click in the Machining References box. Select the edge as shown below:
Click in the Start Point box and drag the point as shown below. Flip the direction by
clicking the arrow.
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Select the Parameters tab. Edit the values as shown. Play the Path.
The tool tip depth is automatically in the middle of the cutting length. Select the Pa-
rameters tab and Edit Machining Parameters and create the LEAD IN and LEAD
OUT parameters.
Edit values as shown below. OK. Play the Path.
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All NC Sequences are ready and all material removals are completed. Now the ma-
chined part looks like below (Expect the latest hole chamfer). At first there was the
workpiece and after two operations the model is ready.
Notice! The machined part looks now ok. But you have to make several simulations
and checking before running the final NC code.

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3.12 Toolpath Simulation
A machine crash can be very expensive, potentially ruin the machine, and delay your
entire manufacturing schedule and can hurt you or someone in the workshop. So it is
very important to detect errors, potential collisions, or areas of inefficiency.
In Creo Parametric you can simulate the toolpath in many ways and even NC Ma-
chine Tool Simulation can be done.
Collision detected!
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3.12.1 Play Path
You can display tool path for an operation or a step. The step has to be completely
defined. When you display tool path for an operation, only steps that are completely
defined are included.
Operation Play Path, the picture below left.
You can also display the toolpath during the creation of the NC Sequence as shown
in the picture above right.
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3.12.2 Material Removal Simulation
Material Removal simulation is a dynamic simulation of material removal on the
computer screen. It allows you to view a step-by-step simulation of material removal
as the tool is cutting the workpiece (See the Vericut Simulation Chapter).
Do not confuse the automatic material removal feature with the Material Removal
simulation process.
Material Removal:
Permanently removes material from the workpiece; creates a new feature.
Is based on a set of assumptions and may produce simplified representation
of material removal, depending on the NC sequence type.
Material Removal simulation:
Simulates material removal for display purposes only; does not create geome-
try.
Always takes into account the actual tool path and shape.
Operation Material Removal Simulation, above and below left. You can also display
the cutting tool removing material during the creation of the NC Sequence as shown
in the picture above and below right.
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3.12.3 Machine Play
You can display tool path and machine simulation for completely defined steps or
operations. For operations, the simulation is played only for the steps that are com-
pletely defined.
You should have defined the machine assembly in the Machine Assembly tab of the
Machine Tool Setup dialog box.
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3.13 Camshaft Plate Toolpath Simulation
Task 3.12: Toolpath simulations
Activate the first operation:
In the model tree, select operation PLATE_BOTTOM_NC. Right-click and select
Play Path. If necessary, click the CL data bar to make the CL data visible. Click
Play. Observe the toolpath and corresponding CL data file, as shown.
Click Close in the Play Path dialog box.

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You can display tool path for a single step or select steps from the model tree:
Task 3.12: is ready.
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3.13.1 Vericut Simulation
Since 1988 CGTech’s product, VERICUT software, has become the industry stand-
ard for simulating CNC machining in order to detect errors, potential collisions, or
areas of inefficiency. It is used by companies of all sizes, universities/trade schools,
and government agencies in more than 55 countries. VERICUT enables you to elim-
inate the process of manually proving-out NC programs. It reduces scrap loss and
rework. The program also optimizes NC programs in order to both save time and
produce higher quality surface finish. VERICUT simulates all types of CNC ma-
chine tools, including those from leading manufacturers such as Mazak, Makino,
DMG / Mori Seiki, Okuma, etc. VERICUT runs standalone, but can also be integrat-
ed with all leading CAM systems.
Task 3.12.1: Vericut Toolpath simulations.
In the model tree, select operation PLATE_BOTTOM_NC. Right-click and select
Material Removal Simulation. The Vericut simulation software opens.

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When the Vericut is open you can see the workpiece and the fixture:
The Vericut-software inside Creo Parametric is not fully version, but there is enough
functions for simulating. If you try something what is in the fully version you get the
message.
You can manipulate the model on the Vericut screen almost in the same way than in
Creo Parametric.
Rotating (LMB)
Zooming (MMB)
Moving (RMB)
Under the case menu (RMB) founds the mostly needed functions:
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You can select the models from the model tree and change the colors and adjust the
other functions.
You can select different types of windows to show simulating:
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After definitions, start simulating:
From start to end: Single Step:
Stop: Rewind:
Reset:
Adjust Animation Speed of the Machining:
Green lights show the situation:
You can play with Solid-tools if defined. If there is a collision, you get the
message and see the red color in the model.
When simulating is ready, close the Vericut.

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3.13.2 Machine Play Configuration
You can display tool path and machine simulation for completely defined steps or
operations. For operations, the simulation is played only for the steps that are com-
pletely defined.
Before the Machine Play, you should have defined the machine assembly in the Ma-
chine Assembly tab of the Machine Tool Setup dialog box.
When creating a machine assembly to be used for machine simulation, you must fol-
low the rules below:
Use the configuration option pro_mf_workcell_dir to specify the default di-
rectory for the machine assembly files. NC Manufacturing locates the ma-
chine assembly files in the following order:
 Default directory, if set
 All first level sub directories of the default directory, if default directory
is set
 Current directory
To enable motion kinematics, the components of the machine assembly
should be connected to each other only using sliders and pins. That is, the rel-
ative motions between the components should be defined. Optionally, you
can specify the limits for the slider and pin motions.
You must define the absolute origin of the machine assembly using a coordi-
nate system named MACH_ZERO. This coordinate system is used to assem-
ble the manufacturing model or fixture. You must define this coordinate sys-
tem at the assembly level and not within a component of the assembly.
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Define the spindle loading position of the machine assembly using a coordi-
nate system named TOOL_POINT.
Any solid tool model present in the machine assembly should contain a coor-
dinate system named TOOL_POINT. This coordinate system is used to as-
semble the solid tool model.
Task 3.12.2: Workcell directory
Click File > Options. Select Configuration Editor.
Click Find…

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Type: pro_mf and click Find Now:
You can see all the options starting pro_mf. Select pro_mf_workcell_dir.
Click Browse. Select the folder where the workcell files are. OK.
Click Add/Change > Close
You should now see the new option on the list.
Click OK.

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Select Yes to Save the configuration file. The default folder is active working
directory.
If possible (writing rights), try save the config.pro to the installation directory and to
the text folder:
If this is not possible, save the config.pro to your working directory.
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3.13.3 Machine Play Simulation
Before the Machine Play, you should have defined the machine assembly in the Ma-
chine Assembly tab of the Machine Tool Setup dialog box.
Task 3.12.3: Define the machine assembly.
Select the workcenter (here FADAL) and Edit Definition.
Select the Assembly tab. Select Open machine center assembly model.
Now, if you have defined the pro_mf_workcell_dir path to config.pro, the folder
opens and you can select the assembly. Select the machine and Open. Click Preview.
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Next you need to select the coordinate system. This coordinate system have to be
named as MACH_ZERO. In this case the MACH_ZERO coordinate system is in the
NC_VICE fixture assembly. You can not select the coordinate system, because the
fixture is defined after the workcenter.
Click Apply. Select the fixture assembly and move it before the workcenter.
Click OK.
Now the fixture locate before the workcenter. Select the workcenter and Edit
Definition.
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Select the Assembly tab. Click the Coordinate System box and select the
MACH_ZERO from the fixture.
Click Apply.Selct the operation or single step from the model tree. Right click and
you should see the Machine Play option.
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Click Machine Play. NC_Analysis starts.
Click Play. You can zoom, move and rotate the assembly during the animation.
Close when ready.
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4
POSTPROCESSING
4.1
What is a Postprocessor
A postprocessor is an application that is designed to process the toolpath data (CL or
Cutter Location) file produced by a CAD or APT (Automatically Programmed Tool)
system. The toolpath data file contains the machining instructions specified by the
user for the production of a part from an engineering drawing. The postprocessor
converts the machining instructions from the toolpath data file into code understood
by a specific NC/CNC machine tool by producing a machine control data file. The
figure below shows how you get from a blueprint or a CAD system to a punch file
(.PU1) using Austin N.C. Inc.‘s generalized postprocessor (G-Post):
The machine control data (MCD) file is the file produced that ultimately is taken to
the machine controller to produce the part being programmed. Historically this file
has also been referred to as the tape image file (. TAP) and/or the punch file (. PU1).
You can change the extension (.TAP, .PU1) if needed for example: (.CNC or .EIA or
whatever you want to use.
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An option file is a file created by the user via the Option File Generator. The file is
read at postprocessor execution time. Upon reading the option file, the postprocessor
assumes characteristics specified by the user for a specific machine tool/control
combination. The characteristics include machine configuration, machine control
register requirements (such as address assignments and format), preparatory code re-
quirements to invoke specific functions, feedrate control functions and so forth.
The Option File Generator creates an option file, which is read by the postprocessor
at execution time in order to obtain its ‘personality’ (or behavior). The file naming
convention for this file is:
Lathes: uncl01.pnn
Mills: uncx01.pnn
While using the Option File Generator, the user has the option to create a FIL file via
the built in FIL editor. When the user exits or saves the option file they have been
creating, the Option File Generator automatically saves any work the user may have
done in the FIL editor. The file naming convention for the FIL file is:
For Lathes: uncl01.fnn
For Mills: uncx01.fnn
FIL (Factory Interface Language) is a macro language that dramatically extends the
capabilities of the postprocessor and Option File Generator. No generalized postpro-
cessor will ever have the ability to accommodate the many features available on to-
day’s controls, not to mention the new features being added to controls every day!
Through our customer’s experience we have implemented new features in every re-
lease of the G-POST since it was released many years ago. It is not possible to ad-
dress the many special features available; thus, this was the primary driving force in
creation of FIL.
FIL allows the user to go beyond any postprocessor’s capabilities through the ability
to intercept records read by the postprocessor and manipulate them in ways limited
only by the user’s imagination. The FIL macro language allows users to:
Add, delete or modify CL file data
Alter postprocessor output
Add or modify APT vocabulary words
Read or write data into/from up to two files
Call other applications
In addition, the FIL macro language has many features for logic control:
Case statements
If / then /else logic
Do loops
Jumpto labels
There are many text string manipulation functions and many other tools available as
well.
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For example, if you want to use canned cycles with CAM you may need the FIL-file:
CIMFIL/ON,CYCLE
$$ ****************************************************
$$ * Turning Cycle
$$
$$ * CYCLE/TURN,DEPTH,Depth,XAXIS,xval,ZAXIS,Zval,FEED,feed_rough
$$ * …
$$ * roughing motions
$$ * …
$$ * CYCLE/TURN,NOMORE,FEED,feed_finish
$$ * …
$$ * finish motions
$$ * …
$$ * CYCLE/TURN,OFF
$$ *
$$ *
$$ * Will generate G70 / G71 turning cycles :
$$ * N… Ffeed_rough
$$ * N… G70 Pstart_seq Qend_seq Uxval Wzval Ddepth
$$ * Nstart_seq …
$$ * …
$$ * Nend_seq …
$$ * G71 Pstart_seq Qend_seq Ffeed_finish
$$ ****************************************************
CYCTYP=POSTF(7,4)
IF (CYCTYP.EQ.ICODEF(TURN)) THEN
DVAL=POSTF(7,6)
UVAL=POSTF(7,8)
WVAL=POSTF(7,10)
FVAL=POSTF(7,12)
$$ Activate macro on motion
XX=POSTF(26,5,5,1)
ELSE
XX=POSTF(13)
ENDIF
CIMFIL/OFF
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4.2
CL Data
Post-processing is the final stage in the manufacturing process. When toolpaths have
been completed, you can create ASCII format Cutter Location (CL) data files for
operations or selected NC steps. You can then post-process CL data files into specif-
ic Machine Control Data (MCD) files using a post-processor. It is important to un-
derstand that changing NC steps requires you to recreate the CL data file for the op-
eration and post-process this file again to produce an updated MCD file.
You can create the CL Data file from the operation. You can also create a set of NC
Sequences and save them to CL Data file:
You can select the sequences and save the CL File.
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Post-Processing Method
The following steps describe the method of post-processing data to control machine
tools.
Complete NC Sequences – You first need to complete the operation by creat-
ing all necessary NC sequences.
Create CL Data Files – When the operation is complete, you can create CL
data files.
 You can create CL data files of one or more selected NC sequences, or a
whole operation.
 The files are ASCII format files.
 The default filename format is filename.ncl.
Post-Process CL Data Files – You can then post-process CL data files into
specific machine control data (MCD) files.
 You have the option of creating the CL and MCD files simultaneously.
 The default filename format is filename.tap.
Note! Any subsequent changes made to NC sequences means you must recreate the
CL data files and MCD files.
Configuration Options
A number of configuration options control the post-processing method.
Each Pro/NC module includes a standard set of NC post-processors that you
can use directly or modify using an optional module.
ncpost_type – You can control which post-processing module to use by set-
ting the configuration option ncpost_type. The values are:
 gpost (default) – Use the G-Post™ post-processors provided by Intercim
Corporation.
 ncpost – Use the NC manufacturing post-processors.
You can also use other post-processors capable of reading APT (automatical-
ly programmed tools).
gpostpp-_dir – Specifies the directory for gpost post-processors.
pro_mf_cl_dir – Specifies the location to store CL data files.
In the earlier N/C systems, the most commonly used program storage medium was
paper tape. A paper tape is one inch wide.
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4.3
CL Data for the Camshaft Plate Bottom side
Task 4.3: Create a CL data file and MCD file for the CAMSHAFT PLATE opera-
tions.
Activate the first operation:
Create a CL data file for a set of sequences. Select Save CL File for a Set from the
Save a CL File Type drop-down menu and select Create.
Type PLATE_BOT_SIDE for the name, and press ENTER.
You can select the operation or single steps. Select PLATE_BOTTOM_NC check
box (operation name). Click Done Sel. Click PLATE_BOT_SIDE.
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Click File. Select the MCD File check box, and click Done. Accept the name for the
CL File and click OK. Click Done for the PP OPTIONS.
From the menu manager, move the cursor on the list to see the available post-
processors. See the Status bar: The name of the selected machine postprocessor is
shown
Click UNCX01.P14 to select the post-processor. Click Close in the information
window.
Click Close in the information window. Click Done Output.
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Notice the message: Post processed file plate_bottom_nc.tap was created successful-
ly. View the contents of the browser. Click the Web Browser from the Status
toolbar:
Select Folder Browser, and Working Directory:
Among other things, notice that the listing for the working directory contains
plate_bottom_nc.ncl and plate_bottom_nc.tap. The tap extension means tape and it
is the NC-code file. You can open it for example in the Notepad or another text edi-
tor.
Click Close to close the browser.
Task 4.3 is ready.
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4.3.1 CL Data for the Camshaft Plate Top side
The other way to make CL Data for the operation is Play Path.
Task 4.3.1: Create a CL data file and MCD file for Top side, operation 2.
In the model tree, select the second operation, (here PLATE_TOP). Right-click and
select Play Path. (Activate first if needed).
Click the CL data bar to make the CL data visible. Click Play.
Observe the toolpath and corresponding CL data file, as shown.
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In the Play Path dialog box, click File > Save As MCD. Select the Save CL File Al-
so check box. Select the Verbose and Trace check boxes. Click Output.
Click OK to create a CL data file named plate_top.ncl.
From the menu manager, move the cursor on the list to see the available post-
processors. See the Status bar: The name of the selected machine postprocessor is
shown
Click UNCX01.P14 to select the post-processor. Click Close in the information
window. Click Close in the Play Path dialog box.

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Click the Web Browser from the Status toolbar.
Select Folder Browser, and Working Directory:
Notice that the listing for the working directory contains plate_top.ncl and
plate_top.tap. The tap extension means tape and it is the NC-code file. You can
open it for example in the Notepad or another text editor.
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4.3.2 Manipulating CL Data for the Camshaft Plate
When the CL Data has been created, you can use it in many ways. You can create
the Material Removal Simulation: Select CL File > Select from the folder > Done.
You can Post a CL File:
Select the PP OPTIONS and the postprocessor:
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5
CNC LANGUAGE AND STRUCTURE
5.1
NC or CNC
In a Numerical Control (NC) machine, the program is fed to the machine through
magnetic tapes or other such media. The original NC machines were essentially
basic machine tools which were modified to have motors for movement along the
axes.
In a Computer Numerical Controlled (CNC) machine, the machines are interfaced
with computers. This makes them more versatile in the sense that, suppose a change
in dimension of a part is required. In a NC machine, you would have had to change
the program in the tape and then feed it to the machine again. But in a CNC machine,
you just change a variable in the computer and your modification is done.
In order to understand where CNC Machining first appeared, it is important to note
that the said machine’s advent can be traced back to the invention of the NC (numer-
ical controlled) machine made by John T. Parsons during the 1940s-1950s. The NC
was a breakthrough invention that led the way towards modern automated machines.
The CNC machine first appeared when John Runyon managed to produce punch
tapes under computer control. This showed dramatic results in terms of time, reduc-
ing the normal production duration of 8 hours to 15 minutes. In June 1956, the Air
Force accepted the proposal to produce a generalized “programming” language for
NC.
Today you can see that the both terms are used. For example, there can be job adver-
tisement for the CNC Programmer or NC Programmer.
In this book the language is based on G-code which is the common name for the
most widely used programming language. In the world, the standard ISO 6983 is of-
ten used, although in varied states of Europe sometimes used other standards, exam-
ple DIN 66025
There are also the other languages as Heidenhain, Siemens, Mazak and more. Many
of the other languages can be translated to G-code if needed.
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5.2
Structure of an NC program
An NC program is a text that is normally stored as a sequence of ASCII codes in a
file on the hard disk. It consists of a sequence of NC blocks separated by line breaks.
Usually it is executed by being interpreted and worked through, character by charac-
ter and line by line.
The NC program can be divided by three parts:
Program start (optional)
A number of blocks (NC words)
Program end
Program start
At the beginning of an NC program the character ‘%’ can represent the start of the
program. The name of the program is then found following this character.
%
O1234 (program start)
N10 G0 X100 Y100 Z0
M30 (program end)
NC block:
Each NC blocks consists of one or several NC words, or even of none (an
empty line), separated by spaces or tab characters. It is therefore not possible
to use a space within a word.
N10 G0 X100 Y100 Z0
NC word:
The first character of an NC word specifies its meaning. It is either a letter or
a special character. The optional following characters specify the meaning
more precisely, or supply parameters for the execution. In G-code we refer to
the letters as “words” because each is a “word” telling the controller some-
thing to do
G0 = Move in a straight line at rapids speed.
Program end:
The end of the program is indicated by an M-function. Either M2 or M30 is used for
this.
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Between the start and end of the program are NC Blocks as mentioned above. NC
block can have a certain number – usually N-word.
N10 G0 X100 Y100 Z0
N20
N30
Mostly used G-code words are G and M (for General and Miscellaneous).
%
O1702
N10 G50 X100. Z50. S2800
N20 G00 T0202 M41
N30 G96 S120 M04
Modal or Non-Modal codes:
Many G codes and M codes cause the machine to change from one mode to
another, and the mode stays active until some other command changes it im-
plicitly or explicitly . Such commands are called “modal”.
Non-modal” codes effect only the lines on which they occur. For example,
G4 (dwell) is non-modal.
You can find a lot of G-code lists from the internet for example. The G-codes can be
varying depending if you are programming lathes or milling machines. Even every
machine could have own codes. So you should know the machine functions and con-
trol before making CNC programs!
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5.3
Common G- and M-Codes
Not all codes are available on all controls, and some controls have other codes. See
your machine manual for detailed explanations.
G00 - Positioning at rapid speed; Mill and Lathe
G01 - Linear interpolation (machining a straight line); Mill and Lathe
G02 - Circular interpolation clockwise (machining arcs); Mill and Lathe
G03 - Circular interpolation, counter clockwise; Mill and Lathe
G04 - Mill and Lathe, Dwell
G09 - Mill and Lathe, Exact stop
G10 - Setting offsets in the program; Mill and Lathe
G12 - Circular pocket milling, clockwise; Mill
G13 - Circular pocket milling, counterclockwise; Mill
G17 - X-Y plane for arc machining; Mill and Lathe with live tooling
G18 - Z-X plane for arc machining; Mill and Lathe with live tooling
G19 - Z-Y plane for arc machining; Mill and Lathe with live tooling
G20 - Inch units; Mill and Lathe
G21 - Metric units; Mill and Lathe
G27 - Reference return check; Mill and Lathe
G28 - Automatic return through reference point; Mill and Lathe
G29 - Move to location through reference point; Mill and Lathe (slightly different
for each machine)
G31 - Skip function; Mill and Lathe
G32 - Thread cutting; Lathe
G33 - Thread cutting; Mill
G40 - Cancel diameter offset; Mill. Cancel tool nose offset; Lathe
G41 - Cutter compensation left; Mill. Tool nose radius compensation left; Lathe
G42 - Cutter compensation right; Mill. Tool nose radius compensation right; Lathe
G43 - Tool length compensation; Mill
G44 - Tool length compensation cancel; Mill (sometimes G49)
G50 - Set coordinate system and maximum RPM; Lathe
G52 - Local coordinate system setting; Mill and Lathe
G53 - Machine coordinate system setting; Mill and Lathe
G54~G59 - Workpiece coordinate system settings #1 t0 #6; Mill and Lathe
G61 - Exact stop check; Mill and Lathe
G65 - Custom macro call; Mill and Lathe
G70 - Finish cycle; Lathe
G71 - Rough turning cycle; Lathe
G72 - Rough facing cycle; Lathe
G73 - Irregular rough turning cycle; Lathe
G73 - Chip break drilling cycle; Mill
G74 - Left hand tapping; Mill
G74 - Face grooving or chip break drilling; Lathe
G75 - OD groove pecking; Lathe
G76 - Fine boring cycle; Mill
G76 - Threading cycle; Lathe
G80 - Cancel cycles; Mill and Lathe
G81 - Drill cycle; Mill and Lathe
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G82 - Drill cycle with dwell; Mill
G83 - Peck drilling cycle; Mill
G84 - Tapping cycle; Mill and Lathe
G85 - Bore in, bore out; Mill and Lathe
G86 - Bore in, rapid out; Mill and Lathe
G87 - Back boring cycle; Mill
G90 - Absolute programming
G91 - Incremental programming
G92 - Reposition origin point; Mill
G92 - Thread cutting cycle; Lathe
G94 - Per minute feed; Mill
G95 - Per revolution feed; Mill
G96 - Constant surface speed control; Lathe
G97 - Constant surface speed cancel
G98 - Per minute feed; Lathe
G99 - Per revolution feed; Lathe
G98 - Return to initial Z plane after canned cycle; Mill
G99 - Return to initial R plane after canned cycle; Mill
M00 - Program stop; Mill and Lathe
M01 - Optional program stop; Lathe and Mill
M02 - Program end; Lathe and Mill
M03 - Spindle on clockwise; Lathe and Mill
M04 - Spindle on counterclockwise; Lathe and Mill
M05 - Spindle off; Lathe and Mill
M06 - Toolchange; Mill
M08 - Coolant on; Lathe and Mill
M09 - Coolant off; Lathe and Mill
M10 - Chuck or rotary table clamp; Lathe and Mill
M11 - Chuck or rotary table clamp off; Lathe and Mill
M19 - Orient spindle; Lathe and Mill
M30 - Program end, return to start; Lathe and Mill
M97 - Local sub-routine call; Lathe and Mill
M98 - Sub-program call; Lathe and Mill
M99 - End of sub program; Lathe and Mill

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5.3.1 G-Code Canned Cycles
What is the definition of “canned cycle”? A sequence of machine operations initiated
by a single G-code. Canned cycles act as shortcuts that simplify the program.
A powerful and common option available on most CNC machines is the ability to
perform canned cycles. Canned cycles give the programmer the option to do some
routine functions with a simple G-code instead of writing many lines of information.
Below are a few examples of canned cycles for milling:
G73 - Chip break drilling cycle
G80 - Cancel cycles
G81 - Drill cycle
G82 - Drill cycle with dwell
G83 - Peck drilling cycle
G84 - Tapping cycle
G85 - Bore in, bore out
G86 - Bore in, rapid out
G87 - Back boring cycle
NOTE: A canned cycle stays in effect until cancelled by a G80.
G98 - Return to initial Z plane after canned cycle; Mill
G99 - Return to initial R plane after canned cycle; Mill
Most CAM systems will take advantage of CNC-based canned cycles. If you want to
use canned cycles with CAM, you need to set up the postprocessor less or more. In
addition you need to specify more parameters in NC Sequence.

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5.4
Camshaft Plate NC Code
When the NC Code is ready, you can open it.
Task 5.4: Open and edit NC Code.
Open the working directory and find the file with extension .tap. Open the file for
example to the Notepad.
%
N1 T1 M6
N2 S286 M3
N3 G0 X37.904 Y-21.017
N4 Z10. M7
N5 Z7.
N6 G1 Z0. F60.
N7 X-37.903
N8 G0 X-40.999
N9 Y21.009
N10 X-37.883
N11 G1 X37.886 F60.
N40 G2 X18. Y13.5 I0. J-10.
N41 X18. Y-13.5 I-18. J-13.5
N42 X10. Y-17.5 I-8. J6.
N43 G1 X0.
N44 G3 X-10. Y-27.5 I0. J-10.
N45 G1 Y-37.5
N46 Z10.
N47 M5
N48 M30
%
Task 5.4 is ready.

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5.5
Customizing NC Code Output
Whenever you output CL data to a file, the system checks the PPRINT table. If any
flag is set to YES and the appropriate information is available, the corresponding
PPRINT command outputs to the CL file.
Task 5.5: Configure a PPRINT table.
Select the work center and edit definition. Click the PPRINT button. Click Create
from the menu manager.
Edit the following items to Yes.
Click OK to close the PPRINT window.

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In the menu manager, click Save. Type “FADAL_OPTIONS“ and press ENTER to
save the PPRINT table.
Click Done/Return.
Click Accept in the Milling Work Center dialog box.
Test the created PPRINT by creating the new NC Code for the TOP-side operation.
Note! Note, any subsequent changes made to NC sequences means you must
recreate the CL data files and MCD files.
%
N1 ( / PART NAME : CAMSHAFT_PLATE_NC)
N2 ( / DATE TIME : 03-OCT-13 15:19:47)
N3 ( / NC SEQUENCE NAME : FACE_MILLING_2)
N4 T1 M6
N5 S286 M3
N6 G0 X37.904 Y-21.017
N7 Z10. M7
N8 Z7.
N9 G1 Z0. F60.
N10 X-37.903
N11 G0 X-40.999
N12 Y21.009
N13 X-37.883
Task 5.5 is ready.
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6
3 AXIS MACHINING
6.1
2.5 versus 3 Axis
An axis is a direction of motion controlled by the CNC machine control. It can be
linear (motion along a straight line) or circular (a rotary motion). The number of axes
a machine has determines it’s machining capabilities. A 2.5 axis machine really has
three moving axes, but only two axes can move together (most machines sold today
are full three axis machines). For machining centers, a three axis machine will have
three linear axes. A four or five axis machine will have three linear axes as well as
one or two rotary axes.
Note that 2.5 versus 3 axis has yet another context. 2.5 axis machining requires that
the machine have three axes, but only two axes must be moving simultaneously at
any one time. (Simple operations, like drilling and most milling, fall into this catego-
ry). On the other hand 3-axis machining requires that all three axes be moving at the
same time (More complex operations, like the machining of sculptured surfaces re-
quired in molds and airfoils, fall into this category.)
Below are two examples from the various types of machining centers.
4 axis rotary table
5 axis (3+2) tilt/rotary
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6.2
3 Axis Surface Machining
As mentioned before, the 3 axis machining is needed for example to the machining
of sculptured surfaces.
Straight cut surface milling sequences enable you to mill contoured and horizontal
surfaces with a series of straight cuts. You can use straight cut surface milling to cre-
ate semi-finish sequences for contoured surfaces of components, or mold cavities.
When you create surface milling sequences, you can use mill surfaces as alternate
references when model surfaces are inappropriate, for example, when the model be-
ing machined is made up of many surfaces, or if you need to extend the toolpath be-
yond the model.
You use surface milling to mill horizontal or contoured surfaces. There are four types
of surface milling sequences that you can configure. It is important to understand the
benefits of each type of surface milling sequence.
Surface Milling:
Machine horizontal or contoured surfaces.
Continuous toolpath required.
Cut types:
 Straight Cut
 From Surface Isolines
 Cut Line
 Projected Cuts
Surface Milling Options
Cut Type
Geometry Selection
 Model
 Mill Volume
 Mill Surface
 Mill Window

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6.2.1 Straight Cut Surface Milling
You can use the following features to describe straight cut surface milling.
You mill the selected surfaces by a series of straight cuts.
The machining direction is controlled by the cut angle parameter.
You completely machine the selected surface(s).
 If a surface is not bound by walls on the outside, the tool “straddles” or
overruns the surface boundary by half the tool diameter.
Any inner protrusions, as well as the outer walls extending up from the sur-
face, are automatically avoided. The stock allowance, if any, applies to the
side walls as well.
If you select a surface from the model, any slots or holes on the surface are
“patched.” By default, the toolpaths are generated as if they were not there.
Task 6.2.1: Create a straight cut surface milling sequence and edit parameter values.
Download the Gator.prt and NC-Vice-300.asm
1. Create a new manufacturing model using a template manufacturing model. (See
chapter 2.2 if needed).
2. Reference model, coordinate systems are ready in the model
3. Workpiece
4. Workcell
5. Operation
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The result should be as shown below:
In the ribbon, select the Mill tab. Click Surface Milling from the Milling group.
Notice that in the SEQ SETUP menu, the Tool, Parameters, Surfaces, and Define
Cut check boxes are automatically selected. You must configure these items to gen-
erate a toolpath. Select also the Name check box.Click Done.
Edit the name for the sequence:
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Define the tool, 10 diameter ball mill.
Edit the parameters for the NC sequence.
Edit ROUGH_STEP_DEPTH to 2.
Edit PROF_STOCK_ALLOW to 1.
Select TYPE_3 from the SCAN_TYPE drop-down menu.
Click OK.
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Configure the surface for machining.
Click Model > Done. Press CTRL and select the all surfaces on the top of the refer-
ence model, as shown above. Click OK. Click Done/Return.
Configure the Cut Definition. Notice that the Cut Type option is configured as
Straight Cut by default. Select Preview.
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Change Cut Angle to 45. Click OK.
Click OK. Review the resulting toolpath. From the menu manager, click Play Path
-> Screen Play. Click Play.
Click Close in the Play Path dialog box.
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Click Done Seq. Select the surf roughing NC Sequence from the model tree and se-
lect Material Removal Simulation.
Play the Vericut. Notice the affect of the STEP_OVER parameter (5) and
PROF_STOCK_ALLOW (1).

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Roughing is ready. You can adjust the final result by changing parameters.
The next step is finishing the surface. You can create many different types of finish-
ing NC Sequence. You can use the same NC Sequence as roughing, but change the
smaller ball mill and change also a few parameters.
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6.2.2 Mill Window Surface Milling
The simplest way to define geometry for a Volume or a 3-Axis Conventional Surface
milling NC sequence is by using a Mill Window, that is, by projecting the silhouette
of the reference part on the Mill Window start plane, by sketching or by selecting a
closed contour. All surfaces visible within the contour are milled.
Task 6.2.2: Mill Window Surface Milling
In the ribbon, select the Mill tab. Click Surface Milling from the Milling group.
Notice that in the SEQ SETUP menu, the Tool, Parameters, Surfaces, and Define
Cut check boxes are automatically selected. You must configure these items to gen-
erate a toolpath. Change the Surfaces check box to Window. Select also the Name
check box. Click Done.
Edit the name for the sequence:
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Define the tool, 3 diameter ball mill.
Edit the parameters for the NC sequence.
Edit ROUGH_STEP_DEPTH to -.
Edit STEP_OVER to 0.5.
Edit PROF_STOCK_ALLOW to 0.
Select TYPE_3 from the SCAN_TYPE drop-down menu.
Click OK.
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Configure the surface for machining. Select Mill Window from the ribbon. Select
the top surface of the workpiece as the window placement plane.
Select the Depth tab and To Selected and select the surface as shown below:
Click Complete Feature. Edit the Cut Angle to 45. Click Preview. Click OK.

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Review the resulting toolpath. From the menu manager, click Play Path -> Screen
Play. Click Play.
Click Close in the Play Path dialog box. Click Done Seq.
Create the CL Data file from the two NC Sequences and create the material removal
simulation.
Notice the STEP_OVER parameter 0.5 and working allowance 1mm after roughing.
You can also notice that the mill window could be a little bigger. You change the
size of the mill window.
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Select Mill Window from the model tree and edit definition. Select the Options tab
and select the Offset window contour box. Edit 3 for the offset value.
Note, any subsequent changes made to NC sequences means you must recreate the
CL data files.
Update the changes by selecting the previously created CL Data file.
Notice the updated CL File extension .ncl.2

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Create the material removal simulation again.
This completes the procedure.

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7
APPENDIX
7.1
Creo Parametric Quick Reference Card
File Menu:
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UI Customization
Command Locator
240/244
Selection and Mouse Control
Keyboard Shortcuts
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Common Dashboard Controls
Orienting the Model
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Model Appearance
Advanced Selection: Chain & Surface Set Construction (1/2)

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Advanced Selection: Chain & Surface Set Construction (2/2)
PTC.com
244/244
INDEX
A
L
APT………………………………………………. 200, 201, 204
Layers ……………………………………………………… 22, 23
ASCII …………………………………………. 7, 203, 204, 213
Austin N.C. Inc
M
……………………………………………… 200
Machine Assembly . 7, 56, 57, 59, 60, 86, 185, 192, 193,
B
196
Basic Drilling………………………………………………….. 149
Machine Simulation ……………… 7, 59, 60, 86, 185, 192
Boring Cycle …………………………………… 215, 216, 217
MCD ………………..7, 203, 204, 205, 206, 208, 209, 220
MCD file ……………………………………………………… 200
C
M-Codes ………………………………………………………. 215
CAM ……………………………………………………………… 5
Milling Manufacturing ……………………………………….. 6
Canned Cycle …………………………………………. 216, 217
Modal………………………………………………………….. 214
CL Data ….. 7, 55, 56, 58, 62, 74, 77, 78, 118, 121, 148,
N
151, 154, 158, 160, 186, 203, 204, 205, 208, 209,
219, 220, 234
NC block ………………………………………………. 213, 214
Clearance Level ……………………………………………….62
NC program ………………………………………………….. 213
CNC ……6, 7, 42, 59, 123, 188, 200, 212, 214, 217, 221
NC steps …………………………………………………… 7, 203
Cutter Compensation ………….54, 55, 56, 123, 124, 160
NC word ………………………………………………………. 213
Non-Modal…………………………………………………… 214
D
Datum Features
O
………………………………………………..31
DIN 66025 ……………………………………………………. 212
Operation ………………………………………………………..67
Output Tab ………………………………………………………54
E
EN40B
P
…………………………………….. 46, 67, 71, 82, 102
Entry/Exit Motions ……… 107, 119, 141, 142, 166, 177
Postprocessor ……….. 125, 200, 201, 206, 209, 211, 217
Profile Milling ………………………………………………. 115
F
Face Milling
Q
………………………………………………….. 101
Feed rate ………………………………………………….. 40, 45
Quick Reference Card …………………………………….. 236
Fixture ………………………………………………….. 6, 68, 71
R
G
Rapid Feed ………………………………………………………55
G-code…………………………………….. 212, 213, 214, 217
Reference Model …. 7, 28, 48, 50, 51, 62, 116, 117, 128,
Groove …………………………………………………………. 100
130, 133, 134, 136, 226
Retract plane ………………………………………………….62
H
RPM ………………………………………………………. 40, 215
Hardness HB ……………………………………………………46
Holemaking ………………………………………………….. 147
S
I
Solid Tools……………………………….. 11, 74, 84, 87, 102
ISO 6983 ……………………………………………………… 212
Standard Tools ……………………………………. 76, 88, 90
STEP-format
J
……………………………………………….. 5, 28
Surface Milling …………………………………. 77, 222, 223
Job ………………………………………………….. 40, 101, 212
T
K
Tensile Strength ……………………………………………….46
Keyboard Shortcuts ……………………………………… 238
Tool Parameters ……………………………….. 76, 84, 85, 87
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U
X
Units ………………………………………………………………35
X-axis ……………………………………………… 18, 111, 138
V,W
Y
Vericut ……………………………… 184, 188, 189, 191, 228
Y-axis …………………………………………………………….18
Work Center …………………………………………………. 219
Yield Stress ……………………………………………………..46
Workcell .12, 54, 60, 61, 62, 74, 78, 100, 118, 124, 160,
Z
192, 194, 196
Workpiece ………………………………………………………50
Z-axis ………………………………. 18, 62, 84, 86, 159, 160

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