Global solutions innovation collaboration © 2001 PTC Training Exercises VERICUT for Pro/ENGINEER Machine Simulation.

© 2001 PTC3 Exercise 1 - Outline Outline l 3 axis milling machine l Work in Pro/E l Create machine components and assembly in Pro/E l Export STL file of each machine component against Machine Zero CSYS l Create tool path file(NCL and TAP) using Pro/NC and G-Post l Work in VERICUT Machine Simulation l Build machine kinematics in VERICUT Machine Simulation l Load machine components (STL file) to VERICUT MS l Load Control file l Save MCH, CTL and JOB file in your working directory l Test machine with MDI l Job, Machine setting l Create or load tool library file, tool gauge length setting l Load tool path file and simulate tool path Outline l 3 axis milling machine l Work in Pro/E l Create machine components and assembly in Pro/E l Export STL file of each machine component against Machine Zero CSYS l Create tool path file(NCL and TAP) using Pro/NC and G-Post l Work in VERICUT Machine Simulation l Build machine kinematics in VERICUT Machine Simulation l Load machine components (STL file) to VERICUT MS l Load Control file l Save MCH, CTL and JOB file in your working directory l Test machine with MDI l Job, Machine setting l Create or load tool library file, tool gauge length setting l Load tool path file and simulate tool path

© 2001 PTC4 Exercise 1 - 3 axis milling machine Build 3 axis milling machine and simulate tool path l Work in Pro/E l Preparation l Copy all the machine simulation exercise folder and files to your computer, set Pro/E working directory to: …\exercise 1 l Machine components and assembly l In Pro/E, Open file ‘3axis-mill.asm’ Build 3 axis milling machine and simulate tool path l Work in Pro/E l Preparation l Copy all the machine simulation exercise folder and files to your computer, set Pro/E working directory to: …\exercise 1 l Machine components and assembly l In Pro/E, Open file ‘3axis-mill.asm’ base-x-slide x-axis y-axis z-axis stock fixture z-axis-cylinder base base-z-slide

© 2001 PTC5 l Export component: ‘base.prt’ in STL format l In Pro/E, choose: File/Export/Model/STL l Select ‘Include’, pick part ‘BASE.PRT’, click ‘Done Sel’ l Click Pick Coordinate System icon, select machine zero ‘ACSO’ l Give chord Height=0.1, File name: ‘base’ l Click ‘Apply’ l Export component: ‘base.prt’ in STL format l In Pro/E, choose: File/Export/Model/STL l Select ‘Include’, pick part ‘BASE.PRT’, click ‘Done Sel’ l Click Pick Coordinate System icon, select machine zero ‘ACSO’ l Give chord Height=0.1, File name: ‘base’ l Click ‘Apply’ Exercise 1 - 3 axis milling machine

© 2001 PTC6 l Export all of other components in STL format l Tips l Choose the right Coordinate System - machine zero (ACSO) for all components, because there is no rotary axis on this machine l Give Chord Height: 0.1 or smaller l Change file name l Pro/E assembly ‘3ax-mill.asm’ includes two ‘base-y-slide’ components, choose both of them when exporting ‘base-y-slide’, same comments for ‘base-z-slide’ l Export all of other components in STL format l Tips l Choose the right Coordinate System - machine zero (ACSO) for all components, because there is no rotary axis on this machine l Give Chord Height: 0.1 or smaller l Change file name l Pro/E assembly ‘3ax-mill.asm’ includes two ‘base-y-slide’ components, choose both of them when exporting ‘base-y-slide’, same comments for ‘base-z-slide’ x-axis y-axis z-axis stock fixture z-axis-cylinder base base-y-slide base-z-slide Exercise 1 - 3 axis milling machine

© 2001 PTC7 Exercise 1 - 3 axis milling machine l Work in VERICUT Machine Simulation l Access VERICUT Machine Simulation l In command line, type in ‘proems’ then click enter l Or click batch file ‘proems.bat’ (‘$PRO_DIRECTORY \bin\proems.bat’) l Choose: File/New l Save JOB file in your working directory (… \exercise 1) l In MS, choose: File / Save as, give file name ‘3ax-mill.job’ l Build machine kinematics l In MS, choose: Machine / Components l Work in VERICUT Machine Simulation l Access VERICUT Machine Simulation l In command line, type in ‘proems’ then click enter l Or click batch file ‘proems.bat’ (‘$PRO_DIRECTORY \bin\proems.bat’) l Choose: File/New l Save JOB file in your working directory (… \exercise 1) l In MS, choose: File / Save as, give file name ‘3ax-mill.job’ l Build machine kinematics l In MS, choose: Machine / Components

© 2001 PTC8 Exercise 1 - 3 axis milling machine l Build components tree as following figure shows l In components window, click Add l Add base component: In Add components window, give type as base, color as cyan, then click ‘Apply’ l Build components tree as following figure shows l In components window, click Add l Add base component: In Add components window, give type as base, color as cyan, then click ‘Apply’ Components Tree

© 2001 PTC9 Exercise 1 - 3 axis milling machine l Using the same method to add other components, make sure ‘Type’, ‘Color’, motion axis, and ‘Connect To’ is right. See following figure for details. Z Linear Tool Y Linear

© 2001 PTC10 Exercise 1 - 3 axis milling machine l Components: X-Linear, Fixture and Stock l After finish last component - ‘Stock’, click OK in Add Component window l Components: X-Linear, Fixture and Stock l After finish last component - ‘Stock’, click OK in Add Component window X LinearFixtureStock

© 2001 PTC11 Exercise 1 - 3 axis milling machine l Load STL files to VERICUT MS l Load base STL files l In Components window, choose ‘Base’ (Base is highlighted), click STL file icon l Open file ‘base.stl’, (find this file in …\exercise 1 folder) l Using the same method, load STL files: ‘base-y-slide.stl’, ‘base-z-slide.stl’, to component base. l Load STL files to VERICUT MS l Load base STL files l In Components window, choose ‘Base’ (Base is highlighted), click STL file icon l Open file ‘base.stl’, (find this file in …\exercise 1 folder) l Using the same method, load STL files: ‘base-y-slide.stl’, ‘base-z-slide.stl’, to component base.

© 2001 PTC12 Exercise 1 - 3 axis milling machine l Load STL files to other components l Load ‘z-axis.stl’ and ‘z-axis-cylinder.stl’ to component Z l Load ‘y-axis.stl’ to component Y l Load ‘x-axis.stl’ to component X l Load ‘fixture.stl’ to component Fixture l Load ‘stock.stl’ to component Stock l Change color of Primitives l In Components window, choose ‘base-y-slide.stl’, click ‘Atrib button’, choose Color: White l Using save method, change color of ‘base-z-slide.stl’ to white l Change ‘z-axis-cylinder.stl’ to color white l Load STL files to other components l Load ‘z-axis.stl’ and ‘z-axis-cylinder.stl’ to component Z l Load ‘y-axis.stl’ to component Y l Load ‘x-axis.stl’ to component X l Load ‘fixture.stl’ to component Fixture l Load ‘stock.stl’ to component Stock l Change color of Primitives l In Components window, choose ‘base-y-slide.stl’, click ‘Atrib button’, choose Color: White l Using save method, change color of ‘base-z-slide.stl’ to white l Change ‘z-axis-cylinder.stl’ to color white

© 2001 PTC13 Exercise 1 - 3 axis milling machine l Change Tool connect position l In Pro/E, find distance from gauge point to work table plane (machine zero), It is 15.2 inch. We will move tool connect position from machine zero to gauge point l In VERICUT MS, choose: Machine / Components l In Components window, choose: ‘Tool’, then click Modify l In Modify window, set Connect position=(0 0 15.2), then click OK l Close Components window l Change Tool connect position l In Pro/E, find distance from gauge point to work table plane (machine zero), It is 15.2 inch. We will move tool connect position from machine zero to gauge point l In VERICUT MS, choose: Machine / Components l In Components window, choose: ‘Tool’, then click Modify l In Modify window, set Connect position=(0 0 15.2), then click OK l Close Components window 15.2 Gauge Point Machine Zero

© 2001 PTC14 Exercise 1 - 3 axis milling machine l Save machine file in your working directory l In VERICUT MS, choose: Machine / Save as, give file name ‘3ax-mill.mch’, make sure you save it in …\exercise 1 folder l Load control file l In VERICUT MS, choose: Control / Open, open file ‘generic.ctl’, find this control file in category ‘CGTECH_RP2LIB’ l Save control file in your working directory l In VERICUT MS, choose: Control / Save as, give file name ‘generic.ctl’, make sure save it in …\exercise 1 folder l Save machine file in your working directory l In VERICUT MS, choose: Machine / Save as, give file name ‘3ax-mill.mch’, make sure you save it in …\exercise 1 folder l Load control file l In VERICUT MS, choose: Control / Open, open file ‘generic.ctl’, find this control file in category ‘CGTECH_RP2LIB’ l Save control file in your working directory l In VERICUT MS, choose: Control / Save as, give file name ‘generic.ctl’, make sure save it in …\exercise 1 folder

© 2001 PTC15 Exercise 1 - 3 axis milling machine l Test your machine with MDI l In VERICUT MS, choose: Job / MDI l Test X axis, type in ‘x10’ in MDI, click Apply. Notice movement of X axis l Test negative direction of X axis (x-10) l Test Y and Z axis l (Notes: if axis doesn’t move, check if you load control file correctly) l Test your machine with MDI l In VERICUT MS, choose: Job / MDI l Test X axis, type in ‘x10’ in MDI, click Apply. Notice movement of X axis l Test negative direction of X axis (x-10) l Test Y and Z axis l (Notes: if axis doesn’t move, check if you load control file correctly)

© 2001 PTC16 Exercise 1 - 3 axis milling machine l Set machine table l In Pro/E, use Analysis/Measure, check distance between gauge point to stock surface, It is 7.7 inch. We will set top surface center of stock as programming zero l In VERICUT MS, choose: Machine / Table l In Machine Table window, choose: Table Name=‘Input Program Zero’, Sub-System ID=1, Index=1, Values=‘0 0 -7.7’. Click Add, then close l (Notes, Machine Table contents can also be defined in Job Table, if a Job Table is defined, it will over write Machine Table) l Set machine table l In Pro/E, use Analysis/Measure, check distance between gauge point to stock surface, It is 7.7 inch. We will set top surface center of stock as programming zero l In VERICUT MS, choose: Machine / Table l In Machine Table window, choose: Table Name=‘Input Program Zero’, Sub-System ID=1, Index=1, Values=‘0 0 -7.7’. Click Add, then close l (Notes, Machine Table contents can also be defined in Job Table, if a Job Table is defined, it will over write Machine Table) 7.7

© 2001 PTC17 Exercise 1 - 3 axis milling machine l Set Travel Limits l In VERICUT MS, choose: Machine / Travel Limits l In Travel Limits window, type in Min and Max travel limits of each axis, then click Modify l See following figure for limits value of 3 axis l Toggle Overtravel Detection On l Click OK l Set Travel Limits l In VERICUT MS, choose: Machine / Travel Limits l In Travel Limits window, type in Min and Max travel limits of each axis, then click Modify l See following figure for limits value of 3 axis l Toggle Overtravel Detection On l Click OK

© 2001 PTC18 Exercise 1 - 3 axis milling machine l Collision setup l In VERICUT MS, choose: Job / Collision l Set: Component 1=Fixture, Component 2=Tool, Tolerance=0.1 l Toggle Collision Detection On l Click OK l Collision setup l In VERICUT MS, choose: Job / Collision l Set: Component 1=Fixture, Component 2=Tool, Tolerance=0.1 l Toggle Collision Detection On l Click OK

© 2001 PTC19 Exercise 1 - 3 axis milling machine l Tool library l Method 1, retrieve tool library in VERICUT exercise 4a&b folder l copy file ‘cgtpro.tls’ from ‘VERICUT exercise 4a&b folder’, paste it in your current working directory - ‘VERICUT MS exercise 1 folder’ l In VERICUT MS, choose: Tools / Tool File, open file ‘cgtpro.tls’, find it in your current working directory l Change tool gauge length. In VERICUT MS, choose: Tools / Tool Manager l In Tool Manager window, click Modify l Tool library l Method 1, retrieve tool library in VERICUT exercise 4a&b folder l copy file ‘cgtpro.tls’ from ‘VERICUT exercise 4a&b folder’, paste it in your current working directory - ‘VERICUT MS exercise 1 folder’ l In VERICUT MS, choose: Tools / Tool File, open file ‘cgtpro.tls’, find it in your current working directory l Change tool gauge length. In VERICUT MS, choose: Tools / Tool Manager l In Tool Manager window, click Modify

© 2001 PTC20 Exercise 1 - 3 axis milling machine l In Tool Modify window, click Properties l In Tool Properties window, set Gage Length=4, click OK l In Tool Modify window, click OK l In Tool Manager window, click Save, then Close l In Tool Modify window, click Properties l In Tool Properties window, set Gage Length=4, click OK l In Tool Modify window, click OK l In Tool Manager window, click Save, then Close

© 2001 PTC21 Exercise 1 - 3 axis milling machine l Method 2, create tool library in VERICUT MS by yourself l In Tool Manager window, click Add l In Tool Add window, give: ID=1, Description=‘1 inch FEM’, l Choose FEM icon, give: Diameter=1, Length=4, click Add then click OK l Save tool library file. In Tool Manager window, choose: File / Save as, give file name ‘3ax- mill.tls’, save it in exercise 1 folder l Close Tool Manager window l Click ‘Yes’ in the small question window l Method 2, create tool library in VERICUT MS by yourself l In Tool Manager window, click Add l In Tool Add window, give: ID=1, Description=‘1 inch FEM’, l Choose FEM icon, give: Diameter=1, Length=4, click Add then click OK l Save tool library file. In Tool Manager window, choose: File / Save as, give file name ‘3ax- mill.tls’, save it in exercise 1 folder l Close Tool Manager window l Click ‘Yes’ in the small question window

© 2001 PTC22 Exercise 1 - 3 axis milling machine l Load tool path l In VERICUT MS, choose Job / Setting l In Job Settings window, open Toolpath file ‘tool-com.tap’, find this file in exercise 1 folder l Other settings: see following figure for details l For Log file, give file name: ‘3ax-mill.log’, and select exercise 1 folder l In Job Setting window, click OK l Reset Machine Simulation l Run machine simulation l Load tool path l In VERICUT MS, choose Job / Setting l In Job Settings window, open Toolpath file ‘tool-com.tap’, find this file in exercise 1 folder l Other settings: see following figure for details l For Log file, give file name: ‘3ax-mill.log’, and select exercise 1 folder l In Job Setting window, click OK l Reset Machine Simulation l Run machine simulation

© 2001 PTC23 Exercise 2 - Outline Outline l 4 axis milling machine l Build machine kinematics l Load STL files l Machine Table, Travel Limits, Collision setting l Load tool library, set tool gauge length offset l Load tool path file, control file l Tool path simulation Outline l 4 axis milling machine l Build machine kinematics l Load STL files l Machine Table, Travel Limits, Collision setting l Load tool library, set tool gauge length offset l Load tool path file, control file l Tool path simulation

© 2001 PTC24 Exercise 2 - 4 axis milling machine Build 4 axis milling machine l Build machine kinematics l See following figures for machine kinematics l Make sure component Type, Connect to, Motion axis and Connect Position is right l Notice connect position of rotary axis A is: (0 0 4), Design is: (0.5 0 0) l (Notes: For Multi-Axis machine uses CSYS on rotary centerline for rotary axis) Build 4 axis milling machine l Build machine kinematics l See following figures for machine kinematics l Make sure component Type, Connect to, Motion axis and Connect Position is right l Notice connect position of rotary axis A is: (0 0 4), Design is: (0.5 0 0) l (Notes: For Multi-Axis machine uses CSYS on rotary centerline for rotary axis)

© 2001 PTC28 Exercise 2 - 4 axis milling machine l Load STL files l Base - ‘base.stl’ l Z - ‘head.stl’ and ‘spindle.stl’ l Tool - Nothing l Y - Nothing l X - ‘table.stl’ l Other - ‘rotary_box.stl’ l A - ‘rotary_chuck.stl’ l Design - ‘ncmach.stl’ l (Notes 1: all Primitives connect position is: [0 0 0] ) l (Notes 2: find STL files in …\exercise 2 folder) l Load STL files l Base - ‘base.stl’ l Z - ‘head.stl’ and ‘spindle.stl’ l Tool - Nothing l Y - Nothing l X - ‘table.stl’ l Other - ‘rotary_box.stl’ l A - ‘rotary_chuck.stl’ l Design - ‘ncmach.stl’ l (Notes 1: all Primitives connect position is: [0 0 0] ) l (Notes 2: find STL files in …\exercise 2 folder)

© 2001 PTC29 Exercise 2 - 4 axis milling machine l Set Machine Table l See following Machine Table figure for details l Set Travel limits l See following Travel Limits figure for details l Save machine file l Give file name: ‘prolight.mch’, save it in …\exercise 2 folder l Set Machine Table l See following Machine Table figure for details l Set Travel limits l See following Travel Limits figure for details l Save machine file l Give file name: ‘prolight.mch’, save it in …\exercise 2 folder

© 2001 PTC30 Exercise 2 - 4 axis milling machine l Job setting l Load tool path file: ‘op010.tap’, find this file in …\exercise 2 folder l Other settings, see following figure l Collision setup l See following Collision Setup figure for details l Job setting l Load tool path file: ‘op010.tap’, find this file in …\exercise 2 folder l Other settings, see following figure l Collision setup l See following Collision Setup figure for details

© 2001 PTC31 Exercise 2 - 4 axis milling machine l Load tool library and set tool gauge length offset l Load tool library file ‘ncmach_gage.tls’, find it in …\exercise 2 folder l Set gauge point at top of each tool l Control file l Load control file ‘tmc2000.ctl’, find this file in …\exercise 2 folder l Save Job file l Give JOB file name: ‘prolight.job’, save it in …\exercise 2 folder l Tool path simulation l Load tool library and set tool gauge length offset l Load tool library file ‘ncmach_gage.tls’, find it in …\exercise 2 folder l Set gauge point at top of each tool l Control file l Load control file ‘tmc2000.ctl’, find this file in …\exercise 2 folder l Save Job file l Give JOB file name: ‘prolight.job’, save it in …\exercise 2 folder l Tool path simulation Gauge Point

© 2001 PTC32 Exercise 2a- Outline Outline l 5 axis laser machine l In Pro/E, export components in STL format l Base and linear axis - Against Machine Zero CSYS l Rotary axis - Against CSYS at rotary center l Build machine kinematics, rotary axis and tool connect position calculation l Load STL files to machine l Machine Table, initial machine location, RTCP pivot offset calculation l Load tool library and set gauge length offset l Load tool path file, control file l Tool path simulation Outline l 5 axis laser machine l In Pro/E, export components in STL format l Base and linear axis - Against Machine Zero CSYS l Rotary axis - Against CSYS at rotary center l Build machine kinematics, rotary axis and tool connect position calculation l Load STL files to machine l Machine Table, initial machine location, RTCP pivot offset calculation l Load tool library and set gauge length offset l Load tool path file, control file l Tool path simulation

© 2001 PTC33 Exercise 2a - 5 axis laser machine Build 5 axis laser machine l Preparation l Set Pro/E working directory to …\exercise 2a l Open file ‘laserdyne.asm’ l Export components in STL format l Export base and all linear axis using CSYS at machine zero Build 5 axis laser machine l Preparation l Set Pro/E working directory to …\exercise 2a l Open file ‘laserdyne.asm’ l Export components in STL format l Export base and all linear axis using CSYS at machine zero Base XAXIS YAXIS ZAXIS Table CAXIS DAXIS

© 2001 PTC34 Exercise 2a - 5 axis laser machine l Export rotary components (C and D axis) using CSYS at centerline of rotary axis l Using ‘ACS0’ for CAXIS, and ‘ACS1’ for DAXIS l (Notes: Use same name as Pro/E part for STL files) l Export rotary components (C and D axis) using CSYS at centerline of rotary axis l Using ‘ACS0’ for CAXIS, and ‘ACS1’ for DAXIS l (Notes: Use same name as Pro/E part for STL files) CAXIS DAXIS

© 2001 PTC35 Exercise 2a - 5 axis laser machine l Build machine kinematics & load STL files l Base l Type: Base, Name: Base, Color: Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l XAXIS l Type: X Linear, Name: X, Motion Axis, X, Connect To: Base, Connect Position: (0 0 0) Color: Cyan, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘xaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l ZAXIS l Type: Z Linear, Name: Z, Motion Axis, Z, Connect To: X, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘zaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l YAXIS l Type: Y Linear, Name: Y, Motion Axis: Y, Connect To: Z, Connect Position: (0 0 0) Color: Yellow, Mixed Mode:Shade, Angles: (0 0 0) l Primitives: ‘yaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Build machine kinematics & load STL files l Base l Type: Base, Name: Base, Color: Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l XAXIS l Type: X Linear, Name: X, Motion Axis, X, Connect To: Base, Connect Position: (0 0 0) Color: Cyan, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘xaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l ZAXIS l Type: Z Linear, Name: Z, Motion Axis, Z, Connect To: X, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘zaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l YAXIS l Type: Y Linear, Name: Y, Motion Axis: Y, Connect To: Z, Connect Position: (0 0 0) Color: Yellow, Mixed Mode:Shade, Angles: (0 0 0) l Primitives: ‘yaxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC36 Exercise 2a - 5 axis laser machine l CAXIS l Type: C Rotary, Name: C, Motion Axis: Z, Connect To: Y, Connect Position: (0, -16.5, 21) Color: orange, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘caxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l DAXIS l Type: B Rotary, Name: D, Motion Axis: Y, Connect To: C, Connect Position: (0 8 -6) Color: Tan, Mixed Mode:Shade, Angles: (0 0 0) l Primitives: ‘daxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool l Type: Tool, Name: Tool, Motion Axis: Z, Connect To: D, Connect Position: (0, 8.5, -15) Color: Red, Mixed Mode: Shade, Angles: (0 0 0) l Table l Type: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘table.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l CAXIS l Type: C Rotary, Name: C, Motion Axis: Z, Connect To: Y, Connect Position: (0, -16.5, 21) Color: orange, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘caxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l DAXIS l Type: B Rotary, Name: D, Motion Axis: Y, Connect To: C, Connect Position: (0 8 -6) Color: Tan, Mixed Mode:Shade, Angles: (0 0 0) l Primitives: ‘daxis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool l Type: Tool, Name: Tool, Motion Axis: Z, Connect To: D, Connect Position: (0, 8.5, -15) Color: Red, Mixed Mode: Shade, Angles: (0 0 0) l Table l Type: Other, Name: Table, Connect To: Base, Connect Position: (0 0 0) Color: Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘table.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC37 Exercise 2a - 5 axis laser machine l Design l Type: Design, Name: Design, Connect To: Table, Connect Position: (0 0 0) Color: Green, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘test_laserdyne.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Design l Type: Design, Name: Design, Connect To: Table, Connect Position: (0 0 0) Color: Green, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘test_laserdyne.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) Components Tree

© 2001 PTC38 Exercise 2a - 5 axis laser machine l Rotary axis & tool connect position calculation l C-axis connect position is measured from Machine Zero to C-axis CSYS l D-axis connect position is measured from C-axis CSYS to D-axis CSYS l Tool connect position is measured from D-axis CSYS to Gauge Point (in this case it is Machine Zero) l Rotary axis & tool connect position calculation l C-axis connect position is measured from Machine Zero to C-axis CSYS l D-axis connect position is measured from C-axis CSYS to D-axis CSYS l Tool connect position is measured from D-axis CSYS to Gauge Point (in this case it is Machine Zero) Machine Zero -16.5 21 8 -6 C-axis CSYS D-axis CSYS

© 2001 PTC39 Exercise 2a - 5 axis laser machine l Set machine table l Set Initial Machine Location=(0 0 20) l Set RTCP pivot offset=(0 -16.5 15) l RTCP Offset Xval-Zval are calculated by subtracting the location of the Tool component origin from the rotary pivot point location (with all axes at their Initial Machine Location ) l Save machine file l Set machine table l Set Initial Machine Location=(0 0 20) l Set RTCP pivot offset=(0 -16.5 15) l RTCP Offset Xval-Zval are calculated by subtracting the location of the Tool component origin from the rotary pivot point location (with all axes at their Initial Machine Location ) l Save machine file -16.5 15

© 2001 PTC40 Exercise 2a - 5 axis laser machine l Load tool library and set gauge length offset l Load file ‘tool.tls’, find it in exercise 2a folder l Set gauge offset=8 l Load control l Load control file ‘laserdyne.ctl’, find it in exercise 2a folder l Load Toolpath file l Load file ‘op010.tap’, find it in exercise 2a folder l Save JOB file l Run simulation l Load tool library and set gauge length offset l Load file ‘tool.tls’, find it in exercise 2a folder l Set gauge offset=8 l Load control l Load control file ‘laserdyne.ctl’, find it in exercise 2a folder l Load Toolpath file l Load file ‘op010.tap’, find it in exercise 2a folder l Save JOB file l Run simulation

© 2001 PTC41 Exercise 3 - Outline Outline l Build your own machine l Choose one machine from list shown in next 7 slides l Build machine components and assembly in Pro-E l Export components in STL format against right CSYS l Create machine kinematics in VERICUT Machine Simulation l Load machine components (STL file) to VERICUT MS l Load control file (fan16M, find it in category of CGTECH_RP2LIB) and save it in your current directory l Machine & Job setting l Test your machine with MDI l Create or load tool library file, set tool gauge length l Create Post-Processor (optional), generate TAP file l Load a tool path file (TAP file), run simulation Outline l Build your own machine l Choose one machine from list shown in next 7 slides l Build machine components and assembly in Pro-E l Export components in STL format against right CSYS l Create machine kinematics in VERICUT Machine Simulation l Load machine components (STL file) to VERICUT MS l Load control file (fan16M, find it in category of CGTECH_RP2LIB) and save it in your current directory l Machine & Job setting l Test your machine with MDI l Create or load tool library file, set tool gauge length l Create Post-Processor (optional), generate TAP file l Load a tool path file (TAP file), run simulation

© 2001 PTC49 Exercise 4, 4a, 4b Exercise 4 l Menu View l Attributes l View Select/Store Exercise 4a l Menu Job l Job Setting l Job Table l Collision Exercise 4b l Menu Machine l Machine Tables l Travel Limits Exercise 4 l Menu View l Attributes l View Select/Store Exercise 4a l Menu Job l Job Setting l Job Table l Collision Exercise 4b l Menu Machine l Machine Tables l Travel Limits

© 2001 PTC50 Exercise 4 - Menu/View Menu View l Open file ‘prolight.job’ in …\exercise 4 folder l Attributes l In VERICUT MS, choose: View / Attributes l Show CSYS l Toggle Component Origin, Primitive Origin and Machine Zero On, then click Apply l CSYS appears Menu View l Open file ‘prolight.job’ in …\exercise 4 folder l Attributes l In VERICUT MS, choose: View / Attributes l Show CSYS l Toggle Component Origin, Primitive Origin and Machine Zero On, then click Apply l CSYS appears

© 2001 PTC51 Exercise 4 - Menu/View l Draw Mode l Choose Draw Mode=Lines, click Apply, notice the change l Choose Draw Mode=Hidden, click Apply, notice the change l Change Draw Mode back to ‘Shade’ l You can also use the icon show below to switch draw mode l Usage of line mode, when simulation, if tool is not shown up, you can switch to line mode, find where tool is l Draw Mode l Choose Draw Mode=Lines, click Apply, notice the change l Choose Draw Mode=Hidden, click Apply, notice the change l Change Draw Mode back to ‘Shade’ l You can also use the icon show below to switch draw mode l Usage of line mode, when simulation, if tool is not shown up, you can switch to line mode, find where tool is LineHidden

© 2001 PTC52 Exercise 4 - Menu/View l View Select/Store l Choose: View / Orient. In Orientation window, click ISO icon l Choose: View / Select/Store. In Select/Store View window, click Add l In View Add window, give view name: ‘iso1’, then click OK l Using same method, add XY and YZ view l You can switch view by clicking view name l View Select/Store l Choose: View / Orient. In Orientation window, click ISO icon l Choose: View / Select/Store. In Select/Store View window, click Add l In View Add window, give view name: ‘iso1’, then click OK l Using same method, add XY and YZ view l You can switch view by clicking view name

© 2001 PTC53 Exercise 4a - Menu/Job Menu Job l Job Setting l Choose: Job / Setting l In Job Setting, click ‘Select (beside output file)’ to specify output APT file name(ex4a.apt) and directory(…\exercise 4) l In Job Setting, click ‘Select (beside Log File)’ to specify output Log file name(ex4a.apt) and directory(…\exercise 4) l In Job Setting window, Click OK l Toggle Conversion: On l Reset VERICUT MS l Run simulation l Find file ‘ex4a.apt’ and ‘ex4a.log’ in your …\exercise 4 folder Menu Job l Job Setting l Choose: Job / Setting l In Job Setting, click ‘Select (beside output file)’ to specify output APT file name(ex4a.apt) and directory(…\exercise 4) l In Job Setting, click ‘Select (beside Log File)’ to specify output Log file name(ex4a.apt) and directory(…\exercise 4) l In Job Setting window, Click OK l Toggle Conversion: On l Reset VERICUT MS l Run simulation l Find file ‘ex4a.apt’ and ‘ex4a.log’ in your …\exercise 4 folder

© 2001 PTC54 Exercise 4a - Menu/Job l Job Table l (Notes: Job Table performs same function as Machine Table. If the same tables are defined in both job and machine configurations, the job table values override those in the machine) l Choose: Job / Tables, in Job Table window, select ‘Initial Machine Location’, give Values= (0 0 12), click Add then Close l Reset VERICUT MS, see change of initial machine location l Delete Job Table contents l Job Table l (Notes: Job Table performs same function as Machine Table. If the same tables are defined in both job and machine configurations, the job table values override those in the machine) l Choose: Job / Tables, in Job Table window, select ‘Initial Machine Location’, give Values= (0 0 12), click Add then Close l Reset VERICUT MS, see change of initial machine location l Delete Job Table contents

© 2001 PTC55 Exercise 4a - Menu/Job l Collision l Choose: Job / Collision l In Collision Setup window, select first line (component A and Tool), change Tolerance to 5 (this is for exercise purpose only). Click ‘Modify’, then click ‘Ok’ l Reset VERICUT MS, run simulation l During simulation, both A axis and tool are in error color-red l Change tolerance back to ‘0.1’ l Collision l Choose: Job / Collision l In Collision Setup window, select first line (component A and Tool), change Tolerance to 5 (this is for exercise purpose only). Click ‘Modify’, then click ‘Ok’ l Reset VERICUT MS, run simulation l During simulation, both A axis and tool are in error color-red l Change tolerance back to ‘0.1’

© 2001 PTC56 Exercise 4b - Menu/Machine Menu Machine l Tables l Choose: Machine / Tables l In Machine Tables, change Initial Machine Location values to: (0 0 12), click Modify, then close l Reset VERICUT MS, notice change of machine initial location l Change it back to (0 0 8) l (Notes: 1. if there is the same record in Job Table, Machine Table will be over written. 2. Changes to Table are only effective after reset VERICUT MS) Menu Machine l Tables l Choose: Machine / Tables l In Machine Tables, change Initial Machine Location values to: (0 0 12), click Modify, then close l Reset VERICUT MS, notice change of machine initial location l Change it back to (0 0 8) l (Notes: 1. if there is the same record in Job Table, Machine Table will be over written. 2. Changes to Table are only effective after reset VERICUT MS)

© 2001 PTC57 Exercise 4b - Menu/Machine l Travel Limits l Choose: Machine / Travel Limits l Change Z limits to: (Min=-1, Max=7), click Modify l Toggle Overtravel Detection On, click OK l Reset VERICUT MS, run simulation l Z axis becomes red (error color) during simulation. An error message also appears in message line. Open Log file to view error information l Change Z limits back to (-1, 8) l Travel Limits l Choose: Machine / Travel Limits l Change Z limits to: (Min=-1, Max=7), click Modify l Toggle Overtravel Detection On, click OK l Reset VERICUT MS, run simulation l Z axis becomes red (error color) during simulation. An error message also appears in message line. Open Log file to view error information l Change Z limits back to (-1, 8)

© 2001 PTC58 Exercise 5 - Outline Outline l Run VERICUT and Machine Simulation simultaneously l Machine simulation setting l Change Fixture and Stock connection position l Job Table setting l Job Setting l Load tool library, set gauge length offset l VERICUT Setting l Tool retract setting Outline l Run VERICUT and Machine Simulation simultaneously l Machine simulation setting l Change Fixture and Stock connection position l Job Table setting l Job Setting l Load tool library, set gauge length offset l VERICUT Setting l Tool retract setting

© 2001 PTC59 Exercise 5 - Run VERICUT & Machine Simulation simultaneously Run VERICUT and Machine Simulation simultaneously l Machine Simulation setting l Open file ‘3ax-mill.job’, find it in exercise 5 folder l Notes: differences between this job file and the one in exercise 1 are: l Fixture and Stock STL files are replaced by those in VERICUT exercise 6 - ‘sub.usr’ l Tool library file is replaced by ‘tools.tls’ in VERICUT exercise 6-’sub.usr’ l We find fixture and stock are not in right position Run VERICUT and Machine Simulation simultaneously l Machine Simulation setting l Open file ‘3ax-mill.job’, find it in exercise 5 folder l Notes: differences between this job file and the one in exercise 1 are: l Fixture and Stock STL files are replaced by those in VERICUT exercise 6 - ‘sub.usr’ l Tool library file is replaced by ‘tools.tls’ in VERICUT exercise 6-’sub.usr’ l We find fixture and stock are not in right position

© 2001 PTC60 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Move fixture and stock to center of machine table l In VERICUT MS, choose: Machine / Components l In Components window, choose ‘Fixture’, then click ‘Modify’ l In Modify Component window, give connect position (-12.5, -12.5, 1) l Hint: Fixture Dimension is (25x25x1), by setting connect position, it is moved 12.5 inch left, 12.5 inch back and 1 inch up l Move fixture and stock to center of machine table l In VERICUT MS, choose: Machine / Components l In Components window, choose ‘Fixture’, then click ‘Modify’ l In Modify Component window, give connect position (-12.5, -12.5, 1) l Hint: Fixture Dimension is (25x25x1), by setting connect position, it is moved 12.5 inch left, 12.5 inch back and 1 inch up

© 2001 PTC61 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Job table setting l Set Input Program Zero l In VERICUT MS, choose: Job / Tables l In Job Tables, choose ‘Input Program Zero’, give value (-12.5, -12.5, -14.2), this is to move input program zero to ‘near-top-left corner’ of fixture l (Notes, distance from gauge point to machine table is: 15.2, fixture thickness is: 1) l Job table setting l Set Input Program Zero l In VERICUT MS, choose: Job / Tables l In Job Tables, choose ‘Input Program Zero’, give value (-12.5, -12.5, -14.2), this is to move input program zero to ‘near-top-left corner’ of fixture l (Notes, distance from gauge point to machine table is: 15.2, fixture thickness is: 1) 15.2 X Y Z

© 2001 PTC62 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Set work offset (fixture offset) l Refer Job Table figure on last slide, and VERICUT exercise 6 (sub.usr) for details l (Notes: Stock thickness is 2) l Job setting l Choose: Job / Settings l Select tool path file ‘sub.tap’ in exercise 5 folder l Give Log file name: ‘3ax-mill.log’, save it in exercise 5 folder l Other settings: Programming method, Tool Tip. Simulation, On. Conversion, Off. Conversion Method, Scan On. Default Tolerance, 0.05. (notes, if tool path contains subroutines, Conversion Method must be set to: Scan On) l Set work offset (fixture offset) l Refer Job Table figure on last slide, and VERICUT exercise 6 (sub.usr) for details l (Notes: Stock thickness is 2) l Job setting l Choose: Job / Settings l Select tool path file ‘sub.tap’ in exercise 5 folder l Give Log file name: ‘3ax-mill.log’, save it in exercise 5 folder l Other settings: Programming method, Tool Tip. Simulation, On. Conversion, Off. Conversion Method, Scan On. Default Tolerance, 0.05. (notes, if tool path contains subroutines, Conversion Method must be set to: Scan On) X Y Z (1, 1, 2) (13, 1, 2) (1, 13, 2) (13, 13, 2)

© 2001 PTC63 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Test your machine with MDI l Give (X0Y0Z0), machine should be at position as following figure shows l Rest machine simulation l Test your machine with MDI l Give (X0Y0Z0), machine should be at position as following figure shows l Rest machine simulation XZ plane YZ plane

© 2001 PTC64 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Load tools and Set gauge length offset l In VERICUT MS, choose: Tools / Tool File, open file ‘tools.tls’, find it in exercise 5 folder l Tool gauge length setting l Choose: Tools / Tool Manager l In Tool Manager window, choose a tool then click ‘Modify’ l In Tool Modify window, choose Tool Properties l In Tool Properties window, give tool gauge length value l Change gauge point of all five tools to the most top point of each tool l Load tools and Set gauge length offset l In VERICUT MS, choose: Tools / Tool File, open file ‘tools.tls’, find it in exercise 5 folder l Tool gauge length setting l Choose: Tools / Tool Manager l In Tool Manager window, choose a tool then click ‘Modify’ l In Tool Modify window, choose Tool Properties l In Tool Properties window, give tool gauge length value l Change gauge point of all five tools to the most top point of each tool Gauge point

© 2001 PTC65 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Save machine file, save job file l Set Layout to 3 views l Run simulation l Save machine file, save job file l Set Layout to 3 views l Run simulation

© 2001 PTC66 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l VERICUT Setting l Open user file ‘sub.usr’, find it in exercise 5 folder l Machine simulation window is opened too l (Notes: this user file is same as the one in VERICUT exercise 6) l Change user file setting l In VERICUT, choose: Toolpath / Toolpath Control l In toolpath control window, choose toolpath file ‘sub.tap’(it’s in VERICUT MS exercise 5 folder) l VERICUT Setting l Open user file ‘sub.usr’, find it in exercise 5 folder l Machine simulation window is opened too l (Notes: this user file is same as the one in VERICUT exercise 6) l Change user file setting l In VERICUT, choose: Toolpath / Toolpath Control l In toolpath control window, choose toolpath file ‘sub.tap’(it’s in VERICUT MS exercise 5 folder)

© 2001 PTC67 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l G-Code setting l In G-Code Setting window, open Job file ‘3ax-mill.job’, find this file in VERICUT MS exercise 5 folder. Close window l Right after successfully change Job file, machine appears in VERICUT MS window. l Save User file l Resize VERICUT, and Machine Simulation window l Run simulation (Hint: you can control simulation in both window) l G-Code setting l In G-Code Setting window, open Job file ‘3ax-mill.job’, find this file in VERICUT MS exercise 5 folder. Close window l Right after successfully change Job file, machine appears in VERICUT MS window. l Save User file l Resize VERICUT, and Machine Simulation window l Run simulation (Hint: you can control simulation in both window)

© 2001 PTC68 Exercise 5 - Run VERICUT & Machine Simulation simultaneously l Tool retract setting l We find there is a gouge in both fixture and stock, it because that there is no tool retract when tool changing l Set tool retract l In VERICUT MS, choose: Modals / Tooling l In Tooling window, change Tool Change Retract Method to ‘Retract (Z-Axis only)’,then click OK l (Notes: this can also be set in VERICUT / Toolpath / Toolpath Control / G-Code setting) l Save Job file, reset VERICUT l Run simulation, now everything is running well l Tool retract setting l We find there is a gouge in both fixture and stock, it because that there is no tool retract when tool changing l Set tool retract l In VERICUT MS, choose: Modals / Tooling l In Tooling window, change Tool Change Retract Method to ‘Retract (Z-Axis only)’,then click OK l (Notes: this can also be set in VERICUT / Toolpath / Toolpath Control / G-Code setting) l Save Job file, reset VERICUT l Run simulation, now everything is running well

© 2001 PTC69 Exercise 6, 6a - Outline Exercise 6 l Menu Control l Use Control/Subroutine l Create main program and subroutine l Load subroutine to control l Load new toolpath file (main program) Exercise 6a l Menu Modals l Control simulation l Slow down machine simulation l Stop simulation when error occurs Exercise 6 l Menu Control l Use Control/Subroutine l Create main program and subroutine l Load subroutine to control l Load new toolpath file (main program) Exercise 6a l Menu Modals l Control simulation l Slow down machine simulation l Stop simulation when error occurs

© 2001 PTC70 Exercise 6 - Menu/Control Use Control / Subroutine l Create new main program and subroutine file l Create two new text file in exercise 6 folder, named ‘main- program.tap’ and ‘subroutine.sub’ l Open file ‘sub.tap’, copy lines from beginning to N510(the end of main program), paste it in file ‘main-program.tap’. Copy remaining of ‘sub.tap’ (subroutines) and paste it in file ‘subroutine.sub’ Use Control / Subroutine l Create new main program and subroutine file l Create two new text file in exercise 6 folder, named ‘main- program.tap’ and ‘subroutine.sub’ l Open file ‘sub.tap’, copy lines from beginning to N510(the end of main program), paste it in file ‘main-program.tap’. Copy remaining of ‘sub.tap’ (subroutines) and paste it in file ‘subroutine.sub’

© 2001 PTC71 Exercise 6 - Menu/Control l (Notes, we divided toolpath file to two files, main program and subroutines) l Load subroutine to Control l In VERICUT MS, choose: Control / Subroutines l In Subroutine window, open file ‘subroutine.sub’, find it in exercise 6 folder l Choose file ‘subroutine.sub’, click ‘Insert’, then click OK l (Notes, we divided toolpath file to two files, main program and subroutines) l Load subroutine to Control l In VERICUT MS, choose: Control / Subroutines l In Subroutine window, open file ‘subroutine.sub’, find it in exercise 6 folder l Choose file ‘subroutine.sub’, click ‘Insert’, then click OK

© 2001 PTC72 Exercise 6 - Menu/Control l Change toolpath file l Choose: Job / Job Setting, change toolpath file to ‘main- program.tap’ l Run simulation l (Note 1: Subroutine can also be defined in: Job / Subroutine) l (Note 2: When M98 is executed) l 1. Search the remainder of the current tool path file for the specified subroutine l 2. If not found, access job subroutine files for the specified subroutine l 3. If still not found, access control subroutine files for the specified subroutine l Change toolpath file l Choose: Job / Job Setting, change toolpath file to ‘main- program.tap’ l Run simulation l (Note 1: Subroutine can also be defined in: Job / Subroutine) l (Note 2: When M98 is executed) l 1. Search the remainder of the current tool path file for the specified subroutine l 2. If not found, access job subroutine files for the specified subroutine l 3. If still not found, access control subroutine files for the specified subroutine

© 2001 PTC73 Exercise 6a Menu/Modals Control machine simulation l Open file ‘3ax-mill.job’, find it in exercise 6 folder l Slow down machine movements l In VERICUT MS, choose: Modals / Motion / Max Distance l Give Max Distance=0.1, run machine simulation l Notice speed difference l Change Max Distance back to 0 Control machine simulation l Open file ‘3ax-mill.job’, find it in exercise 6 folder l Slow down machine movements l In VERICUT MS, choose: Modals / Motion / Max Distance l Give Max Distance=0.1, run machine simulation l Notice speed difference l Change Max Distance back to 0

© 2001 PTC74 Exercise 6a Menu/Modals l Stop simulation when an error occurs l In VERICUT, choose: Modals / General / Max Errors l Give Max Errors=1 l Toggle ‘Collision Detection’(find it in menu: Job / Collision) and ‘Over Travel Detection’(find it in menu: Machine / Travel Limits) On l Run simulation l It stops when an error occurs l Stop simulation when an error occurs l In VERICUT, choose: Modals / General / Max Errors l Give Max Errors=1 l Toggle ‘Collision Detection’(find it in menu: Job / Collision) and ‘Over Travel Detection’(find it in menu: Machine / Travel Limits) On l Run simulation l It stops when an error occurs

© 2001 PTC75 Exercise 7 - Outline Turning machine l Build turning machine l In Pro/E, export STL file of each component (optional) l Build machine kinematics l Load STL files l Load control l Set Input program zero l Test machine with MDI l Transfer tools from Pro/NC to VERICUT l Load tool library to Machine Simulation l Set tool gauge offset l Load tool path file, build tool index table l Run simulation l Use X-Caliper to check dimension of model after cut Turning machine l Build turning machine l In Pro/E, export STL file of each component (optional) l Build machine kinematics l Load STL files l Load control l Set Input program zero l Test machine with MDI l Transfer tools from Pro/NC to VERICUT l Load tool library to Machine Simulation l Set tool gauge offset l Load tool path file, build tool index table l Run simulation l Use X-Caliper to check dimension of model after cut

© 2001 PTC76 Exercise 7 - Turning machine Build turning machine l In Pro/E, export STL file of each component (optional) l Export all components except Turret against machine Zero CSYS l Machine Zero is located at right plane center of spindle Build turning machine l In Pro/E, export STL file of each component (optional) l Export all components except Turret against machine Zero CSYS l Machine Zero is located at right plane center of spindle Z X Machine Zero

© 2001 PTC77 Exercise 7 - Turning machine l Export Turret l Use CSYS-ACS4 l It is at located at left plane center of turret l Export Turret l Use CSYS-ACS4 l It is at located at left plane center of turret

© 2001 PTC78 Exercise 7 - Turning machine l Build machine kinematics l Read next two pages for details l Find STL files in exercise 7 folder l Build machine kinematics l Read next two pages for details l Find STL files in exercise 7 folder Base Spindle Fixture Stock Z-axis X-axis Turret

© 2001 PTC79 Exercise 7 - Turning machine l Machine components l Base l Type: Base, Name: Base, Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘base-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Spindle l Type: Spindle, Name: Spindle, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘spindle.stl’, Color, inherit, Position (0 0 0), Angle (0 0 0) l Fixture l Type: Fixture, Name: Fixture, Connect To: Spindle, Connect Position: (0 0 0) Color: 5Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘fixture.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Stock l Type: Stock, Name: Stock, Connect To: Fixture, Connect Position: (0 0 0) Color: 6Yellow, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘stock.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Machine components l Base l Type: Base, Name: Base, Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘base-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Spindle l Type: Spindle, Name: Spindle, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘spindle.stl’, Color, inherit, Position (0 0 0), Angle (0 0 0) l Fixture l Type: Fixture, Name: Fixture, Connect To: Spindle, Connect Position: (0 0 0) Color: 5Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘fixture.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Stock l Type: Stock, Name: Stock, Connect To: Fixture, Connect Position: (0 0 0) Color: 6Yellow, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘stock.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC80 Exercise 7 - Turning machine l Z l Type: Z Linear, Name: Z, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘z-axis.stl’, Color, Inherit,Rapid Rate, 200, Position (0 0 0), Angle (0 0 0) l Primitives: ‘z-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0 l X l Type: X Linear, Name: X, Motion Axis: X, Connect To: Z, Connect Position: (0 0 0) Color: 3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Turret l Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: X, Connect Position: (12.9103, 0, 15) Color: 2Green, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l (Notes: Offset value is measured from machine zero to left plane center of turret) l Primitives: ‘turret.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 1 l Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Red, Mixed Mode: Shade, Angles: (0 0 0) l Z l Type: Z Linear, Name: Z, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘z-axis.stl’, Color, Inherit,Rapid Rate, 200, Position (0 0 0), Angle (0 0 0) l Primitives: ‘z-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0 l X l Type: X Linear, Name: X, Motion Axis: X, Connect To: Z, Connect Position: (0 0 0) Color: 3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Turret l Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: X, Connect Position: (12.9103, 0, 15) Color: 2Green, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l (Notes: Offset value is measured from machine zero to left plane center of turret) l Primitives: ‘turret.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 1 l Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Red, Mixed Mode: Shade, Angles: (0 0 0)

© 2001 PTC81 Exercise 7 - Turning machine l Tool 2 l Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 -90) l Save machine file in exercise 7 folder, give file name ‘2xturn.mch’ l Add control file to machine l use control file ‘2xturn-inch.ctl’, find it in exercise 7 folder l Tool 2 l Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 -90) l Save machine file in exercise 7 folder, give file name ‘2xturn.mch’ l Add control file to machine l use control file ‘2xturn-inch.ctl’, find it in exercise 7 folder

© 2001 PTC82 Exercise 7 - Turning machine l About control file l A super group ‘Toolchange’ must be in control file to enable turret rotation when tool change. l See right box for details l Open control file ‘2xturn-inch.ctl’ to find this super group l About control file l A super group ‘Toolchange’ must be in control file to enable turret rotation when tool change. l See right box for details l Open control file ‘2xturn-inch.ctl’ to find this super group SUPERGROUP "Toolchange" { WORD_VALUE "T" { COND_AND "G" "65" { MACRO "MacroVar" } WORD_VALUE "T 1" { COND_AND "G" "65" { MACRO "NullMacro" } WORD_VALUE "T 2" { COND_AND "G" "65" { MACRO "NullMacro" } MACRO "TurretRetract" MACRO "TurretIndex" MACRO "TurretLoadTool" MACRO "TurretActivateTool" MACRO "DwellTime" { OVERRIDE_VALUE 29.1655 } MACRO "DwellMacro" } WORD_VALUE "T 3" { COND_AND "G" "65" { MACRO "NullMacro" } MACRO "XAxisIncreMotion" { OVERRIDE_VALUE 0 } MACRO "ZAxisIncreMotion" { OVERRIDE_VALUE 0 } MACRO "ToolOffsetIndex" MACRO "ToolOffsetUpdate2" MACRO "ToolOffsetAptAdj2" MACRO "CutterCompValue" MACRO "ToolNoseCompValue" }

© 2001 PTC83 Exercise 7 - Turning machine l Set Input Program Zero l Choose: Job / Tables l In Job Tables window, choose: ‘Input Program Zero’, see following figure for other parameters setting l Give Index=1 l (Note 1: Values (-12.9103, 0, -8) is measured from left plane center of turret to right plane center of stock) l (Note 2: We are going to use right plane center of stock as programming center) l Set Input Program Zero l Choose: Job / Tables l In Job Tables window, choose: ‘Input Program Zero’, see following figure for other parameters setting l Give Index=1 l (Note 1: Values (-12.9103, 0, -8) is measured from left plane center of turret to right plane center of stock) l (Note 2: We are going to use right plane center of stock as programming center) X Z

© 2001 PTC84 Exercise 7 - Turning machine l Test your machine with MDI l X0Z0 position is shown in the following figure l Stock and turret center lines are coincident l Right plane of stock and left plane of turret are adjacent l Test your machine with MDI l X0Z0 position is shown in the following figure l Stock and turret center lines are coincident l Right plane of stock and left plane of turret are adjacent

© 2001 PTC85 Exercise 7 - Turning machine l Transfer tools from Pro/NC to VERICUT l Open MFG file in Pro/NC l Change Pro/E working directory to …\exercise 7 l Open MFG file ‘turn.mfg’, l In Pro/NC, choose: CL Data / NC Check / CL File (open ‘turn.ncl’) /Done l Run simulation, exit VERICUT l (Notes, by running VERICUT simulation, tools data can be transferred from Pro/NC to VERICUT automatically, which will be called in VERICUT MS) l Load tool library to VERICUT MS l In VERICUT MS, choose: Tools / Tool File l Open file ‘cgtpro.tls’, find this file in exercise 7 folder l Transfer tools from Pro/NC to VERICUT l Open MFG file in Pro/NC l Change Pro/E working directory to …\exercise 7 l Open MFG file ‘turn.mfg’, l In Pro/NC, choose: CL Data / NC Check / CL File (open ‘turn.ncl’) /Done l Run simulation, exit VERICUT l (Notes, by running VERICUT simulation, tools data can be transferred from Pro/NC to VERICUT automatically, which will be called in VERICUT MS) l Load tool library to VERICUT MS l In VERICUT MS, choose: Tools / Tool File l Open file ‘cgtpro.tls’, find this file in exercise 7 folder

© 2001 PTC86 Exercise 7 - Turning machine l Set Tool gauge offset l In VERICUT MS, choose: Tools / Tool Manager l In Tool Manager window, choose Tool 1, then click Modify l In Tool Modify window, choose Properties l In Tool Properties window, change Gage Offsets to: (7, 0, 0.25) l Change Tool 2 gauge offset to (7 0 0.25) l Save tool library l Close Tool Manager window l Set Tool gauge offset l In VERICUT MS, choose: Tools / Tool Manager l In Tool Manager window, choose Tool 1, then click Modify l In Tool Modify window, choose Properties l In Tool Properties window, change Gage Offsets to: (7, 0, 0.25) l Change Tool 2 gauge offset to (7 0 0.25) l Save tool library l Close Tool Manager window

© 2001 PTC87 Exercise 7 - Turning machine l Load tool path file l In VERICUT MS, choose: Job / Setting l In Job Setting window, load tool path file to ‘turn.tap’, find in exercise 7 folder l Change Log file to ‘2xturn.log’, save it in exercise 7 folder l See following figure for other settings l Load tool path file l In VERICUT MS, choose: Job / Setting l In Job Setting window, load tool path file to ‘turn.tap’, find in exercise 7 folder l Change Log file to ‘2xturn.log’, save it in exercise 7 folder l See following figure for other settings

© 2001 PTC88 Exercise 7 - Turning machine l Build Tool Index Table l In VERICUT MS, choose: Tools / Tables l In Tool Tables window, choose Table Name as ‘Tool Index Table’, then click Build Tool List, 2 lines of tool index info appears. Two tools appears on turret too. l Close Tool Tables window. l Save JOB file l Give JOB file name ‘2xturn.job’, save it in exercise 7 folder l Build Tool Index Table l In VERICUT MS, choose: Tools / Tables l In Tool Tables window, choose Table Name as ‘Tool Index Table’, then click Build Tool List, 2 lines of tool index info appears. Two tools appears on turret too. l Close Tool Tables window. l Save JOB file l Give JOB file name ‘2xturn.job’, save it in exercise 7 folder

© 2001 PTC89 Exercise 7 - Turning machine l Run simulation l Check dimension after simulation l Use Analysis / X-Caliper to check diameters, D1 and D2, see if it is same as design model in Pro/NC l Run simulation l Check dimension after simulation l Use Analysis / X-Caliper to check diameters, D1 and D2, see if it is same as design model in Pro/NC D1D2

© 2001 PTC90 Exercise 8 - Outline Outline l Mill/Turn machining center l Create components and assembly in Pro/E l Export components in STL format l Linear components l Rotary components l Build machine kinematics and load STL files l Set input program zero l Load control file, mill-turn control introduction l Create MFG file in Pro/NC, generate TAP file using PP l Run NC Check to transfer tools and Stock data from Pro/NC to VERICUT, which will be used later l Load tool library file to Machine Simulation. Set turning tool gage offset l Load Tool path file Outline l Mill/Turn machining center l Create components and assembly in Pro/E l Export components in STL format l Linear components l Rotary components l Build machine kinematics and load STL files l Set input program zero l Load control file, mill-turn control introduction l Create MFG file in Pro/NC, generate TAP file using PP l Run NC Check to transfer tools and Stock data from Pro/NC to VERICUT, which will be used later l Load tool library file to Machine Simulation. Set turning tool gage offset l Load Tool path file

© 2001 PTC91 Exercise 8 - Outline l Build tool list l Set Turret rotation angle for milling tools l Play Machine Simulation l Run VERICUT and Machine Simulation simultaneously l Open USR file l Load stock file l Set toolpath orientation l Load Tool library file l Load Tool path file l G-Code setting, connect USR file with a JOB file l Open Machine Simulation form VERICUT l Run VERICUT and Machine Simulation together l Build tool list l Set Turret rotation angle for milling tools l Play Machine Simulation l Run VERICUT and Machine Simulation simultaneously l Open USR file l Load stock file l Set toolpath orientation l Load Tool library file l Load Tool path file l G-Code setting, connect USR file with a JOB file l Open Machine Simulation form VERICUT l Run VERICUT and Machine Simulation together

© 2001 PTC92 Exercise 8 - Mill/Turn Build Mill/Turn machining center l Load machine components and assembly in Pro/E l Set Pro/E working directory to: …\exercise 8\machine-proe\ l Open file: ‘mill-turn.asm’ l Find all components and assembly file in folder: …\exercise 8\machine-proe\ Build Mill/Turn machining center l Load machine components and assembly in Pro/E l Set Pro/E working directory to: …\exercise 8\machine-proe\ l Open file: ‘mill-turn.asm’ l Find all components and assembly file in folder: …\exercise 8\machine-proe\

© 2001 PTC93 Exercise 8 - Mill/Turn l Export components in STL format l Export non rotary components l It includes all components except ‘turret’ and ‘tool-holder’ l User CSYS in machine zero, it is located at right side plane center of spindle l Take both ‘z-slide’ components when exporting ‘z-side’, same comments for ‘x-slide’ l Use ‘0.1’ or smaller for chord height l Give STL files same name as proe part l Export components in STL format l Export non rotary components l It includes all components except ‘turret’ and ‘tool-holder’ l User CSYS in machine zero, it is located at right side plane center of spindle l Take both ‘z-slide’ components when exporting ‘z-side’, same comments for ‘x-slide’ l Use ‘0.1’ or smaller for chord height l Give STL files same name as proe part X Z ACS3

© 2001 PTC94 Exercise 8 - Mill/Turn l Export rotary components l It includes ‘turret’ and four ‘tool-holder’ l Use CSYS (ACS4) at rotating center of turret l Export four holder components separately, give them name ‘holder-1, holder-3, holder-5, holder-7. See following figure for holder number and location l Export rotary components l It includes ‘turret’ and four ‘tool-holder’ l Use CSYS (ACS4) at rotating center of turret l Export four holder components separately, give them name ‘holder-1, holder-3, holder-5, holder-7. See following figure for holder number and location Holder-1 Holder-5 Holder-3 Holder-7

© 2001 PTC95 Exercise 8 - Mill/Turn l Build machine kinematics l See following figure and next 3 pages for details l Tips l Make sure Tool Index Number is set right l Make sure Angle is right l Build machine kinematics l See following figure and next 3 pages for details l Tips l Make sure Tool Index Number is set right l Make sure Angle is right

© 2001 PTC96 Exercise 8 - Mill/Turn l Machine components l Base l Type: Base, Name: Base, Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘base-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Spindle l Type: Spindle, Name: Spindle, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘spindle.stl’, Color, inherit, Position (0 0 0), Angle (0 0 0) l Fixture l Type: Fixture, Name: Fixture, Connect To: Spindle, Connect Position: (0 0 0) Color: 5Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘fixture.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Stock l Type: Stock, Name: Stock, Connect To: Fixture, Connect Position: (0 0 0) Color: 6Yellow, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘stock.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Machine components l Base l Type: Base, Name: Base, Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘base.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘base-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Spindle l Type: Spindle, Name: Spindle, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 3Light Steel Blue, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘spindle.stl’, Color, inherit, Position (0 0 0), Angle (0 0 0) l Fixture l Type: Fixture, Name: Fixture, Connect To: Spindle, Connect Position: (0 0 0) Color: 5Magenta, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘fixture.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Stock l Type: Stock, Name: Stock, Connect To: Fixture, Connect Position: (0 0 0) Color: 6Yellow, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘stock.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC97 Exercise 8 - Mill/Turn l Z l Type: Z Linear, Name: Z, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘z-axis.stl’, Color, Inherit,Rapid Rate, 200, Position (0 0 0), Angle (0 0 0) l Primitives: ‘z-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0 l X l Type: X Linear, Name: X, Motion Axis: X, Connect To: Z, Connect Position: (0 0 0) Color: 3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘x-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Y l Type: Y Linear, Name: Y, Motion Axis: Y, Connect To: X, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘y-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Z l Type: Z Linear, Name: Z, Motion Axis: Z, Connect To: Base, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘z-axis.stl’, Color, Inherit,Rapid Rate, 200, Position (0 0 0), Angle (0 0 0) l Primitives: ‘z-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0 l X l Type: X Linear, Name: X, Motion Axis: X, Connect To: Z, Connect Position: (0 0 0) Color: 3Light Steel Blue, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘x-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Primitives: ‘x-slide.stl’, Color, white, Position (0 0 0), Angle (0 0 0) l Y l Type: Y Linear, Name: Y, Motion Axis: Y, Connect To: X, Connect Position: (0 0 0) Color: 4Cyan, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l Primitives: ‘y-axis.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC98 Exercise 8 - Mill/Turn l Turret l Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: Y, Connect Position: (12.9103, 0, 13) Color: 2Green, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l (Notes: Offset value is measured from machine zero to left plane center of turret) l Primitives: ‘turret.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 1 l Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (4.5, 0, -5.5) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 1 l Primitives: ‘holder-1.stl’, Color, Inherit, Position (-4.5,0,5.5), Angle (0 0 0) l Tool 3 l Type: Tool, Name: Too l 3, Motion Axis, Z, Connect To:Turret, Connect Position: (0, 4.5, -5.5) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 3 l Primitives: ‘holder-3.stl’, Color, Inherit, Position (0, -4.5,5.5), Angle (0 0 0) l Tool 5 l Type: Tool, Name: Too l 5, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 5 l Primitives: ‘holder-5.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Turret l Type: B Turret, Name: Turret, Motion Axis, Z, Connect To: Y, Connect Position: (12.9103, 0, 13) Color: 2Green, Rapid Rate, 200, Mixed Mode: Shade, Angles: (0 0 0) l (Notes: Offset value is measured from machine zero to left plane center of turret) l Primitives: ‘turret.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 1 l Type: Tool, Name: Too l 1, Motion Axis, Z, Connect To:Turret, Connect Position: (4.5, 0, -5.5) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 1 l Primitives: ‘holder-1.stl’, Color, Inherit, Position (-4.5,0,5.5), Angle (0 0 0) l Tool 3 l Type: Tool, Name: Too l 3, Motion Axis, Z, Connect To:Turret, Connect Position: (0, 4.5, -5.5) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 3 l Primitives: ‘holder-3.stl’, Color, Inherit, Position (0, -4.5,5.5), Angle (0 0 0) l Tool 5 l Type: Tool, Name: Too l 5, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 5 l Primitives: ‘holder-5.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0)

© 2001 PTC99 Exercise 8 - Mill/Turn l Tool 7 l Type: Tool, Name: Too l 7, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 7 l Primitives: ‘holder-7.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 2 l Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 45), Tool Index Number: 2 l Tool 4 l Type: Tool, Name: Too l 4, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 135), Tool Index Number: 4 l Save machine file, give name: ‘mill-turn.mch’ l Tool 7 l Type: Tool, Name: Too l 7, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 0), Tool Index Number: 7 l Primitives: ‘holder-7.stl’, Color, Inherit, Position (0 0 0), Angle (0 0 0) l Tool 2 l Type: Tool, Name: Too l 2, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 45), Tool Index Number: 2 l Tool 4 l Type: Tool, Name: Too l 4, Motion Axis, Z, Connect To:Turret, Connect Position: (0 0 0) Color: Magenta, Mixed Mode: Shade, Angles: (0 0 135), Tool Index Number: 4 l Save machine file, give name: ‘mill-turn.mch’

© 2001 PTC100 Exercise 8 - Mill/Turn l Set Input program zero l It is measured from left side turret plane center to right side stock plane center l Load Control file l Open control file ‘mill-turn.ctl’ l Save JOB file, ‘mill-turn.job’ l Test your machine with MDI l Set Input program zero l It is measured from left side turret plane center to right side stock plane center l Load Control file l Open control file ‘mill-turn.ctl’ l Save JOB file, ‘mill-turn.job’ l Test your machine with MDI X Z X0Y0Z0

© 2001 PTC101 Exercise 8 - Mill/Turn l About Mill-Turn Control l A super group ‘Toolchange’ must be in control file to enable turret rotation when tool change. l About Mill-Turn Control l A super group ‘Toolchange’ must be in control file to enable turret rotation when tool change. SUPERGROUP "Toolchange" { WORD_VALUE "T" { COND_AND "G" "65" { MACRO "MacroVar" } WORD_VALUE "T 1" { COND_AND "G" "65" { MACRO "NullMacro" } WORD_VALUE "T 2" { COND_AND "G" "65" { MACRO "NullMacro" } MACRO "TurretRetract" MACRO "TurretIndex" MACRO "TurretLoadTool" MACRO "TurretActivateTool" MACRO "DwellTime" { OVERRIDE_VALUE 29.1655 } MACRO "DwellMacro" } WORD_VALUE "T 3" { COND_AND "G" "65" { MACRO "NullMacro" } MACRO "XAxisIncreMotion" { OVERRIDE_VALUE 0 } MACRO "ZAxisIncreMotion" { OVERRIDE_VALUE 0 } MACRO "ToolOffsetIndex" MACRO "ToolOffsetUpdate2" MACRO "ToolOffsetAptAdj2" MACRO "CutterCompValue" MACRO "ToolNoseCompValue" }

© 2001 PTC103 Exercise 8 - Mill/Turn l X multiplier l X multiplier for word X must match the setting in Lathe post-processor l X multiplier l X multiplier for word X must match the setting in Lathe post-processor

© 2001 PTC104 Exercise 8 - Mill/Turn l MFG file in Pro/NC l Set Pro/E working directory to: …\exercise 8\mfg-pronc\ l Open file: ‘mill-turn-2.mfg’ l Create NCL file for whole operation, give name: ‘mill- turn.ncl’ l Performing NC Check to transfer Tools from Pro/NC to VERICUT l In Pro/NC, choose: CL Data / NC Check / CL File / (choose file ‘mill-turn.ncl’) /Done l Create TAP file l Using Post-Processor ‘fan16t’ to post the NCL file, give TAP file name ‘mill-turn.tap’ l PP ‘fan16t’ is merged with PP ‘fan16m’, it is a mill/turn merged post-processor l MFG file in Pro/NC l Set Pro/E working directory to: …\exercise 8\mfg-pronc\ l Open file: ‘mill-turn-2.mfg’ l Create NCL file for whole operation, give name: ‘mill- turn.ncl’ l Performing NC Check to transfer Tools from Pro/NC to VERICUT l In Pro/NC, choose: CL Data / NC Check / CL File / (choose file ‘mill-turn.ncl’) /Done l Create TAP file l Using Post-Processor ‘fan16t’ to post the NCL file, give TAP file name ‘mill-turn.tap’ l PP ‘fan16t’ is merged with PP ‘fan16m’, it is a mill/turn merged post-processor

© 2001 PTC105 Exercise 8 - Mill/Turn l Load Tool and Tool Path file l Copy file ‘cgtpro.tls’ and ‘mill-turn.tap’ to folder …\exercise 8\VERICUT. Change file name of ‘cgtpro.tls’ to ‘mill-turn.tls’ l Load tool library l In VERICUT MS, choose: Tools / Tool File, open file ‘mill- turn.tls’ l Set turning tool gage offset l Set both turning tool (T2 and T4) gage offset to (7, 0, 0.25). Refer Exercise 7 for details l Load Tool and Tool Path file l Copy file ‘cgtpro.tls’ and ‘mill-turn.tap’ to folder …\exercise 8\VERICUT. Change file name of ‘cgtpro.tls’ to ‘mill-turn.tls’ l Load tool library l In VERICUT MS, choose: Tools / Tool File, open file ‘mill- turn.tls’ l Set turning tool gage offset l Set both turning tool (T2 and T4) gage offset to (7, 0, 0.25). Refer Exercise 7 for details

© 2001 PTC106 Exercise 8 - Mill/Turn l Load Tool path file l In VERICUT MS, choose: Job / Job Setting l Load tool path file ‘mill-turn.tap’ l Build tool list l Choose: Tools / Tables / Tool Index Table /Build Tool List l Reset Machine Simulation, tools appear on turret l Load Tool path file l In VERICUT MS, choose: Job / Job Setting l Load tool path file ‘mill-turn.tap’ l Build tool list l Choose: Tools / Tables / Tool Index Table /Build Tool List l Reset Machine Simulation, tools appear on turret

© 2001 PTC107 Exercise 8 - Mill/Turn l Set turret rotation angle for two milling tools l Turret rotation angle only need to be set for milling tools l Choose: Tools / Tables / Turret Rotation, see following figure for details, index # here reflects Tool ID # l Turret rotates this angle when the tool is called in tool path file l The angle is measured from the tool original orientation to dash line (position when tool in use) l Save JOB file l Set turret rotation angle for two milling tools l Turret rotation angle only need to be set for milling tools l Choose: Tools / Tables / Turret Rotation, see following figure for details, index # here reflects Tool ID # l Turret rotates this angle when the tool is called in tool path file l The angle is measured from the tool original orientation to dash line (position when tool in use) l Save JOB file X Y Tool 1 Tool 3 Rotate To

© 2001 PTC108 Exercise 8 - Mill/Turn l Play simulation l Reset VERICUT MS, play simulation l Run VERICUT and Machine Simulation simultaneously l USR file setting l Copy files ‘cgpro.usr’ and ‘cgpro1.stk’ in folder …\exercise 8\mfg-pronc\ then paste then in folder …exercise 8\vericut\ l Change USR file name to: ‘mill-turn.usr’ l Open USR file ‘mill-turn.usr’ l Load stock file. In VERICUT choose: Model / Model Definition / Stock / (open polygon file ‘cgtpro1.stk’) / Apply l Play simulation l Reset VERICUT MS, play simulation l Run VERICUT and Machine Simulation simultaneously l USR file setting l Copy files ‘cgpro.usr’ and ‘cgpro1.stk’ in folder …\exercise 8\mfg-pronc\ then paste then in folder …exercise 8\vericut\ l Change USR file name to: ‘mill-turn.usr’ l Open USR file ‘mill-turn.usr’ l Load stock file. In VERICUT choose: Model / Model Definition / Stock / (open polygon file ‘cgtpro1.stk’) / Apply

© 2001 PTC109 Exercise 8 - Mill/Turn l Set Toolpath orientation l In VERICUT, choose: Toolpath / Toolpath Orientation l Give (0 0 7) for Ref(XYZ) l Notice that from right side of stock (input programming zero) to it primitive origin is 7 l Set Toolpath orientation l In VERICUT, choose: Toolpath / Toolpath Orientation l Give (0 0 7) for Ref(XYZ) l Notice that from right side of stock (input programming zero) to it primitive origin is 7 7

© 2001 PTC110 Exercise 8 - Mill/Turn l Load Tool library file l In VERICUT, choose: Tools / Tool Control / Tool Library (open tool library file ‘mill-turn.tls’) / OK l Load Tool library file l In VERICUT, choose: Tools / Tool Control / Tool Library (open tool library file ‘mill-turn.tls’) / OK

© 2001 PTC111 Exercise 8 - Mill/Turn l Load Tool path file l In VERICUT, choose: Toolpath / Toolpath Control l In Toolpath Control window, open Tool path file ‘mill-turn.tap’, set toolpath type=G-Code Data, Multiple Toolpath Files=No l Load Tool path file l In VERICUT, choose: Toolpath / Toolpath Control l In Toolpath Control window, open Tool path file ‘mill-turn.tap’, set toolpath type=G-Code Data, Multiple Toolpath Files=No

© 2001 PTC112 Exercise 8 - Mill/Turn l G-code settting l In Toolpath Control window, choose G-code setting l In G-Code Setting window, choose: File / Open (open file ‘mill- turn.job’) l Choose: File / Close l Choose Ok in Tool path control window l Connect to Machine Simulation l In VERICUT, choose: Applications / Machine Simulation l G-code settting l In Toolpath Control window, choose G-code setting l In G-Code Setting window, choose: File / Open (open file ‘mill- turn.job’) l Choose: File / Close l Choose Ok in Tool path control window l Connect to Machine Simulation l In VERICUT, choose: Applications / Machine Simulation

© 2001 PTC113 Exercise 8 - Mill/Turn l Resize VERICUT and Machine Simulation window l Click Play button (in either window) l Resize VERICUT and Machine Simulation window l Click Play button (in either window)

Global solutions innovation collaboration © 2001 PTC Training Exercises VERICUT for Pro/ENGINEER Machine Simulation.

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Global solutions innovation collaboration © 2001 PTC Training Exercises VERICUT for Pro/ENGINEER Machine Simulation.

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