Lab Manual

For

CAD/CAM using Pro/Engineer Wildfire 5.0

Lecture 10- Milling Operations (Continued)

Prepared by: Nabeel Nisar, SE

Table of Contents

1. 2. 3. 4.

Volume Milling............................................................................................................................................. 3 Profile Milling .............................................................................................................................................. 6 Local Milling ................................................................................................................................................ 9 Holemaking ................................................................................................................................................ 13

1. Volume Milling
A Volume milling NC sequence removes the material inside a Milling Volume slice-by-slice. All slices are parallel to the retract plane; the axial depth of cut (slice depth) is defined by the combination of STEP_DEPTH and WALL_SCALLOP_HGT parameters. The first slice is generated at slice depth below the top of the mill volume. In case the mill volume extends above the top of the workpiece, the first slice is generated at slice depth below the top of the workpiece, to avoid air machining. All planar surfaces inside the volume that are normal to the Z-axis of the NC Sequence coordinate system produce additional slices across the whole volume; use the MIN_STEP_DEPTH parameter to control the minimum acceptable distance between slices. The step-over distance inside a slice can be controlled by the following parameters: STEP_OVER, NUMBER_PASSES, BOTTOM_SCALLOP_HGT, and STEPOVER_ADJUST. Some typical applications for Volume milling are: Facing down the workpiece General material removal on the outside of the workpiece Rough milling of a vertical slot or cut, or a blind slot with islands

To Create a Volume Milling Sequence 1. Select File > New, select Type Manufacturing and sub-type NC Assembly. Type the name of your assembly (for example vol_mill_1). 2. Uncheck the option use default template, click OK, select mmns_mfg_nc in next diolag box and click OK. 3. Assemble the Reference Model vol_mill_1.prt, then create a Workpiece as discussed in previous sequence. 4. Create a new coordinate system as shown in figure. Click OK.

5. Select Steps > Operation from the Menu bar. Select machine type is Mill and number of axes are 3. Click OK.

in front of NC machine. Make sure that

6. Select Machine Zero in Reference box. Select the coordinate system created in step 4. 7. Select Surface in Retract box, set value equal to 5. Click OK twice.

8.

Select Mill Window

on the Mfg Geometry Features toolbar. NC Manufacturing activates the ). Select Placement > Window

Mill Window dashboard. Click the silhouette window type (

Plane and select top surface of the part, as shown in figure. Click the Depth slide- up panel to specify the depth of the Mill Window. Create a new datum plane by selecting the edges of the lower surface, as shown in figure. Click OK and complete the Mill Window feature. 9. For Volume Milling, click settings and click OK. 10. In the tools setup, set the diameter of tool = 10, click OK. 11. Select the Mill Window created in step 8. on the toolbar or click Steps Volume Rough. Retain the default

12. Edit

the

parameters

as

shown

in

figure.

Click

OK.

13. Click Playpath > Screenplay. In Playpath window, click play button to view the toolpath of the sequence. 14. Click Playpath > NC Check. Play the simulation of metal cutting in vericut. 15. Practice the sequence by using other reference models. Parameters in Volume Milling CUT_FEED ARC_FEED FREE_FEED RETRACT_FEED TRAVERSE_FEED PLUNGE_FEED STEP_DEPTH

TOLERANCE STEP_OVER PROF_STOCK_ALLOW ROUGH_STOCK_ALLOW BOTTOM_STOCK_ALLOW CUT_ANGLE SCAN_TYPE CUT_TYPE ROUGH_OPTION CLEAR_DIST SPINDLE_SPEED COOLANT_OPTION

2. Profile Milling
Profile milling is used to rough or finish mill vertical or slanted surfaces. The surfaces selected must allow for a continuous tool path. The depth of the cut is defined by the depth of the selected surfaces.

To Create a Profile Milling NC Sequence 1. Repeat steps 1-8 of volume milling sequence, but select the Reference Model prof_mill_1.prt. 2. For Profile Milling, click on the toolbar or click Steps Profile Milling. The MACH AXES

menu appears with the required options for Profile Milling selected. Go with defaults and click OK. 3. In the tools setup, change the diameter of the endmill to 5. Click OK. 4. Edit the parameters as shown in figure. Click OK.

5. In the Surface panel, select the surfaces to which you want to profile cut. Select Reference Model Surface from selection filter, and select the surfaces as shown in figure.

6. Click Playpath > Screenplay. In Playpath window, click play button to view the toolpath of the sequence. 7. Click Playpath > NC Check. Play the simulation of material removal in vericut, as shown in figure. 8. Practice the sequence by using another reference model.

Parameters in Profile Milling CUT_FEED ARC_FEED FREE_FEED RETRACT_FEED PLUNGE_FEED STEP_DEPTH TOLERANCE PROF_STOCK_ALLOW CHK_SRF_STOCK_ALLOW WALL_SCALLOP_HGT CUT_TYPE CLEAR_DIST SPINDLE_SPEED COOLANT_OPTION

3. Local Milling
There are four types of Local Milling: Prev NC SeqRemove material left after a Volume, Profile, or another Local Milling NC sequence, usually with a smaller tool. Corner EdgesSpecify one or more corners to clean up by selecting edges. By Prev ToolCalculates the remainder material on specified surfaces after being machined by a larger tool; then removes this material by the current (smaller) tool. Pencil TracingCleans up edges of selected surfaces by creating a single-pass tool path along the corners.

Local Milling by Referencing a Previous NC Sequence This type of Local Milling NC sequence removes material left after a Volume, Profile, or another Local Milling NC sequence, usually with a smaller tool. When you create such a Local milling NC sequence, you will be prompted to select a reference NC sequence. The system will then compute the material left by the reference NC sequence and machine away this material only. After a Volume or Profile NC sequence, you can do region-by-region milling. The following illustration shows Local Milling by reference.

1 Volume milling performed with a large tool 2 Local milling removes the leftover material To Create a Local Milling NC Sequence by Referencing a Previous Sequence 1. Create new manufacturing file, local_mill_prev_seq. Assemble the reference model having same name. 2. Setup the milling operation as before. First remove the material from inner cavity using Volume Milling sequence, 12 mm end mill cutter. Use either Mill Window or Mill Volume for this sequence.

3. After completing Volume Milling, select Steps > Local Milling > Previous Step as shown in figure. 4. Select reference milling operation for which you want local milling. In this case, select NC SEQUENCE > Volume Milling > CUT MTN#1 5. Select Tool and Parameters from the Options menu. Select 3 mm end mill cutter. Enter the parameters as shown in figure.

6. Local milling is completed. 7. Practice the sequence using another reference model.

Local Milling by Using Corner Edges In this type of Local Milling NC sequence, you specify one or more corners to clean up by selecting edges. The amount of material to remove will be calculated by the system based on the value of the CORNER_OFFSET parameter that you supply. The following illustration shows Local milling using Corner Edges.

1 Select corner 2 CORNER_OFFSET 3 This material will be removed

To Create Local Milling NC Sequence by Using Corner Edges 8. Create new manufacturing file, local_mill_corner_edge. Assemble the reference model having same name. 9. Setup the milling operation as before. First remove the material from inner cavity using Volume Milling sequence, 10 mm end mill cutter. Use either Mill Window or Mill Volume for this sequence.

10. After completing Volume Milling, select Steps > Local Milling > Corners as shown in figure. 11. Select Tool, Parameters, Surfaces and Corner Edges from the Options menu. Select 3 mm end mill cutter. In edit parameters, select ALL tab instead of BASIC. Enter CUT FEED = 30, STEP DEPTH = 1, STEP OVER = 1, CLEAR DIST = 1, SPINDLE SPEED = 500 12. Set CORNER OFFSET = Diameter of Larger tool Diameter of Smaller Tool. So in this case, it will be 10 3 = 7 13. In surface pick drop-down menu, select Model > Done. Now select the surfaces whose intersections give the required corners (i.e. select all inner surfaces in this case). Select OK, then DONE/RETURN. Now select SUGGEST to view the required corners. If satisfied, click SELECT ALL, then click DONE/RETURN. 14. Local milling sequence is completed. C lick Playpath > Screenplay or NC check to review it.

4. Holemaking
A Holemaking NC sequence is created by selecting the cycle type and specifying the holes to drill by defining the Hole Set(s). The order of machining the holes is defined by the SCAN_TYPE parameter value. A Hole Set includes one or more holes to be drilled; each Hole Set has a drilling depth specification or countersink diameter value associated with it. You can include more than one Hole Set in a single Holemaking NC sequence; this allows drilling of holes with different depth specifications, as well as having multiple countersink diameter values, within a single NC sequence. There are various methods of selecting the holes to be included in a Hole Set: By selecting individual hole axes By including all holes on a specified surface By including all holes of a specified diameter

By including all holes with a certain value of a feature parameter By including all holes with chamfers machinable by the current tool (for countersinking) By selecting individual datum points to mark the drill locations By including all datum points on a specified surface If you need to perform a series of Holemaking NC sequences on the same group of holes, you can define a Drill Group using the techniques above, and then reference this Drill Group when defining Hole Sets. This simplifies the selection process; you can also parametrically update all the NC sequences b y modifying the Drill Group.

To Create a Holemaking NC Sequence 1. Create new manufacturing file DRILL_1.asm. Assemble the reference model DRILL_1.prt in it. Also create automatic workpiece as well as machine coordinate systems as discussed in earlier sequences. 2. Create new operation, select milling machine. 3. Select Steps > Drilling > Standard for holemaking sequence as shown in figure.

4. Select tools, parameters and holes in menu manager. 5. Create 7 mm basic drill, click OK. In parameters, enter cut feed = 50, clear dist = 1 and spindle speed = 500. In hole set, select DETAILS in front of select diameters, then select 7 in available and send it to selected ( holes of 7mm will be selected). Click done, again done. 6. Repeat steps 3-5 for 5 mm holes, using 5 basic drill. 7. Sequence is completed. Review it using playpath. To Define Depth All Hole Sets (except for Countersink and Web drilling), require specifying the drill depth type. To define the depth type and references, click Depth in the HoleSet dialog box. The Hole Set Depth dialog box opens. Select one of the following Hole Depth icons to specify the depth or surface for drilling: (Blind)Drill from the start surface to specified depth. Specify the Start and End surfaces. If yo u select the checkbox next to the Use breakout distance option, the system adds the BREAKOUT_DISTANCE parameter value when calculating depth.

(Auto)Depth of drilling is determined automatically, by referencing hole geometry. If the selected axis is associated with several coaxial hole features, the maximum depth will be selected as long as the tool fits inside the hole diameter.

(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. By default, all the reference parts and workpieces are used for depth calculation. You can unselect some of the parts or explicitly select parts, by using the Models collector of the Options tab in the Hole Set Depth dialog box. The All Models option selects all the reference parts and workpieces.

Drill from the start surface to the depth of the selected reference. Surfaces and datum planes are selected by default.